Mounting Instructions for Back Gears with

Airflex Coupling
Table of Contents

1 Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Required conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools and mounting parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dismounting the outside coupling drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preparing the back gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Aligning and screw--fastening the back gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Final mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Lubricating grease recommendation and grease quantity . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lubricating grease recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Grease quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

en FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 1 / 14
Preliminary Remark
These instructions shall be of information and help for Given that SCHOTTEL systems are subject to further
every person engaged in initial start--up, operation and development we reserve the right of technical modifica-
maintenance of SCHOTTEL systems. This requires to tions.
read, understand and observe these documents.
Important instructions relevant to technical and oper-
These instructions are to be made available to every- ational safety are pointed out by the following symbols:
body carrying out works on the system.
We do not accept any liability for damages and troubles ! CAUTION
in operation resulting from disregard of these instruc-
tions. Indicates working and operating methods that are to be
It is taken for granted that every user is familiar with the strictly observed to exclude any risk for persons.
systems and informed on all possible dangers.
Only trained personnel is allowed to carry out any work
on the system.
! ATTENTION
Refers to working and operating methods that are to be
References to illustrations in the text are written in strictly observed to avoid damages to or destruction of
brackets, e.g. (1/3). The first number indicates the il- the material.
lustration number in the manual, the second number is
the position number in the illustration.
NOTE
All illustrations are diagrammatic projections without
any claim for completeness. Indicates exceptional features in the working process
Any technical modification to SCHOTTEL systems not that are to be observed.
carried out by personnel appointed by SCHOTTEL
does require written consent.
i INFORMATION
This excludes modifications or control settings detailed
in our instructions. Application references and information.
During any work carried out on SCHOTTEL systems it
is required to observe the Safety and Environmental
Protection Regulations SV 1 as well as the relevant
laws in force in the respective country of utilization.

These instructions were elaborated with utmost care.

In case of further information required, please contact:
SCHOTTEL GmbH
Mainzer Straße 99
D--56322 Spay
Phone +49 (0) 2628 / 61--0
Fax +49 (0) 2628 / 61--300
E--Mail info@schottel.de

2 / 14 FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 en
1 Technical Description

In combination with the pneumatic coupling, the back mounting of the SRP, the back gear is aligned and
gear is the link between driving motor and SRP. After mounted on the prepared base.

Structure
The back gear shaft (1/7) with drive flange (1/11) is
bedded in two bearings, the movable bearing (1/8) and
the fixed bearing (1/10). On a shaft flange between the
bearings is mounted the belt pulley (1/9) for the hy-
draulic pump drive.
At the power take--off side of the back gear shaft is
mounted a flange hub (1/5) for fastening the inside
coupling drum (1/6).
For structure and function of the coupling, see manu-
facturer’s documentation company KENDRION.
The back gear is supplied pre--assembled. The inside
drum of the coupling is screwed together with the flange
hub.
The flange plate (1/2) of the coupling and the outside
coupling drum (1/4) are mounted to the flange hub (1/1)
of the SRP propeller shaft.

1 2 3 4 5 6 7 8 9 10
.

11
SRP

12

13

16 14

17 4
15
Figure 1
1 Flange hub 10 Bearing (fixed bearing)
2 Flange plate 11 Driving flange
3 Compressed air supply 12 Bearing housing base
4 Outside coupling drum 13 Bearing distance plate
5 Flange hub 14 Bearing base plate
6 Inside coupling drum 15 Cast resin layer
7 Back gear shaft 16 Base
8 Bearing (movable bearing) 17 Compressed air supply
9 Belt pulley

en FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 3 / 14
2 Mounting

NOTE ! ATTENTION
The back gear is available in two versions: For details please, see the mandatory drawings.

D Version with COOPER bearing COOPER bearing Id--No. 1150609

D Version with SKF bearing SKF bearing Id--No. 1169299 or 1167276.

The mounting sequence is described only by the

example of the version COOPER bearing, because the
mounting sequence is identical for the version with SKF
bearing.

Required conditions
Prior to mounting the following required conditions are D The base with jacket and set--screws for seating
to be met in the dockyard: and aligning the back gear must be prepared ac-
cording to the mandatory mounting drawing.
D The SRP must be installed in the ship stationary in
its final position. D Base and jacket must be clean and free of grease.

