Renk RSV 1120c

B31495000-0 1/201
Electronic Manual
Remark:
This is an electronic manual!
This file is build out of different separate files.
For inquiry calls please use the RENK commisioning no.

and the RENK document no..
You will find this number on the particular page in this file.
Example: RENK document no.
B012345XX-Y
B012345 XX Y
document no. sheet no. revison
Printing:
text documents DIN A4
- as shown on the drawing or
drawings
- minimum DIN A3
technical service:
Tel.: +49 5971 / 790 – 260
Fax.: +49 5971 / 790 – 444
internet: www.renk.biz
mailto:service.rheine@renk.biz
RENK Aktiengesellschaft · Werk Rheine · Postfach 19 53 · 48409 Rheine · Telefon +49 5971 790-0 · Telefax +49 5971 790-208
Brief_intern / 2003-01 Fo.1063
B31495000-0 2/201
Technische Dokumentation
Technical Documentation
Getriebebaureihe: RSV-1120-C
Gearbox series
Kunde MAN B&W Diesel AG

Customer
Bestell Nr. 1130389-90; 1130402-03
Order no.
Werft Admarin
Shipyard
Neubau Nr. 10 - 11; 16 - 17
Hull no.
RENK Auftrags Nr. 859823 -859824; 860600-860601
RENK commission no.
Baujahr 2006; 2007
Construction year
Hersteller RENK AG
Manufacturer Postfach 19 53, 48409 Rheine
Rodder Damm 170, 48432 Rheine
Tel.: +49 5971 / 790 - 0
Fax: +49 5971 / 790 - 208
Technischer Service: Tel.: +49 5971 / 790 - 260
Technical service Fax: +49 5971 / 790 - 444
internet: www.renk.biz
mailto:service.rheine@renk.biz
RENK Aktiengesellschaft · Werk Rheine · Postfach 1953 · D-48409 Rheine · Tel. 05971/790-0 · Telefax 05971/790-208
Dokument in PDM B131831-1 Seite/page 1
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Schutzvermerk ISO 16016 beachten

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zugänglich gemacht werden.
Alle Rechte (für den Fall der Patent-, Gebrauchsmuster-, oder Geschmacksmustereintragung) vorbehalten."
RENK Aktiengesellschaft
Refer to protection notice ISO 16016

„All documents such as drawings, data and programmes, etc. and models, templates etc. shall remain our ex-
clusive property. They are only handed over to the agreed purpose and must not be used for any other purpose.
Copies or other reproductions including storage, processing or distribution by using electronic systems may only
be made to the agreed purpose. Neither originals nor copies may be handed over to third parties or be made
available in any other form.
All rights (in case of registration of patent, utility patent, design patent) reserved.“

B31495000-0 4/201
Ausfertigung der technischen Dokumentation

Issue of technical documentation
Ausgabe Adresse Anzahl Sprache Datum Abt. / Name

Edition Address Number Language Date Dep. / Na-
me
1. MAN B&W Diesel AG je 5 x 859823 Englisch 09.05.2007 RTKM-Br
Stadtbachstraße 1 1 CD
86153 Augsburg je 5 x 859824
z. Hd. Frau Reisenzahn 1CD
2. Mustafa SAYIN PDF Englisch 11.09.2009 RTKM-Brun
Gemi İnşaa ve Makinalari Mühendisi Kom.860600
Galata Denizcilik Tic. A.Ş.
Auszutauschende Dokumente
documents to change
Benennung Dokumentenart Dokumentennummer
name kind of document Document no.
alt / old neu / new

B31495000-0 5/201
Dokumentenliste / documentlist
859823-24; 860600-01
Bureau Veritas (BV)
Admarin
10; 11; 16; 17
Pos.-Nr. Beschreibung Hersteller Dokument Sprache Dok. nr.

Type / type
pos.-no. description manufacturer document language doc. no.
0.1 technical information RSV-1120C RENK DS D-E B131831

0.2 document list RSV-1120C RENK DS D-E B131827
1 technical information
1.1 data sheet marine gearbox RSV-1120C RENK DS D-E-F B087923
1.2 technical data gearbox RSV-1120C RENK DS D-E B087974
2 Manuals
2.1 operation manual marine gearbox RENK HB E B032423
2.2 lubrication instructions VG100 / SAE30 RENK DS E B198283
3 Drawings
Maßblatt
3.1 RSV-1120C RENK DW D-E 797487
dimensional drawing
Zusammenstellung
3.2 RSV-1120C RENK DW D-E 797488
assembly drawing
Ausrichtzeichnung
3.3 RSV-1120C RENK DW D-E 800173
alignment drawing
Hydraulik Schema
3.4 RSV-1120C RENK DW D-E 797391
hydraulic scheme
Überwachungsinstrumente
3.5 RSV-1120C RENK DS D-E B087925
supervision instruments
Drehschema
3.6 RSV-1120C RENK DS D-E B087924
torsional vibration scheme
Schaltschema
3.7 RSV-1120C RENK DW D-E 797392
wiring scheme
Fundamentbefestigung
3.8 RSV-1120C RENK DW D-E 803714
foundation fastening
4 Spare Parts Gearbox
4.1 gear box RSV-1120C RENK SL D-E B157111
5 Pumps
5.1 oil pump KF3/-6/.../196+197 Kracht HB E B012004
5.2 oil pump KF 4/150 Kracht SL E B000407
5.3 oil pump KF 4/180 Kracht SL E B000568
6 Cooler
6.1 pipe bundle cooler Bloksma HB E B007923
6.2 pipe bundle cooler P-2P-IV Bloksma SL E B004070
7 Filters
7.1 double filter DU… Internormen HB E B010953
7.2 double filter DU 101-401.34210 Internormen DS E B010756
7.3 clogging indicator AE 40.33848 Internormen DS E B010754
8 E-Motors
8.1 three phase motor HB E B000396
9 valves
9.1 pressure limiting valve SPVF Kracht HB E B000304
10 Instruments
10.1 pressure transmitter MBS 5100,5150 Danfoss DS E B000146
10.2 pressure control switch MBC 5000,5100 Danfoss DS E B000148
Page 1 of 2
Tabelle von PDM B131827-1 11.09.2009
B31495000-0 6/201
Dokumentenliste / documentlist
859823-24; 860600-01
Bureau Veritas (BV)
Admarin
10; 11; 16; 17
Pos.-Nr. Beschreibung Hersteller Dokument Sprache Dok. nr.

Type / type
pos.-no. description manufacturer document language doc. no.
10.3 pressure test valve MBV 5000 Danfoss DS E B014390

10.4 temperature sensor MBT 5252 Danfoss DS E B000150
10.5 temperaure switch MBC 8100 Danfoss DS E B036126
10.6 liquid level switch UNS 2000 Barksdale HB E B000206
9999 Bemerkungen / Remarks
HB = Handbuch / handbook *1): Pos.Nr. bzgl. Hydraulikplan

DS = Datenblatt / datasheet *1): pos.no. acc. to hydraulic scheme
SL = Ersatzteilliste / sparepart list
DW = Zeichnung / drawing
D = Deutsch
E = Englisch
Page 2 of 2
Tabelle von PDM B131827-1 11.09.2009
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chapter content
1 technical information
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Datenblatt Schiffsgetriebe
Data sheet marine gearbox
Feuille des donnees reducteur marin
Maßblatt-Nr.: Auftrags-Nr.:
Dimension sheet no. 0797487 Com.-no. 859823-4
Plan cote no. Com.-no.
860600-1
Schiffsgetriebe Type: Drehschwingungsschema Nr.:

Marine gearbox type RSV-1120C Torsional vibration scheme no. B087924
Type reducteur Plan des vibr. tortion. no.
Gültig ist der letzte Zeichnungs-Index ( ). The last drawing index ( ) is valid.
Besteller:
Customer Client MAN B&W Diesel AG
Bestell-Nr.: Klassifikationsgesellschaft:
Order-no. 1 130 389-90 Classification Society BV
No. de commande Societe de Classification
1 130 402-03
Eisklasse: Automation:
Ice class 1C AUT
Glace
Eisklassenauslegung erfolgte im Ballastzustand mit vollständig eingetauchtem Propeller / Ice-class design based on ballast state with totally submerged
propeller / Dimensionement pour la glace effectue sur lest, avec helice completement immergee
Bau-Werft: Motor:
Building yard Admarin Engine MAN B&W 6L48/60
Chantier de construction Moteur
Neubau-Nr.: Propeller:
Newbuildingno. 10,11 Helice Schottel
Construction neuve no.
16,17
Reederei:
Owner
Armateur
Betriebsdaten / Operating data / Donnes de service
Leistung:
Power PN = 6300 kW
Puissance
Motordrehzahl: min-1 Untersetzung:
Engine speed n1 = 500 rpm Reduction ratio i = 4,737
Vitesse du moteur tr/min Rapport
Propellerdrehzahl: min-1
Propeller speed n2 = 105,6 rpm
Vitesse d`helice tr/min
P.T.O.: P.T.O. II:
P.T.O. PN = 1277 kWmech P.T.O. II PN = kW
Prise de force Prise de force II
P.T.O.-Drehzahl: min-1 P.T.O. II-Drehz.: min-1
P.T.O.-speed n = 1816,7 rpm P.T.O. II-speed n= rpm
Vitesse du P.T.O. tr/min Vitesse du P.T.O. II tr/min
Motor elastisch aufgestellt: ja nein Motor umsteuerbar: ja nein
Main engine resiliently mounted yes no Engine reversible yes no
Moteur principal monte elastiquement oui noni Moteur reversible oui non
Kupplung zwischen Motor und Getriebe:

Coupling between engine and gearbox Vulkan Rato-R G383T
Accouplement entre moteur et reducteur
Kupplung zwischen Motor und P.T.O.: Gewicht:
Coupling between engine and P.T.O Vulkan Rato-R K5711 Weight
20.000 Kg
Accouplement entre moteur et prise de force Poids
Konstruktion Abt. RTKM

Datum: 23.06.2006 Name: Brüning Engineering Dept. RTKM
Date Nom Construction Dept. RTKM
RENK Aktiengesellschaft · Werk Rheine · Postfach 19 53 · D-48409 Rheine · Telefon 05971/790-0 · Telefax 05971/790-208
Dokument in PDM B087923-3

B31495000-0 9/201
Technische Daten / technical datas
Oil pumps
Part-no. 6010
Manufacturer Kracht
Type KF4/180
Speed [rpm] 1816,7
Yield [L/min] 305
Discharge pressure [bar] 6
Standby- pumps
Part-no. 6011
Manufacturer Kracht
Type KF4/150
Speed [rpm] 1715
Yield [L/min] 238
Discharge pressure [bar] 6
E-Motor Type AM 112MAA-4
Manufacturer STN
Electrical power [kW] 4,8
Voltage [V] 440
Frequency [Hz] 60
Speed [rpm] 1715
Rated current IN [A] 8,8
Starting current ratio IA/IN [-] 5,9
Efficiency [%] 83,4
Power factor cos ϕ [-] 0,83
Thermal class F
Protection IP55
Lube oil cooler

Part-no.
Manufacturer Bloksma
Type P20-2P-L=800
Cooling capacity [kW] 90
Lube oil side
- Flow quantity [L/min] 305
- Temperature, out [°C] 50
- Max. pressure [bar] 16
- Diff. pressure ∆p [bar] 0,34
Cooling water side Fresh water
- Flow quantity [L/min] 366* *May be reduced to
- Temperature, in [°C] 38 50% at low temperature
- Max. pressure [bar] 10
- Diff. pressure ∆p [bar] 0,14
Filters
Part-no.
Manufacturer Internormen
Type DU 251.40G
Filter surface per side [cm2] 3000
Mesh size [mm] 0,04
Operation pressure [bar] 30
Diff. pressure ∆p [bar] 10
Flow quantity [L/min] 300
Pressure controller AE40.33848
Control voltage [V DC] 110
Output signal [mA] 1000
Alarm pressure [bar] 2,5
Contact type Change over
Dokument in PDM B087974-1

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chapter content
2 manuals
B31495000-0 11/201
Operation Manual
Marine Gearboxes
B032423 – 2 / 01.2009
B31495000-0 12/201
‚Observe Copyright acc. to ISO 16016’
"All documents such as drawings, data and programs etc. as well as patterns, models,
templates etc. remain our exclusive property. Such documents or means are only
furnished for the agreed purpose and shall not be used for any other purpose. Copies or
other reproductions, incl. the storage, processing or distribution by using electronic
systems, shall only be made for the agreed purpose. Neither originals nor reproductions
shall be handed over to or made available to any third person.
All rights (for the case of patent, pattern or design registration) reserved."
Page 2
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Note:
Instead of the term ‚Marine Gearbox’ the short form
‚Gearbox’ is used throughout this operation manual.
This operation manual is applicable for the following basic

construction series of marine gearboxes not equipped with
multi-disk clutches:
1. RSV/RSH
2. HSU/HSN
3. SHH
4. NDS
RENK AG is certified according to DIN ISO 9001 / EN 29001.

No part of this manual may be reproduced in any way without the
prior written permission by RENK AG.
B032423 – 2 / 01.2009 – Page 3

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Index page
1 GENERAL ................................................................................................................. 7
1.1 Introduction ....................................................................................................................... 7
1.2 Copyright and Patent Rights ........................................................................................... 7
1.3 Reference to Classification Societies ............................................................................. 7
1.4 Important Notes for the User ........................................................................................... 8
1.5 Instruction/ Training ......................................................................................................... 8
2 SAFETY .................................................................................................................... 9
2.1 General............................................................................................................................... 9
2.2 Symbols and Signs........................................................................................................... 9
2.3 Safety Instructions for the Operating Personnel ......................................................... 10
2.4 Operation of the Gearbox............................................................................................... 11
2.5 Gearbox Repair and Troubleshooting .......................................................................... 12
2.6 Instructions on Particular Hazards ............................................................................... 13

2.6.1 Electrical energy .......................................................................................................................13
2.6.2 Noise.........................................................................................................................................13
2.6.3 Hydraulic/ pneumatic equipment ..............................................................................................14
2.6.4 Oils, greases and other chemical substances ..........................................................................14
3 GEARBOX SPECIFICATION.................................................................................. 15
3.1 Intended Application ...................................................................................................... 15
3.2 Residual Risk .................................................................................................................. 15
3.3 Symbols and Signs......................................................................................................... 18
4 THE PRODUCT....................................................................................................... 19
4.1 Function Description ...................................................................................................... 19
4.2 Product Description........................................................................................................ 19

4.2.1 Gearbox housing.......................................................................................................................19
4.2.2 Helical gear stage and secondary input and output shaft (PTH, PTI or PTO) ........................20
4.2.3 Hydraulic System and Piping System.......................................................................................21
4.2.4 Visual and electrical monitoring equipment ..............................................................................21
4.3 Protective Devices .......................................................................................................... 23
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5 TRANSPORT, STORAGE AND INSTALLATION ................................................... 25
5.1 Scope of Delivery ............................................................................................................ 25

5.1.1 Examination of the delivery.......................................................................................................25
5.2 Gearbox Connection Dimensions.................................................................................. 25
5.3 Transport ......................................................................................................................... 27

5.3.1 Transport by crane ....................................................................................................................27
5.3.2 Transport by road, rail and water ..............................................................................................28
5.4 Storage and Corrosion Protection................................................................................. 29
5.5 Installation and Control of Installation.......................................................................... 30

5.5.1 Foundation ................................................................................................................................30
5.5.2 Preparatory work prior to installation ........................................................................................31
5.5.3 Alignment of the gearbox to the propeller shaft ........................................................................32
5.5.4 Alignment of the driving engine to the gearbox ........................................................................35
5.5.5 Installation of shims ..................................................................................................................36
5.5.6 Tooth contact check..................................................................................................................36
5.5.7 Support of the thrust bearing ....................................................................................................37
5.5.8 Alignment of the auxiliary unit to the secondary input or output shaft (PTH, PTI or PTO
operation) ..................................................................................................................................................37
5.6 Connection of the hydraulic system ............................................................................. 38
5.7 Connection of the electrical control .............................................................................. 38
6 COMMISSIONING AND OPERATION .................................................................... 39
6.1 Filling Up Lube Oil .......................................................................................................... 39
6.2 Operation ......................................................................................................................... 40

6.2.1 Operation with the prime mover................................................................................................41
6.2.2 Disconnecting the prime mover ................................................................................................42
6.3 Special Operation Modes ............................................................................................... 42

6.3.1 First test run (Sea trial) .............................................................................................................42
6.3.2 Towing operation.......................................................................................................................44
6.3.3 PTH/PTI and PTH - operation...................................................................................................44
6.3.4 Local emergency control...........................................................................................................44
7 OPERATION FAULTS ............................................................................................ 45
7.1 Introduction ..................................................................................................................... 45
7.2 Operation Faults and their Correction .......................................................................... 45
7.3 Monitoring System .......................................................................................................... 47

7.3.1 Introduction ...............................................................................................................................47
7.3.2 Lube oil pressure.......................................................................................................................47
7.3.3 Lube oil temperature .................................................................................................................48
7.3.4 Lube oil differential pressure at the filter ...................................................................................48
7.3.5 Oil level .....................................................................................................................................48
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8 MAINTENANCE ...................................................................................................... 49
8.1 Introduction ..................................................................................................................... 49
8.2 Maintenance Schedules ................................................................................................. 51

8.2.1 Daily Maintenance ....................................................................................................................51
8.2.2 Maintenance Time Schedule ....................................................................................................53
8.3 Maintenance Work .......................................................................................................... 54

8.3.1 Cleaning the double oil filter .....................................................................................................54
8.3.2 Adjusting the pressure relief valve............................................................................................55
8.3.3 Gear teeth inspection................................................................................................................56
8.3.4 Lube oil level check...................................................................................................................57
8.3.5 Inspection of the thrust bearing pads........................................................................................57
8.3.6 Filling up lube oil .......................................................................................................................59
8.3.7 Lube oil change.........................................................................................................................61
8.4 Lubrication Instructions................................................................................................. 62

8.4.1 Lubricant requirements .............................................................................................................62
8.4.2 Table of lubricants.....................................................................................................................62
8.5 Repair............................................................................................................................... 63
8.5.1 General Instructions..................................................................................................................63
8.5.2 Screw tightening torques ..........................................................................................................64
8.5.3 Screw locking with Loctite.........................................................................................................64
9 DISPOSAL .............................................................................................................. 67
10 SPARE PARTS.................................................................................................... 68
11 NOTES ................................................................................................................. 69
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1 General
1.1 Introduction
This operation manual is an important guide for the efficient and reliable
operation of the gearbox. It contains essential instructions to operate the
gearbox in a safe, appropriate and economic manner. The observance of the
manual helps avoiding dangers, reducing repair costs and downtimes and
increases the reliability and lifetime of the gearbox.
The operation manual must be available near the gearbox at all times and has to
be read and applied by all persons being charged to work with, on or at the
gearbox, e.g.
− Operation, including troubleshooting during service,
− Disposal of fuel and auxiliary products or agents, and/or
− Maintenance (servicing, maintenance, repair).
1.2 Copyright and Patent Rights

This operation manual shall be treated confidentially. It shall be made available
to authorised persons only. It is not allowed to pass it on to a third party without
the prior written permission of RENK AG, Rheine Works.
All the documents are protected according to the copyright law. It is not allowed
to copy or reproduce any documents as a whole or in part or to use them or
make them known to others unless explicitly approved in writing.
Contravention is punishable and subject to claims for compensation. All rights to
exercise commercial trademarks are reserved.
1.3 Reference to Classification Societies

The gearbox is designed and built according to classification rules. The basis for
the classification of ships, other floating units or appertaining technical
equipment are:
− the building regulations with respect to the individual type of vessel or
equipment in question, which are in force at the time of the contractual
agreement between the gearbox manufacturer and the buyer,
− the rules for the classification and surveys in the most recent edition.
B032423 – 2 / 01.2009 – Page 7

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1.4 Important Notes for the User

The operation manual is an essential component of the gearbox. The operator is
responsible to ensure that the operating and servicing staff take due note of
these instructions.
The operator shall complete and supplement this operation manual by additional
instructions and regulations on the prevention of accidents and the protection of
the environment, including relevant instructions about supervision and reporting
obligations with respect to operational peculiarities, e.g. as far as the
organisation of work, work sequences and personnel are concerned.
In addition to the operation manual and the binding regulations on safety at work
being in force in the country and site of installation, all recognised subject-
specific and technical rules and standards on the safe and proficient execution of
work have to be carefully observed.
The operator/ user of the gearbox is not allowed to carry out any modifications,
conversions or changes to or at the gearbox or its accessory equipment and
devices which may effect the safety, without the prior written approval from
RENK AG!
This also applies to the installation and adjustment of safety devices and valves
as well as for welding operations at supporting structures.
All spare parts that are put in service have to comply with the technical
requirements specified by RENK AG. This is only ensured if original spare parts
are used.
Skilled and trained personnel shall be employed only. Responsibilities and
competencies of the personnel with regard to operation, maintenance and repair
have to be clearly defined!
For reasons of warranty, RENK AG has to be informed in writing about the date
of the first start-up of the equipment. The same applies if the gearbox is put out
of service or if it is resold to others.
1.5 Instruction/ Training

As the operator of the equipment you are obliged to advise and instruct the
operating personnel on valid legal provisions and regulations regarding the
prevention of accidents as well as on existing safety equipment at and around
the gearbox. The respective qualifications of the employees have to be taken
into account.
The operating personnel must have understood the instructions. It is of utmost
importance to ensure that the instructions are followed and observed.
This way only will promote and enhance the personnel’s awareness of danger
and safety at work.
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2 Safety
2.1 General
The gearbox has been designed and built according to recognised technical
safety regulations and in compliance with the latest state of technology.
Nevertheless, the use of the gearbox may cause risks for the operator or other
persons, or may deteriorate the gearbox or other equipment and property, if it is
- operated by unskilled and non-instructed personnel,
- not used for the intended application and purpose,
- improperly maintained or serviced.
2.2 Symbols and Signs

The following signs and symbols are used in this operation manual in order to
highlight particularly important details:
Danger!
This is to be understood as a warning that personal injuries can
occur if the given instruction is not followed exactly.
All WARNINGS must be strictly observed!
Attention!
This means that the gearbox and/or the associated equipment can
be damaged due to false and inaccurate observance of the specified
measure or instruction.
All the resulting PRECAUTIONARY MEASURES must be strictly
observed.
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Note
This refers to a procedure or to a circumstance of special interest or
importance. Within the interest of the proper application of the
gearbox as intended, all the stated measures and notes should be
carefully observed.
• This eye-catching point marks work sequences or operation steps. The steps
are to be followed in the order from up to down!
− This dash identifies enumerations.
Carefully observe all instructions given on plates and symbols directly affixed to
the gearbox, such a warning plates, operation plates, arrows indicating the
direction of rotation, component markings, etc.
Do not remove the plates and symbols that are directly attached to the
gearbox and maintain them in a clear and legible state!
2.3 Safety Instructions for the Operating Personnel

