Gearbox SV-320-C.pdf

Issue 1.0 March 2010

i

TECHNICAL MANUAL

GEARBOX DREDGE PUMP

BEAVER 1200

SV-320-C

AEvanderWaarden

Tekstvak

20.11/3


ii

COMPLETE DESCRIPTION

COPYRIGHT

ALL RIGHTS RESERVED THE CONTENTS OF THIS DOCUMENT MAY NOT BE PRINTED, MICROFILMED, PHOTOCOPIED, DIGITALLY REPRODUCED AND/OR PUBLISHED IN ANY FORM WITHOUT THE PRIOR WRITTEN AGREEMENT OF IHC MERWEDE BV. THIS APPLIES TO THE ASSOCIATED ILLUSTRATIONS AND PICTURES TOO. IHC MERWEDE BV RESERVES THE RIGHT TO MAKE MODIFICATIONS TO THIS MACHINE AT ANY TIME WITHOUT NOTICE.

TECHNICAL MANUAL

GEARBOX DREDGE PUMP

BEAVER 1200

SV-320-C

PARTS & SERVICES ORDER Nr: 009086

BEAVER DREDGERS Nr: 02759

In case of correspondence

please indicate above number.


iii

CONTENTS

COMPLETE DESCRIPTION .................................................................................. ii

COPYRIGHT.......................................................................................................... ii

CONTENTS ............................................................................................................. iii

LIST OF FIGURES............................................................................................... vii

LIST OF TABLES ................................................................................................. vii

FOREWORD............................................................................................................ ix

PURPOSE MANUAL............................................................................................. ix

GENERAL CONDITIONS...................................................................................... ix

MANUAL........................................................................................................ ix

OWNERSHIP..................................................................................................x

LIABILITY .......................................................................................................x

WARRANTY ..................................................................................................xi

WARNING SYMBOLS.......................................................................................... xii

CONTACT ADDRESS......................................................................................... xiii

1 | INTRODUCTION ............................................................................................. 1-1

1.1 | GENERAL DESCRIPTION GEARBOX................................................... 1-1

1.1.1 | Gearbox Principle of Operation ......................................................... 1-1

1.1.2 | Gearbox Construction ....................................................................... 1-1

1.2 | STRUCTURE MANUAL.......................................................................... 1-3

2 | SAFETY .......................................................................................................... 2-1

2.1 | SAFETY PRECAUTIONS DURING OPERATION .................................. 2-1

2.2 | SAFETY PRECAUTIONS DURING MAINTENANCE ............................. 2-2

3 | TRANSPORT / STORAGE AND INSTALLATION .......................................... 3-1

3.1 | DELIVERY.............................................................................................. 3-1

3.2 | HANDLING............................................................................................. 3-1

3.2.1 | Shipping............................................................................................ 3-1

3.2.2 | Loading/unloading............................................................................. 3-2


iv

3.3 | STORAGE.............................................................................................. 3-2

3.4 | INSTALLATION ...................................................................................... 3-3

3.4.1 | General ............................................................................................. 3-3

3.4.2 | Alignment of the gearbox .................................................................. 3-3

3.4.3 | Coupling on input shaft...................................................................... 3-4

4 | START-UP ...................................................................................................... 4-1

4.1 | COMMISSIONING.................................................................................. 4-1

4.1.1 | Lubrication ........................................................................................ 4-1

4.2 | START-UP.............................................................................................. 4-1

4.2.1 | START-UP CONDITIONS DIAGRAM ............................................... 4-2

4.3 | SHUT-DOWN ......................................................................................... 4-2

4.3.1 | Short period (2-4 months) ................................................................. 4-2

4.3.2 | Long period (> 4 months) .................................................................. 4-3

5 | SPECIFIC DESCRIPTION MAIN PARTS ........................................................ 5-1

5.1 | Hydraulic clutch ...................................................................................... 5-1

5.1.1 | Description........................................................................................ 5-1

5.1.2 | Technical information ........................................................................ 5-1

5.2 | Oil pump ................................................................................................. 5-3

5.2.1 | Description........................................................................................ 5-3


5.3 | Oil cooler ................................................................................................ 5-4

5.3.1 | Description........................................................................................ 5-4


5.4 | Oil filter ................................................................................................... 5-5

5.4.1 | Description........................................................................................ 5-5


5.5 | Manometer ............................................................................................. 5-7

5.5.1 | Description........................................................................................ 5-7


5.6 | Thermometer .......................................................................................... 5-8


v

5.6.1 | Description........................................................................................ 5-8


5.7 Speed monitoring system ......................................................................... 5-9

5.7.1 | Description........................................................................................ 5-9


5.7.3 | Adjusting preset value..................................................................... 5-11

5.7.4 | Calculation preset value .................................................................. 5-11

5.8 | Pilot operated sequence valve.............................................................. 5-12

5.8.1 | Description...................................................................................... 5-12

5.8.2 | Technical information ...................................................................... 5-12

5.9 | Electronic system.................................................................................. 5-14

6 | INSPECTION................................................................................................... 6-1

6.1 | REGULAR INSPECTION........................................................................ 6-1

6.1.1 | Lubricating oil level............................................................................ 6-1

6.1.2 | Lubricating oil pressure ..................................................................... 6-1

6.1.3 | Oil temperature ................................................................................. 6-2

6.1.4 | Condition of bearing .......................................................................... 6-2

6.1.5 | Breathing .......................................................................................... 6-3

6.2 | PERIODICAL INSPECTION ................................................................... 6-4

6.3 | INSPECTION SCHEDULE ..................................................................... 6-5

7 | TROUBLESHOOTING AND ALARM SETTINGS ........................................... 7-1

8 | Maintenance................................................................................................... 8-1

8.1 | safety precautions................................................................................... 8-1

8.2 | prepare system for maintenance............................................................. 8-1

8.3 | Specific maintenance instructions on gearbox ........................................ 8-2

8.3.1 | Replacement of lubricating oil ........................................................... 8-2

8.3.2 | Maintenance hydraulic clutch ............................................................ 8-3

8.3.3 | Maintenance oil cooler ...................................................................... 8-4

8.3.4 | Maintenance oil filter ......................................................................... 8-7

8.3.5 | Cleaning the outside of the gearbox.................................................. 8-8


vi

Appendix A: After Sales Services .......................................................................... a

| Order address.............................................................................................. b

Appendix B: General Specification........................................................................ c

Appendix C: Lubricants.......................................................................................... e

Appendix D: Parts List ............................................................................................ g

Appendix E: General Arrangement Drawings ...................................................... m

Appendix F: Lubrication system gear box ............................................................ o


vii

LIST OF FIGURES

Figure 1: Sketch hydraulic clutch............................................................................................ 5-1

Figure 2: Overview of important parts of an oil pump............................................................. 5-3

Figure 3: Overall dimension oil filter ....................................................................................... 5-6

Figure 4: Dimensions of manometer ...................................................................................... 5-7

Figure 5: Picture thermometer................................................................................................ 5-8

Figure 6: schematic layout of location inductive sensor on pump shaft ................................. 5-9

Figure 7: Inductive sensor .................................................................................................... 5-10

Figure 8: Circuit diagram speed monitoring system ............................................................. 5-10

Figure 9: Front panel ............................................................................................................ 5-11

Figure 10: Schematic layout pilot operated sequence valve................................................ 5-12

Figure 11: Dimension sketch Pilot operated sequence valve .............................................. 5-13

Figure 12: Order Address .......................................................................................................... b

LIST OF TABLES

Table 1: Start-up conditions diagram...................................................................................... 4-2

Table 2: Parts of the hydraulic clutch ..................................................................................... 5-2

Table 3: Specification oil cooler.............................................................................................. 5-4

Table 4: Specification oil filter................................................................................................. 5-5

Table 5: Specification manometer .......................................................................................... 5-7

Table 6: Technical specification thermometer........................................................................ 5-8

Table 7: Specification speed monitoring system .................................................................. 5-10

Table 8: Calculation preset value speed monitoring system................................................ 5-11

Table 9: Specification pressure sequence valve .................................................................. 5-12

Table 10: Inspection schedule for gearbox ............................................................................ 6-5

Table 11: Troubleshooting and alarm settings ....................................................................... 7-2

Table 12: Example After Sales Order........................................................................................ b

Table 13: General Specification Gearbox ..................................................................................c


ix

FOREWORD

PURPOSE MANUAL

This manual relates to a gearbox for the application in dredging and contains useful

and important information relevant to the correct installation, operation and

maintenance of this product. The instructions in this manual are intended for

technicians, operating personnel and maintenance staff and those who are in charge

of ordering spare parts. It also contains important information on safety procedures

and precautions to be taken to prevent accidents to personnel and damage to the

equipment.

