PART II

Reduction Gearbox

Instruction Manual

Page 2 Printed 01.08.2012

Instruction manual for Servogear Marine Reduction gear

This manual is valid for the following configurations: HD 180 B HD 180 C HD 195 B HD 195 C

Servogear A/S, N-5420 Rubbestadneset, NORWAY - Telefon: + 47 53 42 39 50 - Telefax: +47 53 42 39 99 e-mail: main.office@servogear.no

Instruction Manual TABLE OF CONTENTS

Page 3 Printed 01.08.2012

TABLE OF CONTENTS...................................................................................................3 2 GEAR...............................................................................................................................4 2.1 GEARBOXE VERSIONS, MAIN GEAR DATA ................................................... 4 2.2 TEKNICAL DATA.................................................................................................... 7 2.3 MONITORING.......................................................................................................... 7 2.4 OIL CIRCUIT............................................................................................................ 8 2.5 OIL PUMP, OILFILLING ....................................................................................... 9
2.5.1 Approved oil types for the reduction gearbox: .......................................................................... 10

2.6 COOLINGWATER ................................................................................................. 10

2.6.1 Cooling Water flow rates: ......................................................................................................... 10

2.7 2.8 2.9 2.10 2.11 2.12 2.13

HYDRAULIC CLUTCH................................................................................... 10 SERVOSYSTEM ............................................................................................... 10 STARTING AND ADJUSTING OF PROPELLER PITCH ......................... 11 MAINTENANCE............................................................................................... 11 Periodical Maintains.......................................................................................... 11 New gear/ gear overhaul.................................................................................... 11 PROTECTION OF PROPELLER SHAFT .................................................... 12

Servogear A/S, N-5420 Rubbestadneset, NORWAY - Telefon: + 47 53 42 39 50 - Telefax: +47 53 42 39 99 e-mail: main.office@servogear.no

Instruction Manual 2 GEAR

2.1 GEARBOX VERSIONS, MAIN GEAR DATA
Type U- gear H- gear H- gear U- gear H- gear H- gear Gear type HD 180 A HD 180 B HD 180 C HD 195 A HD 195 B HD 195 C Direction of rotation Left (ccv) Right (cv) Right (cv) Right (cv) Left (ccv) Left (ccv) Red. 2,14:1 2,14:1 2,14:1 2,14:1 2,14:1 2,14:1 weight (dry) 200 kg 200 kg 220 kg 240 kg 240 kg 260 kg

Page 4 Printed 01.08.2012

Max. Torque1 2180 Nm 2180 Nm 2180 Nm 2180 Nm 2180 Nm 2180 Nm

P/n 0,22 0,22 0,22 0,22 0,22 0,22

HD 180 B and HD 195 B are separately mounted H-gear, HD 180 C and HD 195 C are flanged directly to the engine. 1 2 3 4 5 6 7 8 9 10 11

Pict. 1, HD 180 C

Type approval certificate form DnV for these rating

Servogear A/S, N-5420 Rubbestadneset, NORWAY - Telefon: + 47 53 42 39 50 - Telefax: +47 53 42 39 99 e-mail: main.office@servogear.no

Instruction Manual
11 10 8 7 12 13 14 15 16

Page 5 Printed 01.08.2012

Pict. 2, HD 180 C 1. Pitch lever 2. Pitch indicator 3. Air Ventilation 4. Clutch pressure adjusting (on top), and servo pressure adjusting 5. Solenoid valve for clutch engagement. 6. Valve block (Clutch, Servo and safety valves) 7. Manometer for Clutch pressure 8. Oil Cooler 9. Sign with gear type and serial number. 10. Manometer for servo oil pressure 11. Oil pump 12. Temperature alarm 13. Oil level alarm 14. Dip stick 15. Differential pressure indiakator for oilfilter 16. Oilfilter The actual gear configuration can be different from showed on pictures (pict. 1 4)

Servogear A/S, N-5420 Rubbestadneset, NORWAY - Telefon: + 47 53 42 39 50 - Telefax: +47 53 42 39 99 e-mail: main.office@servogear.no

Instruction Manual
1 2 3 8 9 10

Page 6 Printed 01.08.2012

11

Pict. 3 11 10

HD 195 C 16 15 8 9 13 5 4 6 7 14

Pict. 4

HD 195 C

Servogear A/S, N-5420 Rubbestadneset, NORWAY - Telefon: + 47 53 42 39 50 - Telefax: +47 53 42 39 99 e-mail: main.office@servogear.no

Instruction Manual

Page 7 Printed 01.08.2012

2.2 TEKNICAL DATA

Oil volume: Diameter Servo piston: Stroke servo piston: Max servo pressure: Max servo force: Clutch pressure: Main Safety valve: Safety valve, clutch: Oil temperature: Oil pump: Weight: HD 180 8 liter HD 195 12 liter 110 mm 64 mm 110 bars 9 ton 14 16 bar 110 bars 10 bars over clutch pressure setting 65 75C 16 ccm se table kap. 2.1

The gear housing is made of cast iron. The gearbox has build in: Servo system for operating of propeller pitch. Hydraulic coupling (clutch) for engaging/ disengaging of propeller shaft. Thrust bearing for propeller thrust. Where it is requirement for stopping the propeller shaft fast or secures the propeller against rotation, it is possible to mount on hydraulic actuated shaft brake.