Every person charged or involved with the erection, commissioning, operation or
maintenance is obliged to have fully read and understood this operation manual,
in particular section 2 ‘Safety’.
It is too late to read the manual when the gearbox is already in service. This
applies in particular to personnel who operate the gearbox occasionally only.
The operation manual shall always be kept at hand in the vicinity of the gearbox.
The gearbox must only be used in a technically unobjectionable state and in
accordance with the intended purpose as agreed, while being fully aware of
safety regulations and the risks involved and in full compliance with this
operation manual! In particular, disturbances that affect the safety have to be
eliminated without delay!
Responsibility will not be assumed for any damages and/or accidents resulting
from the non-observance of this operation manual.
The relevant regulations for the prevention of accidents and all other generally
recognised provisions on safety at work, occupational medicine and health care
must be strictly observed.
Long hair must be protected appropriately. Do not wear loose clothes or
jewellery! The risk of injuries by getting caught, being drawn in or dragged along
by rotating parts prevails!
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Responsibilities and competencies with respect to the different activities in

conjunction with the operation, maintenance and repair of the gearbox have to
be clearly defined. This will ensure that mistakes are avoided, in particular in
situations of danger.
The operator shall oblige the operating personnel to wear personal protective
clothing. In addition to safety shoes and gloves, this also includes personal
protective equipment that is prescribed in accordance with internal factory
regulations on health and safety.
First aid equipment (first aid box etc.) must be available within reach!
The place where fire fighting equipment is stored and instructions how to use it
must be advised. Observe the obligation concerning fire notification and fire
fighting resources!
If works have to be performed which affect the operation, the adjustment and the
safety equipment of the gearbox, the switching on and off sequences as
specified in the operation manual have to be carefully observed!
Only reliable and qualified staff are allowed to work on the gearbox. The
minimum age as permitted by law must be observed!
Only qualified and trained personnel are allowed to work on the gearbox!
Personnel still to be trained or instructed, or that are still in the stage of general
education, are only allowed to work on the gearbox under the supervision of a
qualified and experienced person!
2.4 Operation of the Gearbox

The gearbox must only be put into service in an assembled state, ready for use.
Before starting any work, the personnel have to familiarise themselves with the
working environment around the gearbox.
The gearbox must only be operated if all the protecting equipment and safety
devices such as e.g. detachable protective equipment have been mounted and
are operable.
Functions of relevance to safety are to be permanently monitored from the
control station. Any changes observed during the operation of the gearbox, such
as increased service temperatures, changing gearbox noises, too high or too low
pressures, have to be reported immediately to the responsible post/ person and
the causes have to be ascertained instantly. The decision as to whether the
operation of the gearbox has to be discontinued depends on the determined
cause.
All faults and troubles have to be immediately corrected or remedied by qualified
specialists!
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2.5 Gearbox Repair and Troubleshooting

The operating personnel are to be informed about special measures and repair
works before such work is carried out. A supervisor has to be appointed.
It is essential that the workshop be appropriately equipped to perform the
necessary servicing and repair works.
Prescribed time periods or intervals which are specified in this operation manual
for the performance of routine and recurring checks/ inspections have to be
observed.
Pneumatic or power lines have to be replaced at specified or appropriate time
intervals, even if safety affecting defects can not be recognised!
Work on the electrical equipment of the gearbox shall only be performed by
specialist electricians or by instructed personnel under the supervision of a
specialist electrician in accordance with electro-technical regulations!
A wide area around the maintenance and servicing place shall be secured as far
as necessary. Such working area shall be marked by a red-white safety chain
and a warning sign.
If the drive has to be disconnected to carry out maintenance or repair work, it
has to be secured against unexpected re-engagement:
− The main control devices, such as switches and valves have to be closed and
the key has to be removed,
and/or
− warning signs have to be attached to the main control devices.
If it is necessary to dismount safety devices for maintenance and repair works,
these safety devices have to be re-mounted and carefully inspected immediately
after completion of the maintenance or repair works.
Screwed connections, which have been loosened for maintenance and repair
works have to be re-tightened. If specified, the screws have to be tightened with
a torque wrench.
Prior to commencing any maintenance or servicing works, the gearbox and
especially the connections and bolted connections have to be cleaned of oil,
fuel, dirt and cleaning products.
The gearbox must not be cleaned with a high-pressure washer.
Do not use aggressive cleaning products. Use a non-fibrous cleaning cloth.
If individual parts or major assemblies have to be replaced, these have to be
carefully attached and secured to the lifting appliance, so as to minimise all risks.
Only use suitable and technically unobjectionable lifting appliances and load
lifting elements of sufficient lifting capacity.
Only experienced personnel shall be charged with the arresting of loads and the
instruction of crane drivers!
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The instructing person has to stay in visual or verbal contact with the crane
driver!
Do not work or stay under suspended loads!
Use climbing ladders or working platforms to carry out overhead assembly
works. Do not use machinery parts as a climbing aid!
Secure yourself with safety ropes when assembly work has to be performed at
great height!
All grips, handles, steps, rails, platforms, scaffolds and ladders have to be kept
free from dirt.
Always ensure the safe and environmentally friendly disposal of fuels, oils,
chemical substances and other products used for operating the equipment!
2.6 Instructions on Particular Hazards
2.6.1 Electrical energy

In case of failures of the electrical equipment, the main switch has to be
switched off immediately!
Only use original fuses of the specified current intensity!
Never perform any work on live parts!
If work has to be carried out on live parts (only in exceptional cases), an
additional person has to be present to actuate the EMERGENCY OUT key or
main switch in emergency situations. Only use voltage-insulated tools.
When carrying out repairs, be sure not to modify any constructional features,
which results in diminished safety (e.g. make sure that creepage paths,
clearances to earth and other distances are not reduced through insulations).
Components of the plant on which inspections, maintenance or repair works are
carried out, have to be de-energized. Devices used for the purpose of
disconnecting the voltage have to be secured against unintentional or self-acting
re-engagement (lock away fuses, block circuit breakers etc.). Electrically cleared
components have to be checked whether they are dead, then grounded and
short-circuited. Energized neighbouring parts have to be isolated.
The unobjectionable grounding of the electrical equipment has to be ensured by
a protective circuit.
2.6.2 Noise
The noise pressure level LpA of the gearbox is measured acc. to DIN 45635. The
level is below 92 dB(A).
Every person staying near by the gearbox has to wear ear protectors as
personal protection equipment.
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2.6.3 Hydraulic/ pneumatic equipment

Only persons with special knowledge and experience in the hydraulic/ pneumatic
field are allowed to perform work on the hydraulic/ pneumatic equipment.
All the pipes, hoses and unions have to be regularly checked for leakages and
visible damages. Any damage has to be remedied immediately!
The pressure pipes have to be laid and mounted in a workmanlike manner. Do
not mix up connections. All the fittings, the length and the quality of the hose
pipes have to comply with the requirements set forth by RENK AG.
Before opening any sections of the system or pressure pipes, the pressure has
to be released completely!
2.6.4 Oils, greases and other chemical substances

When handling and using oils, greases or other chemical products, the
applicable regulations and safety data sheets supplied by the manufacturers of
such products with respect to their storage, handling, application and disposal
have to be carefully observed and complied with!
Wear protective equipment made from suitable material while working with
etching products, (protective glasses, rubber gloves, rubber boots, protective
garment)!
Avoid any contact with the eyes or skin. In the event of a mishap, rinse the
affected area with ample water. Suitable equipment (eye washing bottle, hand
basin, shower) has to be available near the working place!
Skin strained by the use of cleaning or disinfection products should be treated
with care products. The use of skin protection products and appropriate skin
care will avoid damages to the skin. The care product to be used is to be
selected according to the nature of the harmful substances and the individual
skin type. Care products containing grease should be given preference.
Do not eat, drink, smoke or keep foodstuff in rooms in which chemical products
are stored!
Never store hazardous substances in containers for foodstuff. Only use the
container, which is especially approved for the product in question, and mark the
container with the contents.
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3 Gearbox Specification
3.1 Intended Application

The marine gearbox described in this operation manual is exclusively intended
for use on ships to transmit the input power of the driving engine to the propeller
shaft and, if specified, to transmit power over secondary power take-ins or power
take-offs. The secondary input or output shaft serves the purpose of attaching
the required auxiliary units within the propulsion line of the ship.
The order-specific Technical Data have to be observed and complied with.
Any other application or use beyond the above-mentioned application is not
regarded as the intended application. The operator of the gearbox is solely
responsible for any damages resulting therefrom. This also applies to
unauthorised modifications, which are carried out at the gearbox.
The observance of instructions and notes with respect to:
− safety,
− operation,
− maintenance/ repair
as described in this manual also forms part of the intended application.
The gearbox is designed and built for use on board of ships. The written
approval from RENK AG has to be obtained if the gearbox is to be installed in
other places or is to be used for other purposes of application.
3.2 Residual Risk

Even if all the safety rules and instructions are strictly observed, there still
remains a residual risk when operating the gearbox.
Everyone working near or on the gearbox must know these residual risks and
has to comply with the instructions, which prevent these residual risks from
causing any damage or accident.
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Danger!
Hands and arms can sustain burns
− from the housing parts,
− from the piping and the vessels of the hydraulic system and
− from the lube oil itself.
Higher ambient temperatures also lead to increased temperatures on
the housing surfaces of the gearbox.
• Wear safety gloves while working on the gearbox.
Danger!
Authorised electricians are exclusively allowed to work on the
electrical equipment.
Components of the plant on which inspections, maintenance or repair
work has to be carried out, have to be de-energised. Devices used
for this purpose have to be secured against unintentional or self-
acting switching-on (lock away fuses, block circuit breakers, etc.).
Isolated components first have to be checked whether they are dead,
then have to be earthed and short-circuited. Adjacent energized parts
have to be isolated.
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Danger!
Severe injuries can be sustained as a result of the after-running
and slowing down of rotating parts at the gearbox and at
external input and output locations.
On account of the mass moment of inertia some of the rotating parts
need a certain time until they come to a complete standstill after the
drive of the gearbox has been disconnected. Therefore, all work on
or inside the gearbox must only commence following the complete
standstill of all the rotating parts.
• Protective devices at rotating input and output parts have to be
provided for by the project manager responsible for the ship’s
overall machinery.
Danger!
Serious injuries can be sustained from hot fuel oil spraying out
under high pressure.
• The lube oil system must be depressurised before any work is
carried out to the piping or to the components of the lube oil
system.
Attention!
Oil and oily waste are a high risk to the environment. For this
reason, specialised companies have to be charged with the
disposal of such products.
• Collect oil and oily waste and ensure the appropriate and correct
waste disposal by specialized companies.
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3.3 Symbols and Signs

The following markings and signs are attached to or near the gearbox:
Caution, danger due to electric current!

This is attached to all electrical switchboards, terminal boxes and
distribution boxes, which shall only be opened by specialist
electricians.
The definition of the denomination specialist electrician is given in the
Standards DIN VDE 0105 and IEC 364.
Wear protective gloves!

On all access sides of the gearbox.
Warning! Overpressure!
To all accessible areas of the hydraulic equipment, hydraulic piping
and pneumatic system.
Warning! Hot surfaces!

To all accessible surfaces of the gearbox.
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4 The Product
4.1 Function Description

The gearbox is a single or multi-stage helical gearbox. It transmits the power of
the propulsion engine through one or several helical reduction gear stage(s) to
the propeller shaft of the ship, and (if specified), transmits power over further
helical gear stage(s) to the secondary input and output shafts.
Secondary drives are designated as PTI (Power Take In) or PTH (Power Take
Home) and the secondary outputs as PTO (Power Take Off).
The input shaft, the main output shaft and the secondary input or output shafts
are arranged offset to each other in the gearbox housing. The hydraulic pump
serving for the lubrication and cooling of the gearbox is attached to an input
shaft.
The thrust of the propeller is taken up by the thrust bearing of the gearbox output
shaft and is transmitted across the gearbox housing to the ship’s hull.
Specific details on the gearbox can be found in the order-related technical data,
on the drawings, part lists and subsuppliers’ documentation attached to this
Manual.
4.2 Product Description

The gearbox is a marine spur gear unit with single or double helical gear teeth.
The input speed is reduced to the output speed in the spur gear stage.
Depending on the order specification, secondary inputs or outputs, i.e. PTI, PTH
or PTO may be installed. Respective details are given on the order-specific
drawings.
The gearbox comprises the following functional units:
− Gearbox housing,
− Helical gear stage and, if specified, secondary input and output shafts,
− Hydraulic system and piping system,
− Visual and electrical monitoring equipment.
The individual functional units are described in the following subsections.
4.2.1 Gearbox housing

The torsionally rigid housing is provided with strong ribs, and, depending on the
requirement, manufactured of grey cast iron or in welded construction. The
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housing has machined foundation supports. The lower housing part is equipped
with machined stopper rails for axial support purposes.
In addition to absorbing the bearing forces of the gearbox shafts, the housing
also absorbs the axial forces, which act on the input shaft through the propeller.
The resulting forces are transmitted over the foundation supports and stoppers
to the ship’s hull.
All the machinery components necessary to operate the gearbox, such as the
hydraulic equipment etc., are attached on the outside of the gearbox housing.
Note
Depending on the specification of the gearbox, the starting and
stand-by pump can also be mounted on its own base near the
gearbox.
The oil sump in the lower housing part accommodates the necessary oil
quantity. An oil drain screw in the lower housing part serves for emptying the
gearbox housing completely.
4.2.2 Helical gear stage and secondary input and output shaft
(PTH, PTI or PTO)
The engine speed is reduced to the speed of the propeller over a spur gear
stage. All the gear wheels and pinions have single or double helical gear teeth
and are case-hardened or annealed.
The input shaft transmits the torque taken from the propulsion engine over a
pinion-gear wheel combination to the output shaft. The torque taken up by the
gear wheel is transmitted over the coupling flange to the driving shaft of the
propeller.
At the output shaft, the bearing forces and the thrust force of the propeller sum
up to a high axial force. This axial force is absorbed by the axial bearing and led
to the ship’s hull.
Secondary input and output shafts (PTH, PTI and PTO):
The secondary input or output is arranged as a gear stage above the main input
shaft. The secondary input or output shaft is either led outside the gearbox
housing at one or at both ends. The hydraulic pump which serves for the
lubrication and cooling of the gearbox is driven at one of the shaft ends. An
auxiliary unit (e.g. water pump, generator or the like), which is required to
operate the ship, can be mounted to the second shaft end.
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4.2.3 Hydraulic System and Piping System

The hydraulic system and the piping system are both mounted at the gearbox.
The lube oil serves for:
− the lubrication of all the gearbox bearings,
− the lubrication of the meshes of the gear stages,
− the cooling of all heat-radiating areas of the gearbox.
The directly connected hydraulic pump is shaft-driven and flange-mounted to the

gearbox. It ensures the supply of lube oil while the driving engine is running. The
entire lube oil quantity of the pump is fed into the lube oil system.
As long as the driving engine does not turn, lube oil is supplied by the electrically
driven starting and stand-by pump.
The double filter is mounted to the gearbox. Dirt and wear particles are retained
in the filter before the lube oil is led to the lubrication points. If specified, an
optical fouling indicator is attached to the filter. When changing the filter, the lube
oil flow is changed over from the fouled filter to the clean filter.
In the oil cooler, the power loss from the gearbox is transferred to the cooling
medium water. The oil cooler is directly fitted to the gearbox. While the hydraulic
system is in operation, water is conveyed through the oil cooler. To this end, the
two cooling water connections of the oil cooler have to be connected to the water
supply network of the ship.
The lube oil pressure relief valve protects the hydraulic system against over-
pressure. The lube oil that flows out from the pressure relief valve is returned to
the oil sump.
Note
Hydraulic components, which are not included in the delivery scope
of RENK AG, are marked with an asterisk (*) on the hydraulic
scheme.
Components which have to be connected or assembled by the
customer are marked on the hydraulic scheme with: - – or - - -
4.2.4 Visual and electrical monitoring equipment

Various instruments for the local monitoring of the lube oil temperatures and
pressures are directly fitted to the gearbox.
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The following instruments are mounted to the gearbox:
Instrument Measured Variable Place of

Measurement
pressure gauge lube oil pressure gearbox inlet
pressure gauge lube oil pressure double filter inlet
thermometer lube oil temperature gearbox inlet
thermometer lube oil temperature oil cooler inlet
differential pressure pick-up* differential pressure double oil filter
thermometer * bearing temperature bearing location
thermometer * thrust bearing bearing location
temperature
pressure gauge* underpressure pump suction
pipe
*if specified
The following switches and sensors are provided for the remote monitoring of the
gearbox, for both remote indication and alarm signals:
Measured Variable Place of Signal

Measurement
minimum lube oil pressure gearbox inlet emergency stop of the
propulsion line
lube oil pressure gearbox inlet indication and alarm
lube oil pressure gearbox inlet start release -main engine
lube oil temperature gearbox inlet indication and alarm at
increased temperature
max. differential oil double oil filter alarm at max. permissible
pressure* differential oil pressure
temperature thrust bearing 1xalarm at over-
temperature
1x reduction of power
temperature* plain bearing alarm at over-temperature
lube oil level oil dipstick alarm at minimum
* if specified
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4.3 Protective Devices

The gearbox is designed and built according to the recognised state of the art,
so that there are no hazards for the safety and health of the operator, if the
gearbox is properly used as intended and if all the safety instructions given in
this manual are carefully observed.
The protective devices are designed in accordance with DIN EN 294 - safety
distances against reaching hazardous locations with the upper limbs -.
Protective devices which are not frequently removed or serve for maintenance
purposes only, are fastened in such a manner that they can only be dismounted
with the use of tools.
Further protective devices for the supervision of temperatures, oil pressures and
vibrations are specific features of the gearbox and specified in the order.
Attention!
If the gearbox is only supplied with provisions for measurement
instruments, the operator is responsible for the selection and
installation of the correct measuring instruments to be used.
Improperly mounted or wrongly wired measuring instruments may
result in false evaluation of the operating state of the gearbox. This
may lead to gearbox damages.
Danger!
In order to exclude all electrical hazards:
− Cables which are VDE-tested and approved by the classification
society are used only,
− components which are CE-marked and approved by the
classification society are used only,
− all cables are protected against accidental contact.
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The constructional details in terms of electromagnetic compatibility have been

selected in such a way that no hazards exist with respect to emitted interference
and interference immunity of the gearbox.
Attention!
The shipyard or the operator of the ship is responsible for
equipping the gearbox with additionally required protective
devices. The following protective equipment has to be
retrofitted as a minimum:
− Covers for moving components, e.g. for couplings, rotating shaft
ends, etc.
− Covers or insulations for surfaces and piping that reach
temperatures above 60°C during operation.
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5 Transport, Storage and Installation
5.1 Scope of Delivery

The gearbox is supplied ready for installation. The hydraulic system and the
electrical lines for control and measuring pick-ups are mounted to the gearbox.
The scope of supply relative to the gearbox includes:
− the hydraulic system attached to the gearbox housing, including hydraulic
pump, double oil filter, oil cooler and piping network,
− the coupling flange for the propeller shaft connection or the cylindrical shaft
end for the OK-coupling,
− adjusting screws,*
− couplings *,
− starting and stand-by pump *.
* if specified
The scope of delivery may deviate from the above list. The exact scope of
delivery is described in the gearbox specification.
5.1.1 Examination of the delivery

• The delivery has to be checked for completeness against the packing list.
• RENK AG or the suppliers are to be contacted immediately if parts are
missing or if wrong parts have been supplied. The same applies to transport
damages.
5.2 Gearbox Connection Dimensions

The connection dimensions of the gearbox are specified on the order-specific
dimension drawing.
When transporting the gearbox to the site of installation, the dimensional
restrictions existing on site have to be taken into account (especially height and
width).
The gearbox foundation must be sufficiently stiff, so as to avoid misalignments
during operation impairing the tooth contact in the gearbox. In this regard, it is of
particular importance to consider the forces generated by the propeller thrust in
addition to the various operation modes (loaded/ unloaded ship).
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The top plate must have a thickness of at least 40 mm. If the thickness of the
engine foundation exceeds this dimension, the top plate must at least be as thick
as the engine foundation.
Steel or cast plates are inserted at each bolt between the top plate and the
gearbox. In the area of the foundation bolts, cast resin may be used. The height
of the fitting shims varies from 30 - 80 mm, depending on the gearbox. The
foundation is normally arranged in such a manner that the plates can be inserted
with a taper of 1 : 50 to 1 : 100.
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5.3 Transport
5.3.1 Transport by crane

The gearbox shall only be lifted by a crane. The following safety instructions
have to be carefully observed:
Danger!
Critical injuries and contusions due to improper lifting of the
gearbox!
− The valid safety provisions for the prevention of accidents and
applicable health and safety regulations must be strictly followed!
− The instructions of the freight carrier have to be strictly observed.
− Do not stay under suspended loads!
− Only use ropes (belts) which are suitable for the total weight of the
gearbox and which are in a technically unobjectionable state!
− The gearbox has to be lifted by using the hoisting lugs provided to
this end (see order-specific dimension drawing)!
− Check firm fit of the ropes (belts) in the hoisting lugs and in the
hook of the crane.
− When lifting, the ropes (belts) have to be stretched uniformly. Take
care that the gearbox is lifted very slowly from the ground.
− Avoid a lop-sided position of the gearbox of more than 15° once it
is hooked on the crane.
− Avoid hard shocks to the gearbox when setting it down.
− Keep well away from surrounding obstacles.
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5.3.2 Transport by road, rail and water
Attention!
The transport vehicle may be damaged due to the weight of the
gearbox!
− It is of utmost importance to ensure that the transport vehicle is
approved to carry the total weight of the gearbox and accessory
parts.
− Avoid hard shocks when setting down the gearbox on the loading
platform of the transport vehicle.
− The gearbox has to be secured against slipping on the transport
vehicle.
In order to prevent weather influences as much as possible, it is
essential that a tarpaulin or the like covers the gearbox for the
duration of the transport. The tarpaulin has to be tightened firmly so
that it cannot be blown off by the airflow.
Danger!
Sea transport is only permissible below deck!
The gearbox may be severely damaged!
Deviations from the above require the express prior approval in
writing by RENK AG, Rheine Works!
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5.4 Storage and Corrosion Protection
Prior to shipment, the gearboxes are protected against corrosion by RENK AG

Werk Rheine.
The effectiveness duration of the corrosion protection depends on
• the storage place,
• the packing and
• the used corrosion protection fluid.
Achtung!
Detailed information are available in the handbook
„Corrosion Protection Marine Gear Units“!
(RENK-doc.no. B267919)
If this handbook is not available please contact RENK AG Werk
Rheine.
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5.5 Installation and Control of Installation
5.5.1 Foundation
The gearbox foundation shall be sufficiently stiff so that misalignments, which
affect the tooth contact, are avoided during operation. In addition to the various
operation modes (loading and unloading), it is of essential importance to
consider the forces resulting from the propeller thrust.
The top plate must have a minimum thickness of 40 mm. If the thickness of the
engine foundation exceeds the dimension of 40 mm, the top plate has to be at
least as thick as the engine foundation.
Danger!
Danger to life and irreparable damages to the gearbox or to the
ship’s hull are possible due to carelessness and inattentiveness
during transportation/ installation!
− Before starting the gearbox installation, all the persons involved
have to read:
- the safety instructions in section 2 ‘Safety’,
- section 5: ”Transport, Storage and Installation” and, in addition,
- the present section ”Installation and Control of Installation”.
− Alignment work shall only be carried out by skilled service
engineers.
− The gearbox has to be set up and aligned in accordance with the
installation plans.
The propulsion line (incl. the gearbox) is mounted in the following order:
1. Alignment of the propeller shaft,
2. Alignment of the gearbox on alignment screws to the propeller shaft,
3. Check of contact pattern
(for gearboxes with a centre distance more than 875mm)
4. Alignment of the driving engine to the gearbox,
5. Bolting down the gearbox to the gearbox foundation,
6. Bolting down the driving engine to the foundation (recommendation),
7. Tightening the coupling between propeller shaft and output shaft,
8. Tightening the coupling between input shaft and driving engine shaft,
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9. Connection and alignment of the auxiliary unit to the secondary input or output
shaft.
Note
We recommend to ask for the RENK checklist for works to be carried
out on board for controlling and commissioning of marine gearboxes!
5.5.2 Preparatory work prior to installation

• The gearbox has to be lifted by a crane to the place of installation in the ship’s
hull (see chapter 5, ‘Transport, Storage and Installation’).
• The adjusting screws are to be screwed into the threaded bores provided to
this end. As required in each case, they have to protrude 40 to 90 mm approx.
of the underside of the gearbox base.
Note
If the adjusting bolts form part of the delivery, they are already
screwed into the gearbox base in the RENK-workshops.
• At the place of installation, the gearbox has to be put down on the adjusting
screws.
• Prior to starting the alignment of the gearbox, bring the propeller shaft into its
final position.
Note
For the alignment of the propeller shaft, the special alignment
instructions given by the shipyard must be strictly observed!
• If the coupling between the propeller shaft and the gearbox has not yet been
firmly mounted to the gearbox output shaft, the shaft end of the propeller shaft
and the bore of the coupling have to be carefully cleaned so that they are free
of rust preventive products.
Note
Use cleaner’s naphtha solvent, detergents or alkali products for
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cleaning.
• Thereafter, the coupling is flanged to or drawn onto the gearbox shaft.

