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    WAL - 400-500 - XI 80 - en

    Uploaded by

    Kacam Rasan

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    Download as pdf
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    Marine Reverse Reduction Gearboxes Type WAL 400-500 Operating Manual WAL 400-500 /X1/80E EISENWERKE REINTJES G.M.8.H.HAMELN YEAR BUILT REDUCTION DIRECTION OF ROTATON [~ axpur S Loins Frow oureur PROPELLER TO ur ENGINE Aouissia.e INPUT CAPACITY. AW INRIPTOROUE Nom INeur SPEED MN SRE) van ot. wscosty WEIGHTOF GEAR KG rage roma ES ovouanry — xo FERED sacrive Table of Oil Quantities in Litres (approx.} Gear WAL 400500 Reduction 25 28 over 1,15-4,5:1 Reduction . 30 40 over 4,5- Page Table of Contents General Particulars Function Materials and Design Controt Alignment Operation Maintenance Oil Pressure Oil Filter Oil Change Recommended Control Method. Emergency Control Emergency Operation Failures | Spare Parts Elsenwerke REINTJES GmbH 325 Hameln Federal Republic of Germany Post Office Box 567 Telephone 05151/104 - 1 Telex 09 2862 E19 K10 K6 K3 K17 K15 K23 K22 A1 Wi R2 PI /komm-Nr. General particulars General Particulars With REINTJES Marine Reduction Gearboxes with hydraulically operated clutch of Type WAL the power is transmitted by disc clutch and spur wheals, 1 ‘The gearboxes are in vertical or horizontal offset design, To ensure a proper pro- : pelier thrust transmission, they are equipped with e sufficiently dimensioned | thrust bearing. | Counter Rotation The output shaft and thus the propeller shaft rotate in the direction opposite to that of the dirive shaft, ‘The Oil Pump E 19 is driven by Drive Shaft W 1. The pressure oil is delivered through the hollow shaft of Pump E 19 and through the bore of the drive shaft behind Annular Piston K 17. Annular Piston K 17 presses the inside and outside discs K 22 and K 23 together. Through the force-locking of the discs, Pinion R 1 is carried along, and the power is transmitted to output shaft P 1, vie the wheel A 2, When shifting into the STOP position, the clutch is emptied via the non-return valve K 10 and the oil bore. The annular piston K 17 is foread into its original position by return spring K 6, Path of Drive Drive shaft W 1 - clutch cover K 3 - outside-toothed clutch casing K 16 - dises K 22 and K 23 - carrier K 30- pinion R 1 - wheel R 2 - output shaft P 1. Stop Position In the stop position the control valve only diverts the oll to the lube oil pipes and the sump. The annular pistons K 17 are held in their original position by the return springs K 6. Thus, both clutches are disengaged and output shaft P 1 is stationary. Lubrication ‘The oil pressure is built up by gearwheel pump E 19. Sufficient service pressure is available as soon as the engine is started. This pressure is controlled via a spring-loaded and easily adjustable overpressure valve. The ample amount of overflow oil from this valve is used for lubrication. Unlimited operation in the stop position is guaranteed, Direction of Rotation ‘The direction of rotation registered on the nameplate indicates the direction of input rotation and the direction of output rotation as seen in the direction of travel (see illustration of nameplate). If the engine has a direction of rotation different from that indicated on the nameplate, absolutely necessary to check back with the works as the gearbox must then be mo In standard design, the output shaft rotates in the opposite direction to that of the engine, when the control lever is at AHEAD. Materials and design, operation Materials and Design The selection of the most suitable materials, excellent workmanship, and the strength of all parts as well as the sophisticated dasign guarantee a maximum of reliability in service and a long service life. Helical spur wheels made of case- hardened and heat-treated special steel with ground tooth flanks are used. Only anti-friction bearings from reputable manufacturers are installed. All gearbox components manufactured by us are machined in our warks on machines incor- porating the latest engineering features. The clutches of the gearbox are so dimensioned that they can safely transmit the torque in continuous operation. The outside discs are lined with highly wear-resistant Sinter metal and the inside discs have been provided with a sinus. Thus, the sinusoidal shape of the inside discs reduce friction to a minimum when the clutch is not engaged. The gearbox rotors are arranged inside a sturdy oil and dust-proof casing. An amply dimen- sioned thrust bearing has been installed to absorb the propeller thrust. The gearbox is supplied without an oil filling. The inside is anticorrosion treated. In Europe, this anti-corrosion treatment will protect the gearbox for about six months, if itis stored in a dry and temperate room. All bright parts on the outside (flange on the propeller side, drive shaft) are protected by an anti-corrosion agent. All connections (oil and water etc.}, which can- not be fitted until the unit has been installed, are closed with plugs in our works, All connections and pipes which must be modified, i. e. renewed, in the course of installation, should definitely be acidified and cleaned before use. If accessories (filters, coolers, pipes) other than those supplied from our works are used, these must definitely have the same properties as the parts supplied with the gearbox. Adjustable units (pressure limiting valves and perhaps pressure controllers) have been set for the specified pressure befare delivery from our works. Gearboxes are supplied in accordance with the general conditions of the VDMA. Operation Operation can be effected at the gearbox itself or from the wheelhouse by means of a control unit. The transmission élement between the gearbox-mourited con- tro! valve and the control unit in the gearbox can consist of a wire cable with guide rollers or other mechanical connections and hydraulic or pneumatic con- trols. If wire cable and guide rollers are used, it is necessary to ensure that the wire” cable is sufficiently flexiblé and that the