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Installation Instructions

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No part of this document may be reproduced in any form(by printing, photocopying or other means) or processed,duplicated or circulated electronically without prior writtenapproval of REINTJES GmbH.

© 2013 REINTJES GmbH

All Rights Reserved.

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Table of contents

Installation Instructions 3

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Table of contents

1 Safety ..........................................................................................................................................................11

1.1 Meaning of Warnings and Notes ........................................................................................................... 11

1.2 Basic measures of caution ..................................................................................................................... 12

1.3 Requirements for installation personnel ............................................................................................... 13

1.4 Safety information for installation .......................................................................................................... 14

1.5 Protective measures against fire and danger of explosion ...............................................................15

2 Introduction to th is Documentat ion .............................................................................................. 17

2.1 Maintaining the documentation ............................................................................................................. 18

2.2 Preconditions of warranty ....................................................................................................................... 18

2.3 Brief product description ......................................................................................................................... 19

2.4 Area of application and manner of intended use ................................................................................20

2.5 Use of the gearbox within the European Union ..................................................................................20

3 Technical Data ........................................................................................................................................ 21

4 Transport, Storage and Preservation ...........................................................................................25

4.1 Transport ...................................................................................................................................................25

4.2 Storage ......................................................................................................................................................26

4.3 Preservation .............................................................................................................................................28

5 Description ...............................................................................................................................................35

5.1 Gearbox execution .................................................................................................................................. 35

5.2 Power Take Off PTO K41 ....................................................................................................................... 40

5.3 Power Take Off PTO K51 ....................................................................................................................... 41

5.4 Gearbox with shaft brake ....................................................................................................................... 43

6 Installation and Alignment ................................................................................................................ 45

6.1 Responsibility ...........................................................................................................................................45

6.2 Steps in preparation ................................................................................................................................ 45

6.3 Place of installation requirements ......................................................................................................... 46

6.4 Demands on the installation personnel ................................................................................................ 46

6.5 Setting up the gearbox ............................................................................................................................ 46

6.6 Alignment ..................................................................................................................................................48

6.7 Connection to Propeller Shaft ................................................................................................................ 48

6.8 Fixing the gearbox to the foundation .................................................................................................... 50

6.9 Seat Chocks .............................................................................................................................................57

6.10 Screwed Connections ............................................................................................................................. 58

6.11 Connection to Engine .............................................................................................................................. 61

6.12 Connection to the gearbox PTO ............................................................................................................ 64

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4 Installation Instructions

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Table of contents

6.13 Alignment Check ......................................................................................................................................65

6.14 Connection of Gearbox Components ...................................................................................................65

Index ............................................................................................................................................................69

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Safety


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1 Safety

1.1 Meaning of Warnings and Notes

Warnings and notes indicating various levels of danger or importance are used within

this documentation.

The signal word indicates the danger level in each case. Important notes to be observed for

problem-free, safe operation are indicated with an exclamation mark in front of them. These

are the individual danger levels:

1.1.1 Warnings

1.1.2 Notes

DANGER!

Imminent danger!

Death or serious injury will occur!

Human lives are acutely endangered

WARNING!

Possibly imminent danger

Death or serious injury may occur

Human lives are possibl y endangered

CAUTION!

Possibly imminent danger

Light injury may occur

Danger of personal injury

NOTICE!Important info rmation for safe and problem-free operation.

Possibly imminent danger of damage to the gearbox

Note without signal word:

... Here you will fi nd notes on working effectively and safely.

Addi tional informat ion and recommendations

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Safety

1.2 Basic measures of caution

Frequently, accidents occur as a result of not observing general safety regulations or

cautionary measures.

The individual chapters of this installation instructions contain specific safety notes.

Accidents may often be avoided by recognizing potential hazard situations in advance.

Dangerous places on the gearbox

Symbol Meaning Symbol Meaning

General Warning Sign

These warnings must be

observed!

Smoking and open fires prohibited!

Danger of being drawn or caught

in by rotating components

Wear tightly fitting protective

clothing e.g. coverall

Danger of electric shock!

Do not disconnect or service this

device until power supply has been

disconnected!

Wear ear protectors

1

Caution, hot components Read instructions carefully!

Output sideInput side

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1.3 Requi rements for installat ion personnel

Installation personnel must be trained in the use of transport aids and lifting equipment and

have a mastery of the tasks required in safely carrying out installation and alignment. This

includes skilled use of the tools required.

In order to maintain safety during operation, and to avoid any damage to the

gearbox, it is necessary for you to carefully read and to understand the chapters

“Transport, Storage and Preservation” from page 19 and “Installation and Align-

ment” from page 39.

In order to ensure your safety and the safety of others during installation, utilise only tools,

procedures, and methods of working in line with the most recent technology.

If the gearbox appears to require work not described in the documentation, please consultthe REINTJES service department or a REINTJES representative.

General protective measures and personal pro tection in the engine room

The gearbox may be operated and maintained only by qualified staff knowledgeable in its

operation and maintenance.

Immediately repair any faults that pose a safety hazard!

Ensure that no foreign objects enter the inside of the gearbox during assembly.

Wear protective eyewear when cleaning with compressed air.Danger of eye injuries due to dirt particles.

While the engine is running, wear ear protectors to prevent hearing

impairments.

Do not wear long hair loosely or any loose clothing or jewelry, including

rings, when near the gearbox while in operation.

Danger of injury due to getting caught or drawn in!

Do not touch the gearbox while it is warm from operation.

Danger of burns!

In addition to th is documentation, please observe and follow appli cable laws and

any other binding regulations governing accident prevention and environmental

protection!

DANGER!

Rotating Parts!

Danger of accidents due to getting caught or drawn in !

Prior to trial run mount covers to all rotating parts to p revent being

caught or drawn in.

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Safety

1.4 Safety information for installation

The gearbox has been built in accordance with the most recent technology and with

recognized safety regulation standards. Yet, even when the gearbox is used appropriately,

due to its manner of functioning and depending on how it is installed, a danger of personal

injury or death to the user or other individuals may arise.

Observe the following procedures!

Safety prior to working on the gearbox

Before performing adjustments or repairs on the gearbox or on aggregates powered by thegearbox, shut down the engine.

Secure the propeller and drive shafts against unchecked rotation.

Before loosening or dismantling any tubes or accessory parts in air, oil or water circulating

systems, first reduce the pressure.

WARNING!

When working on the gearbox, prevent the engine from being swi tched on!

Danger of death due to rotating components!

Shut down the compressed air feed and bleed the air tubes.

Prior to any assembly work on the gearbox, place a sign reading "OUT OF

ORDER" or a similar warning sign on the start-up switch or starter button and on

the remote s tarter.

Make sure that the remote starter of the drive motor on the bridge is also d isabled

and not functioning.

WARNING!

Oil pipes on the gearbox are under pressure when in operation!

Any o il escaping as a result of cracks or other leakage can resul t in serious injury.

Avoid damaging p ip ing dur ing assembly.

Perform a daily sight check of the piping in order to recognize any leakage at any

early stage.

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1.5 Protective measures against f ire and danger of explosion

General information

Immediately remove any oil residues completely.

Do not leave on the gearbox any rags or cloths used to wipe oil residues.