Read the instructions carefully before installation, operation or maintenance is done

on the equipment.

GENERAL CONDITIONS

MANUAL

THE INFORMATION IN THIS MANUAL HAS BEEN CHECKED CAREFULLY AND IS ASSUMED TO BE ENTIRELY RELIABLE. HOWEVER, IHC TAKES NO RESPONSIBILITY FOR INACCURACIES. IHC MERWEDE (OR ASSOCIATED COMPANY) RESERVES THE RIGHT TO CHANGE SPECIFICATIONS OR DESIGN WITHOUT NOTICE.


x

OWNERSHIP

LIABILITY

ALL INVENTIONS, TRADEMARKS, TECHNICAL DATA, DRAWINGS, PLANS, MANUALS, TEST RESULTS AND OTHER MATERIAL PROVIDED BY IHC ARE TO BE CONSIDERED CONFIDENTIAL INFORMATION AND SHALL REMAIN THE EXCLUSIVE PROPERTY OF IHC. (EXCEPT WHEN PROVIDED FOR IN CONTRACT) ALL INFORMATION IS SUPPLIED SOLELY FOR THE OPERATION AND MAINTENANCE OF THE DESIGNATED EQUIPMENT AND THE USER SHALL NOT COPY SUCH MATERIAL, OR COMMUNICATE INFORMATION CONCERNING SUCH MATERIAL TO THIRD PARTIES.

THIS MANUAL IS INTENDED TO SERVE AS A GUIDE FOR THE MAINTENANCE, SERVICING AND/OR REPAIR OF THE EQUIPMENT DESCRIBED THEREIN, AND SHOULD ONLY BE USED BY QUALIFIED PERSONNEL. THE USE OF THIS MANUAL SHALL, UNDER ALL CIRCUMSTANCES, REMAIN THE SOLE RESPONSIBILITY OF THE USER. ON NO ACCOUNT IHC SHALL BE LIABLE FOR ANY OPERATIONAL DELAYS OR DAMAGE, EITHER SPECIAL, INDIRECT, CONSEQUENTIAL OR OTHERWISE.


xi

WARRANTY

EXCEPT WHEN OTHERWISE PROVIDED FOR IN CONTRACT, IHC WARRANTS THEIR EQUIPMENT AGAINST ANY DEFECT OR FAULT, ARISING FROM OR CAUSED BY FAULTY WORKMANSHIP, MATERIAL AND PARTS FOR A PERIOD OF SIX MONTHS FROM THE DATE OF DELIVERY, PROVIDED THAT JUSTIFIED CLAIMS IN WRITING ARE RECEIVED BY IHC WITHIN THIS PERIOD OR AT THE LATEST WITHIN 15 DAYS AFTER THE EXPIRY DATE THEREOF. THIS WARRANTY DOES NOT INCLUDE WEAR ON EQUIPMENT. THE LIABILITY OF IHC WILL BE LIMITED TO THE FREE REPAIR OR REPLACEMENT OF ANY DEFECTIVE PARTS AT THEIR PREMISES. IF THE REPAIR OR THE REPLACEMENT IS CARRIED OUT ELSEWHERE, IHC’s LIABILITY WILL BE LIMITED TO THE AMOUNT THE REPAIR OR REPLACEMENT WOULD HAVE COST IF CARRIED OUT AT IHC’s PREMISES DURING NORMAL WORKING HOURS. SUBJECT TO THE ABOVE STIPULATIONS OF GUARANTEE, IHC SHALL BE RELEASED FROM ANY LIABILITY WHATSOEVER AND THE BUYER SHALL PROTECT AND INDEMNIFY IHC IN RESPECT OF ANY DEMANDS, CLAIMS OR ACTIONS, MADE BY THIRD PARTIES ON ACCOUNT OF DAMAGES AND/OR INJURIES, CAUSED OR ALLEGED TO BE CAUSED BY ANY DEFECT OF GOODS, SUPPLIED BY IHC.


xii

CAUTION!

CAUTION!

WARNING SYMBOLS

This manual contains symbols and text that refer to dangerous situations and

operations. These symbols and text may also appear on the machine. The symbols

mentioned below are being used in this manual and have the following meaning:

THIS SYMBOL INDICATES A SITUATION OR OPERATION

WHERE THERE IS POSSIBLE DANGER TO PERSONNEL.

THIS SYMBOL INDICATES A SITUATION OR OPERATION

WHERE THERE IS A POSSIBLE DANGER TO BURNS

THIS SYMBOL DRAWS ATTENTION TO OPERATING INSTRUC-

TIONS WHICH SHOULD BE ESPECIALLY OBSERVED.


xiii

CONTACT ADDRESS

IHC PARTS & SERVICES B.V.

Smitweg 6, 2961 AW Kinderdijk

P.O. Box 50, 2960 AB Kinderdijk

The Netherlands

Telephone : +31 (0)78 - 6910430

Telefax : +31 (0)78 - 6910439

Internet : www.ihcmerwede.com

E-mail : [email protected]


1-1

1 | INTRODUCTION

This introduction states a general description of the Gearbox Process and

Construction in paragraph 1.1. The structure of this manual is explained in paragraph

1.2

1.1 | GENERAL DESCRIPTION GEARBOX

This paragraph provides a general process and constructional description of the

gearbox.

1.1.1 | Gearbox Principle of Operation

The gearbox consists of a one-step gear wheel transmission. It is driven by a diesel

engine by means of a flexible clutch. The gearbox directly drives the dredge pump,

which is mounted to the housing of the gearbox. The forces which originate from the

dredge pump are transmitted via the gearbox towards the foundation plate.

The gearbox is equipped with a hydraulic clutch on the incoming shaft, which will be

excited when the diesel engine reaches 700 rpm. This enables the gearbox to start-

up in the idle running mode.

After the hydraulic clutch has been engaged the number of revolutions of the diesel

engine can be increased.

In case the number of revolutions of the diesel engine drops below 700 rpm, the

hydraulic clutch will be disengaged automatically. This means that the diesel engine

will be disconnected from the gearbox and the dredge pump.

1.1.2 | Gearbox Construction

The housing of the gearbox consists of nodular cast iron. The teeth of the main gear

wheel are made of case hardening steel. After the hardening the teeth are being

grinded according to DIN 3962 (quality ≤ 6). The shafts of the gearbox are supported

on roller bearings with a minimum lifetime of 30.000 operating hours.

The lubrication of the gearbox is carried out with a lubricator pump, which is driven by

the gearbox itself. The lubrication system consists also of a cooler and an oil filter.


1-2

The lubricant is also used for the hydraulic clutch. First the lubricator pump provides

the pressure, necessary for the engagement of the hydraulic clutch by means of a

special valve. After the clutch has been engaged, the oil pressure is relieved, but

remains high enough to lubricate the gearbox.

A more detailed description about the construction and most important parts of the

gearbox is given in chapter “Specific Description Main Parts”. The main design

parameters and specification for this gearbox are listed in Appendix “General

Specification”. A technical description of the complete lubrication system is given in

Appendix “Lubrication system gear box”.