rollers have the correct diameter. In the case of remote controls, sufficient adjustability must be possible, since the posi- tions of the deck-mounted control unit must definitely agree with the positions of the control vaive, itis advisable to set the operating facilities of the control valve in such a way that change-over is only possible at an idling speed. For this reason, the installa- tion of a combined control unit is recommended (see Recommended Control). Alignment of the engine to the gearbox shaft must be effected in accordance with the specification of the engine manufacturer. Checking Alignment Upon alignment and tightening of the engine and gearbox foundation bolts, it is advisable to check both bearbox connection flanges for flanging accuracy. For this purpose, the flange fixing bolts must be removed. If the two gearbox connection flanges are nat in parallel alignment, we cannot accept any responsi- bility (guarantee), In the case of all REINTJES Reverse and Reverse Reduction Gearboxes the gearbox shafts on both the propeller side and the engine side are fixed Operation Commencement of Operation ‘The oil to be used must be in accordance with the oil grades specified by the works in the Table of Lubricants. It must be frea from impuritiesas well as molyadenum sulphide and graphite. in many cases, trouble is due to oil conta- mination or wrong lubricants Before commencement of operation, the oil must be filled up to the upper dip- stick mark. The oil quantity is specified on the nameplate. After 5 - 10 minutes of operation, the oil level must be checked again and the oil must be filled up if necessary, as the pipe system is then full. The oil cen Gnly be checked with the aid of the dip-stick E 23, when the plant is shut down, Upon commencement of operation, it is necessary to check if the rate of water flow through the heat exchanger is as specified. The rate of water flow per hour depends on the water inlet temperature, The rate of water flow may be noted from the installation drawing. IMPORTANT Atwater inlet temperatures up to 35°C, the rate of water flow through the heat exchangers is es follows: WT 12 (12,000 keal/h) min, 4000 litres/h max. 4600 litres/h WT 30 (30,000 kcal/h) — min, 6000 Iitres/h max. 7000 litres/h ‘These maximum rates of flow must not be exceeded. If the water inlet tempe- atures are higher than 35° C, it is necessary to check back with the works. ‘Twin Unit Operation If two gearboxes are installed in @ ship and only ane is operated for a long period (more than three hours), either the engine must be operated for about 5 minutes (after 3 hours) or the propeller shaft must be blocked. Maintenance Oil level and oil pressure must be checked daily. Oil Pressure and Pressure Gauge The pressure gauge on the gearbiox indicates the operating pressure, which must be between 18 - 20 bar when the engine is running at full load speed, the clutch is engaged and the temperature is the normal operating temperature. The operating pressure is automatically regulated by a spring-loaded overpres- sure valve and is set by set screw V 13, ifan adjustment is to be carried out, the nut V 12 must be released; the pres- sure is increased by turning the set screw V 13 clockwise and is decreased by turning this screw anti-clockwise. Oil Filter A filter is arranged in the main oil circuit of the gearbox. Cleaning is effected by turning the handle clockwise. Anti-clockwise rotation Of the handle may result in damage to the oil filter elements and must there- fore be avoided. Cleaning should be effected daily and only when the unit is shut down. Whenever the oil is changed, the oil filter should be thoroughly cleaned, For this purpose, the filter pot must be removed The disc must never be taken apart during this work. Oil Change The oil must be changed after about 200 operating hours, the process being as follows: 1. Drain oil upon removal of oil drain screw G 3. 2. Firmly screw in oil drain screw and fill up oil to upper dipstick mark, as specified, 3. Clean oil filter. Oil changes must be carried out every six months or after 1,000 operating hours. Emergency conirol Emergency Control for AHEAD If the pressure oil supply fails, emergency control is possible with the aid of the hexagon screws K 8, For this purpose, the engine must be shut down. Upon removal of the locking wire and release of the hexagon nuts K 9, the hexagon bolts K 8 are to be tightened while the clutch is being rotated evenly. Annular piston K17 presses the disc packet together and the disc clutch is force-locking. Before re-starting the engine, the gearbox control lever must be shifted to STOP. ; Faults Possible causes for high gearbox temperature Possible causes for low operating pressure Possible causes for loss of oil Possible Causes Oil level in gearbox too high Cooler fouled up by brackish water Rate of flow through cooler too low Clutch slips, operating pressure too low Anti-friction bearing damaged Operating pressure too low on account of normal wear Filter blocked Oil level too low Control valve defective Control vaive not set correctly Pump drive or pump damaged Leak in oil inlet pipe Non-return valve defective Oil drain screw not tight Shaft seals not tight Remedial Measures Bring oil to level specified Clean cooler Set correct rate of water flow Adjust operating pressure Renew ani -friction bearing Adjust operating pressure Clean filter Top up oii, locate causa for joss of oil Replace or repair control valve Adjust remote controls Replace pump Replace oil inlet pipe Check non-return valve Fit oil drain screw with new seal and tighten it Replace seal rings,re-seal bearing cap List of Spare Paris Marine Reverse Reduction Gearboxes Type WAL 400-500 Data to be specified in enquiries or orders for spare parts: EISENWERKE REINTJES GMBH. HAMELN 1. Commission Number 2. Gearbox Type 3. Output and Drive Speed of Engin | Homan NaonGue 1 ‘nan oust Seep ‘The commission number is also embossed on the engine side on the lug of the bearing casing (see sectional drawing, page 4). 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