Innovative Power Transmission

RENK-MAAG

Field Service
Always Nearby

RENK-MAAG service team

We are ready for takeoff!

Professional, swift and customer
focused this is our dynamic service
team. Our service technicians work
tirelessly the world over all year round
to install and maintain gearboxes for
our customers. Any necessary repairs
are undertaken on site wherever
possible.
In the event of more complex issues,
such as vibrations in the train, we provide
professional assistance which could
include a vibration measurement and
analysis by our testbed specialists.
More information about our services can
be found in this brochure.

We maintain contact with our customers before, during and after the sale
of a gearbox. Our goal is the satisfaction of our customers. They appreciate having a competent and reliable
partner our RENK-MAAG service team.

Our dynamic
service team
is ready for takeoff.

Even the best machines need maintenance

On-site support

You have chosen to put your trust

in a RENK-MAAG gearbox. It is in your
hands to preserve the legendary
longevity and robustness of this quality
product by following the corresponding
service and inspection intervals.

RENK-MAAG offers world-wide services

for all MAAG turbo and marine gear
boxes. Certified service technicians with
years of experience inspect and maintain
the gearboxes in accordance with the
customized maintenance schedule to suit
your needs. Regular gearbox maintenance ensures safe and reliable system
operation.

Gearbox condition and availability with maintenance

Critical range

Operating condition

New

Safe range

Certified technicians with years

of experience inspect
and maintain the gearboxes on site anywhere
in the world.

Gearbox maintenance

0
Check 1

Check 2

Check 3

Service life

Other checks...

Service intervals
Extend the overall service life through regular maintenance
(see Maintenance Schedule attached).
Lifetime without service

After each inspection or overhaul, our

service technicians will provide you on
the spot with a system report containing the following points of importance to
safety and optimum availability:
General condition of the gearbox
Possible and detected defects
Recommended spare parts
Due date and scope of next inspection

 egular gearbox
R
maintenance
ensures safe and reliable
system operation.

Regular maintenance long operating life

Maintenance schedule
Depending on the number of years
of operation or operating hours since
commissioning or the last maintenance
work, we recommend the following
RENK-MAAG standard inspections:

20000 operating hours check

The gearbox is opened but not dis
mantled to gauge the condition of its
interior. This is ideal if you have only
a brief shutdown or a limited budget.

1000 operating hours check

This check is undertaken on gearboxes
when taken into service.

40000 operating hours check

This large-scale check involves dismant
ling, cleaning and re-assembling the
gearbox. If necessary, individual components or worn parts are replaced.

8000 operating hours check/annual check

A brief check through the inspection
cover provides an overview of the
gearbox condition.

Inspection example using a 20 000 operating hours check

Phone:

No.

Process name

-2

-1

Check spare parts stock

Project:

Process

Milestone

External processes

Interruption

Collective process

External milestone

Underway

Collective process for project

Page 1

Qualifying date

Check
1000 oph 8000 oph 20000 oph 40000 oph
Installation of installation/
check
check
check
check
Commissioning
Working days

10

13

34

67

Operating
years since
last inspection

23

5+

An operating year is considered to be 8000 operating hours in this table.

RENK

-M

AAG
Sulze
P.O. r-Allee 46GmbH
B
CH-8 ox 3068
Switz 404 Win
erland terth
ur

RENK-MAAG GmbH

Phone +41 (0)52

262 89 88
Fax
+41 (0)52 262
89 89
info@renk-maag.c
h
www.renk-maag.c
h

Main

nce

Phon
Fax e +41 (0
+41 )52 26
info
2
(0
@r
www enk-m )52 262 89 88
89 89
.renk aag.ch
-maa
g.ch

Sche

Weekly

The maintenance
schedule is attached
to this brochure.

work

iption

of

+ 41 52 262 87

RENK-MAAG

GmbH, CH-840

4 Winterthur,

Switzerland
We reserve all

rights in connec

tion with this docume

nt.