1-3

1.2 | STRUCTURE MANUAL

This technical manual is divided in 8 chapters, supplemented with specifications,

drawings and schemes. The structure of this manual is explained below.

CONTENTS

The contents consist of a numbered index off all paragraphs in this manual including

a list of figures and a list of tables.

FOREWORD

Description of the purpose of this manual, the general conditions and warning

symbols used and the contact address.

1 | INTRODUCTION

General description of the gearbox process and construction

Overview of the structure of this manual.

2 | SAFETY

General safety instructions during operation and maintenance of this equipment.

3 | TRANSPORT / STORAGE AND INSTALLATION

Instructions for proper transporting, storing and installing this equipment.

4 | START-UP

Instructions for the start-up and shut-down of the equipment.

5 | SPECIFIC DESCRIPTION MAIN PARTS

General description of the main parts and options for this type of equipment.


1-4

6 | INSPECTION

Overview of the most important regular and periodical inspections on the equipment,

including an inspection schedule.

7 | TROUBLE-SHOOTING AND ALARM SETTINGS

Overview of the operating limits for this equipment.

Instructions on how to handle when these limits are exceeded

8 | MAINTENANCE

Maintenance instructions for the most important parts

APPENDICES

Here the general specification, technical drawings and additional information on

options of the equipment can be found, including instructions to order spare parts.


2-1

2 | SAFETY

This chapter provides general safety procedures and precautions that must be

obeyed on operation and maintenance of the gearbox. Specific precautions while

maintaining the installation are given in chapter “Maintenance”.

The purchaser and/or user must make sure all installation, operating and

maintenance personnel understand and obey all safety instructions.

2.1 | SAFETY PRECAUTIONS DURING OPERATION

Obey following safety precautions on operation of the gearbox:

1. Only qualified personnel are allowed to operate the gearbox.

2. This manual is to be read and understood by the operating staff.

3. All personnel have to understand all emergency procedures and have to

know the location of all emergency equipment.

4. Obey the instructions given.

5. Use the gearbox for its designed purpose only.

6. Before operating, make sure no maintenance is being performed on the

system.

7. Report all defects immediately.


2-2

2.2 | SAFETY PRECAUTIONS DURING MAINTENANCE

Before maintaining the system, first read the following precautions carefully:

1 Turn off all the electrical and hydraulic activators.

2 Place sign:

On all control units linked with the system, like the control desk on the bridge, but

also all main electrical and hydraulically switches.

3 Use electronically communication systems when working in remote areas.

4 Before working on the hydraulic system, make sure the pressure is down.

5 Obey all instructions given in this manual.

6 Only qualified personnel are allowed to work on the installation.

7 Always use suitable protective clothing.

8 Always use the correct tools and Genuine IHC Spare Parts.

9 Make sure the area is clear of unnecessary personnel, equipment, parts and

tools.

10 Never stand underneath heavy parts being lifted.

11 Do not start welding on the gearbox without consulting IHC Parts & Services.

12 Use special equipment before working on high wear-resistance materials.

13 Do not modify the system before written approval is given by the manufacturer.

DO NOT OPERATE

APPLY NO POWER

SYSTEM IS BEING MAINTAINED!


3-1

3 | TRANSPORT / STORAGE AND INSTALLATION

3.1 | DELIVERY

Before leaving the factory the condition and operation of the gearbox is tested by

submitting the installation to running tests. After the tests are executed, the gearbox

is carefully cleaned. The shafts and gears are preserved with special oil. This

conservation oil will dissolve in the lubricating oil used during normal operation.

Each gearbox is provided with a nameplate showing the main design parameters.

These parameters are also listed in the appendix “General Specification”.

In order to keep full guarantee and maintaining the perfect condition of the gearbox

the following terms should be respected:

Unauthorised conversion and modifications on the gearbox are not

permitted;

Before disassembling the gearbox or any other part of the gearbox,

the manufacturer has to be notified.

3.2 | HANDLING

3.2.1 | Shipping

The gearbox is shipped in the assembled state. The method of shipping determines

the type of material used for packing the gearbox.

The contents of the shipment are listed in the shipping documents. The shipment

should be checked for completeness and possible damage immediately on receipt. If

necessary, the manufacturer should be consulted.


3-2

CAUTION!

CAUTION!

WHEN HANDLING, LOADING AND UNLOADING THE

GEARBOX MAKE SURE NO EXCESSIVE FORCES ARE

APPLIED ON THE GEARBOX, TO AVOID DAMAGE.

DAMAGED GEARBOXES MUST NOT BE PUT INTO

OPERATION.

3.2.2 | Loading/unloading

Loading or unloading of the gearbox is done best with the lifting eyes which are

located on the gearbox. The ones, which can be used for hoisting the gearbox, are

indicated on the general arrangement drawing. Lifting is carried out with at least three

of these eyes.

WHEN HOISTING: ALWAYS USE APPROPRIATE LIFTING

TOOLS. MAKE SURE NOBODY ENTERS THE HOISTED AREA.

WHEN LIFTING KEEP THE GEARBOX IN A HORIZONTAL

POSITION

3.3 | STORAGE

The gearbox should be stored in a dry room with minimum temperature fluctuation.

The drive should be stored in a horizontal position free from the floor, preferably in its

original support frame.

Initially the gearbox is provided with internal preservation (see also paragraph 3.1). In

case of a prolonged storage (> 4 months) the preservation should be checked and if

necessary renewed (IHC Parts and Services may be consulted).


3-3

3.4 | INSTALLATION

3.4.1 | General

This chapter describes the method of installation of the gearbox.

NOTE: THE INSTALLATION OF THE GEARBOX SHOULD BE

CARRIED OUT BY SPECIALISTS ONLY AND THE INSTALLATION

PROCEDURE SHOULD BE EXECUTED WITH EXTREME ACCURACY.

3.4.2 | Alignment of the gearbox

The following procedure should be carried out for the proper alignment of the

gearbox:

1 The gearbox is to be levelled horizontal and mounted stress free. The foundation

bolts are kept loose;

2 The in- and output shafts of the gearbox must be aligned with great accuracy.

The driving and driven shafts should be aligned both vertical and horizontal. This

can be achieved by using shims and wedges. These are applied between the

foundation and the mounting plates of the gearbox, motor and driven unit.

Special attention must be paid to proper cleaning of the foundation and the

mounting plates of the gearbox and the motor as well as the driven units;

3 When the shafts have been aligned in both horizontal and vertical direction, the

deviation is measured. The maximum allowable deviation is not allowed to

exceed 0.05 mm. (The effect of the weight of the overhanging couplings on the

shaft may not be neglected!);

4 The thickness of the shims used is determined by measuring the height between

the foundation and the mounting plates of the gearbox. The shims are to be

made out of one piece and should be machined to the correct thickness;

5 Now the foundation bolts are tightened to the correct moment;

6 The alignment of the shafts is to be checked again. If the alignment is correct,

proceed with the next step, otherwise loosen the bolts again and the steps 2-5

have to be repeated;


3-4

CAUTION!

7 The holes for the dowel pins are reamed and the pins are fitted;

8 Upon completion and before commissioning, the alignment is to be checked

again. If the deviation is too large, the above mentioned procedure is to be

repeated.

USE APPROPRIATE LIFTING TOOLS WHEN LIFTING THE

GEARBOX.

3.4.3 | Coupling on input shaft

The connection between the input shaft of the gearbox and the driving shaft of the

engine is by means of a coupling. The type of coupling used, is a coupling with

sunken keys.


4-1

4 | START-UP

4.1 | COMMISSIONING

4.1.1 | Lubrication

Before commissioning, the gearbox should be topped up with lubricating oil. (For the

recommended lubricating oil, see Appendix “Lubricants”)

4.2 | START-UP

When the system is started, the gearbox should be operated first without any load.

During this test run the gearbox is being checked on proper functioning. The start-up

conditions are displayed in the start-up conditions diagram (Table 1). In case of a

possible defect consult chapter “Troubleshooting and Alarm Settings”.