• Care has to be taken that the weight of the engine-side coupling part does not
load the gearbox. If necessary, provide for a support of the engine-side
coupling part.
• Use a roller block to bring the overhanging coupling shaft at the gearbox into
zero position. Observe the alignment value specified on the gearbox
alignment drawing.
• Steel or cast shims are fitted at each screw between the top plate and the
gearbox.
Depending on the size of the gearbox, the height of these shims amounts to 30 -
80 mm approx. The foundation is normally arranged such that the shims can be
inserted with a taper from 1 : 50 to 1 : 100.
Note
Depending on the construction of the gearbox or of the foundation,
cast resin may also be used in the area of the foundation bolts.
The use of cast resin is, however, only allowed if the written approval
from RENK AG has been obtained beforehand.
5.5.3 Alignment of the gearbox to the propeller shaft

The shipyard is responsible for the alignment of the drive line components. The
following documents are needed by the shipyard for the gearbox alignment:
− Propeller shaft calculation,
− order-specific alignment drawing of RENK,
− arrangement drawing of the propulsion line.
The gearbox has to be moved to the propeller shaft in such a way that the
prescribed values for the radial offset Δr and for the gap Δw or angular offset α,
resp. are obtained. The nominal values are derived from the propeller shaft
calculation performed by the shipyard.
Misalignments of the gearbox output shaft in axial and radial direction have to be
taken into account as stated on the order-specific alignment drawing of RENK.
All the other influences on the propeller shaft bending line have to be
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considered, too (ship’s deformation, thermal growth, influences exerted by the

propeller etc.).
During all the operation modes, the bearing forces occurring at the two bearings
of the gearbox output shaft have to act in an almost unidirectional downward
manner. In warm operation state, the difference between the two gearbox
bearing locations shall amount to 40 % at most. These forces result from the
weight portions of the gearbox parts and the weight portions of the propeller
shaft according to the propeller shaft calculation. The forces originating from the
gearbox itself are shown on the alignment drawing.
RENK AG is to be informed in writing about the forces acting on the gearbox
bearings in all operation modes, which result from the propeller shaft calculation.
The actually obtained values for the radial shaft offset Δr and for the gap Δw or
angular offset α, resp., are to be determined from the values measured with a
dial gauge or feeler gauge by using the below-mentioned formula. The values
have to be recorded. The differences between the nominal values and the actual
values must not be bigger than 0.1 mm for the radial shaft offset (0.2 mm
deflection of the dial gauge), or 0.02 mm per 100 mm flange diameter for the gap
Δw, resp.
Note
With a difference of the indicated value on the dial gauge of
0.02 mm per 100 mm flange diameter, the angular offset amounts
to α 0.0002 rad.
In axial direction, the gearbox has to be moved toward the propeller shaft up to a
gap of 0.3 - 0.5 mm.
The final alignment values to the propeller shaft have to be recorded.
The following values shall be calculated (see figures on the following page):
(r3 − r1 ) ΔWv (a 3 − a1 )
in the vertical plane Δrv = and αv = = .
2 dp dp
( r4 − r2 ) ΔWh (a 4 − a 2 )
in the horizontal plane Δrh = and αh = = .
2 dp dp
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Measured values r1 to r 4
(dial gauge)
Propeller shaft
Gearbox shaft
Δr
Δw y
Measured
values a 1 to a 4 (feeler gauge)
α
top r1 top a1
left r2 right r4 left a2 right a4
bottom r3 bottom a3
Fig. 5-1 Alignment of gearbox output shaft to propeller shaft
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5.5.4 Alignment of the driving engine to the gearbox

The axial, radial and angular positions have to be considered when aligning the
driving engine to the input shaft of the gearbox. The correct axial position is
derived from the assembly control dimension of the flexible coupling. This
dimension must be maintained in warm condition while travelling ahead.
In order not to fully utilise the misalignment capability of the coupling between
gearbox and driving engine due to circumstances, which can be precisely
determined by calculation, the misalignment due to thermal growth and the
bearing clearances of the driving engine and of the gearbox should be
adequately considered for the radial alignment. The alignment in the cold,
unloaded condition is, therefore, not done to zero, but to the value, which results
from the difference of the mentioned misalignment of the propulsion engine shaft
and the gearbox shaft.
Particular attention has to be paid to the fact that both influences have to be
known in each case. It is not permissible to only take one of the mentioned
influences into account (engine or gearbox misalignment). The misalignment to
which the gearbox input shaft is subjected due to the effect of thermal growth or
due to bearing clearance is shown on the alignment drawing. The instructions
given by the manufacturer of the flexible coupling must be observed, too.
The verification of the correct radial and angular alignment between engine and
gearbox input shaft is performed with dial gauges as shown in fig. 5-2. To this
purpose, a special micrometer gauge is used. The radial offset (runout) and the
angular offset (plane parallelism) between the primary-side coupling part and the
input shaft are measured. The difference between the nominal and the actual
values of the radial shaft offset Δr must not be bigger than 0.1 mm.
Note
With a difference of the indicated value on the dial gauge of 0.02 mm
per 100 mm flange diameter, the radial shaft offset amounts to Δr
0.0002 rad.
flexible
Gearbox propulsion engine
coupling
Fig. 5-2 Dial gauge positioning on the shafts of gearbox and driving engine
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Two dial gauges offset by 180° are to be used to measure the plane parallelism.
The final values have to be noted down upon completion of the alignment. These
values have to be checked again when the equipment is in warm operation state
at 50°C.
5.5.5 Installation of shims

• After having completed the alignment of the gearbox to the propeller shaft, at
first mount the shims for the fitted bolts located directly near the adjusting
screws onto which the gearbox has been put down.
• The shims have to be blued on both sides. The carrying surface must at least
amount to 75 %.
• Only then, retract the adjusting screws.
• In order to ensure that the gearbox will keep its position while the alignment is
continued, the foundation bolts have to be inserted directly near the shims.
• The foundation bolts have to be re-tightened after completion of the final
gearbox alignment.
• The screwed connections shall be selected such that a calculated bolt
elongation of at least 0.25 mm results while considering the required pre-
stretch.
5.5.6 Tooth contact check

The position of the gearbox housing on the foundation influences the contact
pattern of the gear teeth. For this reason, the tooth contact pattern shall be
determined in assembled condition.
• At first, remove the respective inspection hole cover.
• At least 3 teeth on the gear wheel have to be blued (thickness 5 - 10 μm
approx.).
• The shaft is then turned, without opening up the gearbox cover.
• The nominal contact pattern has been determined by RENK AG during the
workshop test run and can be obtained for comparison purposes.
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5.5.7 Support of the thrust bearing

In the area of the thrust bearing the housing has to be supported toward the
foundation by a sufficiently stiff stopper. The foundation has to be sufficiently stiff
in the stopper area in order to transmit the axial thrust from the propeller to the
gearbox foundation without experiencing unacceptable misalignments or
deformations of the gearbox housing.
• In order to ensure proper contact of the stopper with the gearbox housing,
conical shims with a taper of 1 : 50 up to 1 : 100 should be used, which are
fitted with an axial over-measure of 0.01 up to 0.02 mm.
5.5.8 Alignment of the auxiliary unit to the secondary input or output shaft
(PTH, PTI or PTO operation)
The axial, radial and angular positions have to be considered when aligning the
auxiliary unit to auxiliary output shaft of the gearbox. The correct axial position is
derived from the assembly control dimension and the specified dimensions on
the alignment drawing.
In order not to fully utilise the misalignment capability of the flexible coupling due
to circumstances which can be precisely determined by calculation, it is
important to adequately consider for the radial alignment those misalignments
which are due to thermal growth and bearing clearances of the auxiliary unit and
of the gearbox. The alignment in the cold, unloaded condition is, therefore, not
done to zero, but to the value, which results from the difference of the mentioned
misalignment of the auxiliary unit shaft and of the gearbox shaft.
The verification of the correct radial and angular alignment between the shafts of
the auxiliary unit and of the gearbox is performed by the use of dial gauges as
shown in Fig. 5-3. To this purpose, a special micrometer is used to measure the
radial offset (runout) and the angular offset (plane parallelism) between the
secondary output shaft of the gearbox and the shaft of the auxiliary unit.
• The final values have to be recorded after completion of the alignment and
have to be checked again at a later point of time when the equipment is in
warm operation state at 50°C.
• The coupling between the secondary output shaft of the gearbox and the shaft
of the auxiliary unit is to be mounted and the dial gauges are to be attached.
The gearbox input shaft is turned for measurement purposes.
• Two dial gauges offset by 180 ° are used for the measurement of the plane
parallelism.
• It is recommended to verify the alignment between drive/ shaft once a year.
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auxialiary
unit PTO-shaft
flex. coupling
Fig. 5-3 Example: Dial gauge use on the shaft of the auxiliary unit and on the PTO-shaft
5.6 Connection of the hydraulic system

The hydraulic system is normally completely assembled. The cooling water connections
of the oil cooler are closed with blind flanges. These have to be removed before fitting
the pipes.
• Always take care of cleanliness when working on the gearbox. Dirt must not
enter the pipes while assembling them!
• If components of the hydraulic system still have to be attached to the gearbox,
this has to be done first.
• Thereafter, the two cooling water connections of the oil cooler have to be
connected to the water supply network of the ship.
• It is of special importance to check proper flow of water.
5.7 Connection of the electrical control

The electric lines and the measuring pick-ups have to be connected to the
electrical control of the ship. The gearbox itself normally does not have its own
electrical control.
• The wires of the measuring instruments for pressure and temperature have to
be connected first. The respective lines are led to one or several terminal
boxes, which are fitted to the gearbox.
• The electrical measurement and switching points are pre-set in the factory.
• Then connect the starting and stand-by pump to the ship’s power supply
system.
• After having checked all the connections, the gearbox can be put into
operation.
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6 Commissioning and Operation
Attention!
Damages to the gearbox or propulsion line possible due to
improper work and incorrect handling!
The gearbox must only be put into operation by skilled personnel
being specifically trained to perform such work.
6.1 Filling Up Lube Oil

Lube oil is filled into the gearbox oil sump by means of a separate pump to be
furnished by the customer.
Attention!
Damages to gear wheels and gearbox bearings possible!
Suitable precautionary measures have to be taken to prevent dirt
from entering the gearbox.
• A pipe or a sufficiently strong hose is fitted between the oil filler neck of the
gearbox and the pressure socket of the separate pump.
• The suction socket of the separate pump is connected to the oil tank
(reservoir) by means of a pipe or sufficiently strong hose.
• The separate pump is switched on, and the pumping process starts.
• The oil level in the oil sump is checked with the dipstick at short time intervals.
• The separate pump is switched off, as soon as the maximum lube oil level is
reached.
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Attention!
Damages to the starting and stand-by pumps are possible due
to improper commissioning!
It is of utmost importance to read the operation manual for the
starting and stand-by pump before putting it into operation.
If required, the starting and stand-by pump has to be filled up with oil
before it is put into operation.
• The starting and stand-by pump is switched on.

• After about 2 minutes the oil level in the oil sump is checked with the dipstick
and lube oil is pumped in by the separate pump until the oil level is found to
be in between the two markings MIN and MAX on the oil dipstick.
• Finally, the starting and stand-by pump is switched off, the separate pump is
removed and the oil filler neck is closed.
6.2 Operation
Attention!
Irreparable damages to the gearbox and prime mover are
possible!
The operation of the gearbox without the propeller shaft (= unloaded
gearbox) may lead to damages at the prime mover and/or the
gearbox.
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Attention!
Irreparable damages at the gearbox and prime mover are
possible!
The following preconditions must be fulfilled before the prime mover
is started up:
− the monitoring system of the propulsion line/ gearbox is active,
− no alarm is given from the propulsion line/ gearbox.
The gearbox must only be run in the direction of rotation it is intended
for (see arrow for direction of rotation).
The prime mover must only be started after the cold start
temperature of 10°C has been exceeded.
• Switch on the starting and stand-by pump and operate it for about 10 minutes
in order to pre-lubricate the gearbox.
• Take care that the starting and stand-by pump is properly working!
• Before switching on the prime mover check whether sufficient oil is available
in the oil sump. If need be, fill up lube oil.
• Meanwhile, prepare the prime mover for operation (see operation manual for
the propulsion engine), and switch it on.
6.2.1 Operation with the prime mover

The propulsion line is normally operated by remote control from the bridge of the
ship. The propulsion line can also be controlled locally (local emergency control).
• In order to confirm the correct function of the gearbox lubrication, check the
lube oil pressure on the remote indicator of the pressure transducer after
about 15 seconds.
• On release of an alarm or emergency stop signal, stop the prime mover
immediately. The propulsion line has to be checked before a new start up.
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6.2.2 Disconnecting the prime mover
Proceed as follows:
• If a controllable pitch propeller is installed, this has to be brought to zero pitch
first.
• Prepare the prime mover for disconnection (refer to its operation manual) and
shut it off then.
6.3 Special Operation Modes
6.3.1 First test run (Sea trial)

Prior to and during the first test run, the operating conditions of the gearbox have
to be verified in conjunction with the other components of the propulsion line.
This test run is conducted at sea (sea trial). During the sea trial all the measuring
and control signals of the gearbox monitoring system have to be carefully
observed and compared with the nominal values. Every deviating value has to
be verified.
Notes
• RENK AG is to be informed in writing about the date of the
gearbox commissioning.
• It is essential to inform RENK AG if deviating values have been
observed during the measurements!
For the sea trial, the gearbox has to be put into operation as follows:
Attention!
Irreparable gearbox damages due to operating errors and false
handling during the trial run!
It is of utmost importance to read section 6.2 ‘Operation’ before
starting the sea trial.
The safety instructions and handling instructions described in section
6.2 ‘Operation’ and in the following sections have to be strictly
followed.
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• During the sea trial, the prime mover has to be operated in the following load
stages (guiding values), one by one:
- 1 hour at 1/3 of load
- 2 hours at 2/3 of load
- 4 hours at full load
• Continuously check the gearbox and all the appertaining measuring
instruments for proper function.
• Use appropriate measuring devices to measure and record the following
parameters:
- the speed of the prime mover,
- the speed of the propeller,
- the speed of the generator.
Danger!
Personal injuries are possible due to rotating and moving parts
in the propulsion line or at the gearbox!
After having switched off the propulsion engine, wait until the
gearbox has come to a complete rest!
• During the test run, the oil level has to be checked by using the dipstick. If
required, fill up lube oil.
• After the full load test, the oil filter also has to be checked for possible oil
residues or contamination. If required, clean the filter.
• Upon completion of the 4 hours’ full load test, check the contact pattern on the
tooth flanks. The contact pattern on the tooth flanks must show a uniform
contact across the tooth width and tooth height of the loaded flank.
• Should other tooth contact pattern checks be required by the classification
society, these have to be carried out in addition.
Note
Areas with fading out contact pattern or with no contact pattern on the
tooth sides and in the area of the tooth tip and tooth root are
acceptable. The tooth contact has to be checked through the
inspection opening provided to this end (see section ‘Maintenance’).
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If all the values measured on the gearbox correspond with the nominal values
stated in the Section ‘Technical Data’, the operation of the gearbox can be
continued.
6.3.2 Towing operation

For towing operation, the following conditions have to be fulfilled:
− The propeller shaft must be locked,
− the propeller has to be brought to zero pitch.
6.3.3 PTH/PTI and PTH - operation

As soon as the driving engine has been started, the coupled lube oil pump also
runs continuously and lubricates the gearbox.
6.3.4 Local emergency control

In emergency situations, e.g. power failure, proceed as follows:
• The gearbox is started manually by means of a pump, or without pre-
lubrication, at zero propeller pitch.
• The oil pressure must have built up within 15 seconds; otherwise switch off
the equipment again!
Attention!
Damages to the gearbox cannot be excluded completely in this
emergency operation mode!
• The operation fault has to be corrected as soon as possible!
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7 Operation Faults
7.1 Introduction
An operation fault does exist when the monitoring system recognises a deviation
from the nominal operation condition.
If operational restrictions have been defined by the results of the torsional
vibration calculation, these restrictions must be precisely observed.
Depending on the type of deviation, consequential damages to the gearbox or
propulsion line may be possible, which can lead to the complete failure of the
gearbox.
Danger!
Danger to life for unskilled persons if they perform non-
authorised work on the gearbox.
Only skilled maintenance staff are allowed to correct operation faults!
7.2 Operation Faults and their Correction
Note
The maintenance staff must be notified immediately if the monitoring
system signals any operation faults of the gearbox. As far as known,
the kind of fault shall also be advised.
• In the event of critical operation faults the driving engine has to be switched
off.
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Fault Cause Remedial Measure

Increased oil Leakage at seals and/or Seal or replace flange
consumption piping system connection/ piping system
Leakage at the oil drain plug Drain lube oil, replace seal of
the oil drain plug
Leakage at the gearbox Inspect seals and replace
shafts them, if required
Lube oil pressure too Major leakage in the lube oil Inspect respective pipe
low or too high system sections and replace them, if
required
Oil filter considerably Clean oil filter
fouled
Wear or damages of the Replace hydraulic pump
hydraulic pump
Sprays or nozzles are Dismount sprays or nozzles
clogged and clean them
Oil viscosity too high or too Change lube oil (see chapter
low 8, ‘Maintenance’)
Pressure relief valve set Re-adjust pressure relief valve
wrongly/ damaged or replace it
Lube oil temperature Oil cooler fouled Clean oil cooler
too high
Cooling water quantity not Increase cooling water flow
sufficient
Cooling water inlet Check cooling water supply
temperature too high
Unusual gearbox Roller bearings damaged Attention! Reduce input
noises power or put equipment out of
Plain bearings damaged
operation. Ask RENK AG for
assistance of service
engineer!
Gear teeth damaged see above
Gearbox not correctly see above

aligned
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7.3 Monitoring System
7.3.1 Introduction
The measuring sensors and switches in the monitoring system determine the
operation and control conditions, important temperatures and pressures and the
level in the oil sump. If limit values are exceeded or not reached, an alarm is
given which is - depending on the ship’s equipment - announced on the bridge or
in the machinery room. Alarm is given visually and/or acoustically. In order to
avoid personal injuries and damages to the machines, an emergency stop is
activated at certain limit values, so that the driving engine is switched off.
7.3.2 Lube oil pressure
Note
Observe the lube oil pressures (See order-specific data sheet
‘Monitoring Instruments’!).
Measuring Signal Fault Remedial Measures

Location(s)
All pressure alarm alarm value acc. to Reduce load to idle
transducers alarm curve is reached running and inspect
propulsion line
Pressure Emer- Limit pressure value is Switch off driving engine
switches gency reached
stop
Over-pressure Indication Lube oil pressure Check hydraulic system
at pressure > 7 bar exceeds permissible (lubrication)
gauge value
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7.3.3 Lube oil temperature
Measuring Signal Fault Remedial

Location(s) Measures
Resistance Alarm Limit value of lube Check propulsion line
thermometer/ oil temperature is
temperature switch* reached
Resistance Alarm Temperature rise Load to be reduced to
thermometer/ beyond limit value: idle running
temperature switch* + 5 °C
Resistance Alarm Temperature rise Initiate emergency
thermometer/ beyond limit value: stop
temperature switch* + 10 °C
*if specified
7.3.4 Lube oil differential pressure at the filter
Measuring Signal Fault Remedial Measure

location(s)
Differential Alarm Limit value of Change over and clean
pressure differential pressure is double oil filter
switch* reached immediately
*if specified
7.3.5 Oil level
Measuring Signal Fault Remedial Measure

location(s)
Level tester Alarm oil level in the oil sump Check gearbox and
drops below MIN hydraulic system for
marking leakages and check oil
level in the oil sump, fill
up lube oil, if necessary
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8 Maintenance
8.1 Introduction
The chapter Maintenance is divided into the sections maintenance, lubrication
and repair. It is intended as a guide to schedule the required routine
maintenance and repair measures and activities.
The instructions given in this section are to be understood as ‘minimum
recommendations’. Depending on the operation conditions, further measures
may be required in order to preserve the production quality of the gearbox. For
supplementary information, please refer to the annex of this manual.
The maintenance staff of the operator is allowed to only perform such
maintenance and repair measures as described in this chapter. Any other
activities shall only be carried out by qualified expert engineers or by service
specialists from RENK AG.
Refer to the drawings and part lists included in the annex as regards repairs and
spare part orders.
All spare parts used have to comply with the technical requirements set forth by
RENK AG. This is only ensured if original spares are used.
When dealing with gas, grease, oil or other chemical products, carefully observe
the valid regulations and safety data sheets issued by the manufacturers of such
products with respect to their storage, handling, use and disposal.
It is of utmost importance to ensure the safe and environmentally friendly
disposal of all the substances and spare parts needed for operation!
Danger!
Constructional or functional features with sharp edges, sharp
corners, threads etc. bear the risk of injuries to head, arms and
hands! Therefore:
• Wear protective gloves!
• Avoid hasty movements when working at the machines!
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Danger!
Serious injuries are possible when carrying out maintenance or
repair work on the gearbox while the equipment is running!
Maintenance or repair work must only be carried out on the gearbox

after the driving engine has been switched off and protected against
re-engagement.
Please also observe the safety instructions in chapter 2.5: ”Gearbox
repair and troubleshooting”.
Danger!
Danger to life due to electric shock because of incorrect work
on the electrical equipment.
Maintenance and repair work on the electrical equipment shall only
be carried out by skilled and qualified electrical specialists.
Attention!
Gearbox damages are possible due to improper work on the
pneumatic or hydraulic equipment.
Work on pneumatic or hydraulic components must only be carried
out by personnel being qualified for such technical fields.
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8.2 Maintenance Schedules
Attention!
To prevent operation faults that in turn may directly or indirectly
lead to serious injuries and material damages, the following
maintenance activities have to be regularly performed at the
stated time intervals.
• In case of doubt, switch off the gearbox/ driving engine
immediately!
8.2.1 Daily Maintenance

Though the gearbox is equipped with instruments for remote indication and
alarm, it is advisable to regularly take the readings of the most essential
operating data directly on the gearbox.
Several times a day, the following values should be read off on the indicating
instruments that are directly attached to the gearbox and compared with the
calculated values listed in chapter 3. ‘Technical Data’:
• Lube oil pressure at gearbox inlet (pressure gauge),
• Lube oil temperature at gearbox inlet (thermometer),
• Temperatures at the bearing locations (thermometer),*
*if specified
Notes
If only one pressure gauge is fitted, the screw coupling of the
pressure gauge can be detached from one measuring connection
and screwed into the other connection to be checked.
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• Periodic maintenance activities have to be recorded.