Pipes and tubes

Check all tubes and oil pipes daily for wear or damage.

Check to see that these have been laid, supported and fastened in accordance with

professional standards.

Tighten bolt joints only to the required torque.

Note that lubricants are flammable.

Never weld pipes or tubes carrying lubricants.

Do not straighten or bend any pipes or tubes under pressure during operation.

Immediately replace any bent or damaged pipes or tubes.

Do not replace steel pipes with copper ones.

Hoses

Do not damage hoses by subjecting them to mechanical force.

Check all hoses daily for any cracks forming or any mechanical damage.

Keep flames, acids and other corrosive or caustic liquids away from hoses.

Replace hoses no later than after 5 years.

Drained oil

Collect drained oil in a used oil collector.

Collect any rags soiled with oil in containers intended for this purpose.

Store all lubricants in appropr iately labelled containers. Dispose of fi lter elements and

used oil either as recyclable subs tances or as hazardous wastes.

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Safety

Cables connected to the gearbox

Make sure that all cables are maintained in an undamaged condition.

Check to see that all cables are laid properly and cannot be damaged by abrasion.

Immediately after connecting any cables to the gearbox, remove any leftover pieces of cable

or refuse.

Use only wires and cables having the required diameter and type of insulation.

Protect cabling on the board side by means of fuses in front of them in circuits.

Foreign substances near to the gearbox

Ensure that no used parts, dirt or foreign substances are near the gearbox.

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Introduction to this Documentation


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2 Introduction to this Documentation

This installation instruc tions contains information about:

Safety

Technical data

Transport, storage and preservation

Description of gearbox models

Installation and alignment

The operating instruction contains information about:

Putting the unit into operation

Operation

Maintenance

Trouble-shooting

Spare and replacement parts

Drawings for installation and supervision

The procedures described in this documentation are of a general nature.

Actual characteristics may differ from this information depending on the particular

gearbox and equipment.

In order for the unit to operate without fault as well as for any warranty claims to be honoured,

it is necessary to observe this documentation in its entirety.

Anyone responsible for transport, installation, operation or maintenance of this equipment

must adhere to the contents of this documentation.

Your safety as well as the safety of others depends on correctly operating this gearbox.

The best protection against possible accidents is for the party operating the equipment to

exercise caution.

REINTJES will accept no liability for damage or faults during operation if this documentation

is not observed.

This documentation comprises one set of installation and operating instructions fo r

gearboxes belonging to the LAF model series.

!Please read the Installation instructions before installing the gearbox!

Please be especially careful to observe the preceding safety information!

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Constant improvement and continued development may result in changes to your gearbox

that is not yet mentioned in these instructions.

All illustrations show basic principles only and may vary from the actual product. You cannot

derive any claims from the illustrations shown in this documentation.

Please address any questions about your gearbox or about this documentation to REINTJES

customer service:

2.1 Maintaining the documentation

This documentation belongs to the gearbox.

Please maintain the documentation for the entire service life of the gearbox.

Please pass on the complete documentation to any later owner or user.

2.2 Preconditions of warranty

REINTJES will only accept warranty claims when:

You install, operate, monitor and maintain the gearbox in accordance with our instructions.

Only the types of oil listed in the lubricant table are used.

You comply with the performance ratings and labelling stamped on the type plate.

No modifications may be made to the gearbox unless they have been approved by REINTJES.

REINTJES, as supplier of one of the components of the complete propulsion system, will not

assume responsibility for any problems with vibration resulting from the system as a whole.

REINTJES will not therefore assume any liability for complaints or damage resulting from this

type of vibration.

[email protected] or on

working days: Phone +49 5151 104 0

In emergencies and on weekends: Phone +49 5151 104 237

REINTJES strongly recommends that you have a torsional vibration calculationperformed for the entire system.

In any case, a whirl ing calculation must be done for any shaftlines connected to the

input or outpu t shafts.

We additionally recommend having an axial vibration calculation done for propeller

shaftlines.

Torsional, axial and whirling can mutually excite each another. In order to preclude

this possibi lity, the results of the whirling calculation, axial vibration calculation and

torsional vibration calculation should be compared with each other in order to rule out

that any of the vibration types have the same natural frequencies.

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2.3 Brief product description

The gearboxes of the LAF series are axially offset marine reduction gearboxes with

a built-in hydraulic disc clutch.

Marine gearboxes can be supplied with identical and counter rotation of the input and

output shafts. The built-in thrust bearings absorb the propeller thrust.

The gearbox has been designed under the assumption that a highly flexible coupling

will be employed between the motor and the gearbox.

Control is effected by means of directional valves.

2.3.1 Illustration

LAF 2346 K41 (vertically offset)

Pressure build-up systemControl valve

Input shaft

Oil

pump

Heat exchanger

Oilfilter

Output shaft

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2.4 Area of applicat ion and manner of in tended use

The gearboxes are intended for use in the propulsion systems of ships. They represent the

current state of the art.

Please refer to the type plate and/or the documentation for technical data and for information

on permissible conditions of operation (limits).

These details must be absolutely adhered to!

The coupling flange and flexible couplings must be suited to the gearbox. You must observe

the technical details of the gearbox. (see ”Technical Data” on page 15.)

The gearbox may only be used in a flawless technical condition, in a manner consistent with

its intended use and in awareness of safety issues and potential hazards!

Use in accordance with the intended purpose also comprises compliance with mounting and

operating instructions and with inspection and maintenance conditions.

2.5 Use of the gearbox wi th in the European Union

In cases when operation is subject to safety regulations of the European Union, the

manufacturer of the complete system must have it CE-approved and labelled accordingly.

Seagoing vessels are exempted from this requirement in accordance with the Machinery

Directive.

! Any use of the gearbox in a manner not described here wi ll be deemed usage that

is not in accordance with its intended purpose. REINTJES will not be liable for any

damage resulting from such use.

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Technical Data


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3 Technical Data

You will find the technical data for your gearbox on the type plate. The type plate of the gearbox

is mounted at the top part of the gearbox housing.

Copy the data for your gearbox to the type plate printed here:

Requesting spare parts

When making enquiries and ordering parts, please provide the following information:

GEARBOX NO. - e.g.: K xxxxx

TYPE - e.g.: LAF ...

INPUT CAPACITY - e.g.: 2000 kW

GEAR REDUCTION RATIO - e.g.: 4.05 : 1

Please provide this additional information, listed in the spare parts lists, when ordering

spare parts:

Item number of the part

Designation

Required no. of pieces

You will find the spare and replacement parts lists in the operating instruc tions beginning on

page 75.

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Technical Data

The tables below present an overview of the performance data of the gearbox types described

in this documentation.The data of your gearbox may differ from the information in these tables in individual

cases. The data on the type plate is authori tative in cases of doubt.