After this load-free test run, the load should be gradually increased to the normal

level.


4-2

4.2.1 | START-UP CONDITIONS DIAGRAM

The start-up conditions diagram contains the most important conditions for the

lubrication system, which have to be met when starting up the gearbox.

Start–up conditions

Parameter Sensor Condition

Before start-up

Lubricating oil temperature Thermometer > 15°C

Lubricating oil level Dipstick Level at high mark on dipstick

Conditions before clutching the gearbox

Lubricating oil pressure Manometer (0-6 bar) > 0.5 bar

Lubricating oil temperature Thermometer < 70°C

Conditions after clutching the gearbox

Lubricating oil pressure Manometer (0-6 bar) > 2.5 bar

Lubricating oil temperature Thermometer < 70°C

Table 1: Start-up conditions diagram

4.3 | SHUT-DOWN

4.3.1 | Short period (2-4 months)

In case the gearbox will not be used for a rather short period (2-4 months), the

following measures should be taken to preserve the gearbox:

• The used lubricating oil should be replaced with fresh lubricating oil (see

paragraph 8.3.1);

• The outer surface of the drive is cleaned (see paragraph 8.3.5);

• It is recommended that the shafts will be rotated at least once a month in order to

lubricate all rotating parts of the gearbox.


4-3

4.3.2 | Long period (> 4 months)

When the gearbox is taken out of operation for a longer period, the following

additional measures have to be taken:

• Drain the lubricating oil and clean the gearbox with a similar type of lubricating oil;

• Preserve the gearbox with a special type of preserving oil, which forms a

protective coating against corrosion;

• Grease the in- and output shafts;

• Close all openings with plugs.

The recommended lubricating oils are displayed in the Appendix “Lubricants”.


5-1

5 | SPECIFIC DESCRIPTION MAIN PARTS

This chapter provides a more specific description of the main parts of the gearbox.

5.1 | HYDRAULIC CLUTCH

5.1.1 | Description

The hydraulic clutch (425) inside the gearbox consists of a multi plate clutch. The

plates are pressed with lubricating oil by means of a piston. This results in a friction

connection between the outer housing and the hub of the clutch. When the pressure

is released the piston is pushed back by compression springs and the plates will be

separated from each other.

The hydraulic clutch is equipped with metal oil catchers. These oil catchers have a

very precise tolerance. Leakage is restricted to a minimum.

All external bolts on the hydraulic clutch are provided with Loctite bearing.

5.1.2 | Technical information

Figure 1: Sketch hydraulic clutch


5-2

Pos Description Pos Description

1 Housing 7 External lamination

2 Housing piston 8 Internal lamination

3 Hub 9 Outer piston packing ring

4 Pressure plate 10 Inner piston packing ring

5 End plate 11 Pressure ring

6 Piston 12 Drive shaft

Table 2: Parts of the hydraulic clutch


5-3

5.2 | OIL PUMP

5.2.1 | Description

The lubricating system of the gearbox is equipped with an oil or lubricator pump (601)

for pumping the lubricating oil around in the system. The oil pump is mounted on the

gearbox and is directly driven by the diesel engine by means of a pinion wheel (303)

on the incoming shaft of the gearbox.


Figure 2: Overview of important parts of an oil pump


5-4

5.3 | OIL COOLER

5.3.1 | Description

While running, heat is developed inside the gearbox due to friction. This causes the

warm-up of the lubricating oil. The oil cooler is used to dissipate the developed heat

by cooling the lubricating oil with water to prevent the system from overheating. The

cooler is a shell and tube type heat exchanger. On the water side the cooler is

equipped with anodes to protect the cooler against corrosion.


Oil cooler type:

Process data Unit Hot side Cold side

Type of fluid [-] Lubricating oil water

Flow [m3/h] 4.2 2

Design pressure [bar(g)] 16 10

Design temperature [°C] 120 80

Connection inlet [-] N1 (1 ½” BSP) N3 (1½” BSP)

Connection outlet [-] N2 (1 ½” BSP) N4 (1½” BSP)

Anode protection [-] no yes

O-ring [-] NBR NBR

Table 3: Specification oil cooler


5-5

5.4 | OIL FILTER

5.4.1 | Description

The gearbox is equipped with a pressure oil filter type DF160 MA. The filter is used

for filtering the lubricating oil. Table 4 displays the general specification of the filter.


Oil filter type: DF160MA

Description Value Unit

Filter Material Stainless steel wire mesh [-]

Size: filter and element 160 mm

Operating pressure 250 bar

Type of connection 2 mounting holes [-]

Filtration rating in µm 25 µm

Type of clogging indicator with steel blanking plug [-]

Type Code 1 version with 1-piece bowl [-]

Supplementary details - [-]

Temperature range -30 to 100 °C

Table 4: Specification oil filter


5-6

Figure 3: Overall dimension oil filter


5-7

5.5 | MANOMETER

5.5.1 | Description

Manometers are installed to measure the pressure of the lubricating system at

various places.

These meters are liquid filled manometers. The liquid inside the manometer absorbs

the vibrations in the measuring system caused by tremors, pressure drops and

pressure pulses. This results in a higher accuracy for the reading of the meter.

Another effect is the lubricating property of the liquid, which increases the life-time of

the manometer.


Figure 4: Dimensions of manometer


Type ∅ 63 Kl. 1.6 [-]

Connection 1/4” BSPP [-]

Fluid in manometer Glycerine [-]

Operating temperature 0 to 60 [°C]

Range 0 to 6 and

0 to 40

bar

Table 5: Specification manometer


5-8

5.6 | THERMOMETER

5.6.1 | Description

The thermometer on the gearbox is installed to measure the outgoing temperature of

the lubricating oil of the oil cooler.


Figure 5: Picture thermometer


Type of thermometer Glass tube (straight) [-]

Scale range 0 to 120 [°C]

Connection ½” BSPP [-]

Accuracy according to DIN16184, 16188, 16193 [-]

Insert Brass

Max. Pressure 16 bar

Table 6: Technical specification thermometer


5-9

5.7 SPEED MONITORING SYSTEM

5.7.1 | Description

The speed monitoring system consists of an inductive sensor and a monitoring

system. The sensor is positioned on the cover of the outgoing shaft. In the outgoing

shaft a number of holes are present. During operation of the gearbox the sensor

counts the number of holes and sends a signal to the monitoring system. The

monitoring system records the measurements of the sensor and converts these

signals into the speed of the outgoing shaft. This measured speed is compared with

the preset value. If the measured value drops below this preset value the gearbox is

shut-down automatically.

During the start-up procedure of the gearbox the monitoring has a fixed time lag to

prevent that the system is shut down premature before it even reaches the preset

value. The preset value is already set by the manufacturer.


Pos. Description

1 Inductive sensor

2 Cover output shaft

3 Hole 6x

4 Output shaft

Figure 6: schematic layout of location inductive sensor on pump shaft


5-10

Figure 7: Inductive sensor

Type of speed monitor MS24-R

Function Under speed detection

Speed range 0.6….100.000 min-1

or 0.01….1660 Hz

Fixed time lag 0.5…….30 s (adjusting screw)

INPUT CIRCUIT: NAMUR according to EN50227

Sensors 3-wire pnp

OUTPUT CIRCUIT 2 relay outputs; 1 pulse output

LED-indications

Power (2-color LED) Power ON: green / FAULT: red

Output excitation Yellow

Input pulse Yellow

Table 7: Specification speed monitoring system

Figure 8: Circuit diagram speed monitoring system


5-11

5.7.3 | Adjusting preset value

Figure 9 displays the front panel of the monitoring system. By means of adjusting

screws the preset value can be altered. The general specification and ranges of the

monitoring system are displayed in Table 7.

Figure 9: Front panel

5.7.4 | Calculation preset value

Pos. Description Formula/Unit Value

(a) Disengage value clutch [rpm] 224

(b) No. of holes in output shaft [-] 6

(c) Switching frequency (a) x (b) / 60 22.4 Hz.