• The cause for any unusual condition (e.g. noise, vibrations, unusual
temperatures, smoke, etc.) has to be determined and corrected immediately.
Note
Do not operate the gearbox unless the reason for the unusual
observation has been determined and removed.
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8.2.2 Maintenance Time Schedule
Note
The below listed maintenance measures either have to be carried out
following the stated operation hours or after the stated time period
has elapsed, whichever comes first.
Maintenance Item Maintenance Measure Time Interval
Input and output shaft check tightness 500 operation

seal hours or every 30
days
Oil pipes and flanges check pipes and flanges for tightness
Double oil filter clean filter
Gearbox oil check oil level
Gearbox oil change oil for the first time 2,500 operation
hours or after 6
check oil quality
months
Coupling bolts of the check state and tightening torque 10,000 operation
input and output flange hours or after 2
years
Foundation bolts check state and tightening torque
Gears and pinions check gear teeth
Components check fastening
Gearbox oil change oil
Oil cooler clean oil cooler
Hydraulic pumps check function 15,000 operation

hours
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8.3 Maintenance Work
Danger!
Severe injuries are possible when performing maintenance and
repair work on the gearbox while it is still in operation!
Repair measures shall only be carried out on the gearbox after the
driving engine has been switched off and secured against re-
engagement.
For maintenance work on the hydraulic system, the lube oil has to be
drained from the hydraulic pipes to be serviced.
Carefully observe the safety instructions in chapter 2.5: Gearbox
repair and troubleshooting.”
8.3.1 Cleaning the double oil filter
Note
As far as practicable, a fouled filter element should only be replaced
when the ship is in the harbour or lies at anchor.
Dismounting the filter

• Switch off the driving engine and secure it against re-engagement.
• Open oil drain plug at the double oil filter and let oil drain into a container put
underneath.
• Drain the remaining lube oil by venting. To this purpose, loosen the screw
plug on the cover of the double filter casing.
• Loosen the screws in the casing cover of the double filter and lift off the cover.
Pull out the filter element vertically of the filter casing.
• Clean the strainer with a commercial cleaning product and dry it carefully with
compressed air from the clean side of the filter.
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Note
Observe the instructions given by the cleaning product manufacturer!
Mounting the filter

• Insert the clean filter element vertically from the top into the filter casing.
Check for correct and tight fit.
• Inspect the seal between cover and the double filter casing and replace it, if
necessary.
• Put on the cover and tighten the screws.
• Switch on the starting and stand-by pump.
• Ventilate double oil filter by loosening the screw plug in the cover. As soon as
lube oil comes out of the bore, tighten the screw plug.
• Check oil level and fill up oil, if required.
8.3.2 Adjusting the pressure relief valve

• Remove protective cap from the pressure relief valve.
• Loosen adjusting screw and counter nut, then turn the spindle to adjust the
pressure:
clockwise pressure increase
counter-clockwise pressure decrease
Note
Observe and maintain the adjustment values for the pressure relief
valves as specified on the order-specific hydraulic scheme!
• Hold the adjusting screw in the required position and tighten counter-nut.
• Screw on protective cap and seal it.
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8.3.3 Gear teeth inspection
Attention!
Severe permanent gearbox damages result if the cause for gear
teeth damages is not determined!
The gear teeth have to be checked for damages on the flanks, such
as pitting, wear or scuffing.
Should gear teeth damages or a poor contact pattern be observed on
one of the gears, contact RENK AG immediately as regards the
assistance of an expert.
Inspection of the main gear teeth of the spur gear

• Remove the inspection hole covers for the main gear teeth.
• The gear teeth of the pinion and of the spur gear have to be visually
inspected.
• Thereafter, re-mount the inspection hole covers.
Inspection of the secondary input and output gear teeth

• Remove the inspection hole covers for the gear teeth to be inspected.
• The teeth of the pinion and of the gear wheel have to be visually inspected.
• Thereafter, re-mount the inspection hole covers.
Note
The location of the inspection hole covers is shown on the order-
specific arrangement drawing.
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8.3.4 Lube oil level check

The lube oil level in the oil sump is checked by using the dipstick inserted in the
lower housing part. The lube oil level at the dipstick or level tester has to be
between the markings MIN and MAX (Fig. 8-1).
If specified, the lube oil level is automatically measured by an additional level
tester inserted in the lower housing part, On principle, this part is of the same
construction as the dipstick shown in Fig. 8-1.
The level tester gives alarm as soon as the lube oil level falls below the MIN
marking.
Max X Min Alarm point / contactor
Fig. 8-1 Oil level dip stick/ level tester with alarm point
8.3.5 Inspection of the thrust bearing pads

The part descriptions used in the following text refer to Fig 8-2.
• Remove the inspection hole cover or locking pin cover for the thrust bearing
pads.
• Take out the visible thrust bearing pads. To this end, threaded bores are
provided on the circumference.
• Fasten the dismounting square with a cap screw to the shaft. With the aid of
the dismounting square, turn the remaining thrust bearing pads toward the
opening and dismount them.
• Thereafter, remove dismounting square and cap screw.
• Install the thrust bearing pads.
• Place the inspection hole cover or locking pin cover in the correct position and
bolt it down.
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Fig. 8-2 Removal and installation of thrust bearing pads
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8.3.6 Filling up lube oil
Attention!
Damages to the gears and bearings of the gearbox are possible!
When working on the gearbox, appropriate measures have to be
taken to prevent dirt from entering the gearbox.
Carefully observe the lubrication instructions (see chapter 8.4)!
• A pipe or sufficiently strong hose is arranged between the oil filler neck of the
gearbox and the pressure socket of the separate pump furnished by the
customer.
• The suction socket of the separate pump is connected to the oil reservoir by a
pipe or sufficiently strong hose.
• The separate pump is switched on and the pumping procedure starts.
• The oil level in the oil sump is measured at short time intervals by using the
dipstick.
• As soon as the maximum lube oil level is reached, the separate pump is
switched off.
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Attention!
Damages to the starting- and stand-by pump are possible due to
improper and inadequate commissioning!
Carefully read the operation manual of the starting and stand-by
pump before putting it into operation.
If required, the starting and stand-by pump has to be filled with lube
oil prior to its first start-up.

• After about 2 minutes, the oil level in the oil sump is checked with the oil
dipstick, and the separate pump fills up oil until the oil level is between the two
markings MIN and MAX on the dipstick.
• The starting and stand-by pump is then shut off, the separate pump is
removed and the oil filler neck closed.
Filling up lube oil by hand

Small quantities of lube oil may also be filled up by hand. To this end, it is of
utmost importance to fill the lube oil through a dirt filter with a max. mesh width
of 0.05 mm. Proceed as follows:
• The oil filler neck is opened and the funnel with the dirt filter is inserted into
the oil filling opening.
• After about 2 minutes, the oil level in the oil sump is checked with the oil
dipstick, and oil is filled up until the oil reaches a level between the two
markings MIN and MAX on the dipstick.
• The starting and stand-by pump is switched off, the oil-filling funnel is
removed and the oil filler neck closed.
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8.3.7 Lube oil change
Attention!
Oils and oily waste are a high risk to the environment. For this
reason, specialised companies have to be charged with the
disposal of such products.
Collect oils or oily waste and ensure the appropriate and correct
waste disposal by specialized and approved companies.
First oil change

The oil has to be changed for the first time after 2,500 operation hours or after 6
months, whichever occurs first.
Oil analysis
The lube oil has to be analysed every 2,500 operation hours or after 6 months,
at latest.
• The lube oil sample is drawn while the propulsion line is in normal operation
mode (at normal operation and temperature conditions), or immediately after
having disconnected the propulsion line.
The results of the oil analyses have to be evaluated by the lubricant supplier.
The lube oil must be changed as soon as the quality of the lube oil no longer
complies with the requirements of the specification (see chapter 8.4 ‘Lubrication
Instructions’), even if the point of time for the routine oil change has not yet been
reached.
• The lube oil has to be separated, if the oil analysis reveals a water content of
more than 0.2 %.
Oil change
The routine oil change has to be carried out every 10,000 operation hours, or
after 2 years, whichever occurs first. Should the oil analyses reveal negative
results, the oil has to be changed, too.
• The propulsion line should have run for at least 30 minutes in order to have
the oil viscous when draining it. Alternatively, the starting and stand-by pump
can be operated for about one hour.
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• The lube oil is drained from the gearbox housing through the oil drain plug
situated at the bottom of the housing. The lube oil is either drained by hand
into a sufficiently large container, or is pumped out by means of an electrical
pump.
• Lube oil is filled into the gearbox as described in chapter 8.3.6. of this
operation manual.
8.4 Lubrication Instructions
8.4.1 Lubricant requirements

The following requirements apply to lubricants used for forced oil lubricated
marine reduction gearboxes:
− non-ageing,
− non-foaming,
− neutral to the shaft seals used in the gearbox, to non-ferrous metals, sealing
compounds and liquids as well as to the internal paint of the gearbox,
− FZG-load stage ≥ 12 acc. to DIN 51354.
− Additives in the lube oil must not affect the friction or the engagement and
disengagement processes of the multi-disk clutch.
8.4.2 Table of lubricants

Different tables of lubricants apply to the various gearbox designs.
The applicable lubrication instructions are a component part of the order
documentation and are specified separately.
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8.5 Repair
8.5.1 General Instructions
Attention!
Improperly carried out work leads to gearbox damages.
It is imperative to observe the following instructions and notes when
carrying out any work on the gearbox.
• Repairs must only be carried out by skilled and qualified personnel.

• For major repairs, a service engineer from RENK AG should be ordered to
assist and supervise the work.
• Prior to dismounting any gearbox parts, all pipes disturbing the disassembly
have to be removed. The pipe openings have to be carefully closed in order to
avoid the entrance of dirt.
• In addition, it has to be ensured that no dirt or foreign particles get into the
gearbox while it is opened up.
• If tools are used for work inside the gearbox, it is recommended to tie up
these tools with a string that is led to the outside.
• All the bolts, screws and other connecting elements as well as safety and
locking means have to be renewed on principle, should they be damaged
during the disassembly.
• If dirt has entered the dismounted pipes, these have to be flushed before
installing them again.
• All the dismounted parts have to be cleaned with suitable washing products
before they are reassembled.
Note
Observe the instructions given by the manufacturer of the cleaning
product.
• Prior to the re-assembly of the gearbox housing, all surfaces have to be

cleaned to remove residues of the old sealant and be coated with new
sealant.
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Note
Observe the instructions given by the sealant supplier.
• It is recommended to change the lube oil after having carried out major
repairs.
• It is also recommended checking the alignment of the gearbox after the

completion of major repairs.
Attention!
Damages to the gearbox due to improper painting.
Components which are not allowed to be painted for functional
reasons and which had not been painted at the time of their delivery
must not be painted.
Examples: Valves, sensors, pressure gauges, noise dampers.
8.5.2 Screw tightening torques

The tightening torques to be applied for all screws with metric thread and
seatings acc. to DIN 931, DIN 912 and DIN 934, (screws slightly oiled, no
Molykote!) are specified on the arrangement drawing in the annex.
8.5.3 Screw locking with Loctite

All the screws inside the gearbox and specifically marked screws outside the
gearbox have to be secured with Loctite. The Loctite product to be used is stated
on the table below.
When using Loctite, the friction coefficient corresponds to that of a slightly oiled
screw (µ=0.125).
Note
Observe the instructions given by the Loctite manufacturer!
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Cleaning prior to mounting

• Screws, nuts and threaded bores, which are dirty or fouled by oil, have to be
cleaned.
• Use alkali-free, neutral cleaning products (e.g. P3-T5125, Per).
Note
Observe the instructions given by the cleaning product manufacturer.
Loctite Type 243 270 1 582

suitable for threads ≤ M 36 ≤ M 12 ≤ M 56
hand-dry after 15 - 30 min 10 - 30 min 2h
operable after abt. 1 h abt. 1 h abt. 6 h
final hard stage after 3h 3h 12 - 24 h
temperature resistance - 55 °C up to +150 °C
Application of the product

• A sufficient quantity of Loctite has to be applied on the entire length of the
thread in order to fill up all the gaps in the thread.
• For screws as of size M 16 approx. and bigger, and as a general rule, for all
blind end bores, the threaded bores have to be coated/wetted, too.
Tightening of screwed connections

The screws have to be tightened to the required tightening torque as long as the
screws can still be turned by hand.
Commissioning
• Screwed connections, which have been coated with Loctite (commissioning of
the gearbox), are only allowed to be loaded after the product has dried for a
sufficient time period.
Re-Use
• If connecting elements are used again which had already been locked by
Loctite prior to the dismounting, the old Loctite has to be removed completely,
e.g. by using a wire brush.
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• Threaded bores also have to be cleaned and Loctite remnants have to be

removed with de-oiled compressed air.
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9 Disposal
If the gearbox is put out of service, all the waste disposal laws and prescriptions
prevailing at that point of time have to be strictly observed.
It is appropriate to check which material can be recycled and to arrange this with
respect to the protection of our environment.
The disposal of waste, oils, greases and cleaning products must be carried out
in accordance with the valid legal regulations.
Attention!
Oils and greases resp. oily and greasy waste are a high risk to the
environment. For this reason, specialised companies have to be
charged with the disposal of such products/ substances.
Ensure the appropriate and correct waste disposal by
specialized and approved companies.
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10 Spare Parts
It is advised that the most essential spare parts are carried as stock at the site of
installation in order to ensure permanent availability of the gearbox.
The spare parts list attached to this manual serves as a basis for spare parts inquiries
and orders.
We only assume guarantee for original spare parts supplied by us.
Note
We point out explicitly that spare parts and accessory parts not
supplied by RENK AG, have not been tested and accepted by us.
The installation and/or use of such parts may under certain
circumstances change the constructional features and properties of
the gearbox. The safe operation is thus jeopardised.
We do not assume any liability or accept claims for compensation for
damages resulting from the use and installation of spare parts and
accessory parts which have not been supplied by RENK AG.
Please pay attention to the fact that particular production and delivery specifications exist
for individual components. RENK AG supplies spare parts that have been designed and
built in accordance with the latest state of technology and in compliance with valid
regulations and laws.
The following information is needed when ordering or enquiring spare parts:

− Serial number
− Part number
− Quantity
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Schmierstoffempfehlung / lubricant recommendation
BP Castrol TOTAL Lubmarine ExxonMobil Shell Chevron

FZG ≥12
Disc Clutch*3
no
VG 100*1
Energol Alpha Mobilgear

Epona Z 100 Omala Oil 100 MEROPA 100
GR XP 100 SP 100 *1 600 XP 100
yes
MHP 153 DISOLA M3015 Gadina AL 30

no
SAE 30 *2
Mobil Delvac 1630 URSA Marine 30

yes
- - -
*1: RENK Empfehlung / RENK recommendation

*2: Motoröle (SAE 30) sind nicht zu verwenden wenn eine Nebenstromfiltartion installiert ist!
Engine oils (SAE 30) are not to be used if bypass-filtration is installed!
*3: Disc Clutch = yes: Lamellenschaltkupplung im Getriebe integriert / Multi Disk Clutch integrated inside gearbox
Disc Clutch = no: Keine Lamellenschaltkupplung im Getriebe integriert / No Multi Disc Clutch integrated inside gearbox
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Schmierstoffempfehlung / lubricant recommendation
Die für das Getriebe anzuwendende ISO VG Viskositätsklasse nach DIN 51519 finden The appropriate ISO VG viscosity class acc. to DIN 51519 is stated on the order-
Sie auf dem auftragsbezogenem Maßblatt und auf dem Getriebetypenschild! specific dimension drawing and on the nameplate of the gearbox!
Schmierstoffanforderungen Requirements:
• FZG-Laststufe ≥ 12 nach DIN ISO 14635-1 unter den Prüfbedigungen A/8,3/90 • FZG-failure load stage ≥ 12 acc. to DIN ISO 14635-1 under the test conditions A/8,3/90
• kin. Viskosität bei 40°C: • Kinematic viscosity at 40°C:
- VG 100 / SAE 30: 90-110 mm2/s (cSt) DIN 51562 - VG 100 / SAE 30: 90-110 mm2/s (cSt) DIN 51562
• Viskositätsindex nach DIN ISO 2909: >80 • Viscosity index acc. to DIN ISO 2909: >80
• Geringes Schäumen • Minor foaming
• Alterungsbeständig • Non-ageing
• Verträglichkeit mit Resten des bei RENK verwendeten Einlauf- und Konservierungsöl • Compatibility with remainders of the run-in and rust-preventing oil
CASTROL ALPHA SP100 S CASTROL ALPHA SP100 S used by RENK
• Verträglichkeit mit dem bei RENK verwendeten Getriebe-Innenanstrich • Compatibility with the internal gearbox paints used by RENK
• Verträglichkeit mit Flüssig-Dichtungen zwischen Anschraubflächen • Compatibility with liquid seals between bolted surfaces
• max. Wassergehalt <0,2% • max. water content <0,2%
Einsetzbar sind: The following oils can be used:
• Umlauföle nach DIN 51502 in der entsprechenden ISO VG Stufe • Circulation oils according to 51502 of the appropriate ISO VG viscosity class
• HD- Schmierstoffe mit gutem Korrosionsschutzverhalten nur für Getriebe ohne CJC Bypass • HD- lubricants with good corrosion inhibition properties only for gearboxes without CJC
System: Bypass system:
• Dieselmotorenöle in der entsprechenden Viskositätsklasse • Diesel engine oils of the appropriate viscosity class
• Mildlegierte Mineralöle wie CLP nach DIN 51517 Teil 3 • Mild-alloyed mineral oils such as CLP according to DIN 51517 Part 3
• Hydrauliköle wie HLP nach DIN 51524 Teil 2 • Hydraulic oils such as HLP according to DIN 51524 Part 2
Additive im Schmieröl dürfen die Reibung und das Ein- und Ausschaltverhalten der The additives in the lube oil must not impair the friction and engagement/disengagement
Lamellenschaltkupplung nicht beeinflussen behavior of the multi-disk clutch.
Bei Verwendung einer anderen Viskosität oder auch eines anderen als hier empfohlenen The operator bears the responsibility for the technical suitability of the lubricant if another
Getriebeöles übernimmt der Betreiber die Verantwortung für die technische Eignung des viscosity or gearbox oil which is not stated in this list is used.
Schmierstoffes.
Mischen unterschiedlicher Schmierstoffe verändert deren Eigenschaften und ist nicht Mixing different lubricants changes their properties and is not allowed!
statthaft!
Abweichungen sind nur nach Rücksprache mit RENK statthaft. Deviations are only permitted if approved by RENK.
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LIST OF MEASURING AND CONTROL DEVICES

Com. No.: 859823-24 Marine gearbox type: RSV-1120C
860600-01
Dimensional drawing No.: 0797487 Classification society: BV
Hydraulic schema No.: 0797391
Switch schema No.: 0797392

quan.
Measuring Signal
Description type Range Setpoint Function maker type comment
point Type
Gearbox
TEAH 100 lubrication oil, inlet 55°C Alarm 2x PT100,
1 sensor analogue Danfoss without indicator and contactors!
TEI 101 temperature high 60°C reduction MBT5252
TEAH 102 thrust bearing 70°C Alarm 2x PT100,
1 sensor analogue Danfoss without indicator and contactors!
TEI 103 oil temperature high, ahead 75°C reduction MBT5252
104 bearing temperature
2 TSAH switch 65°C Alarm binary Danfoss MBC8100
105 output shaft, high
106 bearing temperature
2 TSAH switch 75°C Alarm binary Danfoss MBC8100
107 input shaft, high
axial bearing temperature
1 TSAH 108 switch 75°C Alarm binary Danfoss MBC8100
input shaft, high
lubrication pressure stand by pumps
1 PSL 109 switch 0,4 bar binary Danfoss MBC5100
low "start"
lubrication pressure
1 PTAL 110 sensor 0-10bar 0,6 bar Alarm 4-20mA Danfoss MBS5100
low
lubrication pressure main engine
1 PSZL 111 switch 0,2 bar binary Danfoss MBC5100
low "stop"
lubrication pressure stand by pumps Is to be adjusted on board between 2-6
1 PSH 112 switch 5 bar binary Danfoss MBC5100
high "stop" bar at operating temperature!
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LIST OF MEASURING AND CONTROL DEVICES

Com. No.: 859823-24 Marine gearbox type: RSV-1120C
860600-01
Dimensional drawing No.: 0797487 Classification society: BV
Hydraulic schema No.: 0797391
Switch schema No.: 0797392

quan.
Measuring Signal
Description type Range Setpoint Function maker type comment
point Type
lubrication pressure main engine

1 PSH 113 switch 1 bar binary Danfoss MBC5100
high "release start"
lubrication oil filter
1 PDSAH 114 switch 2,5 bar Alarm binary Internormen AE
diff. pressure high
lubrication oil level change
1 LSAL 115 switch Alarm binary Unimess UNS2000
low over
local indicators
400 cooler inlet
2 TI oil temperature sensor analogue
401 gear inlet
1 TI 402 temperature sensor thrust bearing analogue
403 filter inlet
2 PI oil pressure sensor analogue
404 gear inlet
405 operating pressure
2 PI sensor oil pump analogue
406 suction side
1 LI 407 oil level plunger - oil level -
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Datenblatt / data sheet

Drehschwingungsschema
torsional vibration scheme
Getriebe RSV-1120C Werft: Admarin

Gear box type Yard:
Kom.:-Nr.: 859823-4 Neubau Nr.: 10, 11
Com.No.: 860600-1 Hull No.: 16, 17
Zeichnungs-Nr.: B087924(3) Bestell-Nr.: 1 130 389-90
Drawing No.: Order No.: 1 130 402-03
vorläufig / preliminary verbindlich / obligatory
CT4 Z4 J = Massenträgheitsmoment
J4 moment of inertia
cT = Verdrehsteifigkeit
torsional stiffness
Z1
CT2 J1 CT1 d = kleinster Wellendurchmesser
Z2 smallest diameter on shaft
J2 z = Zähnezahl
number of teeth
Following values were considered for the

gearbox design.
CT3 Z3
J3 Mass moment of inertia:
Propeller with shaft 35955 kgm²
including water addition
Main engine with flywheel 5896 kgm²
including elastic coupling
Generator including 52,8 kgm²
elastic coupling
Propeller diameter 5,6 m
Ice- class design based on ballast state

with totally submerged propeller.
Eisklassenauslegung erfolgte im
Ballastzustand mit vollständig
eingetauchtem Propeller.
Index J [kgm2] cT [Nm/rad · 106] d [mm] z Bemerkung / remarks

1 37,36 97,93 300 109
2 15,22 531,07 355 19
3 2478,06 273,54 400 90
4 0,71 2,85 120 30
5
6
Datum: 07.06.2006 Name: Brüning
RENK Aktiengesellschaft · Werk Rheine · Postfach 1953 · D-48409 Rheine · Tel. 05971/790-0 · Telefax 05971/790-208
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chapter content
5 pumps
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Transfer Gear Pumps

Operating and Maintenance Instructions
KF 3/ - 6/ .../94
KF 3/ - 6/ .../196
KF 3/ - 6/ .../197
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Content
Symbols for safety instructions 3
General safety instructions 3
Manufacturer's address 3
The documentation 4
Description of equipment 4
General 4
Construction 4
Technical data 7
Explanation of the type code 7
Technical data 8
General data 8
Overview of nominal sizes 9
Overview of materials 9
Specified use 9
Corrosion prevention 10
Workmanship of the suction and pressure line 10