2.3 MONITORING
Manometers are mounted on the gearbox for surveillance of: Clutch pressure, normally mounted on valve block pos. 7. Servo oil pressure for propeller pitch control, normally mounted on the outlet side of the oil pump pos. 10.

Standard there are mounted an oil temperature switch, pos 12 which give alarm at 80C 2C. This switch can be another type specified by the yard or the customer. The oil filter have a mechanical difference pressure switch and/ or an electrical one, pos 15, that shows when it is time to change the filter element.

Servogear A/S, N-5420 Rubbestadneset, NORWAY - Telefon: + 47 53 42 39 50 - Telefax: +47 53 42 39 99 e-mail: main.office@servogear.no

Instruction Manual
2.4 OIL CIRCUIT

Page 8 Printed 01.08.2012

The oil pump for the hydraulic system is primary driven of the input shaft, and it is mounted at the aft end of the gearbox on the HD 180/ 195 B & C and at the forward end on the HD 180/ 195 A. Since the pump is directly connected with the input shaft, it means that the oil distribution starts when the engine start. The oil pump, pos 11, takes oil from the bottom of the gearbox and through the oil cooler; pos 8. After the oil pump the oil goes through a high pressure oil filter pos 16. The oil passes through the oil filter before it enters the oil distribution block. If the filter become dirty and clogged the oil will pass through a by-pass valve inside the filter housing and the oil enters the gear without being cleaned. It is important that the filter is being changed before this happen. The filter is supplied with a mechanical differential pressure sensor, and sometimes also an electrical (option). Before the by pass valve opens the electrical indicator will give an alarm or if there is a mechanical indicator, it will show that the filter needs to be changed. If there is only mechanical indicator, it has to be checked regularly. When checking the indicator the engine must be running. When starting the engine with cold oil, a by-pass situation can be arisen. Servogear A/S recommends that the engine is running at slow speed and reduced torque, at least 15min before the rpm is raised. With could oil temperature the servo oil pressure is normally some higher than normal. The pitch manoeuvring is also slower when the system is cold. Note! Remember not to through away the piece of pipe that is located in the upper part of the filter element. This shall be used over again when changing filter element. After the oil has passed the filter, it enters the oil distribution block, pos 6, which distribute the oil to the servo (pitch control) and to the clutch. It also regulates the pressure for the clutch and servo system. Another function that is build into the valve block is the safety valve for the clutch and servo system. A safety valve is build into the oil distribution block to protect the hydraulic system.

Figure 1 shows the oil circuit

Servogear A/S, N-5420 Rubbestadneset, NORWAY - Telefon: + 47 53 42 39 50 - Telefax: +47 53 42 39 99 e-mail: main.office@servogear.no

Instruction Manual

Page 9 Printed 01.08.2012

Figure 1

2.5 OIL PUMP, OILFILLING

The oil pump capacitate for HD 180 and HD 195 gearboxes are 16 ccm and a maximum pressure up to 110 bars. There is no oil on the gearbox when despatch. Before starting the gearboxes have to be filled with oil, note that it normally needs more oil the first time than later when changing oil after intervals. This because that oil cooler and servo cylinder needs to be filled up the first time. If the oil pressure does not rise immediately after starting the engine, it can be because of air in the system. If this happens, let out the air by unscrewing the hose on the pressure side gently, tighten it again as soon at the oil enters. This is done when the engine are idling. Oil changing intervals, see lubrication and maintains schema. To empty the gearbox for oil, unscrew the plug at the bottom of the gearbox. An alternative is to disconnect the pressure hose at the oil pump and start the engine. No the gear pump will empty the system. Be carefully so not spilling oil on people or into the sea. The engine must be stopped as soon as the pump is sucking air. Otherwise the pump will be damaged. Oil filling has to be done at top of the gearbox. A plug has to be unscrewed. When checking the oil level with the dipstick the clutch has to be disengaged, or the main engine stopped. Let the dipstick be at place for at least 30 sec. Because of air can be trapped in the dipstick pipe. This can give uncorrected oil level reading.