ENK-

MAA

G Tu

rbo G

earb

oxes

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

X
X

X
X

X
X

X
X

ing co

nditi

on

We recommend
carrying out
standard inspections.

in un
co
in un upled co
co
nd
in un upled co ition
coup
nd
led co ition
nditi
on

ing co

nditi

on

in op
er
acco ating co
nd
rding
to m ition
anuf
actu
acco
rer
rding
to m
anuf
actu
rer

X
X

X
X
X
X
X

arks

erat

erat

X
X
X

X
X

Rem

in op

in op

in op
er
in op ating co
nd
erat
ing co ition
nditi
on

62

for R

Daily
/Con
stan
Wee
tly
kly
After
first
10
00 op
Year
h
ly or
ever
y 800
Ever
y 20
0 op
000
h
oph
Ever
y 40
000
oph
Spec
(or la
ial se
test
rvice
after
(on re
5 ye
ques
ars)
t)

bo

x
work
Che
ck dr
ive gr
Che
ck ro
oup
fo
to
Che
ck an rs visua r noise an
Other couplings
lly
d re
d leak
Che
(if applicable)
tight
ck
s
Check all bolt
all bo
en ge
Che
connections
lt co
ck lo
box
Remararks
Maintenance
ad co nnec
anch
Che
according to manu
tions
oring
ck
ntac
facturer
Gear driven pump
t pa
X
Che X no load
X
ttern
ck al X toot
of te
Check for noise
ignm
h co
C
he
et
and leaks
ntac
en
h
ck al
t pa to (red in
accor
ignm t Xof gear
Maintenance
ding
Che
tte manufactur
k orer
according to manu
ent
ck, cl
met
of ge box dr rn (blue
facturer
X
ean
allic)
Rotary drive/ Turnin
Dism
ink te
iving
arbo
and
an
g Gear/ barring
x
st)
mac
gear
Check drive for
Lubr tling and if necess driven
hi
noise and leaks
icatio
ary re
insp
mac ne
Xec accor
Che
Check oil level
ding
plac
to manuhifactur
tion
ck oi n system
e air ne er
of
l
al
le
Che
filter
Check all bolt
l gear
ck Dp vel
connections
box
X
C
when
of
pa
Maintenance
he
opera
lube
X ckX
rts
ting
according to manu
lube
oil filt
Che
facturer
oil
Synchronous clutch
er
X ck lu
bricat for water and clea
Che
Check for noise
ion
n/
cont
ck an
and leaks
ent/c replace
d clea system
Che
X
Dismantle, clean,
onta to manu
ding
ck,
for accor
n
minat facturer
check
leak
Maint clean an lube oil
s
X
ion (a
Maintenance
cool
enan
d if ne
according to manu
nalys
er
ce
Extra
cess
facturer
is)
Nondestruvtive
ary re
chec ofX lubric
testing
X atio
Che
plac
Ultrasonic testing
ck va ks for
HET nXsystem e lube
(toothing, bearin
cuum
Che
gs)
gear according to oi
l filter
ck in
Magnetic partic
sy
manu
facturer
le testing (tooth
Instru strumen stem (fu boxes
ing)
Dye penetrant
nc
ts an
men
tio
testing (toothing,
Rec
tatio
d va X n)recom
bearings)
ord
Operational vibrat
lve
n
mend
ed
(mon
oper
s
every 40 000
Che
ion measureme
ating
oph
itorin X (func
ck op
nt and analysis
tion)mended
Miscellaneous
data
g of recom
every 40 000
erat
Che
oph
ing
X sh
ck
aft anmended
recom
Inspection of
special tools for
Func fit and tig data
d ca every 40 000 oph
gearbox
X
tio
sing
htne
Inspection of
vibrat
Instal n chec
ss of
special tools for
k
anchoring
latio
instru
ion +
Inspection of
n ch
Che
men
spare parts / spare
te
ec
mp.)
X
ck
ta
k
gearbox
tion
for vis
Preservation of
Che
spare parts / spare
ual da
ck pr
X
gearbox
Inspection of
mag
otec
X
Che
third-party parts
e X
tive
ck
Verifi passag Xtubes
X
es fo
catio
r leak
n of
Toot
junc
s
hed
X
tion
according to manu
co
Che
box
facturer
ck co uplings
Important:
uplin
Che
gs
ck
fo
all bo
This Maintenan
Che
ce Schedule
lt co r leaks
ck lu
is not plant-specifi
nnec
but does not
be oi
C
take the place
tions
l pipi
ck
of any plant-specifi c; it can also be usedheas
according should
ng
suppl
c information.
placemen
Dism a(re
be adapted to
The work
e) lu t to the instruction manu
operation. We
the
antle
to
be, carrie
brican
recommend having current operating hours
al
d out
shall
cl
epla
of theRgearb
be either consid
all work perfor
ts on
n
ceoxOandeaany
ered
med by one of
coup
d ch malitie
-rings anabnor
our experienced
service@renk-maa
eck s notice
lingsd during
g.ch
specialists.
X