Suction line 10
Suction line in vacuum operation 11
Pressure line 11
Quench connection 12
Pump installation 12
Mechanical installation 12
Determination of the direction of rotation 13
Commissioning 14
Pump removal 16
Maintenance 16
Seals 16
Changing the pump's direction of rotation 17
Repairs 18
Reconsignment 18
Recognise and avert errors 18
2 BKF-0013-11.03-GB
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Safety
Symbols for safety instructions

The safety instruction embodied in these operating instructions are identified with the attention!-
symbol.
If these instructions are not heeded, hazards to personnel and damage to equipment may result.
Further notes which do not have a warning character but provide tips for optimum operation are
symbolised by a hand:
General safety instructions
The operating safety of the pump supplied is only guaranteed if the pump is used
as specified (see "Description of equipment"). The stated limiting values (see also
"Technical data") must not be exceeded under any circumstances.
Personnel having the responsibility for installing, operating or repairing the pump need to
have the appropriate qualifications; these may have been obtained through training or
appropriate instruction. Such personnel must be familiar with the content of these
operating instructions.
During the execution of all work, the prevailing national rules for accident prevention and
safety at the work place and where appropriate the internal regulation of the operator must
be observed, even if the latter are not named in these operating instructions.
Leakages of dangerous substances handled by the pump must be contained and disposed
in such a way that there is no danger to personnel or the environment. The relevant
statutory regulations must be observed.
During all work on the pump and prior to installation, the connecting pipeline must be
depressurised and the motor isolated!
The operator has to ensure that these operating instructions are accessible at all times to
personnel in charge.
Manufacturer's address
Kracht GmbH
Gewerbestraße 20
D- 58791 Werdohl
Germany
Tel.: 00 49 / 23 92 / 935-0
Fax: 00 49 / 23 92 / 935-209
e-mail: info@kracht-hydraulik.de
Internet: www.kracht-hydraulik.de
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The documentation
The present operating instructions describe the installation, the operation and the repair of the
KRACHT transfer pumps KF 3/ – KF 6/ with the special codes 94, 196 and 197.
The device is manufactured in different versions. The specific version can be identified from the
type label affixed to the pump. The structure of the type designation and a detailed description of
the individual versions and nominal sizes can be found in the "Technical data" section (see
"Description of equipment").
Description of equipment
General
KRACHT pumps out of the series KF 3/ – KF 6/ are external gear pumps which operate according
to the displacement principle. Two gear wheels which are rotating in mesh with each other result in
a depression at the pump inlet (suction side) when rotating. Thus, the medium can flow into the
pump. The transport of fluid is achieved through the entrainment along the cavities between the
gear teeth and the walls of the gear chambers. Simultaneously, a corresponding volume is
displaced at the pump outlet (pressure side) through rotation of the gear teeth into the filled area
vacated by the preceding teeth. The so called geometric delivery volume Vg is displaced per
revolution of the gear wheels. A value Vgn referred to as the nominal volume is used in technical
documentation to identify the pump size. The actual delivered fluid quantity is not corresponding
with the theoretical value, it is reduced by losses due to the necessary clearances. The lower the
operating pressure and the higher the viscosity, the lower are the losses.
The lateral play between the gear wheel contact surfaces is set such that the permissible operating
pressure is safely controlled and the losses are as low as possible.
Gear pumps are self-priming in wide confines. It is only after the burden of external loading is
applied, for example if a delivery head is imposed, there is resistance at the pump outlet, pipeline
components, etc. that a working pressure must be generated to overcome these resistances.
Construction
The following illustrations show the construction of the KF for the above mentioned versions. The
versions 196 and 197 are designed for delivering aeriferous gear oils, that means for the use as a
lubricating oil pump at ship gears and stationary gears.
Due to special constructional measures, the usual noise increase at aeriferous gear oils and high
depressions is avoided. The noise level is not or only insignificantly above the measuring values of
non-aeriferous oils. A shift of the noise spectrum to higher frequencies does not occur either.
The pumps with the special code 197 are manufactured as extension pumps or as pumps in
combination with an electric motor. The extension pump (Fig. 2) is equipped with a support bearing
for absorption of external radial forces as they come up when using a cantilever pinion.
The pump in combination with an electric motor (Fig. 3) does not have a support bearing and has
to be driven with an elastic coupling. Extension pump and electric pump are sealed at the shaft end
with a radial shaft sealing ring.
The pumps with the special code 196 are manufactured as extension pumps with (Fig. 4) and
without support bearing. This version has no sealing at the shaft end, thus it can be driven with
primary pressure at the suction side. The discharging leakage oil is dissipated into the gearbox.
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The pumps with the special code 94 (Fig. 1) are designed for the use in vacuum plants for
degasification and cleaning of oils.
These pumps are manufactured as pumps in combination with an electric motor and do not have a
support bearing for absorption of external radial forces.
At this version, a triple sealing with preliminary fluid is used as shaft sealing. The shaft sealing ring
in the middle is mounted for suction operation.
Fig. 1 Pump without support

bearing, special code 94
1 Housing
2 Flange cover
3 Driving shaft
4 Gear
5 End cover
6 Plain bearing bush
7 Shaft sealing ring
8 O-Ring
10 Connection pipeline
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Abb. 2 Pump with support

1 Housing
2 Flange cover
3 Driving shaft
4 Gear
5 End cover
8 O-Ring
9 Support bearing
Fig. 3 Pump without support

1 Housing
2 Flange cover
3 Driving shaft
4 Gear
5 End cover
8 O-Ring
Fig. 4 Pump with support

1 Housing
2 Flange cover
3 Driving shaft
4 Gear
5 End cover
8 O-Ring
9 Support bearing
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Technical data
Explanation of the type code
Product name KF 3/ KF 4/ KF 5/ KF 6/
Nom- size KF3 63, 80, 100, 112

KF4 125, 158, 180
KF5 200, 250, 315
KF6 400, 500, 630
Mounting KF3 F
KF4 G
KF5, KF6 H
Support bearing Size DKF

DKF3, DKF4,
Shaft end DKF5, DKF6
= Size KF
P0 cyl. without support bearing
N0 cyl. with support bearing
R0 cyl. with support bearing
reinforced
KF 4/ 150 G 1 0 B P0 A 7DP 1 / 197 + DKF 4 A 25

Ordering example
Direction Material
of rotaton
A Housing GG,
1 clockwise Connection Sealing NBR
2 counterclockwise D Housing GG,
type
Sealing FPM
B Flange connection G Housing GGG,
Sealing NBR
End cover Pressure area
04 2 ... 4 bar
A Leakage dissipation for
08 4 ... 8 bar
direction of rotation 1 or 2
16 8 ... 16 bar
at version 94, 197
25 16 ... 25 bar
B Leakage dissipation for
direction of rotation 1 or 2 30 4 ... 30 bar
at version 196
0 Version with DKF Special code
94 Sound-optimised, vacuum-
Housing and bearing material
operation, 3 shaft sealing
0DP, 7DP GG-Housing with rings with quench
DU-Plain bearing bush Sealing 196 Sound-optimised, without
0VP, 7VP GGG- Housing with shaft sealing
DU-Plain bearing bush 1 NBR 197 Sound-optimised, with
2 FPM shaft sealing
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Technical data
General data
Type of construction External gear pump
Pipeline connection Flange connection
Installation attitude Any (except special code 94)
Direction of rotation Clockwise or counterclockwise
pe min -0,9 bar
94
pe max 0,2 bar
pe min 196 -0,4 bar, start-up state – 0,6 bar
Operation pressure suction side
pe max 25 bar
pe min 197 -0,4 bar, start-up state – 0,6 bar
pe max 1 bar
Operation pressure pressure side pn max 25 bar*
rpm n See overview "Nominal sizes"
Viscosity νmin 12 mm²/s
νmax 15000 mm²/s
NBR-Sealing FPM-Sealing
Medium temperature ϑmin -10 °C -10 °C
ϑmax 90 °C 150 °C
Surrounding temperature ϑu min -20 °C
ϑu max 60 °C
Permissible media Gear oil, motor oil, hydraulic oil, mineral oil
synthetic oil only after release by Kracht
GmbH
Filtering Filter fineness ≤ 60 µm
* higher pressures only after release by Kracht GmbH
8 BKF-0013-11.03-GB
B31495000-0 105/201
Overview of nominal sizes

geom. delivery rpm range perm. radial Acoustic pressure
volume forces** level
vg nmin nmax Fradial Faxial LA ***
Nom. size* cm³/r 1/min 1/min N N dB(A)
3/100 100,8 ≤ 71
200 2000 1500 200
3/112 112,6 ≤ 72
4/125 129 ≤ 73
4/150 153 200 2000 1500 200 ≤ 73
4/180 184 ≤ 74
5/200 204 ≤ 77
5/250 255 200 2000 2000 300 ≤ 78
5/315 321 ≤ 79
6/400 405 ≤ 80
6/500 505 200 2000 3000 500 ≤ 82
6/630 629 ≤ 83
* see type label at pump, ** radial forces only at version with support bearing. On central shaft journal
*** measured with gear oil, 150 mm²/s, n=1500 1/min, p=25 bar, oil with approx. 4 % air proportion, measuring distance
1m.
Overview of materials
Material and sealing Housing / Cover Gear Bearing Shaft sealing O-Ring
type*
0DP1 / 7DP1 EN-GJL-250 NBR NBR
0DP2 / 7DP2 (GG 25) Carburising FPM FPM
steel P 10
0VP1 / 7VP1 EN-GJS-400-15 (1.7139) NBR NBR
0VP2 / 7VP2 (GGG 40) FPM FPM
* see type label at pump: KF...
For certain operating conditions, the stated minimum and maximum values are not
valid!
Specified use
It has to be ensured that the pumps are only operated with the permissible media (see section
"Technical data").
The maximum permissible operating data mentioned in the section "Technical data" have strictly to
be observed.
Deviations of the technical data and operating conditions are only allowed after release of the
KRACHT GmbH, resp. are mentioned on the type label.
BKF-0013-11.03-GB 9
B31495000-0 106/201
Corrosion prevention
In the factory, all pumps are checked with mineral hydraulic oil regarding their function and suction
and pressure connection are sealed with a plug. The remaining oil conserves the inner parts for a
duration of roundabout 6 months. The pumps have lacquering on the outside.
During transport and storage, the pumps must not expose to weather effects and extreme
variations in temperature and have to be stored dry.
If the pumps are meant to be stored over a longer period, the connection areas as well as the inner
parts of the pump have to be treated with a corresponding corrosion prevention oil. Furthermore,
humidity at the pump should be avoided with humidity absorbing materials.
If extreme air humidity or aggressive atmosphere occurs during transport, corresponding corrosion
avoiding measures should be carried out.
Workmanship of the suction and pressure line

Only pipelines and connection which are permitted for the expected pressure range
must be used.
The instruction of the relevant manufacturer have to be observed!
The pipelines have to be connected absolutely stress-free to the pump supports.

The pipelines are to be constructed in such a way that even during operation, no stresses can be
transferred through the pipelines, for example through changes in length due to variations in
temperature.
To reach an optimised noise protection it is recommended to mount a damping flange

between pump and pump supports and damping elements between the electric motor and
mounting area. The use of suction and pressure hoses reduced the noise level of a hydraulic plant
as well.
Suction line
Provision of the suction workmanship should be carried out with great care, since the operational
behaviour of the pump is greatly affected by this factor.
• The suction line should be as short and straight as possible.
• Avoid high suction heads.
• Additional sources of pipeline resistance, such as formed parts, valves and closed meshed
suction filters, should be avoided.
• The depression in the suction line depends on the sum of all the resistances at the suction side
and the suction head, taking account of the specific data to the medium in the line.
• When laying out the suction line in the medium container, attention should be paid to the
achievement of unimpaired suction. The distances to the ground and to the partition walls have
to be adequately sized.
• The suction inlet must have an adequate distance to the deepest fluid level.
• If hosing is used on the suction side of the pump, then it must be of adequate stability such that
the hose does not deform and constrict the flow under the suction effect.
10 BKF-0013-11.03-GB
B31495000-0 107/201
• Recommended flow velocity in the suction line max. 1,5 m/s.

• If it is possible that the suction line runs dry during
standstill, one possibility of avoiding suction problems is
when the suction line is laid out as a siphon. Thus, the
pump is constantly filled after first initiation.
• When using longer suction lines which may run dry
during standstill, it is advisable to use a foot valve resp.
a check valve. These have to be designed for use in
suction lines and should show the lowest possible flow
restrictor (for example Gestra-valves
Suction line in vacuum operation

• If the pump should suck out of a container which is under pVacuum
vacuum, the pump should be placed approx. 0,8 m below
the container. The suction line should be laid out straight
and without resistances.
For this usage, only pumps with a special shaft sealing and
in noise optimised version with special code 94 must be
used.
The container must not be loaded with vacuum before the
pipeline system and the pump are filled with fluid.
If the permissible depression is exceeded (see

section "Technical data"), a reduction of the delivery volume would be the result
(due to the reduced filling of the pump).
The only exception to this is the start-up condition of the pump when a pressure of -0.6 bar
(depression) is tolerable for up to max. 60 minutes.
The depression can be checked by installing a vacuum meter on the pump/suction
connection.
The nominal diameter of the suction line can be chosen to be considerably larger than that of the
pump connection. The provision of a funnel-shaped suction opening or an oblique intersection at
the end of the suction pipe are recommended for increasing the cross-section on the suction side
Pressure line
Displacement pumps must never be operated against "closed valves", since the
uncontrollable pressure heads which occur in this case could cause damage to the
pump and to the associated plant elements.
This means that the use of a pressure relief valve as closest as possible to the pump
connection or some other means of restricting pressure in the system is essential!
• The nominal diameter of the pressure line should be selected in a way that the flow velocity
does not exceed the values given in the following table.
Pressure ≤ 10 bar >10 bar

Flow velocity ≤ 3 m/s ≤ 3,5 m/s
• The pump pressure should be checked by a manometer installed as close as possible to the
pump connection.
BKF-0013-11.03-GB 11
B31495000-0 108/201
• When operating a pump which has to

deliver via a check valve into an under-
pressure circuit (e.g. reserve pump in a
lubrication circuit), suction difficulties can
occur if the suction line is filled with air.
In these cases, the pressure line should
be vented directly before the check
valve.
This, for example, can be achieved by
providing a restricted bypass.
Quench connection
The version KF 3/ - 6/ .../94 has to be used when fluids should be delivered
which are under vacuum and whose sealing should be gas tight.
At this version, a preliminary container at the quench connection
(tube Ø8) in the flange cover has to be connected.
• The container for the preliminary fluid has to be placed above the pump.
• The installation attitude is restricted, the quench connection has to look up.
• A check of the fluid level in the preliminary container has always to be
possible.
• The preliminary fluid in the quench connection must not be loaded with
pressure or vacuum.
Pump installation
Mechanical installation
• Before installation the pump has to be checked for possible damage and soiling during
transport.
• The corresponding coupling hub has to be mounted on the motor- and pump shaft unless it has
not been done by the manufacturer.
• When installing the coupling, the hub should be heated up and slid onto the shaft in the heated
condition. The installation instructions of the coupling manufacturers have to be
observed.
• When using a driving tooth gear, it has to be heated up as well and to be placed onto the shaft
end in warm state..
• The shaft must not be struck during the mounting operation!!
Each coupling hub has to be secured on the respective shaft against axial
displacement! Rotating parts must be protected by the customer against
unintentional contact!
12 BKF-0013-11.03-GB
B31495000-0 109/201
The coupling has to be dimensioned to the max. start-up torque. Attention has to be
paid to vibrations and peaks of torque. The permissible values of the coupling
manufacturer have not to be exceeded!
• Mount the pump to the pump support resp. to the gear housing.
• Before installing the pump clean the pipeline system, remove dirt, sand, swarf etc. Welded
pipes, in particular, must be scoured or scavenged. Do not use cotton waste/rags for cleaning
purposes.
• Remove the protective stoppers in the pump's suction and pressure connections.
• Wet the inner parts of the pump with the fluid to be delivered.
• Connect the pipelines of both suction and pressure side of the pump and pay attention to the
instructions of the relevant manufacturer.
• Connect suction and pressure side according to the designation at the pump and the details on
the type label (see section "Determination of the direction of rotation").
• The pipelines have to be connected absolutely stress-free to the pump supports.
• When installing it has to be assured that no sealing material an enter the pipeline. Sealing
materials such as hemp and mastic are not permissible since they an lead to soiling and hence
to operating failures.
• Clean filler plugs and caps on fluid transport and storage containers before opening. Check
fluid containers and clean if necessary. The filter gauze on filling tubes and filter inserts on
fitted filters must not be removed under any circumstances.
• Attention should be paid to adequate filling of the fluid container!
Neither the suction nor the pressure side pipelines should transfer loads to the
pump! Damaged pipes and hoses must be replaced immediately!
Determination of the direction of rotation

The pump's direction of rotation is mentioned on the type label (see section "Explanation of the
type code). Please see the following illustration for direction of rotation and flow of the pump.
Without pressure relief valve
Direction of rotation clockwise Direction of rotation counterclockwise
With pressure relief valve
Direction of rotation clockwise Direction of rotation counterclockwise
BKF-0013-11.03-GB 13
B31495000-0 110/201
The pump's direction of rotation and flow is determined as follows:

When viewing on the shaft end of the pump, the pump turns
right, if the shaft turns clockwise,
left, if the shaft turn counterclockwise.
Commissioning
The commissioning is only to be carried out by appropriately trained and qualified
personnel. Before starting-up a plant it has to be ensured that an adequate quantity
of the operating medium is available in order to avoid dry-run.
• Check the permissible operating values against the anticipated operating conditions.
• Check all fixing bolts on the pump.
• Check the direction of rotation. If the direction of rotation has to be changed, refer to the
section "Maintenance".
• The pumps should be started up at either very low or zero pressure loading. The existing shut-
off devices should be fully opened and the pressure relief valve, installed in the pressure line,
should be adjusted to the lowest opening pressure setting.
• Particularity at version 94
The sealing chamber (see fig.) has to be filled with a suitable inhibiting
medium (such as mezamol) before the initial operation of the pump.
The inhibiting medium has to be compatible with the used sealing and
materials.
The inhibiting medium should avoid the penetration of air into the delivering
medium and serves as well as a lubrication for the shaft sealing rings
• The start-up is achieved by repeated rapid switching on and off of the drive
motor (inching mode) without reaching the full rpm, until it is apparent that the pump is
operating satisfactorily. The satisfactory operation being detectable either from gauge reading,
or from the noise generated by the pump, and being achieved over a period of not longer than
30 seconds. This in particular applies when a cold pump must be started-up with a fluid
medium that has already been warmed, in order to achieve a slow heating up of the pump and
to prevent jamming of the pump due to heat shock. After switching on the motor, it is then
allowed to run for a few minutes, under zero or low pressure. The pressure loading can then be
increased in stages until the desired operating pressure is reached.
• Vent the plant at the user lines at the most highest position.
• On attaining the required operating values, the temperature of the medium and of the pump
should be checked. The control points on the pump are the shaft bearing positions and the
shaft seals. The temperatures reached on the surface of the pump housing should be approx.
10°C above the temperature of the medium.
• After several hours of running, the final operating temperature should be checked (for
maximum permissible temperatures see section "Technical data").
• Static seals at the joint of the suctions resp. pressure connection and the pump should be
checked.
14 BKF-0013-11.03-GB
B31495000-0 111/201
• Check the threaded connection regarding leakages. By means of retightening of the threaded
connection these leakages can be eliminated.
• The motor and pump fixing screws should be checked as well after some hours of operating.
The pumps are only designed for running in the direction of rotation indicated by
the arrow resp. indicated by the symbol on the type label.
An operation of the pump in the wrong direction of rotation may lead to failure of
the shaft sealing! When operating in the wrong direction of rotation, the delivery volume of
the pump decreases. The optimised noise level will not be reached.
• Pressure setting of the pressure relief valve

Only valid for pumps with a built-in pressure relief valve
(Pump type code: KF … +DKF ...)
Response pressure
lower higher
To adjust the pressure setting at pressure relief valve (see fig.):

• Pull off the prevention cap (3)
• Loosen the lock nut (2)
• Set the adjuster screw (1)
rotation cw = response presser higher
rotation ccw = response pressure lower
• When the required pressure has been set, re-lock the adjuster screw (1) with the lock nut
(2)
The pressure relief valves of the series DKF are only designed as safety valves!
These valves should only respond briefly! A permanent drawing off of a bigger part
of fluid medium (>ca. 70% of the flow delivery) via the DKF valve will result in the
destruction of the pump due to over-heating!
BKF-0013-11.03-GB 15
B31495000-0 112/201
Pump removal
During all work at the pump and before the removal, the connection lines have to be
depressurised and the motor isolated! In addition, precautions must be taken to
ensure that the motor can not run-up during work on the pump.
• During all work the best possible cleanliness should be assured. Before loosening screwed
connections, the external surrounding should be cleaned.
• Remove the depressurised pipelines from the pump.
• Secure the pump connections and pipelines against the ingress of dirt.
• Pull off the coupling hub resp. the driving pinion with a hub drawer from the shaft end.
When the pumps operate with harmful fluids, the safety data sheets and the
regulations for handling these fluid has to be observed!
At operation temperatures above 60°C, the pump has to be cooled down first due to
danger of scald!
Leakages of dangerous media must be collected and disposed of in such a way that
no danger results to personnel or the environment. The statutory regulations have to be
observed.
Maintenance
Assuming correct installation in accordance with the conditions of use and correct operation,
KRACHT gear pumps are of such a construction that a long and failure-free operational life should
be obtained. They only require a minimum of maintenance which, however, is necessary for
reliable operation, since experience has shown that a high percentage of the failures and damages
which can occur are attributable to the ingress of dirt and inadequate maintenance. The extent of
servicing required and the service and inspection intervals are, in general, laid down by the
manufacturer in an appropriate plan.
A regular check-up of all operating data as there are pressure, temperature, current
consumption, degree of filter soiling etc. contributes to the early detection of potential
failures.
The best possible cleanliness should be ensured during all work. Before loosening screwed
connections, the surrounding areas are to be cleaned. All openings are to be sealed with protective
covers so that there is no ingress of dirt into the system.
Seals
• Static seals at the joint of the suctions resp. pressure connection and the pump should be
checked on a regular base.
• The shaft sealing ring has to be checked carefully of increased leakage. When leakages come
up, the direction of rotation and the operation data have to be checked. If necessary, the shaft
sealing ring has to be exchanged.
16 BKF-0013-11.03-GB
B31495000-0 113/201
Changing the pump's direction of rotation

On pump types KF 3 – KF 6 with special codes 94, 196, 197 with the direction of rotation code 1
and 2, i.e. pure right or left rotating pump, a change of the direction of rotation is only possible by
re-building the pump.
If the direction of rotation of a pump is required to be changed, the cover and the pressure relief
valve on the pump housing must be freed, in order that they can be rotated through 180° and
refitted.
Fixing screws
Leak oil
dissipation
Fixing screws
• Loose fixing screws