(d) Setting value frequency [mHz] 100

(e) Setting value disengage clutch (c) : (d) 224

Table 8: Calculation preset value speed monitoring system


5-12

5.8 | PILOT OPERATED SEQUENCE VALVE

5.8.1 | Description

The pilot operated sequence valve is a pressure relief valve with which the required

pressure to operate the clutch can be adjusted. The set pressure can be read from

the manometer. The sequence valve consists of an internal pilot and an external

drain. The hysteresis is limited to a minimum of ± 1%.


Figure 10: Schematic layout pilot operated sequence valve

pilot operated sequence valve type: RSHC-LAN


Adjustment range 2 to 25 bar

Standard set pressure 14 bar

Typical response time 10 ms

Control Standard screw adjustment

Type of seals Buna-N

Table 9: Specification pressure sequence valve


5-13

Figure 11: Dimension sketch Pilot operated sequence valve


5-14

5.9 | ELECTRONIC SYSTEM

The connection scheme for the electronic system can be found in appendix E

General Arrangement Drawings.

In case of an electronic failure IHC Parts & Services may be consulted.

NOTE: The electronic system of the gearbox is already pre-installed

and connected by the manufacturer. It is not allowed to change

anything on the electronic system without permission of IHC Parts &

Services.


6-1

CAUTION!

6 | INSPECTION

6.1 | REGULAR INSPECTION

6.1.1 | Lubricating oil level

Before the gearbox is started up, the lubricating oil level should be checked. The oil

level is measured by means of a dipstick. This dipstick is provided with an upper and

a lower mark. 2 hours after each operation the oil level should be at the high mark.

WHEN CHECKING OIL LEVEL WITH DIPSTICK, MAKE SURE

THE GEARBOX IS SECURED TO PREVENT FROM

ACCIDENTAL START-UP. AFFIX LOCK OR NOTICE AT THE

SWITCH-ON LOCATION.

6.1.2 | Lubricating oil pressure

When the pressure in the piping is lower than 0.5 bar , the system must shut down

the whole installation, after the discharge pipeline is free of sand. (See chapter

“Troubleshooting and Alarm Settings” for possible causes, IHC Parts & Services may

be consulted in this case). The pressure can be read from one of the manometers

installed on the gearbox.


6-2

CAUTION!

CAUTION!

6.1.3 | Oil temperature

The temperature of the lubricating oil will be around 55ºC under normal operations.

The temperature of the lubricating oil may rise temporarily as high as 60ºC due to an

increased load on the gearbox. This should not cause any damage to the system.

When the temperature exceeds 70ºC, the clutch has to be disengaged.

The cause of this high temperature must be found in any case. Assistance from IHC

Parts & Services may be consulted for detecting the cause. (See also chapter

“Troubleshooting and Alarm Settings”)

6.1.4 | Condition of bearing

Bearings should be in good condition for optimal performance of the installation.

Therefore the condition of all bearings should be checked regularly.

The bearings should be checked also in the following events during operation:

• The housing temperature close to the bearing exceeds 60ºC;

• The gearbox makes an abnormal noise;

• Abnormal vibrations from the gearbox occur.

WHEN CHECKING BEARINGS, MAKE SURE THE GEARBOX IS

SECURED TO PREVENT FROM ACCIDENTAL START-UP.

AFFIX LOCK OR NOTICE AT THE SWITCH-ON LOCATION.

WHEN CHECKING BEARINGS, WEAR PROTECTION GLOVES

TO PREVENT AGAINST BURNS, BEARINGS CAN BE HOT!


6-3

CAUTION!

6.1.5 | Breathing

During normal operation, the air inside the gearbox is heated up due to friction

energy. This causes a certain amount of overpressure. A high overpressure could

cause oil leakage through the seals. Breathing caps are installed on the gearbox,

which will open automatically when the pressure is too high. These breathing caps

should be checked regularly on clogging and they should be cleaned when

necessary.

WHEN CHECKING BREATHING CAPS, MAKE SURE THE

GEARBOX IS SECURED TO PREVENT FROM ACCIDENTAL

START-UP. AFFIX LOCK OR NOTICE AT THE SWITCH-ON

LOCATION.


6-4

CAUTION!

6.2 | PERIODICAL INSPECTION

Every 5000 hours of operation or at least once a year, the gearbox needs to be

inspected carefully. The following procedure is carried out:

1. The gearbox is shut off and prevented from accidental start-up;

2. The inspection cover(s) is/are removed to allow inspection inside the gearbox;

3. When necessary the oil is changed (see paragraph 8.3.1);

4. The breathing caps are checked for clogging;

5. The tooth flanks are checked visually or by marking the teeth with Talbot Blue

again;

6. Bolts and nuts are checked for tightness. If necessary, they are tightened to the

correct moment.

After 30.000 or 40.000 hours of operation, or when necessary, it is recommended to

submit the gearbox to a major overhaul. For this overhaul, IHC Parts & Services may

be consulted.

BEFORE STARTING PERIODICAL INSPECTION, MAKE SURE

THE GEARBOX IS SECURED TO PREVENT FROM

ACCIDENTAL START-UP. AFFIX LOCK OR NOTICE AT THE

SWITCH-ON LOCATION.


6-5

6.3 | INSPECTION SCHEDULE

Type of inspection Frequency Remedy

Observe/check oil level Daily, before start-up paragraph 6.1.1

Visual check for oil leakage Daily, during operation

Observe/check oil

temperature

Daily, during operation paragraph 6.1.2

Observe/check oil pressure Daily, during operation

Check bearing failure Daily, during operation paragraph 6.1.4

Check breathing cap At least once a week paragraph 6.1.5

Check seals visually At least once a week

Initial oil change after start-

up

After 500 operating hours paragraph 8.3.1

Take lubrication oil sample

to check contamination

At least once a month

Check lubricating oil filter

for contamination

At least once a month paragraph 8.3.4

Subsequent oil change Every 5000 operating hours

or once a year

paragraph 8.3.1

Complete inspection of all

parts

Every 5000 operating hours

or once a year

paragraph 6.2

Check all bolts and nuts for

tightness

Every 5000 operating hours

or once a year

paragraph 6.2

Major overhaul of whole

Gearbox

Every 30.000 to 40.000

operating hours

paragraph 6.2

Table 10: Inspection schedule for gearbox


7-1

7 | TROUBLESHOOTING AND ALARM SETTINGS

PROBLEM POSSIBLE CAUSE(S) REMEDY

Gearbox does not

start running or

starts with great

difficulty

• Break of motor is not

released

• External loading on

output shaft too high.

Pump may be blocked

• Viscosity of lubricating oil

is too high

• Release break

• Check if pump is

blocked

• Change lubricating oil

with fresh oil

Excessive operating

temperature gearbox

(T>70°°°°C)

• Lubricating oil level too

high in gearbox

• Lubricating oil is

contaminated or old

• check oil level and drain

the oil if necessary


Low lubricating oil

pressure (P<0,5 bar)

• Oil pump defect

• Oil level too low

• Check if oil pump is

running

• Check oil level and refill

if necessary

Abnormal noises in

gearbox while

running

• Bearing is defect • Consult IHC Parts &

Services when

replacing

Visible leakage of

lubricating oil

• Oil catcher is defect

• Seals are mounted

wrongly

• Breathing caps are

clogged

• Accumulation of dirt

around seals

• Check oil catcher;

replace if necessary

• Check mounted of seals

• Check breathing caps,

clean if necessary

• Remove dirt from seals

and surroundings


7-2

PROBLEM POSSIBLE CAUSE(S) REMEDY

Large vibrations in

gearbox

• Mounting of gearbox has

loosened

• Check bolts and nuts on

loosening; tighten if

necessary

Clutch slips while

running and

connects not entirely

• Lubricating oil pressure

too low

• Stroke of piston too large

as a result of worn plates

• Viscosity lubricating oil

too high

• Check oil level; refill if

necessary

• The multi-plates need to

be replaced (consult

IHC Parts & Services)


Increased noise level

oil pump

• Low oil level in gearbox


too high

• Check oil level; refill if

necessary


Increase in

volumetric losses


too low


Thermal

performance oil

cooler too low

• Accumulation of air

inside cooler and/or

network of pipes

• Oil cooler is

contaminated

• De-aerate whole

cooling system.