Description of

dule

(or latest after

5 years)
(on request)

Gear

Special service

8000 oph
Yearly or every

Descr

Every 20 000 oph

Every 40 000 oph

Daily/Constant

ly

oph

tena

After first 1000

Sulzer-Allee 46
P.O. Box 3068
CH-8404 Winte
rthur
Switzerland

X
X
X

X
X

X
X
X

only

for oi

l-fille

d co

uplin

gs

Insurance spare parts on-site

RENK-MAAG recommends holding
the following key components in stock:
1
1
1
1

spare
spare
spare
spare

set
set
set
set

of
of
of
of

rotors
bearings
oil scrapers
instrumentation

The defective parts can then be replaced

immediately, limiting any production
downtime to a minimum.
Keep in mind that even under the best
conditions, it will take several months for
spare bearings or rotors to be delivered.

Preparing for deployment and planning

Extensive organisation
Both the RENK-MAAG service tech
nicians and the back office are flexible,
quick to respond and reliable.
Our service doesnt just cover technical matters, we also organise all
administrative aspects of the service,
including processing the travel arrange
ments required, organising travel,
special training courses or medical
examination and certification.

Before they set out,

the service technicians
are always prepared
and instructed by our
back office. They are
informed of special
customer concerns
and are provided with
details of the gearbox or entire system.
Once on site, our
service technicians
are therefore ready
to get started right
away.

Coordinating dates
As well as planning deployment, we
will happily provide a customised work
programme. This provides you with
a detailed overview of the work to be
undertaken in advance of the service
date. You can also plan shutdown times
in advance and coordinate them with
other work required on your system.
This can prevent bottlenecks, such as
crane capacities.

Planning deployment

Once you have opted

for a RENK-MAAG
service, you can rely
on us to take care
of everything else.
We are a reliable partner for all gearbox
maintenance!

You can rely

on us to take care
Month
Month
calendar week
calendar week
calendar week
calendar week
calendar week
calendar week
calendar
week else.
calendar week
of everything
M29 T30 W31 T01 F02 S03 S04 M05 T06 W07 T08 F09 S10 S11 M12 T13 W14 T15 F16 S17 S18 M19 T20 W21 T22 F23 S24 S25 M26 T27 W28 T29 F30 S01 S02 M03 T04 W05 T06 F07 S08 S09 M10 T11 W12 T13 F14 S15 S16 M17 T18 W19 T20 F21 S22 S

And if something does happen?

WHAT CAN BE DANGEROUS FOR A GEARBOX?

WHAT DO I NEED TO WATCH OUT FOR?
Poor lube oil quality or incorrect
oil; ask for our list of recommended
lube oils.
Incorrect train alignment
Insufficient oil flow
Poor foundations
Operation during overload
Creepage current on the system
This list is for information only
and is not exhaustive.

The gearbox
is often an indicator of the condition
of the entire system.

10

The condition of the gearbox often indicates the condition of the entire system.
As the most sensitive component in the
train, the gearbox very quickly indicates
negative changes. This can be seen
from a detailed inspection of the gearbox
interior.
RENK-MAAG recommends regular gearbox checks. In case of general system
inspections the gearbox should be part
of the inspection too.

Training and qualification

The RENK-MAAG service technicians

have undertaken all standard safety
trainings and hold the certificates required
to undertake the work.
Our service technicians attend training
courses on an ongoing basis. These
cover all health and safety and environmental protection requirements. For
the work on oil platforms we attend special safety training courses and make
sure knowledge is regularly refreshed.
Our customers appreciate our years of
practical experience and the fact that we
continuously train our staff.

Some impressions
of intense training.

11

Additional on-site services

ULTRASONIC TESTING
WITH PHASED-ARRAY METHOD
The phased-array method uses several
ultrasonic elements and electronic delays
to produce sound beams which can be
electronically controlled, probed, swivelled
and focused. This method allows for rapid
testing, storage of all data and testing
with several angles.