• Pull off the pump housing from the flange cover, refit after rotating of 180°.
• Tight fixing screws with the below mentioned tightening torques
• The re-building has to be done with the most possible carefulness and cleanliness
• The O-ring between housing and flange cover must not be removed or damaged.
When checking, pay attention to the following points:
• The recess in the housing has to be on the pressure side of the pump.
• At pumps without pressure relief valve the leak oil bore has to be on the inner part of the end
cover on the suction side of the pump.
• At pumps with pressure relief valve the adjuster screw of the pressure relief valve has to look to
the suction side of the pump (see section "Mechanical installation")
Tightening torque for cover fixing screws
Nominal size* KF 3/... KF 4/... KF 5/... KF 6/...
Tightening torque 45 + 5 Nm 45 + 5 Nm 45 + 5 Nm 75 +10 Nm
• see type code on device : KF …
BKF-0013-11.03-GB 17
B31495000-0 114/201
Repairs
A repair comprises:
• Error diagnostics, i.e. isolation of the error. Determining and localising the cause of the
error.
Lack of adequate sealing is a frequent source of failure. If this occurs
at the pipeline connections, it may be eliminated by simply tightening
the screwed fittings.
In case of a lack sealing on the pump, the respective seals must be
replaced (see spare lists).
The following list gives the causes of errors which are most frequently
encountered during operational failures together with an indication of
the problem areas to be rectified.
• Elimination of damages, i.e. replacement or repair of defective components and elimination of
the primary cause.
The elimination of the damage takes place on site, predominantly
through exchange of the defective component/s. Their repair is
generally done by the manufacturer.
Given the appropriate know-how and adequate equipment, the repair
may also be done by the end user or the initial equipper. Assistance
on this is available in form of spare lists and repair instructions.
Repairs are only to be done by trained specialist personnel.
Reconsignment
In case of a repair or check in the manufacturer's plant, the device has to be packed appropriately.
Furthermore, a safety data sheet of the used medium has to be added to the device. For known
minerals oils, the exact type designation is necessary at least.
For hardening or sticking media the device has to be cleaned before reconsignment.
Recognise and avoid errors

The following list gives the causes of errors which are most frequently encountered during
operational failures together with an indication of the problem areas to be rectified.
In the event of the occurrence of errors which can not be identified, please ask for assistance from
the KRACHT GmbH.
Error Possible cause

Increased sound Pump cavitation • Suction level too high
• Suction filter blocked or too small
• Internal diameter of the suction line too small
• Suction line too long
• Too many curves in the suction line
• Suction line blocked or not sealed
• Viscosity too high
• Temperature too low
• Wrong direction of rotation
18 BKF-0013-11.03-GB
B31495000-0 115/201
Highly increased • Suction line not sealed

formation of foam or air • Fluid reservoir level too low
inclusion in the medium
• Tank return line not sealed
• Oil reserve to small
• Lack of sealing, suction side or shaft seal
• Return line ends above level of fluid in
reservoir
• Inadequate venting
• Too strong froth up in the gear
Mechanical vibrations • Faulty aligned or loose coupling
• Faulty or inadequate pipeline fixing
• Flittering pressure relief valve
• Construction not noise-optimised (lack of
damping elements)
• Unfavourable installation location of the pump
• Pump worn out, tooth flank wear
• Interferences in the pump motor
Pump does not • Fluid reservoir level too low
suck
• Wrong direction of rotation
• Suction resistance too high
• Suction line not sealed
• Throttling element in the suction line
• Contaminant in the suction line
• Check valve in the pressure line not vented
(Lay out bypass line)
• Start-up pressure too high when suction line
filled with air
• Pump rpm too low
Insufficient supply • Throttling element in the suction line
flow • Fluid reservoir level too low
• Suction filter blocked or too small
• Viscosity too low
• Rpm too high
• Pressure too high
• Pressure relief valve set too low
• Pump sucks air
• Pump worn out
• Pump rotates in the wrong direction of
rotation
• Air part in the oil too high
BKF-0013-11.03-GB 19
B31495000-0 116/201
Insufficient pressure Supply flow too low • Viscosity too low

• Pressure relief valve set too low or does not
lock
Work resistances of the • Rpm too low
pressure line too low • Drive power too low
• Pump worn out
Power consumption • Pressure too high
too high • Viscosity too high
• Drive power too low
• Motor winding defective
Operating • Insufficient cooling and heating dissipation
temperature too
• Fluid supply too low
high
• Fluid conveyed under load into the reservoir
via pressure relief valve
• Pump worn out
Pump heating • Pressure too high
above permissible
level
• Pump worn out
Leakage at the • Inlet pressure above permissible value
shaft sealing • Wrong direction of rotation
• Shat radial load too high
• Seal wear
• Seal temperature too high
• Wrong seal material
• Wear of the sealing due to bad lubricating
medium
• Wear due to abrasive parts
Coupling wear • Faulty aligned or loose coupling
• Inadequate axial play in coupling
• Coupling overloaded
• Temperature too high
Short lifetime Wear at bearing, tooth • Wear due to abrasive parts
gear and housing parts • Wear of the sealing due to bad lubricating
medium
• Corrosion, check material compatibility
• Operating pressure too high for the medium
characteristics
20 BKF-0013-11.03-GB
B31495000-0 117/201
C Subsupplier Documentation
KF 4/150 G20B P0B 7VP1/196

Spare parts list
TYPE: GEAR PUMP

KF 4/150 G20B P0B 7VP1/196
PART-NO.: P.0145430022
DRAWING NO.: 31145431-Ä00
==========================================================================
ITEM OUANT DESCRIPTION PART NO.
UNIT
==========================================================================
10 1 PCS HOUSING E.0201760001
___________________________________________________________________________
20 1 PCS FLANGE COVER E.0196720001
___________________________________________________________________________
30 1 PCS SEAL RETAINER E.0123800001
___________________________________________________________________________
40 1 PCS SHAFT E.0120280001
___________________________________________________________________________
50 1 PCS DRIVEN SHAFT PINION E.0072780001
___________________________________________________________________________
60 1 PCS GEAR E.0055980001
___________________________________________________________________________
80 4 PCS BEARING BUSH E.0197640001
___________________________________________________________________________
90 1 PCS GASKET E.0000910001
___________________________________________________________________________
100 1 PCS NAME PLATE E.9192130001
___________________________________________________________________________
110 1 PCS SNAP RING SPRING STEEL E.9412980001
___________________________________________________________________________
120 4 PCS CENTER SLEEVE E.9427650001
___________________________________________________________________________
130 3 PCS HEX.SOCKET HEAD CAP SCREW M6X16 8.8 N.0069120259
___________________________________________________________________________
140 2 PCS HEX.SOCKET HEAD CAP SCREW M10X80 10.9 N.0009120222
___________________________________________________________________________
160 2 PCS STUD M10X40 8.8 N.0009390001
___________________________________________________________________________
170 2 PCS HEXAGON NUT M10 8.8 N.0009340029
___________________________________________________________________________
180 2 PCS SPRING WASHER 10 SPRING STEEL N.0079800005
___________________________________________________________________________
B00407-e/06.00 – P 1
B31495000-0 118/201
==========================================================================
ITEM OUANT DESCRIPTION PART NO.
UNIT
==========================================================================
___________________________________________________________________________
___________________________________________________________________________
210 2 PCS NOTCHED NAIL 2X5 AL N.0014760002
___________________________________________________________________________
250 1 PCS PARALLEL KEY 8X7X40 C45K N.0068850037
___________________________________________________________________________
260 1 PCS PARALLEL KEY 6X6X36 ST K.0005030085
___________________________________________________________________________
280 1 PCS O-RING 115,0X3,0 NB-90 L.0017010028
___________________________________________________________________________
320 2 PCS PROTECTION CAP L.0064000044
___________________________________________________________________________
410 1 PCS END COVER E.0197730001
___________________________________________________________________________
430 4 PCS HEXAGON SCREW M8X25 8.8 N.0009330115
___________________________________________________________________________
440 4 PCS SPRING WASHER 8 ST N.0001270010
___________________________________________________________________________
610 1 PCS DIRECTIONAL MARKER E.9200410001
___________________________________________________________________________
620 2 PCS NOTCHED NAIL 2X5 AL N.0014760002
___________________________________________________________________________
P2
B31495000-0 119/201
B00407-e/06.00 – P 3
B31495000-0 120/201
KF 4/180 G20B P0B 7DP1/196

Spare parts list
Type: Gear pump

KF 4/180 G20B P0B 7DP1/196
Part-no: P.0144150023
Drawing no.: 31144151/1
==========================================================================
ITEM. OUANT Description Part No.
Unit
==========================================================================
10 1 STCK HOUSING KF 4/180 B .DP./197 E.0203940001
___________________________________________________________________________
20 1 STCK FLANGE COVER KF 4 G 7DP./197 E.0203950001
___________________________________________________________________________
30 1 STCK COVER KF 4 G E.0123800001
___________________________________________________________________________
40 1 STCK SHAFT KF 4/180 P E.0120290001
___________________________________________________________________________
50 1 STCK DRIVEN SHAFT PINION KF 4/180 ..P./197 E.0200130001
___________________________________________________________________________
60 1 STCK GEAR KF 4/180 ..P./197 E.0200160001
___________________________________________________________________________
80 4 STCK BEARING BUSH KF 4 E.0197640001
___________________________________________________________________________
90 1 STCK GASKET KF 4 E.0000910001
___________________________________________________________________________
100 1 STCK NAME PLATE 26X52X0,8 E.9192130001
___________________________________________________________________________
110 1 STCK SNAP RING E.9412980001
___________________________________________________________________________
120 4 STCK CENTER SLEEVE KF 3,4,5 E.9427650001
___________________________________________________________________________
130 3 STCK HEX.SOCKET HEAD CAP SCREW M6X16 8.8 N.0069120259
___________________________________________________________________________
140 2 STCK HEX.SOCKET HEAD CAP SCREW M10X80 10.9 N.0009120222
___________________________________________________________________________
160 2 STCK STUD M10X40-5.8 N.0009390001
___________________________________________________________________________
170 2 STCK HEXAGON NUT M10-8.8 N.0009340029
___________________________________________________________________________
180 2 STCK SPRING WASHER 10-SPRING STEEL N.0079800005
___________________________________________________________________________
190 2 STCK SPRING WASHER 10-ST N.0001270011
___________________________________________________________________________
B00568-d/08.02 – S 1
B31495000-0 121/201
==========================================================================
ITEM. OUANT Description Part No.
Unit
==========================================================================
200 3 STCK SPRING WASHER 6-SPRING STEEL N.0079800016
___________________________________________________________________________
210 2 STCK NOTCHED NAIL 2X5-AL BLANK N.0014760002
___________________________________________________________________________
250 1 STCK PARALLEL KEY A 8X7X40 - C 45 K N.0068850037
___________________________________________________________________________
260 1 STCK PARALLEL KEY 6X6X36-ST K.0005030085
___________________________________________________________________________
280 1 STCK O-RING 115,0X3,0 NB90 L.0017010028
___________________________________________________________________________
320 2 STCK PROTECTION CAP GPN 600 B 498 L.0064000044
___________________________________________________________________________
410 1 STCK END COVER KF 4 B /53 E.0060190001
___________________________________________________________________________
420 2 STCK HEADLESS SCREW M8X12-5.8 N.0005530123
___________________________________________________________________________
430 4 STCK HEXAGON SCREW M8X25-8.8 N.0009330115
___________________________________________________________________________
440 4 STCK SPRING WASHER B 8-ST N.0001270010
___________________________________________________________________________
450 2 STCK SCREW PLUG B G1/8-5.8 N.0009080169
___________________________________________________________________________
460 STCK LOCTITE NO. 273 - 50 CCM G.0225000002
___________________________________________________________________________
610 1 STCK DIRECTIONAL MARKER E.9200410001
___________________________________________________________________________
620 2 STCK NOTCHED NAIL 2X5-AL BLANK N.0014760002
___________________________________________________________________________
S
B31495000-0 122/201
B00568-d/08.02 – S 3
B31495000-0 123/201
chapter content
6 cooler
B31495000-0 124/201
Instructions voor installation, start-up

and maintenance of a
Bloksma heat exchanger.
P-type (P/PF, IV/MV)
Article number of this manual: 7ZZ00P0000010
Bloksma B.V.
P.O. Box 1003
1300 BA Almere
The Netherlands
Tel. +31 (0)36 5492300

Fax +31 (0)36 5492390
e-mail: service@bloksma.nl
web: www.bloksma.nl
B31495000-0 125/201
Rev. 01
Instruction manual P-type Heat exchanger
TABLE OF CONTENTS
Page
Glossary………………….……………………………………………... 3
1 Introduction.…………………………………………………………… 4
1.1 Remarks…………………………………………………………………. 4
1.2 Guarantee and liability…………………………………………………... 4
1.3 Environment.……………………………………………………………. 4
1.4 Safety……………..…………………………………………………….. 4
1.5 Inhibitors………………………………………………………………… 4
2 Installation and start-up………………………………………………. 5
2.1 Receipt…………………………………………………………………... 5
2.2 Installation..……………………………………………………………... 5
2.3 Start-up…………………………………….……………………………. 6
3 Maintenance..…………………………………………………………... 7
3.1 Inspection and cleaning intervals….……………………………………. 7
3.2 Anodic protection…….…………………………………………………. 7
3.3 Cleaning of the heat exchanger………….……………………………… 7
3.3.1 Mechanical cleaning of the tubeside…………..……………………….. 7
3.3.2 Chemichal cleaning of the shell-/tubeside………………………………. 7
3.4 Shut down periods………………………………………………………. 8
3.5 Assembling and disassembling of the heat exchanger………………….. 9
3.6 Instructions for gaskets and bolting…..………………………………… 12
3.6.1 Gaskets….……………………………………………………………….. 12
3.6.2 Bolting………………………………………………………..………… 12
4 Trouble shooting & repairs………..………………………………….. 13
4.1 Thermal performance too low..…………………………………………. 13
4.2 Leaking tubes / tube-tubesheet-connection……………………………... 13
4.3 Leaking gaskets….……………………………………………………… 13
5 Spare parts & tools…………………………………………………….. 14
Appendix A: Instructions for conservation
Appendix B: Adresses
Appendix C: Constructional directions for entering a P-type heat
exchanger in a piping design
The P-type heat exchanger can be subdivided into four sizes: P10, P13, P20 and P28.
The number indicates the shell size in centimeters. The construction of the P10 is slightly
different from the others. When necessary this manual has special texts (indicated with: “For
P10 only:”) which apply to the P10 only.
There are two models (P10 only in MV): the IV (Industrial Version) and the MV (Marine
Version). Main difference is the anodes in the tubeside circuit of the MV. It is pointed out in
the text when there are differences between the two models.
In addition this manual applies to P-heat exchangers with plain tubes as well as PF heat
exchangers with bundles with fins.
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Glossary
Refer to the figure(s) in the paragraph “Assembling and disassembling of the heat exchanger”
for an explanation of the designation of parts of the heat exchanger in the text.
Conditioned circuit Closed circuit with a non-corrosive medium.
Unconditioned circuit Open circuit (for instance seawater) or a closed circuit

with a corrosive medium.
Coating Layer protecting the coated material against corrosion.

The coating separates the coated part from the corrosive
medium.
Inhibitor Additive to a medium flowing through the heat

exchanger which –expressly tailored to that medium-
reduces the quickness of chemical reactions like
corrosion.
Anodes / anodic protection Introducing a base metal to a more precious metal (on
purpose) in order to protect this metal. The part serving
as anode is being sacrificed.
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1 Introduction
1.1 Remarks
• Read this instruction manual before proceeding.
• Important documents besides this instruction manual are the order confirmation, the
specification sheet, the drawing(s) and the sheet with constructional directions (appendix
C). In the specification sheet the design pressures and temperatures are listed that must of
course not be exceeded.
1.2 Guarantee and liability

The “General conditions of Bloksma B.V.” are applicable. Also refer to the confirmation of
the order for possible additions.
Not covered by the guarantee are loss of performance and/or damage to the heat exchanger as
a result of:
• not following the instructions in this manual
• replacement with non-original parts
1.3 Environment
• The environmental laws and rules of the area where the heat exchanger is installed, always
have to be respected.
• Always be on the alert to the possibility of leakage.
• When disposing of the unit at the end of its lifespan, see to it that this takes place
according to the then applicable regulations.
1.4 Safety
Some symbols are used in the text to underline safety aspects:
Pay attention: depending on the application the heat exchanger will be hot during operation
Maintenance and repair: depressurize both circuits of the heat exchanger and let them cool
down to ambient temperature.
In connection with safety every Bloksma heat exchanger is tested under higher pressure than
the design pressure before it leaves the factory. This applies to heat exchangers that are not
tested by a certification agency.
1.5 Inhibitors
There can be reasons to add an inhibitor to one of the circuits of the heat exchanger. Contact a
specialised company, which can also check for harmfulness of the inhibitor to the materials of
the heat exchanger (see specification sheet). Follow the instructions of the supplier for use of
the inhibitor.
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2 Installation and start-up
2.1 Receipt
At receipt check the packaging and the heat exchanger:
• report any damage to Bloksma
• compare the data on the nameplate, confirmation of the order and on the drawing
• check whether or not the correct instruction manual is present by comparing the article
number on the cover sheet with the article number of the instruction manual on the
confirmation of order
Always store the heat exchanger in a dry room, free of large temperature changes. When the
heat exchanger is not being put into operation immediately after receipt, follow the
“Instructions for conservation” (Appendix A).
2.2 Installation
Warning: Beware of any rust preventive layers (see “Instructions for conservation”) that
might still be present in the heat exchanger before proceeding.
• Remove all protective plugs and covers from the connecting flanges prior to installation of
the heat exchanger.
• A 1- or 3-pass model (tubeside) has to be mounted in such a way that shell- and tubeside
will be in counterflow.
• Check whether the positions of the vent and drain connections on the heat exchanger
correspond with the mounting position of the heat exchanger.
• In models with body side wire connections, check to see if the couplings with which the
lines are fastened do not touch the bundle.
• Mount the heat exchanger level and square on a flat surface in order for the pipe
connections to be made without forcing.
• Do not weld anything to the heat exchanger.
• Mount one support in a fixed position, while the other one is mounted in such a way that it
is able to slide in the direction of the longitudinal axis of the heat exchanger. The heat
exchanger will thus be able to expand under thermal stress.
• When installing types bigger than P10 vertically, the waterbox at which the position of the
tubesheet is fixed 1 , has to be located on top.
• Before connecting piping to the heat exchanger flanges, make sure that the gasket surface
is clean and free from scratches and other defects. Always use new gaskets, of the correct
type and tighten the bolts crosswise.
• Take care when lifting the heat exchanger. Use at least two hoops around the shell of the
heat exchanger for lifting purposes.
• Check for the presence and correct positions of drain/vent connections in both circuits.
• Install the heat exchanger and the piping in such a manner that there is still enough room
to disassemble (part of) the heat exchanger (tubebundle, drain plugs, etc.).
1
On a 2-pass model the side of the heat exchanger at which the position of the tubesheet is fixed is always the
side where the tubeside medium enters and exits the heat exchanger. On 1-pass models this is the side on which
fixation plates are bolted between waterbox and shell (on the other side distance rings are bolted between shell
and waterbox). Furthermore the side of the heat exchanger where the serialnumber is, is also the side with the
fixed tubesheet.
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2.3 Start-up
Do not exceed the design temperatures and design pressures as stated on the nameplate and
specification sheet. Avoid abrupt temperature fluctuations; these can cause leaking of tube-to-
tubesheet or other connections.
• Make sure that the cold medium circulation is established first, followed by the gradual
introduction of the hot medium.
• Vent both circuits.
• Vent both circuits again when the operating temperatures and pressures are reached.
• Check for leakage.
Do not deviate from the flows as stated on the specification sheet. Higher or lower velocities
can cause erosion or corrosion respectively.
Avoid standstill: at non-conditioned circuits this may cause corrosion. In case of standstill
follow the instructions for shut down periods.
If the heat exchanger is equipped with anodic protection (see specification sheet) you will
have to inspect the anodes (or part that functions as anode) when you are starting up the heat
exchanger after a shut down period.
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3 Maintenance
If necessary refer to “Assembling and disassembling of the heat exchanger” for

(dis-)assembling instructions.
3.1 Cleaning and inspection intervals

Preventive maintenance of the heat exchanger is a user responsibility. The tubeside circuit is
usually the more fouling side of the heat exchanger. Because the degree of fouling strongly
depends on the operating conditions we recommend the following:
• Inspect the tubeside at least quarterly.
• Inspect the shellside at least twice a year.
With the results of these inspections you will be able to determine the required cleaning
intervals. Always keep performing regular inspections.
3.2 Anodic protection

Not applicable for IV models.
The MV models of P-type heat exchangers are fitted with anodic protection: the tubeside
circuit is provided with anodes. When inspecting the tubeside of the heat exchanger also
inspect the state of the anodes (always drain the tubeside circuit before removing the anodes).
3.3 Cleaning of the heat exchanger
3.3.1 Mechanical cleaning of the tubeside

The tubes can be cleaned with a tube brush. Use original Bloksma brushes only; these have
the correct dimensions and are of a suitable material. Other brushes may damage the
protective layer that is in the normal course of events present on the tubewalls.
3.3.2 Chemichal cleaning of the shell-/tubeside

Warning: Chemical cleaning may damage the heat exchanger. Make sure your supplier of a
cleaning agent verifies and confirms the compatibility of his product with the materials of the
heat exchanger (see specification sheet).
Cleaning of the shellside will normally be necessary seldom.
The shell- as well as the tubeside can be cleaned by circulating a chemical solution through
the heat exchanger. Another possibility is disassembling of the heat exchanger and
submerging the tubebundle in a tank filled with a chemical solution. Remove any plastic
partitions (on 2- or 3-pass heat exchangers to divide the tubeside circuit) from the tubesheet(s)
first.
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There are several international companies (example in Appendix B) which supply equipment
and fluids for chemical cleaning of heat exchangers. Their specialized cleaning centres,
situated at ports all over the world, are able to give you a cleaning advise or to clean the heat
exchanger for you. To give an idea of the possibilities, an example of a cleaning procedure is
given below.
Please note: The cleaning advice below is just an example. Cleaning methods and
procedures, as well as fluids for cleaning will differ depending on the materials of the heat
exchanger (see specification sheet) and the application.
This cleaning advise is meant for waterheaters/coolers.
Descalant NF (inhibited cleaning agent)

• Submerge the tubebundle (time is dependend on the degree of fouling)
in a tank with dissolved cleaning agent
• After cleaning neutralize the tubebundle and the cleaning agent with a
special neutralizing fluid
• Flush the tubebundle with fresh water
• Dry the tubebundle
3.4 Shut down periods

During shut down periods longer than a week the heat exchanger has to be drained completely
and dried by means of preheated compressed air. In fact this also has to be done during short
shut down periods (longer than a day) when there is risk of freezing, and it also applies when
a corrosive medium is used in the heat exchanger. After draining a corrosive medium, the heat
exchanger has to be rinsed with fresh water.
Stopping of the flows, cooling down and draining of the heat exchanger has to be done in a
manner to minimize thermal stresses on the heat exchanger.
Never stop one of the flows of the heat exchanger while the other one stays in operation,
because of the risk of boiling.
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3.5 Assembling and disassembling of the heat exchanger

The circumferences of the tubesheets are fitted with three grooves. The two outer grooves
carry O-rings (sealing between shell- and tubeside). At one of the tubesheets the middle
groove is for the fixation of the position of the tubebundle by means of ‘fixationplates’ (this
tubesheet is called the fixed tubesheet).
1 Tubesheet 4 Shell
2 O-ring 5 Tubes
3 Fixationplate
Figure 1: Schematic drawing of tubesheet construction
For P10 only: Instead of fixationplates the P10 has a metal spring ring in the middle groove
of the tubesheet. As soon as the bolts are untightened the position of the tubebundle is no
longer fixated. Tubeside inspection or cleaning remains possible, but extra attention is
required because the tubebundle is not fixed anymore. Except when performinge a pressure
test, we recommend to drain both circuits.
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For tubeside inspection, shellside pressure testing or cleaning of the tubes with a
tubebrush, only the tubeside connections and the waterboxes (these are the parts
on both ends of the shell, on which the tubeside connections are made) need to be
removed (follow step 1 and 3). Pay attention: when the nuts are untightened the
fixationplates are also untightened, so the tubebundle comes loose. In order to fixate the
tubebundle temporarily, fasten the fixationplates with the nuts.
For shellside inspection (for instance), the tubebundle has to be removed completely
(follow step 1, 2 and 3), and both circuits have to be drained.
When assembling as well as disassembling follow the “Instructions for gaskets and bolting”.
Step 1: Tubeside disassembling
• depressurize both circuits