Table 1: Overview of characteristics for type LAF 2346 – 4575

Type Gear ratio Input torque Nm Weight kg

Base gear

LAF 2346 2,076 32470 5300

2,529 32470

3,033 32470

3,458 309504,041 28670

4,454 26700

LAF 2355 3,923 32470 6300

4,461 31160

4,916 29180

5,454 26750

5,762 25500

LAF 2365 5,074 31270 7200

5,560 28540

6,130 25890

6,455 24580

LAF 2375 6,154 30350 9200

6,440 29000

7,087 26350

7,455 25050

LAF 3445 2,053 41540 6400

2,515 41540

3,038 39620

3,462 37620

4,043 34560

4,524 32630

LAF 3455 4,074 41540 7800

4,480 37810

4,957 37810

5,524 35180

5,955 39920

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LAF 3465 5,077 39740 9700

5,583 36140

5,870 34380

6,524 30930

6,955 28070

LAF 3475 6,160 38090 10800

6,458 36330

7,136 32880

7,524 31190

LAF 4545 1,923 52530 8000

2,455 52530

2,931 52530

3,423 47090

3,952 42050

4,429 38360

LAF 4555 3,960 49850 9500

4,583 44290

5,091 40600

5,429 38460

5,773 36510

LAF 4566 4,958 47910 11100

5,500 43920

6,091 40250

6,429 38420

6,818 36510

LAF 4575 6,120 45300 13100

6,739 41560

7,091 39500

7,476 37460

Type Gear ratio Input torque Nm Weight kg

Base gear

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Transport, Storage and Preservation


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4 Transport, Storage and Preservation

4.1 Transport

Upon receipt, immediately inspect the gearbox and accessories for any damage

incurred in transport.

Report any transport damage to the freight carrier immediately.

Inform the REINTJES service department.

Do not put the gearbox into operation if there is any transport damage

The gearbox weight (without oil but including special accessories) is stamped on the type plate.

Slings must be suitable for this load. Secure slings to all of the eyebolts intended for this

purpose using shackles.

When lifting for transport, the gearbox must be secured against tilting. To ensure this, use all

of the eyebolts intended for this purpose.

With the gearbox suspended from a sling, the angle of the sling may not exceed 45°

from the perpendicular !

WARNING!

The gearbox can fall over if improperly supported!

This may result in serious injury or death!

Under no circumstances should you put slings around shaft ends, pipes or other

externally mounted parts.

When suspending the unit, use only the lifting eyes intended for this purpose.

Traversing bridge

Sling

max.45°Lifting eyebolts

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4.2 Storage

Keep to a minimum the period of time between removal of the original packaging and putting

the gearbox into operation.

During this period, protect the gearbox from any harmful environmental effects and externalinfluences.

Until the gearbox is put into operation, leave all openings in the gearbox closed.

If, for inspection purposes, you cannot avoid opening the gearbox, you must close openings

immediately afterward. (see "Measures against corrosion during storage" on page 22.)

In cases of doubt, please contact the REINTJES service department.

WARNING!Suspended load!

Danger of injury!

Use only transport aids and lifti ng equipment that are approved for the

anticipated load when used in the intended manner.

Transport aids and lift ing equipment must be designed to be able to safely hoist

the load, hold it and set it down once again.

Observe the regulations and instructions for use provided by the manufacturer of

the transport aids and lifting equipment.

During transport, make sure:

Not to damage packaging, if further storage is intended afterward.

Transport is carried out only by individuals competent in the use of transport

and lifting equipment.

Appropriate and adequately d imensioned transport aids (e.g . traversing br idges)

are employed.

Slings do not press against piping or externally mounted parts.

Please note that appropriate storage conditions are necessary in order to avoid any

damage due to corrosion.

REINTJES will not be liable for any damage due to corrosion, nor any subsequent

damage arising from this , in cases when the guidelines and measures included in this

chapter are not observed.

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These factors have a posit ive effect on the permiss ible storage period:

High-quality packaging including an adequate amount of drying agent

Storage in climate-controlled rooms with low humidity

These factors have a negative effect on the permissib le storage period:

Damage to the packaging

Storage under high humidity, with air containing salt or contaminated air

Addi tional s teps are requi red if :

Premature opening of the gearbox cannot be avoided

The gearbox is stored for a longer period or under conditions other than those stipulated

(see "Measures against corrosion during storage" on page 22.)

To avoid damage, the gearbox must be stored in an enclosed area.

This reduces extreme variations in temperature and avoids any exposure to

moisture (e.g. through rain).

Outdoor storage is prohibited!

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4.3 Preservation

4.3.1 General information

Initial preservation is done at REINTJES as specified in agreements by contract.

After a run on the test stand, the gearbox is preserved as specified in the order.

Spare parts or loose parts supplied with the shipment are treated using the preservation

procedures stipulated in the contract.

Preservation for dispatch is designed for a limited period of time and for certain storage

conditions.

The scope and effectiveness of these preservation procedures depend on:

Conditions of storage

Duration of storage

Packaging

Individual customer wishes

4.3.2 Initial preservation

During the factory bench test, the gearbox is run with a corrosion protection oil to preserve it.

In addition, following the bench test, the gearbox is filled with a VCI preservation oil (VCI = volatile

corrosion inhibitor).

Volatile corrosion inhibitors are agents that evaporate very slowly and deposit themselves on

the unpainted metal surfaces within the closed gearbox. Due to their polarity, they interrupt

electrochemical reactions resulting in corrosion.

In order to ensure that these volatile corrosion inhibitors retain their effectiveness for as long

as possible, all of the gearbox openings are closed. The shafts are sealed using v-rings

and/or an acid-free grease.

Externally exposed, unpainted metal parts are protected using a wax-like preservation

substance. When stipulated in the order, the gearbox is additionally protected against

corrosion by means of moisture-proof packaging or special marine packaging.

4.3.3 Measures against corrosion during storage

General information

The following assumes that the storage conditions described in chapter 4.2 are followed.

Here we can merely describe general measures against corrosion.

If you are not certain whether protection is adequate for your particular case of application,

please consult with REINTJES about the necessary measures.

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As a result of damage to packaging, water and harmful environmental influences can have a

direct effect on the gearbox. Excessive moisture can penetrate the inner space of the gearboxas a result of variations in temperature.

Immediately upon receipt of the gearbox, check the packaging for any transport damage.

Regularly check the outside packaging.

Table 2: Inspection intervals for corrosion protection of the gearbox

Inform REINTJES customer service immediately of any corrosion damage discovered

during inspection.

Immediately perform the follow ing measures in the event of damage to packaging:

Dry off any pools of water collecting on the gearbox as a result of rain or condensation.

Check the drying agent provided with the shipment.

Replace the drying agent if its colour changes from white to blue.

Check preservation at shaft ends.

Repair the seal, if necessary, using acid-free grease.

Repair the damaged packaging.

-or better-

Replace the damaged film along with the drying agent.

Use only film of the same quality.

Remove the packaging when:

The gearbox is brought on board the vessel to be installed

The stipulated duration of storage is exceeded by more than 20%.

In this case, consult with REINTJES to decide on further protective measures.

Inspection intervals:

European climate zone every 4 weeks

Tropical climate zone every 2 weeks

Immediately after removing the original packaging, additional preservation measures

will be necessary for ensuring that the gearbox is adequately protected against

corrosion.

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Measures after removing the packaging:

Protect the gearbox as well as possible against water and harmful environmental effects.

For instance, when covering the gearbox with tarpaulins, leave some space between them

and the gearbox. They should not act as a vapour seal!

Regularly inspect the gearbox for external corrosion damage.

During inspection, check to ensure that shaft ends are preserved and sealed.