One unit for two ultrasonic

measurement methods
By using the phased-array method, we
are able to test the toothing of a gearbox
with maximum reliability. The same unit can
be used to precisely locate any damage
and establish its size using conventional
ultrasonic testing. RENK-MAAG can
therefore make optimum use of both
measurement methods and their respective benefits.

Areas of application
Testing complex geometries such
as involute teeth, cycloid teeth etc.
Testing torsion shafts, thrust collars,
couplings, pump rotors
Testing welding seams on gearbox
housings, pressure pipes, basic
frames etc.
Testing the corrosion of flanged areas,
wall thickness measurement etc.
CONVENTIONAL ULTRASONIC TESTING
The sound waves are radiated through
a contact medium into the test body.
The returned or transmitted wave
patterns are recorded and analysed.
Compared with the considerably faster
phased-array method, this method
has the advantage that it calculates
the position and dimension of inclusions,
structural cracks, blow holes etc. in
the sub-surface structure of the workpiece.
Areas of application
T
 esting white metal bearings, especially
the bonding between the bearing body
and layer of white metal.
Testing teeth or other highly loaded
parts.
Long-term monitoring of gearbox
teeth and rotors.

12

Scanning electron microscopy

A tooth replica can be used to examine
the surface structure of the tooth using
scanning electron microscopy. This test is
used to explain the causes of slight to
major tooth damage such as grey staining,
micropitting, electric erosion resulting
from creepage current etc.

Other on-site services

Magnetic powder and dye penetration
testing for crack testing of highly loaded
gearbox parts.
Flow rate and pressure measurements
on the lube oil system.
Endoscopic examination of gearbox
parts.

E ven the slightest

damage to the tooth
surface provide clues as
to the cause.

M
 easuring and aligning shaft trains
using laser measuring methods or dial
gauges.
Casing vibration, airborne noise and shaft
vibration measurements on the gearbox
including the associated analyses.
Other services.

Need a more in-depth analysis?

We will happily send out one of our
specialist to test your gearbox.

13

Modifications and repairs at RENK-MAAG

RENK-MAAG repairs or overhauls all

RENK-MAAG products where necessary.
The same applies for all MAAG turbo
and marine gearboxes, couplings and
GP pumps for which spare parts are
manufactured according to original
drawings. RENK-MAAG also maintains
individual components such as bearings,
rotors, turning gears, etc. and also
conducts repairs of third party products.

A repair is possible
in the majority
of cases.

REPAIR PROCEDURE
A detailed inspection is initially made
of the affected parts. This results in an
objective report regarding the condition
of the parts and any deviations from
the norm, as well as a repair proposal.
The second step is the repair itself.
A test run of each complete gearbox
or coupling can be conducted on our
efficient testbed for certification purposes.
REPAIR GOALS
Quick turnaround time
Original dimensions are maintained
where possible
Reusable as new parts
MODIFICATIONS
RENK-MAAG undertakes modifications
of gearboxes after clarification of the
technical feasibility.
This includes:
Speed alterations
Performance modifications
Additional instrumentation
Turning gear
Mounted pumps
Custom modifications

14

Always nearby

Contact us all over the world

RENK-MAAG is represented by designated agents in over 35 countries around
the world. So we can advise and support
our customers on all continents directly
whether on new gearboxes or couplings,
modifications, replacements, spare parts,
repairs or field service.
The current contact details
are readily available on our website:
www.renk-maag.ch

 e are just
W
next door
simply have a look
at the contact details
on our website.

15

RENK-MAAG
at your disposal

New products / spare parts /

maintenance / testbed
RENK-MAAG supports you before,
during and after the purchase: Our
sales team is happy to support you
when it comes to new equipment or
spare parts for couplings and gearboxes of previous MAAG models.

New gearboxes and components can

be tested on our modern testbed
using the latest technology for monitoring and diagnostics of operating
conditions, vibrations, temperatures or
noise.

RENK-MAAG GmbH
P.O. Box 3068 Sulzer-Allee 46 CH-8404 Winterthur
Telephone +41 52 262 89 88 Fax +41 52 262 89 89
info@renk-maag.ch www.renk-maag.ch

03.2013_2 e

Our manufacturing and other operational activities

are implemented in accordance with our
internal quality assurance system and in strict compliance
with ISO 9001 : 2008 and ISO 14001 : 2004.