• let both circuits cool down to ambient temperature
• drain the tubeside circuit, by opening the drain in the lowest point and the vent in the
highest point
• mark the position of all parts that will be disassembled, so they can be mounted in the
correct position later on
In case the heat exchanger is placed vertical, disassemble the upper waterbox first. This is the
side with the fixationplates. Fasten the fixationplates immediately with the nuts before
proceeding. For P10 only: A vertically placed P10 will always have to be disassembled
completely because the the tubebundle does not stay in position.
• remove the waterboxes by untightening the nuts (the fixationplates come loose as well)
• 2- or 3-pass heat exchangers have plastic partitions on the tubesheet(s) for dividing the
tubeside circuit; mark their position and remove them
• mount the fixationplates again with the nuts (not necessary when the tubebundle is going
to be removed (see step 2))
• remove the first O-ring from both tubesheets
• only for a pressure test: pressurize the shellside again. Depressurize the shellside again
after the pressure test. For P10 only: Remember that the tubebundle is not fixated!
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Step 2: Removing the tubebundle

• drain the shellside circuit, by opening the drain in the lowest point and the vent in the
highest point
• mark the position of the tubebundle
• move the tubebundle to one side until the second O-ring shows (do not move the
tubebundle further than necessary) and remove this O-ring
• move the tubebundle to the other side and remove the second O-ring on this side as well
• carefully pull the tubebundle from the shell
• support the tubebundle at the baffles when lifting it, but be careful not to bend the baffles
(this will affect the thermal performance of the heat exchanger)
Step 3: Assembling
• assemble the heat exchanger in reversed order (pay attention to the earlier made marks):
Mounting of the tubebundle (only in case it was removed):
• push the tubebundle in the shell (let it stick out of the shell a little bit)
• mount the inner O-ring on the first tubesheet
• move the tubebundle further and let it stick out a little bit on the other side of the shell
• mount the inner O-ring on the second tubesheet
Hint: when it is difficult to move the tubebundle through the shell because the already
mounted O-ring is hard to compress, you can use a strip between tubesheet and waterbox and
then tighten two of the four bolts and nuts
• move the tubebundle in its final position
Tubeside assembly:
• mount the outer O-rings on both sides
• mount the plastic partitions on the tubesheets of 2- or 3-pass models
• mount the fixationplates (for P10 only: mount the metal spring ring)
• mount the waterboxes and all connections
• start-up the heat exchanger again:

• make sure that the cold medium circulation is established first, followed by the gradual
introduction of the hot medium
• vent both circuits
• vent both circuits again when the operating temperatures and pressures are reached
• check for leakage
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3.6 Instructions for gaskets and bolting
3.6.1 Gaskets
Two types of gaskets are being used in this heat exchanger:
O-rings : After disassembling the heat exchanger never use the old O-rings again. Replace
them with original Bloksma O-rings.
Warning: The O-rings have to be lubricated with a special O-ring lubricant (O-ring silicone
paste or Parker O-lube) for easy assembly and a good sealing capacity. Lubricants not suited
for O-rings can affect the sealing capacity of the O-ring (for instance do never use vaseline).
Any warranty claim will be rejected when unsuited lubricants are used.
Soft metal rings : After disassembly of the heast exchanger never use the old soft metal rings
again. Replace them with new ones for good sealing.
3.6.2 Bolting
Check bolts and nuts for damages. Tighten the bolts crosswise (see figure 2). This also applies
to connecting piping to the heat exchanger. Make sure the gasket surface is clean (remove dirt
and any corrosion residues) and undamaged.
Figure 2: (Un-)bolting sequence
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4 Trouble shooting & repairs
4.1 Performance too low

Check:
• whether all connections have been made according to the drawing
• whether the heat exchanger and the system have been properly vented
• whether the flows are according to the specification (check all valves, lines and pumps, as
well as the flow directions)
• whether the shell- as well as the tubeside have been cleaned recently (fouling can cause a
drop in performance and an increased pressure loss; an increased pressure drop is a good
indication that cleaning is necessary)
• whether the heat exchanger has been reassembled properly after disassembly
(the plastic partitions on the tubesheet(s) of 2- or 3-pass heat exchangers; the position
of the tubebundle (this might accidentally be mounted rotated 180° around its axis))
4.2 Leaking tubes / tube-to-tubesheet connection

It is often very hard to determine whether leakage occurs because of a leaking tube or because
of a leaking tube-to-tubesheet connection. The shellside of the heat exchanger can be
hydrotested, after disassembling the tubeside. Follow the instructions in “Assembling and
disassembling of the heat exchanger”. Subsequently pressurize the shellside. After
hydrotesting depressurize and drain the shellside again. Assemble the heat exchanger again.
The tubes are roller expanded into the tubesheet. It is either not possible (finned tubebundles)
or relatively complicated (unfinned tubebundles) to replace a leaking tube, but it can be
plugged with soft copper Bloksma plugs (other materials are too hard and may cause leakage
of the adjacent tube-to-tubesheet connections) in both tube ends. A maximum of
approximately 10% plugged tubes will not influence the thermal performance of the heat
exchanger too much. Contact Bloksma when more than 10% of the tubes is plugged.
4.3 Leaking gaskets

• Check the gasket surfaces.
• Remove dirt or corrosion residues
• Mount new gaskets
It is possible to determine which of the O-rings is leaking, by determining the medium that is
leaking from the heat exchanger.
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5 Spare parts & tools
Available spare parts and tools for P-type heat exchangers:
• Set of gaskets (four O-rings)

• Soft copper plugs
• Nylon tube brush
• Bolts / nuts
• Complete tubebundle
• For P10 only: Metal spring ring
• Fixationplates (for types > P10)
• Plastic partitions (not for 1-pass heat exchangers)
• Water box
• Cover
• Anode
When ordering spare parts, please refer to the Bloksma drawing number (listed on name
plate).
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Appendix A: Instructions for conservation
Standard conservation (controlled conditions)

All heat exchangers supplied by Bloksma are treated with a rust preventive layer (on both
shell- and tubeside). This layer will protect the heat exchanger when it is stored at controlled
conditions, i.e. inside, in a dry room at constant temperature . When these conditions are
met, the heat exchanger can be stored without special treatment for a longer period (up till 24
months).
The rust preventive layer can be removed with a mineral solvent (petroleum).
Advise for conservation (uncontrolled conditions)

When the above mentioned storage conditions are not met, you will have to fill the heat
exchanger with an inert gas and all openings have to be closed airtight (additionally silica gel
can be added to absorb liquids). Alternatively, the heat exchanger can be treated with a rust
preventive liquid of a type suited for long term conservation.
When necessary contact a specialised company. Take the materials of the heat exchanger (see
specification sheet) into consideration. Be aware that in uncontrolled storage conditions large
amounts of water can accumulate in the heat exchanger as a result of condensation.
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Appendix B: Adresses
Chemichal cleaning and products for chemichal cleaning
Ashland Chemical Nederland B.V.

Drew Marine Division
Malledijk 20
3208 LA Spijkenisse
The Netherlands
Telephone : + 31 (0)181-457074
Telefax : + 31 (0)181-625792
Internet: www.ashchem.com
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Appendix C: Constructional directions for including a P-type heat

exchanger in a piping design.
Pay attention to the following points:
• Level and square mounting possibility.
• Bends in the piping have to be located at a distance of at least three times the nominal diameter of
the pipe from the inlet of the heat exchanger.
• When a vaporizing cryogenic medium is used, the heat exchanger has to be placed under an angle
of 3° - 10°, in order for the vapor to be able to exit the heat exchanger, helped by natural
circulation.
• Check if vent and drain connections are present in both circuits of the heat exchanger (when not
on the heat exchanger then make them in the piping).
• Put a filter (with a permeability of 3 mm.) before the inlet of both circuits of the heat exchanger.
• Stress- and vibration free mounting possibility of the connections and the supports (fit expansion
bellows and/or silencer blocks when necessary).
• Disassembling possibility of the tubebundle (and other parts like drain and vent plugs).
• Expansion possibility of lockable liquid circuits.
• Danger of freezing of liquid circuits.
• The design data of the heat exchanger on the specifiationsheet2 and the drawing. For instance the
flows: deviating from them can cause unacceptable high or low velocities. A (temporary) lower
flow is acceptable when caused by a controlsystem and a conditioned circuit is involved. Avoid
standstill (unless the heat exchanger is drained and flushed with fresh water).
• When adding an inhibitor to one of the fluids in the heat exchanger, always check whether this
inhibitor can be harmful for the materials of the heat exchanger (see specification sheet).
• Make sure that in case of flow control (with conditioned circuits only) this is done gradually (no
‘on-off-control’).
• Although this will almost never occur in practice, Bloksma reserves the right (according to TEMA
RGP-RCB-2) to plug a maximum of 1% of the tubes.
• Always check whether both fluids are compatible with the materials of the heat exchanger;
Bloksma chooses the materials judging on the fluids specified by the customer, but is often not
well informed about possible contaminations, higher or lower than normal degrees of acidity and
other for the choice of materials important proprties.
• Check whether the materials of the connecting piping are compatible with the materials of the heat
exchanger (when the materials of the bundle are, from a corrosion point of view, weak in
comparison with the materials of the piping, the bundle will corrode faster than expected).
2
In connection with the applied materials the instruction manuals refer to the specification sheet of the heat
exchanger. Therefore always keep the specification sheet.
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chapter content
7 filters
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Manual and maintenance instructions Sheet No.

for INTERNORMEN pressure filters, change-over 20320-4D
DU 63, 101, 251, 401, 631, 635, 1001, 1950, 1050, 2050, related specifications Page 1/3
This manual is effective for all filters of the type DU 63, 101, 251, 401, 631, 635, 1001, 1950, 1050, 2050 and related specifications. It
contains certain requirements and instructions which ensure unobjectionable operation of the filter. It can be completed with specific
additional instructions by the operator himself if necessary.
1. Safety instructions
- Prior to operating the filter, manual and maintenance instructions have to be read carefully.
- Follow the instructions of this manual under any circumstances!
- The manufacturer does not assume liability for any damage, which occurs due to disregarding these instructions.
- If operations are carried out differently, the safety of the pressurized device can not be assured!
- Operating conditions given in the data sheet, especially excess pressure, temperature range and operating fluid, have to be followed
unconditionally. Variation of these parameters can cause damage to important pressure holding parts and sealing. Also take in
consideration the compatibility of filter components with the operating fluid.
- Under working conditions the filter housing is pressurized. Do not try to loosen or remove any part of the filter or the filter housing
during operation. The operating fluid could escape at high pressure and high temperatures.
This does not apply for parts of the decompressed or the turned off side of the filter (see „Maintenance“).
- Leaking operating fluid always bears the danger of injuries and burns!
- Do not open the filter housing until you made sure it is not pressurized any more!
- Touching parts of the filter may cause burning, depending on the operating temperature.
- When exchanging the filter keep in mind that it might have operating temperature. Danger of burning!
- Always wear safety goggles and gloves when working on the filter!
- If you come into contact with the operating fluid please follow the instructions of the fluid manu facturer!!
- Only use original spare parts.
For filters being used in hazardous locations the INTERNORMEN documentation N° 41269 "Supplementation of the Operating Manual
for the use of filters in potential explosive areas.
2. Installation
Note safety instructions!
When removing a new filter from its box it is ready for installation. It is placed on a level area and attached (DU 63) or screwed
(DU 101-2050) to it.
Afterwards remove protective caps from connections and connect those to the present pipe work.
Appropriate pipe work (pipes, hoses) ensures that drain and air-bleed valves are connected to proper containers. For these purposes
original INTERNORMEN drain and air-bleed valves can be used.
When installing the filter please make sure, that:

- sufficient fixation of the filter is assured
- the clogging indicator is accessible and can be checked easily.
- the connections for draining, air-bleeding and pressure measurements can be accessed easily.
- there is enough room above the filter to remove and replace elements.
- no dirt, particles, other contamination or fluids enter the filter.
- both inlet and outlet of the filter are connected to the pipe work correctly.
- counterflanges or screw joints of the pipe system and the filter have to be angled precisely and connected that same way
(if counterflanges or pipe joints are canted or under tension switching filters can be aggravated and it might harm pressure
tightness)
Fitting the counterflanges for DU 101-2050
- the following torques have to be applied when fastening the counterflanges

Type DU 63* DU 101 DU 251 DU 401 DU 631/635 DU 1001/1950 DU 1050/2050
Connection ¾“ 1“ 1 ¼“ 1 ½“ 2“ 2“ 2 ½“ 3“ 4“
Moment [Nm] 100 ±15 10 ±2 12,5 ±3 25 ±5 28 ±6 28 ±6 40 ±8 71 ±15 100 ±25
- sufficient measures were taken to prevent corrosion.
- the filter is protected from other mechanical influences (such as impacts and hits).
EDV 08/04 - Englisch
Friedensstrasse 41, 68804 Altlussheim, Germany

phone +49 - (0)6205 - 2094-0 e-mail sales@internormen.com
fax +49 - (0)6205 - 2094-40 url www.internormen.com
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3. Initial operation
3.1 Prior to initial operation
Prior to the initial operation of the system or the machine, which means prior to filling in any fluid, check the internal condition of the
filter. Proceed as follows:
- Open the filter housing by removing the lit. Check the cleanness of the housing, the presence of an element, the sealing, etc..
- Close the housing tight.
3.2 Filling and air-bleeding

Prior to the initial operation, the filter has to air-bleed as follows:
- Turn the switch of the filter to the middle position. The lever of the DU 63/635/1050/2050 is right in the middle between the two stops.
The stop-pin of the DU 101-1950 also is positioned right between the two stops.
- Fill both sides of the filter using the regular operating fluid flow.
- Open the locking screws on the side of the top edge of the filter (DU 63) or on top the filter lit (DU 101-2050). Wait until it leaks fluid
without any bubbles and there is no more sound of air escaping.
- afterwards tighten the locking screws again.
After this process you can direct the flow of the fluid, which is supposed to be filtered, to pass through either side of the filter. This is
done simply by turning the lever or the switch. To recognize which side is operating at the moment, just note the following:
DU 101/251/401/631/1001/1950: The stop-pin of the switch is pointing at the side which is operating at the moment.
DU 63/635/1050/2050: The lever itself points at the side which is operating at the moment.

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4. Maintenance / Inspection
Also please note all particular site-related instructions for inspection.
Using filters equipped with clogging indicators it is necessary to exchange or clean the element if the signal “Clogged filter” is emitted
(also note the data sheet or the instructions of the clogging indicators).
Contaminated elements have to be replaced as soon as possible! If a clogged element is not removed it may cause severe damage to
the entire system!
Attention!
Always exchange elements with sealing. If a cleaned metal mesh element type „G“ is reused replace its sealing. The exact
markings can be found in spare part lists for each element.
4.1 Replacing the filter element

Maintenance or the exchange of contaminated filter elements has to be performed as follows:
- Open the shut-off valve for pressure equalization.
- Switch the filter to the opposite side.
- Close the shut-off valve.
- Open the air-bleed valve of the discharged side of the housing in order to equalize the pressure with the surrounding atmosphere.
- Open the drain-valves to drain the filter
- Open the lit of the discharged side of the filter housing.
- Loosen and remove the element by light swaying and pulling.
- If necessary cover or close the adaptor end inside the housing and clean the entire inside.
- Close the drain valve and remove the cover of the adaptor end if present.
- Check the sealing of the filter lit and replace the O-ring if necessary.
- Take the replacing element, make sure the serial number matches the number of the old element, and insert it into the housing
(prior check if the elements sealing are undamaged and tighten them)
- Close the filter with it’s lit.
- finally perform the steps described in 3.2 “Filling and air-bleeding”
4.2 Cleaning the filter element

Metal mesh filter elements can be recycled after cleaning. This cleaning procedure can be performed based on the cleaning instructions
for INTERNORMEN metal mesh filter elements on sheets no. 21070-4 and 39448-4.
When removing and reinserting the element please proceed as described in 4.1 “Replacing the filter element”.
The maintained side of the filter is now ready to operate at full strain again.
In addition to that it is possible to maintain or replace the clogging indicator if necessary. Both the DU 101 and the DU 251 separate this
device from the pressurized system when it’s switch is brought into the middle position.
Attention!
Independent from a necessary change of the element, the switching armature has to be actuated at least once per three weeks
in order to maintain full operatibility.
5. Additional information
In addition to the regular clogging indication, the pressure drop, which is evidence for contamination, can be monitored and checked.
On filters DU 101-2050 certain miniature measuring devices with a G ¼ A inside thread can be connected to the flanges. For this
purpose it is necessary to install measuring connections with M16 screw joints.
6. Service
The service will be performed by
INTERNORMEN Technology GmbH phone: +49(0)6205-2094-0

Friedensstr. 41 fax: +49(0)6205-2094-40
D-68804 Altlussheim e-mail: info@internormen.com
Germany url: www.internormen.com
Special questions about the operation of the filter will also be answered within this area.
Spare parts respectively wearing parts have to be ordered according to the spare part list of the filter-data-sheet.

B31495000-0 146/201
PRESSURE FILTER, change-over Sheet No.

Series DU 101-401.34210 DN 32-50 PN 32 34210-4A
1. Type index:
1.1. Complete filter: (ordering example)
DU. 251. 34210. 10VG. 30. E. P. -. FS. 8. -. -. AE
1 2 3 4 5 6 7 8 9 10 11 12 13
1 series:
DU = pressure filter, change-over
2 nominal size: 101, 251, 401
3 execution according to sheet-no. 34210
4 filter-material and filter- fineness:
80 G = 80 µm, 40 G = 40 µm, 25 G = 25 µm stainless steel wire mesh,
25 VG = 20 µm(c), 16 VG = 15 µm(c), 10 VG = 10 µm(c), 6 VG = 7 µm(c), 3 VG = 5 µm(c) Interpor fleece (glass fibre)
25 P = 25 µm, 10 P = 10 µm paper
5 resistance of pressure difference for filter element:
16 = ∆p 16 bar, (01.N 100) ; 30 = ∆p 30 bar, (01NL. 250, 400)
6 filter element design:
E = single-end open
S = with by-pass valve ∆p 2,0 bar
S1 = with by-pass valve ∆p 3,5 bar
7 sealing material:
P = Nitrile (NBR) ; V = Viton (FPM)
8 filter element specification:
- = standard
VA stainless steel
9 connection:
FS = SAE-flange connection 3000 PSI
10 connection size:
6 = 1 ¼ “ DU 101.34210
8 2“ DU 251/401.34210
11 filter housing specification:
- = standard
12 internal valve:
- = without
13 clogging indicator:
AE = AE40.33848...., electrical, see sheet-no. 33848
1.2. Filter element: (ordering example)

01NL. 250. 10VG. 30. E. P. -
1 2 4 5 6 7 8
1 series:
01N. = standard filter element according to INTERNORMEN factory spec ification
01NL. = standard filter element according to DIN 24550, T3
2 nominal size: 100 (01N.); 250, 400 (01NL.)
4 - 8 see type index-complete filter
,
2. Accessories:
- measure- and bleeder connections, see sheet-no. 1650
Cover safety device points to the flown filter side.
- evacuation and bleeder-conections, see sheet-no. 1651
- counter flanges, see sheet-no. 1652
3. Dimensions: - shut-off valve, see sheet-no. 1655
type connection SAE-connection size A B C D E F G H J K L M N O P Q R S W X Y weight kg
DU 101.34210 DN 251) SAE 1 ¼“ 463 310 210 265 55 80 22 16 105 180 60 100 100 140 115 140 115 12 30,2 58,7 M10, 19 deep 23
DU 101.34210 DN 32 SAE 1 ¼“
DU 251.34210 DN 402) SAE 2“ 522 380 260 319 84 100 - 19 140 241 97 110 126 155 130 185 160 13,5 42,9 77,8 M12, 18 deep 40
DU 251.34210 DN 50 SAE 2“
DU 401.34210 DN 50 SAE 2“ 632 530 410 469 84 100 - 19 140 241 97 110 126 155 130 185 160 13,5 42,9 77,8 M12, 18 deep 50 Changes of measures and design are subject to alteration!
1)
by counter flange BFS.6.A.33,7x2,6.St.P.3000 Instaed of P (Nitrile) also V (Viton) can be chosen.
2) Friedensstrasse 41, 68804 Altlussheim, Germany
by counter flange BFS.8.A.48,3x3,7.St.P.3000
EDV 07/04
B31495000-0 147/201
4. Spare parts: 7. Symbol:

item designation qty. dimension/article no. qty. dimension/article no. qty. dimension/article no. with electrical indicator
DU 101.34210 DU 251.34210 DU 401.34210 AE 40.33848
1 filter element 2 01N. 100... 2 01NL. 250... 2 01NL. 400...
32 x 3,5 40 x 3 40 x 3
2 O-ring 2 304378 (NBR) 2 304389 (NBR) 2 304389 (NBR)
304401 (FPM) 305482 (FPM) 305482 (FPM)
76 x 4 115 x 3 115 x 3
3 O-ring 2 305599 (NBR) 2 303963 (NBR) 4 303963 (NBR)
310291 (FPM) 307762 (FPM) 307762 (FPM)
24 x 3 24 x 3 24 x 3
4 O-ring 1 303038 (NBR) 1 303038 (NBR) 1 303038 (NBR)
304397 (FPM) 304397 (FPM) 304397 (FPM)
60 x 2,5 95 x 3 95 x 3
5 O-ring 2 305601 (NBR) 2 305808 (NBR) 2 305808 (NBR)
310267 (FPM) 304828 (FPM) 304828 (FPM)
8. Pressure drop flow curves: Precise flow rates see ‘INF-Expert-System Filter’, respectively
∆p- curves; depending on filter fin eness and viscosity.
6 screw plug 6 G½ 304678
7 screw plug with magnet 2 G½ 308249
8 gasket 2 A 22 x 27 305564
9 screw plug 2 G¼ 305003
10 clogging indicator, electrical 1 AE40.33848 see sheet-no. 33848 9. Test methods: Filter elements are tested according to the following ISO standards:
11 O-ring 2 14 x 2 304342 (NBR) ISO 2941 Verification of collapse/burst resistance
304722 (FPM) ISO 2942 Verification of fabrication integrity
ISO 2943 Verification of material compatibility with fluids
12 pressure balance valve 1
ISO 3723 Method for end load test
ISO 3724 Verification of flow fatigue characteristics
ISO 3968 Evaluation of pressure drop versus flow characteristics
5. Description: ISO 16889 Multi-pass method for evaluating filtration perfo rmance
Pressure filters, change-over series DU 101-401.34210 are suitable for operating pressure up to 32 bar.
Pressure peaks can be absorbed with a sufficient margin o safety.
A three-way-change-over valve which is integrated in the middle of the housing makes it possible to switch from the dirty filter-side to the clean filter-side
without interrupting operat ion.
The filter element consist of star-shaped, pleated filter material which is supported on the inside by a perforated core tube and is bonded to the end caps with
a high-quality adhesive. The flow direction is from outs ide to the inside.
These filters can be installed as suction filters.
Filter finer than 40 µm should use throw-away elements made of paper or Interpor fleece (glass fibre). Filter elements as fine as 5 µm(c) are available; finer
filter elements on request.
INTERNORMEN-Filter elements are known as elements with a high intrinsic stability and an excellent filtration capability, a high dirt-retaining capacity and a
long service life.
INTERNORMEN-Filter are suitable for all petroleum based fluids, HW-emulsions, most synthetic hydraulic fluids and lubrication oils.
Approvals according to TÜV, and the major „Shipyard Classification Societies“ D.N.V.; B.V.; G.L.; L.R.S.; R.I.N.A.; A.B.S. and others are possible.
6. Technical data:
temperature range: - 10°C to + 80°C (for a short time + 100°C)
operating medium: mineral oil, other media on request
max. operating pressure: 32 bar
test pressure: 64 bar
connection system: SAE-flange connection 3000 PSI
housing material: GGG 40.3
sealing material: Nitrile (NBR) or Viton (FPM), other materials on request
installation position: vertical
mini-measuring connections: G¼
evacuation-or bleeder connections: G½
volume tank DU 101: 2x 0,9 l
DU 251: 2x 2,5 l
DU 401: 2x 3,7 l
Classified under the Pressure Vessel Directive 97/23/EC for mineral oil (fluid group 2), Article 3, Para. 3.
Classified under ATEX Directive 94/9/EC according to specific application (see questionnaire sheet-no. 34279-4).
E 34210-4 A
B31495000-0 148/201
CLOGGING INDICATOR Sheet No.