Repair the seal using acid-free grease. (Refer to table 2 on page 23 for inspection intervals)

Regularly refill the gearbox with Branorol preservation oil.

After removing the packaging, initial refilling should be done after half of storage duration,

as stipulated in the contract, has passed.

Initial refilling should, however, be done no later than 12 weeks (European climate zone)

or 8 weeks (tropical climate zone) afterwards.

Table 3: Intervals for refilling VCI preservation oil

You will find the operating oil volume on the type plate.

Please observe section "Opening the gearbox" on page 25 in this regard!

For unpacked gearboxes, apply the measures mentioned above even if the stipulated storage

duration has expired.

Intervals for refi ll ing VCI preservation oil: Volume of preservation oil to be f i lled:

European climate zone every 12 weeks 1% of the operating oil volume, at least 1 litre

Tropical climate zone every 8 weeks 1% of the operating oil volume, at least 1 litre

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Opening the gearbox

The agents of the VCI preservation oil escape when the gearbox is opened.

Measures after opening the gearbox

Refill the gearbox with Branorol preservation oil. (Refer to table 3 on page 24 for volume)

IMPORTANT: Afterwards, close the gearbox air-tight.

A pro tecti ve inh ib itor atmosphere may not be ab le to form again after reclos ing.

This depends on:

The concentration of VCI agents

The amount of moisture that has entered

How well the gearbox is resealed afterwards

4.3.4 Measures against corrosion after putting the gearbox into operation

Long interruptions in operation

If the operation of the vessel or gearbox is to be interrupted for several weeks, measures are

required to protect the gearbox against corrosion.

Corrosion damage to the gearbox cannot be ruled if these measures are not followed.The type and scope of measure that need to be performed depend on the options available

at the particular location. Variants A, B and C, described in the following, are equally as

important.

Table 4:

Perform one of these protective measures once the period mentioned above has passed:

Variant A: Flush with operating oil

Flush the gearbox for 15 minutes using the mechanical gearbox oil pump by starting

the engine.

-or-

using the electrical stand-by pump, if available.

Replace the venting filter using the screw plug.

Repeat flushing weekly.

Measures to protect against co rrosion are required

after an interruption in operation of longer than

European climate zone: 4 weeks

Tropical climate zone: 2 weeks

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Variant B: Flush wi th Valvoline 6 anticorrosive oil

Drain the operating oil.

Fill with Valvoline 6 anticorrosive oil. Volume: approx. 0.8 x operating oil volume.

Flush the gearbox for 15 minutes using the mechanical gearbox oil pump by starting

the engine.

-or-

using the electrical stand-by pump, if available.


Repeat flushing after no later than 12 weeks (Europe) or 8 weeks (tropics).

Seal the shafts using an acid-free grease.

Variant C: Fill the gearbox with B ranorol VCI preservation o il

Drain the operating oil.

Fill with Branorol VCI preservation oil. Volume and further service intervals: see table 3 on

page 24.


Seal the shafts using an acid-free grease.

Note: Residual amounts of operating oil may remain in the gearbox after draining. This will not

reduce the effectiveness of the measures against corrosion. On the other hand, when putting

the gearbox back into operation, small residual quantities of anticorrosive oil may be mixed

with operating oil.

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Corrosion protection of the heat exchanger

Draining the water side of the heat exchanger during interrupt ions in operation

of longer than 2 weeks

Seawater circulating system:

Drain the seawater circulating system of the heat exchanger.Flush the water side of the heat exchanger with freshwater.

Afterwards, fill the water side of the heat exchanger with freshwater mixed with an

anticorrosive additive.

The type of additive depends on the cooling system.

Observe the areas of application recommended by the additive manufacturer.

Freshwater circulating system:

Drain the freshwater circulating system of the heat exchanger.

Afterwards, fill the water side of the heat exchanger with freshwater mixed with ananticorrosive additive.

The type of additive depends on the cooling system.

Observe the areas of application recommended by the additive manufacturer.

4.3.5 Product specifications for corrosion protection and preservation oi ls

VALVOLINE ROSTSCHUTZ 6, full-power anti-corrosion oil for gearboxes

BRANOROL 32/10, VCI preservation oil, mineral-oil-based

At tention !

Remove the v-rings marked with label before commissioning.

Follow the safety instructi ons provided in this Installation Instructions.

(refer to " Safety" beginning on page 5.)

In additi on, observe any applicable safety precautions when mounting or

dismantling equipment.

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Description


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5 Description

5.1 Gearbox execution

5.1.1 Gearbox type

The gearboxes of the LAF series are axially offset marine reduction gearboxes with a built-in

hydraulic disc clutch.

Marine gearboxes can be supplied with identical and counter rotation of the input and output

shafts. The built-in thrust bearings absorb the propeller thrust.

5.1.2 Path of drive

The engine power is transmitted to the input shaft by way of the flexible engine to gearbox

coupling.

Path of drive in counter rotation

Input shaft A - Clutch A (closed) - Pinion shaft A -

Output shaft C.

The output shaft rotates in the opposite direction from

the input shaft.

Path of drive with identical rotation

Input shaft A - Clutch housing A - Clutch housing B -

Clutch B (closed) - Intermediate shaft B -

Output shaft C.

The output shaft rotates in the same direction as the

input shaft.

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Description

5.1.3 Aggregates and addi tional ly mounted par ts

Hydraulic system

The hydraulic system

consists of:

Oil pump

Oil filter

Heat exchanger

Valve block with pressure

limiting valve

Control valve

Pressure oil system with

pressure delay pot

Lubrication oil system

The operating oil pressure is

controlled by the pressure

limiting valve.

Output shaftOilpump

Oilfilter

Heatexchanger

Control valvePressure delaysystem

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Hydraulic diagram (LAF gearbox)

Main clutch

Heat exchanger

Oil filter

Gearbox

pump

Stand-by

pump

Dipstick Lubrication oil

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Description

Oil pump

The oil pump, mechanically driven by the transmission,

is a gear pump that serves to supply the gearbox with

pressure oil and lubrication oil.

Oil filter

The oil filter serves to filter out solid particles from theoperating oil. This is a duplex filter with two filter elements

(during operation it is possible to switch from the soiled filter

element to a clean one).

A mechanical or electrical contamination indicator indicates

when a filter element is contaminated. On changing filters,

please refer to the maintenance chapter of the operating

manual, page 50.

Heat exchanger

The heat exchanger is a tube-bundle heat exchanger.

Seawater or freshwater taken from a closed cooling

water circulating system is used as a coolant.

On maintenance of the oil cooler, please refer to the

maintenance chapter of the operating instructions,

beginning at page 54.

Valve block with pressure limiting function

Operating pressure is regulated by a spring-loaded

pressure limiting valve.

Standard operating pressure is approx. 25 bar (2500 kPa

or 362 psi).

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Control valve, electrical

The gears are engaged by means of axial slide valves which

are brought into the desired position of engagement by axially

shifting the control piston.

LAF gearbox - 4/2 directional valve with lock (without return

spring)

Pressure build-up system

The pressure build-up system ensures smooth

engagement of the gearbox clutch.

Oil manometer and supervision

An oil pressure manometer is mounted on the gearbox for

monitoring oil pressure. This manometer indicates the operating

pressure.