RENK-MAAG GmbH

Sulzer-Allee 46
P.O. Box 3068
CH-8404 Winterthur
Switzerland

Phone +41 (0)52 262 89 88

Fax +41 (0)52 262 89 89
info@renk-maag.ch
www.renk-maag.ch

Every 40 000 oph (or latest after 5 years)

X
X
X
X
X
X
X

X
X
X
X
X
X
X

Special service (on request)

Every 20 000 oph

Yearly or every 8000 oph

After first 1000 oph

Weekly

Description of work

Daily/Constantly

Maintenance Schedule for RENK-MAAG Turbo Gearboxes

Remarks

Gearbox
Check drive group for noise and leaks
Check rotors visually
Check and retighten gearbox anchoring
Check all bolt connections
Check load contact pattern of teeth (red ink or metallic)
Check no load tooth contact pattern (blue ink test)
Check alignment of gearbox driving machine
Check alignment of gearbox driven machine
Check, clean and if necessary replace air filter
Dismantling and inspection of all gearbox parts

in operating condition
X
X
X
X
X
X
X

X
X
X
X

in uncoupled condition
in uncoupled condition
in uncoupled condition
X

Lubrication system
Check oil level
Check Dp of lube oil filter and clean/replace
Check lube oil for water content/contamination (analysis)
Check lubrication system for leaks

X
X
X

Extra checks for

Check and clean lube oil cooler

Check, clean and if necessary replace lube oil filter
Maintenance of lubrication system

HET

in operating condition

in operating condition
according to manufacturer
X
X

according to manufacturer

gearboxes
X
X

Check vacuum system (function)

Check instruments and valves (function)

X
X

X
X

X
X

Instrumentation (monitoring of shaft and casing vibration + temp.)

Record operating data
Check operating data
Check fit and tightness of instrumentation
Function check
Installation check
Check for visual damage
Check protective tubes
Check passages for leaks
Verification of junction box

X
X

in operating condition
in operating condition
X
X
X
X
X
X
X

Toothed couplings
Check couplings for leaks
Check all bolt connections
Check lube oil piping
Check (replace) lubricants on couplings
Dismantle, clean and check
Replace O-rings

X
X

X
X
X

X
X
X

only for oil-filled couplings

Every 20 000 oph

Every 40 000 oph (or latest after 5 years)

Special service (on request)

Yearly or every 8000 oph

Description of work

After first 1000 oph

Phone +41 (0)52 262 89 88

Fax +41 (0)52 262 89 89
info@renk-maag.ch
www.renk-maag.ch

Weekly

Sulzer-Allee 46
P.O. Box 3068
CH-8404 Winterthur
Switzerland

Daily/Constantly

RENK-MAAG GmbH

Remarks

Other couplings (if applicable)

Check all bolt connections
Maintenance according to manufacturer

according to manufacturer

according to manufacturer

when operating

according to manufacturer

according to manufacturer

X
X
X
X

recommended every 40 000 oph

recommended every 40 000 oph
recommended every 40 000 oph

according to manufacturer

Gear driven pump

Check for noise and leaks
Maintenance according to manufacturer

Rotary drive/Turning Gear/barring gear

Check drive for noise and leaks
Check oil level
Check all bolt connections
Maintenance according to manufacturer

X
X

Synchronous clutch
Check for noise and leaks
Dismantle, clean, check
Maintenance according to manufacturer

X
X

Nondestruvtive testing
Ultrasonic testing (toothing, bearings)
Magnetic particle testing (toothing)
Dye penetrant testing (toothing, bearings)
Operational vibration measurement and analysis

Miscellaneous
Inspection of special tools for gearbox
Inspection of special tools for anchoring
Inspection of spare parts / spare gearbox
Preservation of spare parts / spare gearbox
Inspection of third-party parts

X
X
X
X

Important:

This Maintenance Schedule is not plant-specific; it can also be used as a supplement to the instruction manual
but does not take the place of any plant-specific information. The work to be carried out shall be either considered
according should be adapted to the current operating hours of the gearbox and any abnormalities noticed during
operation. We recommend having all work performed by one of our experienced specialists.

RENK-MAAG GmbH, CH-8404 Winterthur, Switzerland

service@renk-maag.ch

+ 41 52 262 87 62

Wereserveallrightsinconnectionwiththisdocument.