Tools and mounting parts

The following parts are to be made available by the The following parts are also supplied by SCHOTTEL:
dockyard:
D 8 dowel pins 12.0x120 for fixing the base plates
D 2 lifting slings of sufficient carrying capacity for re- and the bearings onto the base.
taining the back gear.
D Synthetic lubricating grease Mobilgrease 28
D Crosshead for fastening the lifting slings.

D Lifting gear of sufficient capacity for lifting and

moving the back gear.

D 8 set--screws M24 with locknut according to man-

datory drawing for vertical alignment of the back
gear inside the base.

D 4 set--screws M30 with locknut according to man-

datory drawing for horizontal alignment of the back
gear inside the base.

D 4 screws M30 with nut according to mandatory

drawing for the screwed connection of the bearing
with the base.

D Sponge rubber strips according to mandatory

drawing.

D 2--component cast resin Epocast 36.

4 / 14 FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 en
Dismounting the outside coupling drum
1 2 3 4
1. Secure the outside coupling drum (2/4) against fal-
ling down uncontrolled while it is dismounted.
2. Unscrew the nuts (2/3) and remove the outside
coupling drum from the flange plate (2/1).

! ATTENTION
While removing the outside coupling drum it is required
to pay attention not to damage the sealing rings at the
compressed air supplies (2/2).

Figure 2

Preparing the back gear

1
1. Check the transport box for possible outside dam-
ages before starting to unpack.
2. Open the transport box. Check the back gear and
bulk parts for completeness and condition.
3. For lifting the back gear, put two lifting slings (3/2)
around the back gear shaft and fasten it to an ap- 2
propriate crosshead (3/1).

! CAUTION
Do not step under load in suspension!
MORTAL DANGER

4. Remove the conservation of the back gear using

appropriate means and check again for possible
damages.

Figure 3

en FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 5 / 14
Aligning and screw--fastening the back 1a 1 1a
gear
2
1. Screw the set--screws M24 (4/1 and 4/1a) with
locknut down into the threaded bore holes of the
bearing base plates (4/2).
Screw the outside set--screws (4/1a) down until
they are protruding from the bearing base plates

10
by about 10 mm.

1a 1 1a

Figure 4

2. Insert in the centre of each jacket (5/1) a sponge

rubber strip (5/2).
Cross section about 30 mm 1

Figure 5

3. Deposit the back gear (6/1) into the jackets (6/2) on

the base (6/3).

1
! CAUTION
Danger of bruising while positioning the back gear into
the jackets.

Figure 6

6 / 14 FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 en
4. Move the back gear in longitudinal direction until
the nominal value S = 6 between the flange plate S = 6 mm
(8/1) of the SRP shaft and inner coupling drum 1 2
(8/2) is reached.

Figure 7

5. With the outside screws M24 (8/4) align the back

gear vertically until between the flange plate (8/1)

R max. = 0.1 mm

U max. = 0.1 mm
and the inside coupling drum (8/32 results an 1 2 3
angle of 90_ and the back gear shaft (8/3) is in
alignment with the SRP propeller shaft (8/5).
The admissible axis displacement Rmax is of 0.1
mm.
The admissible angular dislocation Umax is of 0.1
mm.

5
90_
4

Figure 8

6. With the lateral set--screws (9/4) align the back 4

gear horizontally until between the flange plate 3
R max. = 0.1 mm

1 2
(9/1) and the inside coupling drum (9/2) results an
angle of 90_, and the back gear shaft (9/3) is in
alignment with the SRP propeller shaft (9/5).
The admissible axis displacement Rmax is of 0.1
mm.
The admissible angular dislocation Umax is of 0.1
mm.
U max. = 0.1 mm

5 90_

Figure 9

en FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 7 / 14
7. Screw the inside screws (10/3) down until they are 1 2 1
in contact with the base, and secure them with
3
locknuts.
8. Secure outside screws M24 (10/1) and lateral set--
screws (10/2) with locknuts.

3
1 2 1

Figure 10

9. Fill both jackets up to a height of about 30 mm with

Epocast 36 (Figure 11).

NOTE
Observe the instructions for use of the manufacturer!

! ATTENTION
All following mounting steps are to be carried out only
after the complete hardening of the Epocast 36!

Figure 11

10. Through the bore holes ∅16 mm in bearing dis-

tance plates (12/1), drill through holes ∅12 mm for
seating the dowel pins.