Operating pressure is set differently depending on the gearbox

type.Operating pressure is checked with the engine running at nominal

speed, the gearbox at operating temperature and the clutch

engaged.

With the engine running at nominal speed and the clutch

engaged, operating pressure must be within the range indicated

by the markers on the manometer.

The supervision system continuously measures current values

of operating characteristics such as temperature, pressure,

speed (optionnally) and oil level (optionnally). If any parameter

defined in the supervision plan is exceeded (e.g. temperature) or not

attained (e.g. pressure) an alarm is given in the form of an electrical signal.

Electrical stand-by pump

The oil pump with electrical motor is designed to be used as a

stand-by pump in the event that the mechanical gear pump fails.

Danger of electric shock!

Do not disconnect or service this device until

power supply has been disconnected!

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Description

5.2 Power Take Off PTO K41

The power take off may be used for auxiliary units (e.g. generator or an additional pump).

Size and design are built to order. This power take off may therefore only be used for the

application it is designed for.

Power take off Controllable Speed Rotating direction

K 41A No i x nengine Counter to engine

K 41B No i x nengine Counter to engine

K 41A: primary PTO - PTO shaft turns always even if the propeller standstill

K 41B: secondary PTO: PTO shaft turns only, if the propeller turns

K41A/B Position Above input shaft, on the output side

K41 A Operating conditions

primary PTO

Running engine

Path of drive

primary PTO:

Running engine - input shaft with clutch housing - PTO pinion

- PTO shaft

K41 B Operating conditions

secondary PTO

Running engine, oil pressure sufficient, engaged main clutch

Path of drive

secondary PTO:

Running engine - input shaft with clutch housing - engaged

main clutch - pinion shaft - PTO wheel - PTO pinion -PTO shaft

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5.3 Power Take Off PTO K51

The power take off may be used for auxiliary units (e.g. generator or an additional pump).

Size and design are built to order. This power take off may therefore only be used for the

application it is designed for.

Power take off Controllable Speed Rotating direction

K 51A Yes i x nengine Counter to engine

K 51B Yes i x nengine Counter to engine

K 51A: primary PTO - PTO shaft turns always even if the propeller standstill

K 51B: secondary PTO: PTO shaft turns only, if the propeller turns

K 51 A/B Position above input shaft, output sided

K51 A Operating conditions

primary PTO

Running engine, oil pressure sufficient, PTO clutch engaged

Path of drive

primary PTO:

Running engine - input shaft with clutch housing - PTO pinion -

engaged PTO clutch - PTO shaft

K51 B Operating conditions

secondary PTO

Running engine, oil pressure sufficient, main clutch and PTO clutch

engaged

Path of drive

secondary PTO:

Running engine - input shaft with clutch housing -

main clutch engaged - pinion shaft - PTO wheel - PTO pinion -

PTO clutch engaged - PTO shaft

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Description

5.3.1 Control of the PTO

The engaged speed range specified in the order acknowledgement has to be observed. Only

after this the main engine can be regulated to nominal speed. Any increase intended after-

wards must be approved by REINTJES.

STOP-posit ion of the PTO-control valve

In the Stop position the oil is lead to the lube oil lines and the sump. The annular piston is pulled

into his starting position by the return springs.

WARNING!

Manual engaging o f the PTO control valve

Danger of personnel by unintentional turning of the PTO shaft!

Don‘t engage the PTO clutch manually!

The disengaged disc clutch is permanetly supplied with lube oil. This results in an

idling torque.

With disengaged clutch the PTO shaft may rotate provided the idling torque is higher

than the initial friction torque of the driven parts.

The idling torque depends on the present operating conditions.

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5.4 Gearbox with shaft brake

5.4.1 Gearbox execution

The gearbox is the same as the standard execution (refer to 5.1) but with a mounted shaft

brake. This section therefore deals only with the components differing from the standard

model.

5.4.2 Aggregates and addi tional ly mounted par ts

The hydraulic system

The hydraulic system additionally

includes:

A control valve for the brake

The pressure build-up system

for the brake

The pneumatic control for the brake

control valve is additionally mounted

on the gearbox so as to be ready for

operation.

Brake control valve

An additional control valve, for controlling the brake,

is mounted on the gearbox.

The control piston is actuated pneumatically.

Pressure build-up

system brake

Shaft

brake

Control valve brake

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Description

Brake pressure build-up system

The pressure build-up system ensures smooth application

of the brake.

Shaft brake

The shaft brake is applied automatically during disengaging

the clutch.

The brake is always engaged while the clutch is disengaged.

Hydraulic diagram (gearbox wi th brake)

Heat exchanger

Shaft brake

Main clutch

Control air

Gearbox pump Stand-by

pump

Lubrication oilDipstick

Hydraulic block

Oil filter

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6 Installation and Alignment

6.1 Responsibility

6.2 Steps in preparation

Steps before installing the gearbox

Remove all protective coverings (Films, Transport Packaging).

Remove any dust or dirt.

Suspend the gearbox from a crane hook using suitable slings.

Please additionally observe the generally safety information as well as the

information in chapter "Transport" on page 19 and the information provided above!

Installation and alignment are the responsibilit y of the yard.

WARNING!

The gearbox can fall over if improperly secured!

This may result in serious injury or death!

Under no circumstances should you put slings around shaft ends, pipes or

other externally mounted parts.

When suspending the unit, use only the lifting eyes intended for this purpose.

The lifting eye bolts are marked with the label "Sling here".

When installing the gearbox, ensure that:

Transport is carried out only by individuals competent in the use of transportand lifting equipment.

Only suitable transpo rt aids (e.g. traversing bri dges) that are approved for the

weight of the gearbox are used.

Slings do not press against piping or externally mounted parts. A risk of

damage exists !

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6.3 Place of installation requirements

The necessary space for movement of the personnel in the working area must not be

restricted or may be hindered.

Free spaces to be considered especially are indicated in the drawing of installation.

The foundation must be designed to absorb the gearbox weight and working loads.

It has to be strictly considered that sufficient free space for dismantling of housing and shafts

is available for later maintenance.

6.4 Demands on the installation personnel

The installation must be carried out only by authorised staff of the supplier of the propulsion

system or the shipyard.

6.5 Setting up the gearbox

The drawing of installation represents the basis for setting up the gearbox.

This drawing includes all dimensions and values relevant for setting up the gearbox.

The drawing number applying to your gearbox is indicated in the order acknowledgement.

The drawing of installation may also be obtained from REINTJES indicating the commission

number.

Required qualification of the installation personnel:

qualified mechanic for the mechanical installation

electrically skilled person for the electrical installation

The installation personnel must wear protective clothes according the regulations.

The protective clothes must be provided by the supplier of the propulsion system

or the shipyard.

Before setting up the gearbox, make sure that you have current versions

of these documents:

Installation Instructions (this manual)

Drawing of installation

Supervision Plan

Al ignment calculat ion

Make sure that you have read and understood the descrip tions and informationconcerning alignment contained in this Installation Instructions.

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Aleays carry out the lifting of heavy components with several persons or use

lifting equipment.

Set the gearbox on the foundation in the intended position.

Secure the gearbox against shifting on the foundation until it has been aligned and

permanently fastened.