Servogear A/S, N-5420 Rubbestadneset, NORWAY - Telefon: + 47 53 42 39 50 - Telefax: +47 53 42 39 99 e-mail: main.office@servogear.no

Instruction Manual
2.5.1 Approved oil types for the reduction gearbox: STATOIL LOADWAY 100 MOBIL Mobil gear 627 BP GR - XP - 100 SHELL Omala oil 100 ESSO Spartan EP 100 TEXACO Meropa 100 FINA Giram 100 CASTROL Alpha SP100

Page 10 Printed 01.08.2012

2.6

COOLINGWATER

The gearbox have gear oil cooler mounted on that normally are connected to the main engines seawater circuit. The water pipes must not be of smaller dimension the connections on the cooler. 2.6.1 Cooling Water flow rates: HD180 max 100 lpm HD195 max 150 lpm

2.7

HYDRAULIC CLUTCH

The hydraulic clutch is of multi disk type. The disks are pressed together by a hydraulic operated piston. If the oil pressure at the clutch supply is to low, the plates will slip when the gear is loaded. This will cause over heat and the clutch plates will be damaged. The clutch oil pressure is adjusted at factory, but it must be checked at start up and regularly make sure that it is stable. If the pressure drops, check filter. Contact Servogear if needed.

2.8

SERVOSYSTEM

The propeller blades are adjusted with use of the internal servo system in the gearbox, which is transmitting an axial force and movement to the propeller hub through the push/ pull rod. To operate the servomotor for the propeller pitch control the servo slide valve is used. This valve consists of an outer part and an inner part. The outer part is operated mechanical by an actuator that is mounted on the outside of the gearbox (port side). With the piston rod a lever is connected. By moving the outer servo slide valve either forward or backward, the oil is leaded into the servomotor on either the front or backside of the servo piston. The servo piston that is connected directly to the pus pull rod will control the pitch when moving the outer servo slide valve. The inner part of the slide valve will automatically follow the outer part, and the outer and inner slide valve will balance each other when no movement from the outside is done. It will keep the system in position until another adjustment is done. If the servo piston are stopping against the cylinder end, the safety valve will open and this are set to 110 bars. The gear must not be operated with the safety valve open (110bars on the system). The pitch lever must therefore be adjusted so the piston will not reach the end of the cylinder. This can be done with adjusting screws beside the pitch lever. The manoeuvring speed is not decided of the force on the pitch lever, but on the

Servogear A/S, N-5420 Rubbestadneset, NORWAY - Telefon: + 47 53 42 39 50 - Telefax: +47 53 42 39 99 e-mail: main.office@servogear.no

Instruction Manual

Page 11 Printed 01.08.2012

oil capacitate. The oil capacitate depends also on the engine speed. The actuator force on the pitch lever must not exceed 30kp.

2.9

STARTING AND ADJUSTING OF PROPELLER PITCH

The engine has to be started with the clutch disengaged. When engaging the gear the propeller has to be in neutral position (0 pitch). Maximum pitch is adjusted under sea trail and are set by using the adjustment screws beside the pitch lever. The engine speed under manoeuvring should be set to approximately 1000 1200 rpm..

2.10 MAINTENANCE 2.11 Periodical Maintains

After 5000h or 5 years After 1000h or 1 year Engine Overhaul or 15 000h2 After 500h or 0.5 years

2.12 New gear/ gear overhaul

After 100h or 1 year >50-100h or 1 year Daily maintains tersyn

Visual control outside Oil level Control of actuator Control of diff. Press. indikator on filter3 Oil changing Filter change Control of hoses Control of gear mesh Control of oil pump Cleaning of oil cooler Control of shaft sealing Control of foundation Control of clutch plates Control of clutch connections (splines) Control of all bearings

When periodical engine overhaul is done, these points also shall be checked out on the gearbox, or when the gearbox have run for maximum 15 000houers
3

When only having mechanical differential pressure control.

Servogear A/S, N-5420 Rubbestadneset, NORWAY - Telefon: + 47 53 42 39 50 - Telefax: +47 53 42 39 99 e-mail: main.office@servogear.no

Follow periodical maintains

Daily maintains

Instruction Manual
2.13 PROTECTION OF PROPELLER SHAFT

Page 12 Printed 01.08.2012

Normally the stern tube consists of a pipe with rubber bearing inside, ref. The stern tube drawing. The water supply for the stern tube is normally supplied from the inside. This water supply shall lubricate and cool the rubber bearings. When the vessel is laying still over a longer period, the water inside the stern tube is trapped, and over time it will lose it contents of oxygen. This will cause corrosion on the propeller shaft, even when it is stainless steel. It is therefore of most important that vessel that is not in service are being started twice a week to change the water in the stern tube. The propeller shaft must also be connected to an outboard zinc anode.

Servogear A/S, N-5420 Rubbestadneset, NORWAY - Telefon: + 47 53 42 39 50 - Telefax: +47 53 42 39 99 e-mail: main.office@servogear.no