• Clean oil cooler

Table 11: Troubleshooting and alarm settings


8-1

CAUTION!

8 | Maintenance

This chapter gives information about maintenance of the main parts that are

described in chapter 1.

8.1 | SAFETY PRECAUTIONS

OBEY THE GENERAL SAFETY PRECAUTIONS STATED IN

CHAPTER 2 AND THE SPECIFIC SAFETY PRECAUTIONS

GIVEN IN THIS CHAPTER BEFORE WORKING ON THE

SYSTEM! NEGLECTING THIS CAN RESULT IN SEVERE

PERSONAL INJURIES AND/OR DAMAGE.

8.2 | PREPARE SYSTEM FOR MAINTENANCE

• Place sign:

On all control units linked with the system, like the control desk on the bridge, but

also all main electrical and hydraulically switches.

DO NOT OPERATE

APPLY NO POWER

SYSTEM IS BEING MAINTAINED!


8-2

8.3 | SPECIFIC MAINTENANCE INSTRUCTIONS ON GEARBOX

8.3.1 | Replacement of lubricating oil

The lubricating oil needs to be replaced after the first 500 operating hours. After this,

every 5000 operating hours or once a year replacing the lubricating oil has to be

carried out.

The following procedure is carried out for changing the oil:

1. The gearbox is shut down by shutting down the drive unit and the gearbox is

being prepared for maintenance;

2. A suitable receptacle is placed underneath the oil drain plug (110) of the

gearbox housing;

3. The vent plug (111) on top of the gearbox housing is unscrewed;

4. The oil drain plug is unscrewed and the lubricating oil is drained;

5. The gearbox is flushed with the same type of oil or special flushing oil which is

heated up to 50ºC. This is to remove residues of old oil and abraded particles.

(Due to the composition of fresh lubricating oil the gearbox should not be

flushed with gas oil or paraffin.);

6. The oil drain plug is screwed in;

7. The gearbox is refilled with fresh lubricating oil through the filling filter plug.

(During refilling, make sure no dirt or water is entering the gearbox). The

recommended type and quantity of lubricating oil are given in Appendix

Lubricants;

8. The oil level is checked (see paragraph 6.1.1).

NOTE: THE LUBRICATING OIL IN THE GEARBOX IS TO BE DRAINED

OFF DIRECTLY AFTER SHUTDOWN, WHILE THE OIL IS STILL

WARM;


8-3

CAUTION!

CAUTION!

MAKE SURE THE DRIVE UNIT IS SECURED TO PREVENT

FROM ACCIDENTAL START-UP. AFFIX NOTICE AT THE

CONTROL DESK.

WHEN CHANGING OIL ALWAYS WEAR PROTECTION

GLOVES AND CLOTHING, HOT OIL CAN CAUSE BURNS ON

THE SKIN.

8.3.2 | Maintenance hydraulic clutch

Adjustment of the stroke of the piston:

The adjustment of the stroke of the piston is not necessary, because the piston

automatically corrects for any wear on the multi-plate package.

In case the stroke of the piston is close to the maximum stroke as a result of wear,

the multi-plates package needs to be replaced. Consult IHC Parts & Services on

replacing the multi-plate package.


8-4

8.3.3 | Maintenance oil cooler

8.3.3.1 | Inspection of the cooler:

The accumulation of dirt inside the cooler depends to a great extent on the operating

conditions. It is recommended by the manufacturer that the cooler is inspected

regularly on dirt:

• Every three months the coil of the cooler

• Every half year the shell of the cooler

Together with the inspection of the coil the anodic protection is to be inspected also.

In case the anodic protection is not sufficient anymore, IHC Parts & Services may be

consulted.


8-5

CAUTION!

CAUTION!

CAUTION!



CONTROL DESK.

8.3.3.2 | Cleaning of the cooler

Removing dirt inside the cooler can be carried out in two ways:

1) The coil inside the cooler can be cleaned by means of special brushes. Use

only this special type of brush, otherwise the protecting layer on the tubes

might be damaged.

2) The tubes and shell can also be cleaned with a chemical solution, which is

flushed through the cooler or the coil is taken and put into a tank with the

chemical solution. In the latter case the plastic dams on the shell side of the

cooler are being removed.



CONTROL DESK.

8.3.3.3 | De-aeration of the cooler

In case air has been accumulating inside the cooler, the cooler needs to be de-

aerated. The cooler is equipped with two air relief valves: One for the lubricating oil

side (N5) and one for the coolant side (N6). These air relief valves have to be opened

one at the time for de-aerating the system

De-aeration is carried out during normal operation of the gearbox.


8-6

WHEN DE-AERATING THE COOLING SYSTEM BEWARE OF OVERPRESSURE

INSIDE THE SYSTEM. HOT GASSES AND FLUIDS MAY CAUSE SEVERE BURNS

ON EXPOSED BODYPARTS

8.3.3.4 | Putting out of service:

In case the oil cooler is put out of service for more than one week, the cooler has to

be drained entirely and dried with heated compressed air.

8.3.3.5 | Anodes of the cooler

The oil cooler have two anodes which are screwed on both sides. These anodes

must be checked every month.

Anode 1: a new one, Anode 2: should be replaced if a high consumption of the

anodes has been determined, Anode 3: need to be replaced immediately, Anode 4:

need to be replaced immediately.

Please note that above example is indicative only, the user still remains responsible

for the estimation, when anodes need to be replaced.


8-7

CAUTION!

8.3.4 | Maintenance oil filter

The oil filter has to be cleaned regularly. 24 hours after commissioning the gearbox,

the oil filter must be checked for the first time. This is then to be repeated every 500

operating hours or at least once a month.

Cleaning is carried out by taking the filter element out of the filter and cleaning the

element. This can be carried out only a limited number of times. When the element

cannot be cleaned properly anymore, the filter element should be replaced.

The maximum mesh width of the filter is 25 micron. In case the mesh with exceeds

the maximum value it should be replaced.



CONTROL DESK.


8-8

CAUTION!

8.3.5 | Cleaning the outside of the gearbox

Keep the gearbox free from dirt and dust to guarantee sufficient dissipation of heat.

NOTE: IT IS NOT PERMISSIBLE TO CLEAN THE GEARBOX WITH A

HIGH-PRESSURE SPRAYER OR SHARP-EDGED TOOLS



CONTROL DESK.


a

Appendix A: After Sales Services

To maintain the high quality level of the Gearbox constructed by IHC, Genuine IHC

Spare Parts should be used.

The IHC products are fully tested before delivery and guaranteed for the performance

and quality of materials.

IHC strongly recommends using these original spare parts in its products, because

they are designed to meet their specific demands. Using non-genuine parts can

result in reduced performance, damage and limited liability.

The high grade of standardisation of the parts guarantees the interchange-ability of

any subsequently delivered part of IHC components.

To be sure that the correct spare parts will be supplied in the most efficient way, it is

necessary to supply the following information of the desired part in each order:

• The Reference Number of the Manual where the part is described;

This number can be found on the front page of this manual.

• The full description of the part,

• The Item Number of the desired part from the Manual;

• The Quantity of parts needed.


b

Example:

ITEM QTY DESCRIPTION

212 4 BUSH

210 2 PIN

Table 12: Example After Sales Order

| Order address

Orders for Spare Parts should be addressed to:

Figure 12: Order Address

IHC PARTS & SERVICES B.V.