Protect the gearbox against corrosion, contamination and damage (refer to Preservationbeginning at page 22).

[email protected]

On weekdays : Phone +49 5151 104 0

In emergencies and on weekends : Phone +49 5151 104 237

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6.6 Alignment

Determine the permissible GAP and SAG values for all shaft connections taking into

account the technical information (alignment calculation, thermal expansion and

manufacturrers‘ information) applying to the units to be connected.

In addition, take into account settlement effects for the cast-resin foundation. Request the

cast-resin manufacturer to send you detailed information on settlement.

Carry out the alignment work only after the vessel is afloat with absolutely no ground

contact with the sea bed.

The vessel should be equipped as far as possible. Missing heavy equipment, e.g. winches,

cranes, has to be duly considered.

Carry out the alignment work in the early morning. Direct sunlight can influence the

alignment result.

A prerequ is ite for the t rouble-f ree operation of the gearbox is the careful alignment of

the input shaft of the gearbox with the engine shaft

the output shaft of the gearbox with the propeller shaft

the PTO shafts with the connected auxiliary units

Take into account the thermal expansion of the engine, gearbox, aggregates andfoundations at operating temperature.

Also if torsionally flexible couplings or cardan shafts are used, precise alignment with the

engine will be required. Any misalignment will have negative effects on the service life

of the gearbox and the connected components.

Observe the manufacturers' instructions when aligning:

the output shaft of the gearbox with the propeller shaft connection

the engine with the input shaft of the gearbox

the auxiliary units with the additional gearbox shafts (PTO)

6.7 Connection to Propeller Shaft

A prerequisite for the connection of the propeller shaftline with the gearbox is that the

propeller shaft and/or the intermediate shaft be in the static operating position.

To be in the static operating position means:

the propeller shaft and the intermediate shaft are in their bearings

the propeller is mounted

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the intermediate shaft flanges are connected (if present)

the flange facing the gearbox is in the alignment position (if necessary)

Gearbox foot i ncluding fastening options

Steps in connecting to the propeller shaft

Screw the alignment screws into the gearbox foot.

Fix the adjusting screws on the foundation, with which you can align the gearbox

horizontally, in longitudinal and transverse directions.

With the adjusting screws, align the gearbox

vertically and horizontally in longitudinal and transverse directions with the propellerflange, according to the specified data.

If an alignment calculation is available, you must observe the calculations and

procedures specified therein.

Take into consideration thermal expansion at operating temperature.

A thermal expansion diagram may be requested from REINTJES.

Additionally take into account settling effects when setting the gearbox up on a

cast-resin foundation.

Request detailed documentation on this from the manufacturer of the cast resin.

With approved methods

(gauges, laser), measure thehorizontal and vertical GAP and

SAG values between the gear-

box flange and the counter-

flange on the propeller side.

Permissible tolerances:

Radial misalignment 0.05 mm

(centreline run-out 0.025 mm) - SAG

Angular misalignment 0.05 mm related to 300 mm flange diameter - GAP

Document your GAP and SAG values

Surface for

collision chocks

Surface for

lateral

collision chocks

Alignmentscrews

Hole

for foundation bolts

SAG

GAP

Example: Measuring of the GAP and SAG values:

propeller shaft

gearbox outputflange

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Fix the gearbox to the foundation, as described in paragraph 6.8.

Check the gap and sag values.

Connect the propeller shaft to the gearbox output shaft after the gearbox is firmly

fixed to the foundation.

If you have a special, deviating installation situation, agree the necessary steps

with REINTJES prior to the installation.

6.8 Fixing the gearbox to the foundation

Following the alignment with the propeller shaft, the gearbox can be fixed on the foundation,

as described in the following.

The design of the foundation bolts and their tightening torques lies exclusively with the

shipyard.

6.8.1 Gearboxes with Longitudinal Mounting Arrangement, Metal Seat Chocks,

Rigid Mounting

The following combinations are permissible for the gearbox fixation

1. Seat chocks with 4 fitting bolts, through bolts and collision chocks. for propeller

thrust „ AHEAD“ and „ ASTERN!

[email protected]

On weekdays : Phone +49 5151 104 0

In emergencies and on weekends: Phone +49 5151 104 237

fitting bolt

through bolt

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2.Seat chocks with fitting bolts and through bolts without collision chocks,(Number of fitting bolts depending on propeller thrust)

3. Seat chocks wi th colli sion chocks, with the foundation bolts designed as

through bolts.

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6.8.2 Gearboxes with Longitudinal Mounting Arrangement, Cast Resin Seat Chocks,

Rigid Mounting

The following combinations are permissible for the gearbox fixation:

1. Cast-resin seat chocks with 4 fitting bolts, collision chocks for propeller thrust

"AHEAD" and "ASTERN", and through bolts

2. Cast-resin seat chocks with collision chocks , with the foundation bolts designed as

through bolts.

fitting bolt

through bolt

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6.8.3 Gearboxes with Longitudinal Mounting Arrangement, Adjustable metal seat

chocks, Rigid Mounting


1. Vibracon® SM elements or RotaChock elements with 4 fitting bolts, collision chocks

for propeller thrust "AHEAD" and " ASTERN", and through bolts

2. Vibracon® SM elements or RotaChock elements with col lision chocks , with the

foundation bolts designed as through bolts.

fitting bolt

through bolt

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6.8.4 Gearboxes with Transverse Mounting Arrangement, Rigid Mounting


1. Thrust bearing moun ted on the engine side

Cast-resin seat chocks with through bolts and steel seat chocks with fitting bolts in the

area of the thrust bearing

2. Thrust bearing mounted on the engine side

Cast-resin seat chocks with through bolts, collision chocks for propeller thrust

"AHEAD", and fitting steel bushes with expansion bolts for propeller thrust " ASTERN"

with fitting bolts

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3.Thrust bearing mounted on propeller side

Cast-resin seat chocks with through bolts and steel seat chocks with fitting bo lts in thearea of the thrust bearing

4.Thrust bearing mounted on propeller side

Cast-resin seat chocks with through bo lts and fitting sleeves with expansion bolts for

propeller thrust "AHEAD" and "ASTERN"

with fitting bolts

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Basic principle of a simple collision chock

The collision chocks are designed to transfer the propeller thrust to the foundation.

Ensure that the gearbox is installed distortion-free.

The design of the collision chocks lies within the responsibility of the shipyard.

The collision chocks are to be structurally designed so that they can withstand the maximum

occurring propeller thrust without taking into account the foundation bolt preloading. Stopper

chocks are to be made from metallic materials. There must be metal-to-metal contact on

both sides and they must be secured against displacement.

Stopper chocks are to be manufactured to a wedge or double wedge design. Positioning of

the wedge-shaped chocks without clearance must be executed with the plant at its operating

thermal condition. The subsequent fixing of the chocks is to be ensured by screws or weld-

ing up the wedges over the entire wedge length. The design and correct installation of the

stopper chocks lies within the responsibility of the shipyard.

Observe the demands on seat chocks specified in paragraph 6.9.

Fit the seat chocks between the gearbox feet and the top plate.

Back off the alignment screws before tightening the foundation bolts.

