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Issue 1.0 March 2010
i
TECHNICAL MANUAL
GEARBOX DREDGE PUMP
BEAVER 1200
SV-320-C
Issue 1.0 March 2010
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.
Issue 1.0 March 2010
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
Issue 1.0 March 2010
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
5.2.2 | Technical information ........................................................................ 5-3
5.3 | Oil cooler ................................................................................................ 5-4
5.3.1 | Description........................................................................................ 5-4
5.3.2 | Technical information ........................................................................ 5-4
5.4 | Oil filter ................................................................................................... 5-5
5.4.1 | Description........................................................................................ 5-5
5.4.2 | Technical information ........................................................................ 5-5
5.5 | Manometer ............................................................................................. 5-7
5.5.1 | Description........................................................................................ 5-7
5.5.2 | Technical information ........................................................................ 5-7
5.6 | Thermometer .......................................................................................... 5-8
Issue 1.0 March 2010
v
5.6.1 | Description........................................................................................ 5-8
5.6.2 | Technical information ........................................................................ 5-8
5.7 Speed monitoring system ......................................................................... 5-9
5.7.1 | Description........................................................................................ 5-9
5.7.2 | Technical information ........................................................................ 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
Issue 1.0 March 2010
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
Issue 1.0 March 2010
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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
Issue 1.0 March 2010
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.
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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.
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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]
Issue 1.0 March 2010
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.
Issue 1.0 March 2010
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”.
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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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!
Issue 1.0 March 2010
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.
Issue 1.0 March 2010
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).
Issue 1.0 March 2010
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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;
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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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”.
Issue 1.0 March 2010
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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
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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
Issue 1.0 March 2010
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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.
5.2.2 | Technical information
Figure 2: Overview of important parts of an oil pump
Issue 1.0 March 2010
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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.
5.3.2 | Technical information
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
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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.
5.4.2 | Technical information
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
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Figure 3: Overall dimension oil filter
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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.
5.5.2 | Technical information
Figure 4: Dimensions of manometer
Description Value Unit
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
Issue 1.0 March 2010
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.
5.6.2 | Technical information
Figure 5: Picture thermometer
Description Value Unit
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
Issue 1.0 March 2010
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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.
5.7.2 | Technical information
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
Issue 1.0 March 2010
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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
Issue 1.0 March 2010
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
Issue 1.0 March 2010
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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%.
5.8.2 | Technical information
Figure 10: Schematic layout pilot operated sequence valve
pilot operated sequence valve type: RSHC-LAN
Description Value Unit
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
Issue 1.0 March 2010
5-13
Figure 11: Dimension sketch Pilot operated sequence valve
Issue 1.0 March 2010
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.
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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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!
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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.
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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.
Issue 1.0 March 2010
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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
Issue 1.0 March 2010
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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
• Change lubricating oil
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
Issue 1.0 March 2010
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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)
• Change lubricating oil
Increased noise level
oil pump
• Low oil level in gearbox
• Viscosity lubricating oil
too high
• Check oil level; refill if
necessary
• Change lubricating oil
Increase in
volumetric losses
• Viscosity lubricating oil
too low
• Change lubricating oil
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
Issue 1.0 March 2010
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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!
Issue 1.0 March 2010
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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;
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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.
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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CAUTION!
CAUTION!
CAUTION!
MAKE SURE THE DRIVE UNIT IS SECURED TO PREVENT
FROM ACCIDENTAL START-UP. AFFIX NOTICE AT THE
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.
MAKE SURE THE DRIVE UNIT IS SECURED TO PREVENT
FROM ACCIDENTAL START-UP. AFFIX NOTICE AT THE
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.
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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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.
MAKE SURE THE DRIVE UNIT IS SECURED TO PREVENT
FROM ACCIDENTAL START-UP. AFFIX NOTICE AT THE
CONTROL DESK.
Issue 1.0 March 2010
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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
MAKE SURE THE DRIVE UNIT IS SECURED TO PREVENT
FROM ACCIDENTAL START-UP. AFFIX NOTICE AT THE
CONTROL DESK.
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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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]
Issue 1.0 March 2010
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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 [-]
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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
Issue 1.0 March 2010
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
115 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
Issue 1.0 March 2010
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
Issue 1.0 March 2010
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
502 1 SPHERICAL ROLLER BEARING
503 1 SPHERICAL ROLLER BEARING
504 1 SPHERICAL ROLLER BEARING
505 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
Issue 1.0 March 2010
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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
702 1 INSPECTION COVER
703 12 SCREW
704 1 INSPECTION COVER
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
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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
1.05 1 PRESSURE GAUGE
1.06 1 NON RETURN VALVE
1.08 1 PRESSURE GAUGE
1.09 1 TEMPERATURE GAUGE
1.10 1 MEASURING POINT
Issue 1.0 March 2010
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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
Issue 1.0 March 2010
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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.
Issue 1.0 March 2010
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
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
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
Rev. Zone Description Sign. Date
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
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):
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
Rev. Zone Description Sign. Date
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
Pressure gauge (Hydroflex)Type : 1151-063-0040Ø63 mm, BSP1/4"0 - 40 bar
41
Pressure gauge (Hydroflex)Type : 1151-063-0006Ø63 mm, BSP1/4"0 - 6 bar
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
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):
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
Rev. Zone Description Sign. Date
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.