Smitweg 6, 2961 AW Kinderdijk

P.O. Box 50, 2960 AB Kinderdijk

The Netherlands

Telephone : +31 (0)78 - 6910430

Telefax : +31 (0)78 - 6910439

Internet : www.ihcmerwede.com

E-mail : [email protected]


c

Appendix B: General Specification

Below are the most important design parameters of the gearbox listed. These are

also displayed on the nameplate.

Table 13: General Specification Gearbox

1 Lubricant not included

DESIGN PARAMETER VALUE UNIT

Rated Power : 638 kW

Input speed : 1800 rpm

Output speed : 577 rpm

Gear rating : 1 :3.12 [-]

Input shaft connected to Diesel Engine [-]

Output shaft connected to Dredge Pump [-]

Lifetime Bearings 30000 hrs

Type of lubricating oil ISO VG 100 [-]

Amount of lubricating oil to be used 130 litres

Total weight installation1 1800 kg

IHC P & S Order number 009086 [-]

Year of Manufacturing 2010 [-]


e

Appendix C: Lubricants

It is recommended by IHC Parts & Services to use one of the below listed lubricants

for the lubrication of the gearbox

LUBRICATING OIL

IN ACCORDANCE WITH DIN 51502

MINERAL OIL

VISCOSITY CLASS CLP ISO VG100

NUTO H100

Mobil DTE OIL 27

Tellus T100

BP energol HLP 100

Renolin CPL 100

Castrol HYSPIN

AWH100

Further suitable lubricants of the brands ADDINOL, OMV, STATOIL, TEXACO,

TUNAP and VALVOLINE we are pleased to nominate on request at one of our

Service Addresses.


f

Mineral base gear oils in accordance with designation CLP as per DIN 51 502.

These oils comply with the minimum requirements as specified in DIN 51 517 Part 3.

They are suitable for the following operating temperatures:

CLP ISO VG 100: –5°C ... +90°C

The maximum temperatures can be exceeded by 10K for a short time.

STORAGE OIL

IN ACCORDANCE WITH DIN 51502

STORAGE OIL

VISCOSITY CLASS CLP ISO VG100

SHELL VSI 8235


g

Appendix D: Parts List

Posnr Quantity Description

101 1 GEARBOX HOUSING

102 2 BOLT

103 2 BOLT

104 4 BOLT

105 18 BOLT

106 2 DOWEL PIN

107 2 NUT

108 3 STRETCHING PIN

109 4 BOLT

110 2 PLUG WITH INT. HEXAGON

111 1 DE-AERATION

112 6 BOLT

113

114 2 INSPECTION COVER


116 28 BOLT

117

118 1 COVER

119 8 BOLT

120

121 1 COVER

122 16 BOLT

123 2 DOWEL PIN

127 1 COVER

128 5 BOLT

130 1 COVER

131 10 BOLT

132


h

133 1 NAMEPLATE

134 4 CYLINDER HEAD SCREW

135 1 V-RING

136 1 V-RING

137 1 COVER

138 6 BOLT

139 1 SPACING RING

140 1 COVER

141 6 TAPBOLT

142 1 RING

143 8 SPRING

144 1 STRETCHING PIN

146 1 KEY

147 1 SCREW

150 1 OIL DIPSTICK

151 1 O-RING

153 1 TURNING ROD

301 1 PINION SHAFT

302 1 GEARWHEEL

303 1 PINION

304 1 GEARWHEEL

401 1 INPUT SHAFT

402 1 SPACING RING

403 1 KEY

404 1 SAFETY RING

405 1 SAFETY RING

406 1 OUTPUT SHAFT

407 1 SHRUNK-RING

408 1 RING

409 1 RING

410 1 OIL SUPPLY RING

411 3 O-RING


i

412 1 SAFETY BOLT

414 1 END-JOURNAL

415 2 KEY

416 1 KEY

417 1 KEY

418 1 KEY

419 1 RETAINING RING

420 6 BOLT WITH INTERNAL HEXAGON

421 3 DOWEL PIN

423 1 SAFETY RING

425 1 HYDR COUPLING

426 1 COUPLING

427 2 SCREW

501 1 SPHERICAL ROLLER BEARING





506 1 CYLINDER BEARING

507 1 GROOVE BALL BEARING

508 2 GROOVE BALL BEARING

601 1 GEARPUMP

602 1 OIL COOLER

603 1 CONNECTION BLOCK

604 3 THROTTLE

605 3 THROTTLE

606 1 THROTTLE

607 1 THROTTLE

608 4 BOLT

609

610 1 DELIVERY PIPELINE

611 4 BOLT


j

613 1 SUCTION PIPELINE

614 1 SUCTION PIPELINE

615 4 BOLT

616

618 1 FRAME

619 4 BOLT

620 6 BOLT

621 10 NUT

622 4 BOLT

701 1 CONNECTION BOX


703 12 SCREW


705 6 END PIECE

706 63 CONNECTING PIECE

707 12 DIVIDING PIECE

708 1 NAME STRIP

709 1 NAME STRIP

710 1 NAME STRIP

711 1 SPEED COUNTER

712 1 ROTATION SPEED MONITOR

713 2 BUSHING

714 4 SEAL PLATE

715 2 SEAL PLATE


k

1.00 1 MANIFOLD

1.01 1 PRESSURE LINE FILTER

1.02 1 PRESSURE GAUGE

1.03 1 PRESSURE RELIEF VALVE

1.04 1 DIRECTION CONTROL VALVE


1.06 1 NON RETURN VALVE


1.09 1 TEMPERATURE GAUGE

1.10 1 MEASURING POINT


m

Appendix E: General Arrangement Drawings

The following drawings are enclosed in this technical manual:

DESCRIPTION DRAWING NO.

ASSEMBLY 5483892

ARRANGEMENT 50403540

OIL CIRCUIT SCHEME 50410780

LIFTING 50410782

CONNECTION SCHEME 50401180


o

Appendix F: Lubrication system gear box

Technical description lubrication system gear box.

The purpose of the hydraulic manifold is to merge the following functions:

1. Filtration 2. Clutch in/ out 3. Pressure sequence 4. System pressure relief 5. Gauging of pressures and temperature

Technical description according diagram 1.

Diagram 1.


p

Filtration:

The lubrication pump connected on the P port of the manifold delivers the oil for the

system. The incoming oil is getting filtered by the high pressure filter (1.01) with a

fineness of 25 µm. The pump pressure can be gauged at measuring connection

(1.10) (MP1).

Clutch switching:

With the pressure sequence valve (1.03) the required pressure to operate the clutch

can be adjusted. Pressure gauge (1.02) (MP2) indicates the set pressure. Directional

valve (1.04) operates the gear box clutch. In de-energized position the clutch is

clutched out and energized the clutch is in.

The switching time of the clutch is regulated with the fixed orifice (1.11) in the

directional valve. Pressure to the clutch is indicated on the pressure gauge (1.05)

(MPC)

Lubrication:

Between ports C1 and C2 the oil cooler is installed. 8 Threaded ports are available

for connection of piping to the several lubrication ports of the gear box. Orifices in the

couplings on the gear box are regulating the oil flow.

The system is protected against overpressure by a spring loaded check valve (1.06).

Pressure gauge (1.08) indicates the pressure in the system.

Temperature gauge (1.09) indicates the temperature in the system.

DETAIL A

R

A

B

Q

P

N

M

L

K

J

H

G

F

E

D

C

R

A

B

Q

P

N

M

L

K

J

H

G

F

E

D

C

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

This document remains the property of IHC Parts & Services B.V. All rights reserved. This document or any part thereof may not be madepublic or disclosed, copied or otherwise reproduced or used in any form or by any means, including but not limited to use hereof for the design

and manufacturing of identical or similar parts or products, without prior permission in writing from IHC Parts & Services B.V.