Following the alignment with the propeller shaft, screw the gearbox to the foundation, so that

it is protected against displacement. In doing so, observe the demands and notes on the

bolts stated in paragraph 6.10.

Any other foundation methods must be approved by REINTJES.

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6.9 Seat Chocks

6.9.1 Metal Seat Chocks

The seat chocks have the task to keep the gearbox in the desired position and direct the reac-

tion forces into the foundation as evenly as possible. The material to be preferred for metal seat

chocks shall be steel or cast steel. Cast iron may also be used.

The thickness of the seat chock shall amount to between 20 and 80 mm. When using cast

iron, the minimum thickness is 40 mm. The surface of recesses in the seat chock should be

less than 20% of the total surface of the seat chock.

Rectangular seat chocks must be used only.

The seat chock has to be manufactured from one part. Shims or lining plates are not

permissible.

Metal seat chocks have to be fit in through touching on both sides. The bearing share

achieved must be at least 75%.

Tack welding on seat chocks is no t permissib le.

Seat chocks must be sufficiently dimensioned and closely fitted. They have to be made in

accordance with the rules of the Classification Societies.

6.9.2 Cast-resin Seat Chocks

As a matter of principle, only approved material by authorised firms must be used in

compliance with the rules. Before casting resin under the gearbox, the calculations and the

tightening method for the foundation bolts have to be submitted to the Classification Society

for approval.

The foundation has to be designed such that the maximum stress values between the

gearbox and the cast-resin seat chock indicated by the manufacturer are not exceeded.

The height of the cast-resin seat chocks must be between 20 and 80 mm. In any case, the

height must always be less than the width and length of the part.

Observe the cast resin manufacturer's instructions.

The cast-resin seat chocks must be loaded only after thermosetting.

The alignment screws must be backed off before tightening the foundation bolts.

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6.9.3 Adjustable Metal Seat Chocks, type Vibracon® SM or type RotaChock

As a matter of principle, only adjustable metal seat chocks, type Vibracon® SM

(from Co. Machine Support, Netherlands) or type RotaChock, (Chock Design, Netherlands)

must be used in compliance with the instructions. Before installing the gearbox the

calculations and the tightening method for the foundation bolts have to be submitted to

the Classification Society for approval.

The foundation has to be designed such that the maximum stress values between the

gearbox and the Vibracon® SM element or type RotaChock element indicated by the

manufacturer are not exceeded.

The alignment screws must be backed off out of contact with the foundation before

tightening the foundation bolts.

6.10 Screwed Connections

The gearbox foundation bolts comprise fitting bolts and/or through bolts.

The foundation bolts have to be calculated according to the state of the art. Under all operating

conditions, the preload of the bolts must be higher than the workload. The elongation of the

bolt has to be designed such, that the connection is not loosened in case of settlement

(recommendation: elongation of bolts must be greater than 0.17 mm).

Any lifting of the gearbox under dynamic stress must be excluded.

The working forces needed for calculating the bolts may be obtained from REINTJES. In

addition to the working forces, the forces added by mounted components must be included

in the calculation of the bolts.

As a matter of principle, the screwed connection must be secured against loosening.

The seats of bolt heads and nuts have to be plane-parallel. It must be ensured that the seat

under the bolt head and nut is sufficiently dimensioned in order not to exceed the permissi-

ble surface pressure.

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6.10.1 Fitting Bolts

The fitting bolts are designed to firmly fix the gearbox on the foundation.

When using metal seat chocks and a sufficient number of fitting bolts, the propeller thrust can

be transmitted through the foundation bolts exclusively. In this case the fitting bolts have to be

checked for bolt bearing pressure and shear. The fitting bolts have to be positioned in the direct

vicinity of the thrust bearing.

When using cast resin seat chocks the propeller thrust must not be transmitted through the

fitting bolts.

The geometry of the fitting bolts must be designed such that at least 50% of the height of the

gearbox foot and 50% of the height of the top plate are covered by the fitting shank.

The fitting bolts used must at least be of tensile strength 8.8 in accordance with

ISO 898. The fitting bolt bores are predrilled.

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6.10.2 Fitting bolts in combination with adjustable Metal Seat Chocks

The task of the fitting bolts is the exact fixing of the gearbox on the foundation.

A t ransmit ting of the propeller thrust by the f it ti ng bolts isn 't permiss ib le.

The geometry of the fitting bolt has to be so formed that at least 50% of the gearbox foot

height and 50% of the heights of the top plate are covered by the pass shaft.

The used fitting bolts must correspond to at least the strength class 8.8 to ISO 898.

The drillings for the fitting bolts are pre-drilled.

6.10.3 Fi tt ing steel bushes with Expansion Bol ts

The fitting steel bushes are designed to firmly fix the gearbox on the foundation and

transfer the propeller thrust. The fitting steel bushes have to be checked for bolt bearing

pressure and shear. The fitting steel bush bores are predrilled. The expansion bolts

used must at least be of tensile strength 8.8 in accordance with ISO 898. The fitting

steel bushes must have comparable material properties, however, they must at least

have a tensile strength of Rm = 800 N/mm² and a yield point of Re = 640 N/mm².

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6.10.4 Through Bolts

The used through bolts must correspond to at least the strength class 8.8 according

to ISO 898.

The through bolts must comply with application-specific requirements and be tightened

to the specified torque.

6.11 Connection to Engine

Conditions for connection to engine:

The gearbox is aligned with the propeller shaft.

The gearbox is firmly fixed on the foundation.

The engine is aligned axially to the gearbox. The space between gearbox and enginemust correspond to the mounting length of the flexible coupling. The axial reaction

forces of the flexible coupling on engine and gearbox shall be as low as possible.

Observe the initial values of engine and flexible coupling manufacturer.

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Operational steps for connection to engine

Align the engine with the adjusting screws, horizontally in longitudinal and transverse

directions, and vertically in front of the input flange of the gearbox, according to the

specified data.

With approved methods (gauges, laser), measure the horizontal and vertical gap

and sag values.


Radial misalignment 0.05 mm (centreline run-out 0.025 mm) - sag

Angular misalignment 0.05 mm related to 300 mm flange diameter - gap

Document your gap and sag values.

Consider the thermal expansion of the engine, gearbox and foundation at operatingtemperature.

Note that the resilient mounting elements of the engine will settle later.

Consider that displacement of the engine and gearbox can occur and that the working forces

can have an impact on the foundation.

Consider the maximum permissible reaction forces exerted by the flexible coupling on the

gearbox input shaft.

During all operations, observe the instructions of the engine and coupling manufacturers.

When the engine alignment and the alignment check are finished, the engine foundation can

be cast.

Connect gearbox and engine with the flexible coupling according to the manufacturer's

instructions.

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Variables for determining the reaction forces of the flexible coupling

Determine the radial reaction force of the coupling FR due to radial misalignment.

FR = r x Cr dyn

r - radial shaft misalignment;

Cr dyn - radial stiffness of the flexible coupling

Determine the corresponding bending moment MB due to angular misalignment.

MB=0.5 x Cax x D x X1

Cax - axial stiffness of the flexible coupling;

D - diameter of the connection between the flange and the flexible coupling/flywheel

X1 - measured angular misalignment (GAP)

Inform REINTJES of the reaction force FR, the bending moment MB and the

distance L for approval.