∅16

∅12 H12

Figure 12

8 / 14 FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 en
11. Drive the supplied dowel pins 12.0x120 (13/1) into
the through holes until the dowel pins are flush with
the upper edge of the base plate (13/2).

1 2

Figure 13

12. Through the bore holes ∅33 mm, establish

through holes ∅33 mm through the cast resin
(14/1) and base (14/2).

∅33
1

∅33
2

Figure 14

13. Fasten the back gear with four screws M30 (15/1)
to the base (15/2).
Tightening moment: 1900 Nm
1

1 1

Figure 15

en FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 9 / 14
 Final mounting
1. Into the marked points (16/2) bore holes ∅of
12mm x 120 are to be made for seating the dowel
pins.
1 1
2. Unscrew the screws (16/1).
2 2
3. Lift the back gear with an appropriate lifting gear.

! CAUTION
Do not step under load in suspension!

MORTAL DANGER

2 2

1 1

Figure 16

4. Unscrew the set--screws (17/1) and fastening

screws (17/2). 1 1

5. Remove the bearing distance plates (17/3). 2 2

3 3

2 2

1 1

Figure 17

10 / 14 FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 en
6. Position the outside coupling drum (18/3) to the
flange plate (18/1).
The connections for the compressed air supply 1 2 3
(18/2) must align with the according bore holes.

! ATTENTION
While positioning the outside coupling drum, it is re-
quired to pay attention not to damage the sealing rings
at the compressed air supplies.

7. Fasten the outside coupling drum with screws to

the flange plate.
Tightening moment: MA = 180 Nm

Figure 18

8. Place the V--belt for the drive of the hydraulic pump

onto the belt pulley (19/3).
9. Carefully lift the back gear with an appropriate lift-
ing gear, and cautiously move it with the inside
coupling drum (19/2) into the outside coupling
drum (19/1).
1 2
! CAUTION
3
Risk of bruising while positioning.

Figure 19

en FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 11 / 14
 10. Position the bearing distance plates (20/2) be-
tween bearing housing bases (20/1) and bearing
base plates (20/3).
11. Align bearing distance plates and back gear such
that the bore holes (20/4) for seating the dowel pins
are in alignment.
12. Position the back gear onto the bearing distance 1
plate.

2
1 3
4

Figure 20

13. Drive the supplied dowel pins 12.0x120 (21/2) into

the through holes until they are flush with the base
of the bearing housing (21/1).

Figure 21

12 / 14 FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 en
14. Fasten the bearing (22/1) with the screws (22/2).
For tightening moment, see mandatory drawing.

Figure 22

15. Fasten the back gear with the screws (23/2).

For tightening moment, see mandatory drawing.

i INFORMATION
The set--screws (23/1) are of no function and therefore
are not screwed down again.
If required, close the bore holes with sealing caps.
1 2

Figure 23

en FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 13 / 14
 3 Operation and Maintenance

i INFORMATION
For information regarding the Airflex Coupling oper-
ation and maintenance works please, see the manufac-
turer’s instructions of the company KENDRION.
For information regarding maintenance works on the
bearings please, see the SCHOTTEL Instructions.
Id--No. 1160699 SKF bearing
Id--No. 1108613 COOPER bearing
NOTE
For replacing the V--belts for the drive of the hydraulic
pump, it is required to separate the back gear shaft from
the driving branch. For details please, see the separate
mounting instructions.
! ATTENTION
Make sure the back gear input speed does not exceed
1400 rpm when the clutch is disengaged.

Lubricating grease recommendation and grease quantity

Lubricating grease recommendation

! ATTENTION
Do only use Mobilgrease 28!
The lubricating greases mentioned in instructions
1118066 do not have any validity.

Grease quantity
Version with COOPER bearing: 0.2 kg
Version with SKF bearing: 1.4 kg

4 Warranty

The warranty period is fixed in the contract with
SCHOTTEL.
SCHOTTEL will only accept warranty claims within the
fixed period if the following requirements are met:
− Observance of all mounting instructions, safety
regulations and operating instructions.
− Performance of all maintenance works according
to schedule and properly carried out
− Observance of all mounting instructions, safety
regulations and operating instructions.
− Use of the part exclusively for the determined pur-
pose in accordance with the scope of supply.
− Observance of any and all special terms and
regulations that are part of the contract.

14 / 14 FIT--Wa Mounting Instructions for Back Gears with Airflex Couplings 08/1868 1160699 en