IHC Parts & Services B.V.

www.ihcmerwede.com Model number:

Checked:

Released for production:

Author: Title:

RELEASEDFOR

PRODUCTION

Derived from:

Size: Sheet:

Scale: Drawing number: Revision:

Mass:

Material(spec):

A0

Description:

Units:

Projection method:

1/1mm

5483892

1660.0 kg

B 1:2,5

13-10-2009

16-12-2009

16-12-2009

NS

HB

JvH

SV-320-C

ASSEMBLY

ENGINEERING CHANGES

Rev. Zone Description Sign. Date

B Drawing in SE 13-10-2009

106 107

105

150

151

116

114 115420

421LOCK BY PENNING

506

419

423

136

501

144

412

611

610108

605

127

128

411

410

141 108

140 606

139

504

409301408503

425

415414304101110 418508122

123

121

DETAIL A1:2

417

426427

601608

403

405

507

137

416

401

135

404

402

138

108

604

712

130

406

303

502

131

604

102

407

505 143 142

146

147 604 302 111 112

103

104

605

119 108

118

109

110

M10

RECOMMENDED TORQUESIN Nm, FOR METRIC BOLTS

8.8 10.9 12.9

M12

M14

M16

M18

M20

M24

M27

M30

M33

M36

M39

M42

50

87

138

211

289

412

711

1049

1422

1932

2481

3226

3991

71 85

122 147

194 235

299 358

412 490

579 696

1000 1196

1481 1775

2010 2403

2716 3266

3491 4197

4432 5442

5609 6727

ALL THREAD CONNECTIONSLOCK WITH LOCTITE 242

607

605

R

A

B

Q

P

N

M

L

K

J

H

G

F

E

D

C

R

A

B

Q

P

N

M

L

K

J

H

G

F

E

D

C

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24





Checked:


Author: Title:

RELEASEDFOR

PRODUCTION

Derived from:

Size: Sheet:


Mass:

Material(spec):

A0

Description:

Units:

Projection method:

1/1mm

50403540

1779.5 kg

B 1:5

09-11-2009

16-12-2009

16-12-2009

AF

HB

JvH

SV-320-C

ARRANGEMENT

ENGINEERING CHANGES


B Drawing in SE 09-11-2009

A

DETAIL A1:1

12

4h

9O

R 6

140

,4h

9O

12

4h

9O

R 10

151

,5h

9O

16

5f6

O

16

4,7

O

R 10

17

9O

20

0n

6O

2,04+0,05-0,05

R 2

2,3

8

25

3514020155

46

3 x 15v

10

10,4+0,2

0

150 150 150 150 168 267 65

332 ±0,51168

125

60

10

50

O9

5r6

60

83

4 x O32 H7 AT ASSEMBLING ON SHIP(PRE-DRILLED O31)

4 x M24

6 x O33

680

305 ±0,05

57,5

23

05

7,5

35

0

70

0

8 x O26

4 x O25 H7 AT ASSEMBLING WITH PUMP(PRE-DRILLED O24)

172

,5±0,0

21

72

,5±0,0

2

130 130

OIL DRAIN

10

0,7

531,5

798

77

112

45

5

KEY ACCORDING TO DIN.6885

PULSE TRANSMITTER

6 x O25

INSPECTION COVERDIPSTICK

21

8

57040 140

750

17150

124 130

DIMENSION FOR DISASSEMBLY

776,6

840

880

1150

OIL DRAIN

20

0

50

35

03

20

35

0

12

20

287

442,7

448,5

553,3

WATER CONECTIONOIL COOLER

610 ±0,2

90 90

10°

3131353737373737373737

23

0

35

5°

11°+0,1-0,1

516

INPUT RATING

INPUT SPEED

OUTPUT SPEED

RATIO

WEIGHT

OIL QUANTITY

OIL VISCOSITY

P=634 kW

n1=1800 rpm.

n2=576,9 rpm.

i=3,12

m= 1770 kg

130 L

ISO VG 100

R 4

PIPE O 42OUT

IN BSP 1"

OIL PUMP

OIL LEVEL

15

07

BREATHER

40

10

40

30

31

41

42 43

50

32

Ø3

8x2

04.03.02

04.03.01

04.03.03

04.02.0015 kW

1

2

04.01.038,8 bar

A B

P T 04.01.04NG06

04.01.129,3 l/min

04.01.01

04.01.06

2 bar

1

2

0-100°C

04.01.09

0-6 bar

04.01.08

0-40 bar

04.01.05

0-40 bar

04.01.02

04.01.1004.01.00

1/2"BSP

1/2"BSP

1/2"BSP

1/2"BSP

1/2"BSP

1/2"BSP

1/2"BSP

C21 1/4"BSP

MC21/2"BSP

MTC1/4"BSP

T3-048115-100

1/2"BSP

PC1/2"BSP

MPC1/4"BSP

C11 1/4"BSP

MP21/4"BSP

MP11/4"BSP

P1 1/4" SAE6000 PSI

T3/4"BSP

1/2"BSP

1/4"BSP

T3/4"BSP

1 1/2"BSP

1 1/2"BSP

1 1/2" BSP(2x)

Ø42x3 Ø42x3

T3-048115-010

20

3.1 Stop driving motor

3. Stop of gearbox

1.1 Start driving motor

Description of the hydraulic system of the gearbox

1. Start of the gearbox from 0 to idle speed

2.1 The gearbox lubrication will be done by the mechanical lub oil pump at all operating speeds

2. Speed variants during operation

Ø4

mm

Ø1 m

m

Ø2

mmØ

1,5

mm

Ø1

,5 m

m

Ø2

mm

Ø2

mm

8x Ø

2 m

m

Ø1

,5 m

m

1 2 3 4 5 6 7 8 9 10 11 12

A

B

C

D

E

F

G

H

A

B

C

D

E

F

G

H

1 2 3 4 5 6 7 8 9 10 11 12





Checked:


Author: Title:

RELEASEDFOR

PRODUCTION

Derived from:

Size: Sheet:


Mass:

Material(spec):

A2

Description:

Units:

Projection method:

1/1mm

50410780 A

10-11-2009

16-12-2009

16-12-2009

AF

HB

JvH

SV-320-C

OIL CIRCUIT SCHEME

ENGINEERING CHANGES


A Drawing in SE 10-11-2009

Gear pump (Kracht)Type : KF 50 RF1Speed : 1409 rpmOil flow : 68 l/min

Oil filter (Hydac)Type : Df-W\HC-160-M-A-25-A-01Filter element : metal meshSiev mesh size MV = 25 um nominal

Directional control valve(Parker Denison)Type : 4D01-3151-0101-C1GOQ

Sequence valve (Sun)Type : RSJC-LENMax. flow capacity : 40 l/minPressure setting range : 0,5 -30 barPressure set to : 8,8 bar

Non return valve (Sun)Type : CXID-XCNOperating pressure : 2 bar

Pressure gauge (Hydroflex)Type : 1151-063-0040Ø63 mm, BSP1/4"0 - 40 bar

Temperature gauge (Econosto)40 mm, BSP1/2"0 - 120 °C

Oil/water cooler (Bloksma)Type : P13-2P-L=600 MVCooling power : 15 kW

10

20

30

31

32

40

43

50


41


42

1 2 3 4 5 6 7 8 9 10 11 12

A

B

C

D

E

F

G

H

A

B

C

D

E

F

G

H

1 2 3 4 5 6 7 8 9 10 11 12





Checked:


Author: Title:

RELEASEDFOR

PRODUCTION

Derived from:

Size: Sheet:


Mass:

Material(spec):

A2

Description:

Units:

Projection method:

1/1mm

50410782

-

A 1:10

13-11-2009

16-12-2009

16-12-2009

NS

HB

JvH

SV-320-C

LIFTING

ENGINEERING CHANGES


A Drawing in SE 13-11-2009

11

40

108700

SPECIFICATIONS:MASS OF 1 GEARBOX: 1,7 Ton

NO FORKLIFTS ALLOWED

LENGTH OF THE CABLE: MAX 1 m

15

80

AP

RO

X.

Gearbox SV-320-C.pdf

Documents

Transcript of Gearbox SV-320-C.pdf