L = S + X = distance from point of application FR to big cone diameter of gearbox input shaft

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6.12 Connection to the gearbox PTO

Pre-conditions for connection to the PTO:

The gearbox is aligned with the propeller shaft.

The gearbox is aligned with the engine.

The gearbox is firmly fixed on the foundation.

Operational steps for connection to PTO

Align the auxiliary unit driven by the PTO (e. g. generator) with the adjusting screws,

horizontally in longitudinal and transverse directions, and vertically in front of the PTO

shaft of the gearbox, according to the specified data.

With approved methods (gauges, laser), measure the horizontal and vertical gap

and sag values.


Radial misalignment 0.05 mm (centreline run-out 0.025 mm) - SAG

Angular misalignment 0.05 mm related to 300 mm flange diameter - GAP

Document your GAP and SAG values.

Consider the thermal expansion of the gearbox, auxiliary unit and foundation at

operating temperature.

Consider that displacement of the auxiliary unit and gearbox can occur and that the

working forces can have an impact on the foundation.

Consider the maximum permissible reaction forces exerted by the flexible coupling

on the gearbox PTO shaft.

During all operations, observe the instructions of the auxiliary unit and coupling

manufacturers. Fix the auxiliary unit on the foundation according to the supplier's

instructions.

Determine the reaction forces of the flexible coupling (as described in point 6.11).

Connect PTO and auxiliary unit with the flexible coupling, according to the manufacturer's

instructions.

The alignment will on ly be recognised as complete by REINTJES, if you completely

documented the alignment of propeller shaft - gearbox, gearbox - engine and gearbox

PTO - auxiliary uni t!

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6.13 Alignment Check

6.13.1 Alignment Check on Engine Side

Check the gearbox foundation bolts for tightness.

Remove the flexible coupling on the engine.

Finally, check the gap and sag values and compare them with the data specified by the

coupling manufacturer. In case of deviations, please contact REINTJES.

6.13.2 Alignment Check on Propel ler Side


Remove the flange mounting screws on the propeller side.

Finally, check the gap and sag values and compare them with the specified data.

In case of deviations, please contact REINTJES.

6.13.3 Alignment Check PTO


Remove the flexible coupling.

Finally, check the gap and sag values and compare them with the data specified by the

coupling manufacturer. In case of deviations, please contact REINTJES.

6.14 Connection of Gearbox Components

6.14.1 Connection of valve control and supervision system

Lay the cables for the control and supervision system to the gearbox junction box and

connect them in compliance with the supervision drawing.

On the gearbox itself, the cables for the control and supervision system are completelyconnected.

Check the functioning of the valve control and the gearbox supervision system according to

the commissioning instructions.

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6.14.2 Connection of Shaf t Brake

Lay the compressed air line to the brake control valve.

The connection is indicated in the installation drawing.

Install a dehumidifier in the compressed air system.

The initial pneumatic pressure must be 5 - 7 bar.

6.14.3 Connection of Heat Exchanger

Install the pipes on the water side of the heat exchanger

with SAE counterflanges (see installation drawing). They must

be laid vibration-free. We recommend using rubber/steel-wire

compensators.

Seawater cool ing

The parts flown through by water of the heat exchanger consist of

seawater-proof materials. Nevertheless, for proper functioning the

following has to be observed:

Install a filter in the seawater circuit.

Ensure that there is sufficient anodic protection in the water pipes.

Freshwater cooling

Inform REINTJES, if an anticorrosion additive is admixed to the freshwater circuit.

The additive can reduce the cooling capacity of the heat exchanger.

!Note that the cross section at the entry to the heat exchanger on the water

side must not be reduced!

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6.14.4 Connection of Electr ic Standby Oi l Pump

If the stand-by pump is mounted on the gearbox, the pump

is supplied complete with all required pipes.

Lay the electric supply line to the standby oil pump.

Connect the motor according to the enclosed circuit diagram. You will find the circuit

diagram in the junction box of the pump motor.

During commissioning the pump must start running in the indicated sense of

rotation . Check the sense of rotation wi th an induction instrument and make the

proper terminal connections.

If the electric standby oil pump of your gearbox is supplied separately, you must also lay

and connect the suction and pressure pipes between the pump and the gearbox.

When connecting the pump pipes, pay attention to the indicated sense of rotation of the

pump.

Clean the pipes installed on board or changed during installation, e.g. by subjecting them

to acid treatment. The pipes must be free of dirt.

Observe the connection instructions (pipe cross section, length of pipe and number of

pipe bends).

CAUTION!

If the pump direction is reversed, there is danger that excessive pressure

builds up in the pipes

Danger of injury from bursting pipes

When connecting the pump motor electric supply line, pay attention to the

indicated sense of rotation of the pump.

DANGER!

of electric shock!

Do not connect/disconnect or service this device until power supp ly has been

disconnected!

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Index


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Index

A Alignment 48

Alignment Check 65

BBrief product description 19

CCharacteristics of the gearboxes 22

Connection of Gearbox Components 65

Connection to Engine 61

Connection to Propeller Shaft 48Connection to the gearbox PTO 64

Corrosion protection 28

Interruptions in operation 31

Protective measures 31

Corrosion protection oils 33

DDemands on the installation personnel 46

Directional valves 39, 43

E

Electrical lubrication oil pump 67Electrical stand-by pump 39

FFixing the gearbox to the foundation 50

GGearbox type 35

Gearbox with shaft brake 43

HHeat exchanger 38

Hydraulic system 43

IIllustration of the gearbox 19

Initial preservation 28

Installation 45

Introduction 17

LLong interruptions in operation 31

OOil filter 38

Oil pump 38

Operation delay system 39, 44

PPackaging inspection intervals 29

Path of drive 35

Place of installation requirements 46

Preservation 28

Opening the gearbox 31

Preservation oil

Volume to be filled 30

Preservation oils 33

PTO K41 40PTO K51 41

RRequirements for assembly personnel 13

Responsibility 45

SSafety 11

Screwed Connections 58

Seat Chocks 57

Setting up the gearbox 46

Set-up 45Shaft brake 44

Storage 26

TTechnical Data 21

Transport and Storage 25

Types of Documentation 17

Vvalves

Directional 39, 43

Pressure limiting 38

VCI preservation oil 28

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Index

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No part of this document may be reproduced in any form(by printing, photocopying or other means) or processed,duplicated or circulated electronically without prior wr ittenapproval of REINTJES GmbH.

© 2013 REINTJES GmbH All Rights Reserved.

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Table of Contents

Operation Manual 3

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Table of Contents

1 Safety ............................................................................................................................................................5

1.1 Meaning of Warnings and Notes ............................................................................................................. 5

1.2 Basic measures of caution ....................................................................................................................... 6

1.3 Requirements for operating and maintenance personnel ...................................................................7

1.4 Safety information for assembly .............................................................................................................. 8

1.5 Protective measures against fire and danger of explosion ................................................................. 9

2 Putt ing the unit into operat ion ........................................................................................................ 11

2.1 Note this safety information before putting the unit into operation the first time ........................... 11

2.2 Installation check ..................................................................................................................................... 12

2.3 Fill with operating oil (initial filling) ......................................................................................................... 12

2.4 Handling the checklists for putting th

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