Series AE 40.33848 33848-4B
1. Clogging indicator AE
1.1. Type index: (ordering example)
AE. 40. 33848. 1,5. P. Al. B
1 2 3 4 5 6 7
1 series:
AE = clogging indicator electrical
2 version:
40 = see technical data
3 execution according to data sheet-no. 33848
4 indicator-pressure difference: ∆p-nominal
1,5 = 1,5 bar
2,5 = 2,5 bar
5,0 = 5,0 bar
5 sealing material:
P = Nitrile (NBR)
V = Viton (FPM)
6 material:
Al = aluminium
7 execution:
B = block execution
2. Technical data:
temperature range: 0°C to +70°C
max. operating pressure: 200 bar
max. pressure difference: 160 bar
indicator-pressure difference ∆p: 1,5; 2,5; 5,0 bar
switch-over contact: contact maker and
contact breaker
110V DC/AC; 1,0 A; 20 VA
max. display error: ñ 10%
protection: IP 65
3. Spare parts:
item qty. designation dimension article-no.
1 2 O-ring 14 x 2 304342 (NBR) 304722 (FPM)
2 1 line adapter DIN 43650-A 313343
4. Symbol:
p1 = measure connection supply

p2 = measure connection output
Changes of measures and design are subject to alteration!
EDV 01/03
INTERNORMEN -Filter
D-68804 ALTLUSSHEIM Phone 0 62 05 / 20 94 - 0 Fax 0 62 05 / 20 94 - 40
B31495000-0 149/201
5. Description:
The AE 40.33848 pollution indicator is a electrical differential pressure indicator.
The differential pressure indicator can be fitted to all pressure filters p ≤ 200 bar for which there is a corresponding assignment on
the relevant dimension drawing. As the degree of pollution of the filter element rises, so the difference between the entry pressure
p1 and the exit pressure p2 of the filter increases. Depending on this pressure difference and irrespective of the operating
pressure, in the pollution indicator two electrical signals (contact maker/contact breaker) are triggered.
A metering piston subjected to the entry and exit pressure moves against a metering spring according to the pressure differential.
Depending on the path a permanent magnet integrated in the metering piston activates a reed contact (electromagnetic switch)
and triggers the electrical signal.
6. Operating instructions:
Normally filters are supplied with mounted clogging indicators.
It is necessary to make sure the availability and the right positioning of sealing parts O-ring 14 x 2 as well as a dirt-free mounting.
The electrical contacts are to be connected according to the graphical symbol shown on the type plate of the clogging indicator.
7. Maintenance:
The device is maintenance-free.
E 33848-4 B
B31495000-0 150/201
Description of Functional Test Sheet No.

Component Clogging Indicator AE40.33848, installed to DU251 and DU631 43681-4
1) Functional test - electrical only, with installed clogging indicator:
- activate Reed contact on the switch with an external magnet (see sketch) until signal starts and is being
indicated at the signal receiver.
2) Functional test - mechanical and electrical; discharge pressure of unit before commissioning:
- drain the oil at filter outlet at the contamination drainage G ½“ (see sheet 34210 for DU251 and sheet
34211 for DU631, respectively)
- flange off the clogging indicator; maybe it is necessary to close the borings at the filter by locking screw
G ¼“ to avoid any oil leakage
- put pressure into the pressure connection boring p1 (see sheet 33848) at the clogging indicator by means
of a compressed air-pistol until signal is activated
Please pay attention that O-rings 14 x 2 are inserted again when installing the clogging indicator.

B31495000-0 151/201
chapter content
8 e-motors
B31495000-0 152/201
Three-phase cage motors

Operating instructions
Index
SAFETY MESURES ...................................................................................... 3
GENERAL INFORMATION ........................................................................... 4

SCOPE ........................................................................................................................................................4
TRANSPORT / LIFTING EYES ..............................................................................................................4
ROTOR LOCKING DEVICE.....................................................................................................................5
VENTILATION ............................................................................................................................................5
CONDENSATION DRAIN HOLES..........................................................................................................5
RADIO INTERFERENCE SUPPRESSION ...........................................................................................5
INSTALLATION AND COMMISSIONING - MECHANICAL .......................... 6
TRANSMISSION ELEMENTS .................................................................................................................6
SUBSTRUCTURE .....................................................................................................................................7
ALIGNMENT...............................................................................................................................................8
ANGULAR ALIGNMENT ..........................................................................................................................8
PARALLEL ALIGNMENT..........................................................................................................................9
COMBINATION OF ANGULAR AND PARALLEL ALIGNMENT........................................................9
VIBRATIONS DURING OPERATION...................................................................................................10
INSTALLATION AND COMMISSINONING - ELECTRICAL....................... 11
VOLTAGE AND WINDING CONNECTION .........................................................................................11
CONNECTION .........................................................................................................................................11
DIRECTION OF ROTATION..................................................................................................................12
REVERSING THE DIRECTION OF ROTATION ................................................................................12
Y/∆- STARTING ......................................................................................................................................13
MOTOR PROTECTION..........................................................................................................................13
MAINTENANCE........................................................................................... 14
CLEANING................................................................................................................................................14
BEARING LUBRICATION ......................................................................................................................14
MAINTENANCE OF BEARINGS...........................................................................................................14
BALL BEARINGS WITH REGREASING DEVICE AND GREASE SLINGER ................................14
LUBRICANT..............................................................................................................................................15
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SPECIAL INSTRUCTIONS FOR EEX E II MOTORS...................................16

DUTY ........................................................................................................................................................ 16
MOTOR PROTECTION ......................................................................................................................... 16
OVERCURRENT PROTECTION ......................................................................................................... 16
ARDUOUS STARTING CONDITIONS ................................................................................................ 16
REPAIR INSTRUCTIONS ............................................................................17
GENERAL REPAIRS.............................................................................................................................. 17
SPECIAL REPAIRS ................................................................................................................................ 17
INSTRUCTIONS FOR STORAGE OF MOTORS .........................................18
PLACE ...................................................................................................................................................... 18
ROTOR LOCKING DEVICE .................................................................................................................. 18
BEARINGS............................................................................................................................................... 18
INSULATION RESISTANCE ................................................................................................................. 19
WIRING DIAGRAMS FOR ...........................................................................20
THREE-PHASE CAGE MOTORS........................................................................................................ 20
THREE-PHASE POLE-CHANGING MOTORS ................................................................................. 21
SINGLE-PHASE MOTORS WITH CAGE ROTOR............................................................................ 22
SPARE PARTS ............................................................................................23
P2
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Safety mesures
Explanations regarding the safety measures and special instructions for

EEx e motors, brake motors, single-phase motors and generators
Read these Operating Instructions before you transport, install, commission, maintain or repair
industrial motors or generators.
These symbols will draw your attention to the safety measures and additional
instructions given in these Operating Instructions.
Special instructions regarding safety and warranty:
Special information on EEx e motors:
Danger:
For reasons of protection of persons and objects, all the safety measures and
additional instructions for EEx e motors given in these Operating Instructions must be
strictly complied with.
Low-voltage machines have dangerous rotating and conductive parts, as well

as possibly hot surfaces. All transport, installation, commissioning,
maintenance and repair works have to be carried out exclusively by qualified
personnel and checked by responsible experts (observe VDE 0105; IEC 364).
Inappropriate use may cause major damage to persons and objects.
Should additional data be required, you should immediately consult the manufacturer or an
authorized service workshop.
All work on electrical connections to the motors and generators should

only be carried out by qualified personnel.
B000396-e/004.00 – P 3
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General information
Scope
These instructions refer to surface-ventilated three-phase and AC low-voltage cage induction
motors and generators, IP 54 and IP 55 to DIN VDE 0530, part 5, EN 60034, part 5 and IEC
34-5. Higher degrees of protection are indicated on the rating plate.
These low-voltage machines are intended for industrial installations. They comply with the
harmonised standards DIN VDE 0530/EN 60034. Observe any possible special prescriptions
for their use. Air-cooled low-voltage machines are designed for operation at altitudes ≤ 1000 m
above sea level and at ambient temperatures between -20° C and +40° C. Exceptions are
stated on the rating plate.
Observe especially different indications on the rating plate. The conditions at

the place of use must coincide with all the data of the rating plate.
The low-voltage machines are components of a machine according to the directive 89/393/EEC
(machinery). The commissioning of this machine is forbidden until conformity of the final
product with this directive is proved (observe DIN EN 60204-1).
For motors in protection Increased Safety «e» the indications on page 16 are
also applicable.
Transport / Lifting eyes

Should any damage be observed after delivery of the low voltage machine at its destination,
these should be notified immediately to the transport company; avoid commissioning.
Lifting eyes
Lift motors only on lifting eyes provided. Do not add any load to the motor.
Lifting eyes are designed for the motor mass only. Should it be necessary, use
appropriate cable guides.
P4
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Rotor locking device

Motors with roller bearings are protected against bearing damage during
transport by means of a locking device which has to be re-moved before
putting the motor into operation.
Close the fixing hole by means of the plug supplied.
The locking device must also be used for any further transport of the motor.
Ventilation
The distance between air intake of the motor and walls or other machinery must be at least 1/4
of the diameter of the air intake opening. Cooling air flows from the non-drive end towards the
drive end.
Air leaving the motor must not be drawn in again by the fan. Keep air inlets and outlets clean.
For vertical shaft-up designs, suitable protection must be provided at the

mounting end so that no foreign matter can enter the ventilation hole. Such
protection must, however, not affect the cooling and air leaving the
motor/generator - or adjacent groups - must not be drawn in again.
Condensation drain holes

Even after installation the condensation drain holes must be at the lowest point of the motor.
They must be kept clean.
Plug drain hole after each drainage.
Radio interference suppression

The motors meet the requirements of grade N to VDE 0875.
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Installation and commissioning - Mechanical
Mechanical
Transmission elements
Use elastic couplings only; rigid couplings require a special bearing design.
Use only belts that do not develop an electrostatic charge.
When using transmission elements which provoke radial or axial shaft loads during operation
(e.g. pulleys, gearwheels, etc.) take care that the permissible loads are not exceeded. Relevant
data are given in the respective catalogue.
Rotors are at present dynamically balanced with complete key fitted. (As per DIN ISO 2373).
Couplings, pulleys, gear-wheels, etc. must be balanced with empty keyway on a plain shaft.
According to DIN ISO 8821, by 1.6.1998 balancing has to be changed over to half key. Up to
that moment both standards are applicable ( change-over period ).
«H» means balanced with half key

«F» means balanced with full key
«N» means no key
The state of balancing of the motor / generator is indicated on the front part of the shaft or on
the rating plate ( after the serial number ). When the motor / generator is balanced with a half
key (H), the coupling has also to be balanced with half key; machine the overhanging visible
part of the key.
Remove anti-corrosion paint by means of a suitable solvent and grease the shaft extension.
Use only suitable tools to mount or pull off pulleys or couplings, see Fig. 1-3,
(heat to 80-100° C) and cover with a protection against accidental contact. Avoid unadmissible
tension of the belts (technical catalogue).
By no means the bearings may be subjected to any pressure or shock.
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Substructure
Make sure that the feet or flanges are safely fixed and rest positively on their entire surface.
Check also the exact alignment with direct coupling.
All motor feet must rest positively on their entire surface to avoid distortion of
the motor frame.
Avoid resonance of the base with the turning frequency and double mains frequency. Turn the
rotor by hand. Check the direction of rotation with the machine uncoupled ( see page 10
Vibrations during operation ).
Remove fan cover
Fig. 1
Mounting without female thread
Fig. 2 Mounting with female thread
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Fig. 3 Pulling off
Alignment
When the motor is connected to the driven machine via a coupling, the shafts must be aligned
radially and axially to each other. The dial gauges must be firmly secured. Measurements have
to be taken at four points, displaced by 90°, while both coupling halves are turned
simultaneously.
Angular alignment
(Fig. 4)
Deviations are to be equalized by means of shims placed under the motor feet. Permanent
inaccuracies must not exceed 0.03 mm, referred to a diameter of 200 mm.
Re-check alignment with the machine at operating temperature.
Fig. 4 Angular alignment
P8
B31495000-0 160/201
Parallel alignment
(Fig. 5)
Deviations are to be equalized by placing shims under the motor. The remaining inaccuracies
must not exceed 0.03 mm. The adjustment of the axial clearance between the coupling halves
(dimension «E») is to be effected in accordance with the coupling manufacturer’s specification.
Fig. 5 Parallel alignment ( centre offset )
Combination of angular and parallel alignment

(Fig. 6)
Fig. 6 shows a relatively simple method of combining the two measurements. The dial gauges
are inserted into the corresponding screwed or clamped flat iron holders (e.g. by set screws).
Parallel alignment
Angular alignment
Fig. 6
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Vibrations during operation

Vibration levels Veff = ≤ 3.5 mm/s (PN ≤ 15 kW) or 4.5 mm/s (PN > 15 kW) of the coupled
machine are not problematic. When there are differences in comparison with normal operation,
such as higher temperature, noise, vibration, determine the cause and, if necessary, consult
the manufacturer.
Do not switch safety devices off, not even when test running. In the case of
doubt, disconnect the machine.
Electrical
Insulation resistance
Refer to page 17.
P 10
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Installation and commissinoning - Electrical

Voltage and winding connection
The admissible fluctuation between rated voltage and supply voltage is ± 5%; for rated
frequency, ± 2% is allowed. Observe different connection indications and data on the rating
plate, as well as the connection diagram in the terminal box.
Connection
Choose cable cross-sections in accordance with the rated current. The terminal box can be
turned by 90° or 180°.
Work should only be carried out by qualified personnel, always with the
machine out of operation, disconnected and previously secured against
starting. This is also valid for auxiliary circuits (e.g. heaters).
Make sure that there is no voltage.
The supply cables must be connected with special care to ensure permanent and reliable
contact (without loose cable ends); use suitable terminals for the connection cables.
Supply cables must be stress-relieved so that no cantilever loads are exerted on the terminals.
Ensure a good connection of the protective conductor.
The minimum safety distances between conductors and between those and earth should not
exceed the following values: ≤ 500 V 8 mm; ≤ 725 V 10 mm; ≤ 1000 V 14 mm.
Make sure that no foreign matter is left in the terminal box, and that it is clean and dry. Cable
entries which are not used and the terminal box itself have to be sealed dust and water-tight. In
order to maintain the degree of protection, always make sure that the original gaskets are used
when closing the terminal box.
Connect protective conductor here.
For the test run without drive elements, secure the key. Before commissioning
brake motors, make sure that the brake is operating correctly.
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Direction of rotation
Normally, the motors are suitable for both directions of rotation. Exceptions are indicated on the
rating plate by an arrow. For the desired direction of rotation, the stator winding is connected as
follows:
Connection of Direction of rotation

L1, L2, L3 to when viewing drive end
U1, V1, W1 clockwise

W1, V1, U1 counter-clockwise
Check of the direction of rotation, see below.
Test
To check the direction of rotation, switch the properly connected but uncoupled motor quickly
ON/OFF.
Reversing the direction of rotation
Mode of starting and winding Measures
Direct-on-line starting Exchange two supply-

and pole-changing cable conductors on
motors with separate the terminal board
windings of the motor
Star/delta starting Exchange two supply-

and pole-changing cable conductors at
motors with Dah- the incoming supply
lander winding to the contactor
combination
P 12
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Y/∆- starting
In order to avoid excessive transient currents and torques, before changing

over to wait until the starting current of the Y stage has died down or run-up
has concluded (e.g. change over when rated speed is reached).
Motor protection
Connect semiconductor temperature detectors to the release device in accordance with the
wiring diagram. Continuity test, if necessary, to be carried out by means of a measuring bridge
only (max. 2.5 V).
In order to achieve full thermal protection, an additional thermally delayed

overload protection must be installed (Fig. 7). Normally, fuses alone protect
only the supply system not the motor.
For details on protection of EEx e motors, refer to page 16.
Example
Contactor with overcurrent relay. Thermistor protection and fuse.
Fig. 7
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Maintenance
Before carrying out any work on the motor or generator, disconnect it and
secure it against restarting.
Exception: In motors with greasing device, regrease the bearings with

the motor running.
Caution, danger of accidents: Take care not to come in contact

with moving parts!
Cleaning
Depending on the local conditions, air passages should be cleaned regularly.
Bearing lubrication
Observance of regreasing intervals is vital for the operational reliability of the

motor!
Maintenance of bearings
Ball bearing with permanent lubrication. Under normal operating conditions two-pole motors
can be operated for about 10,000 hours, motors with more than 2 poles for about 20,000 hours
without maintenance. However, the maximum period of maintenance-free operation is four
years. The ball bearings and the bearing caps should then be washed with petrol or benzene. If
necessary, replace the bearings. Fill the spaces between the balls and the roller tracks as well
as the grease compartments half with grease. Coat shaft bushings in the bearing caps or end-
shields with a thin layer of grease. Permanently greased bearings (2RS and 2Z bearings)
cannot be washed and regreased. Such bearings must therefore be replaced.
To dismantle the bearings, use pressing screws or other appropriate devices.
Ball bearings with regreasing device and grease slinger

Regreasing interval and required quantity of grease is indicated on the rating plate. Bearings
and bearing caps must be washed with petrol or benzene when they have been regreased
twelve times.
Used petrol or benzene in air-tight tanks should be disposed of as special

refuse with the marking «Petrol» or «Benzene».
P 14
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Afterwards, with the outer bearing cap open but the inner cap screwed on, the rotor should be
turned slowly and grease pressed in through the regreasing device until approximately half the
empty space between the rolling elements and the roller tracks is filled with grease.
If a grease with a different soap base is to be used, clean bearing seats

throroughly. Make sure that the bearing grease used meets the following
requirements:
Pour point approx. 190° C

Ash content 4%
Water content 0.3 %
Lubricant
Grease K 3 N to DIN 51 825 (lithium-based, water resistant to DIN 51 807 Part 1, grade 0 or 1).
Regrease only with a similar grease (e.g. Esso Unirex N 3, Shell-Alvania G 3, Esso Beacon 3,
etc.).
B000396-e/004.00 – P 15
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Special Instructions for EEx e II motors

General
The operation of such motors is subject to the relevant national regulations or

standards, covering the use of electrical apparatus in hazardous locations.
When installing the motors, the stipulations of DIN 57165/DIN VDE 0165 have
to be observed.
The designation of a hazardous area can only be stipulated by the
competent authority.
Duty
Unless otherwise stated in the applicable certificate, these motors are designed for continuous
duty (S1) only.
Motor protection
With a motor connected for direct-on-line starting, the connection of the

protective devices must ensure that, after tripping, all supply phases are
disconnected.
Overcurrent protection
Current-dependent tripping devices or relays must be set to the rated motor current. They must
also ensure that the motor is thermally protected also in case of short-circuit (e.g. with stalled
rotor). This means that the delay time, taken from the tripping characteristic (initial temperature
20° C) referred to IA/IN must be shorter than tE for the respective temperature class.
Arduous starting conditions

Motors for arduous starting conditions (run-up time > 1.7 times tE) must be protected with a
run-up protection in accordance with the Certificate of Conformity.
P 16
B31495000-0 168/201
Repair instructions
Any repair work within the guarantee period is subject to the approval of the
motor manufacturer.
General
It is strongly recommended that only original spares be used for motor repairs.
For EEx e II motors:

Use only original spare parts for replacement.
General repairs
It is work which do not affect the explosion protection and is, therefore, not subject to special
regulations
e.g. Replacement of gaskets or joints

Repair or replacement of fan or fan cover
Replacement of bearings
Replacement of terminal board
Special repairs
It is work which can affect the explosion protection, e.g. work on stator or rotor windings.
Unless the repair is carried our by ourselves, the proper execution of the work in accordance
with the relevant regulations must be certified by an authorised expert.
According to DIN EN 50019, any repair of this kind must be stated on an additional plate,
permanently fixed to the motor.
B000396-e/004.00 – P 17
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Instructions for storage of motors

For prolonged storage of electric motors (e.g. spare motors), the following precautions must be
observed:
Place
Make sure that they are kept in a dry and dust-free place with minimum vibration (Veff ≤ 0.2
mm/s) (damage to stalled bearings).

On motors with roller bearings, fix the rotor in place by means of the locking device, to protect
the bearings against damage due to vibration. Motors shipped on vibration dampers should
also be stored in this condition.
Where pulleys, half couplings, etc. are already mounted on the shaft extension, fit the locking
device or place the motor on vibration dampers, if possible.
Use dampers and locking device also for any future transport of the motor.
Check before commissioning:
Bearings
Before commissioning a motor that has been stored for more than 4 years, check the bearings.
Even minor corrosion can considerably shorten the service life of the bearings.
Bearings that need not be replaced should be packed with new grease.
For grease type and quantity, refer to the rating plate (on the motor) and to
«Bearing lubrication, Lubricant» on page 11/12 of the Operating Instructions.
P 18
B31495000-0 170/201
Insulation resistance
Before commissioning check the insulation resistance. With values ≤ 1kΩ per
Volt rated voltage, dry the winding.
Check the insulation resistance of each phase against earth by means of a hand-driven
generator (max. 630 V DC) until the measured value is constant. The insulation resistance of
new windings is above10 MΩ. The resistance can be lowered considerably by moisture.
If, at room temperature, the resistance is below 0.5 MΩ, the winding must be dried. In this case
the winding temperature must not exceed 80° C. For drying connect the space heater or
another heating device, or apply an AC voltage of 5 or 6 % (connect in delta) of the rated
motor voltage to terminals U1 and V1. Repeat the measurement. The motor can be put into
operation when the resistance is above 0.5 MΩ.
Insulation resistance is temperature-dependent, i.e. if the temperature is increased/decreased

by 10 K, the resistance value is halved/doubled, respectively.
B000396-e/004.00 – P 19
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Wiring diagrams for

Three-phase cage motors
Star connection Delta connection Connection to star- delta starter
P 20
B31495000-0 172/201
Three-phase pole-changing motors

In Dahlander connection : In the type designation the high number of poles = low speed is shown first
(z.B. AM 250 … 8/4).
low speed high speed
With 2 separate windings : In the type designation the low number of poles = high speed is shown first
(z.B. AM 250 … 4/8)
low speed high speed
B000396-e/004.00 – P 21
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Single-phase motors with cage rotor
Clockwise Anticlockwise
P 22
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Spare parts
Designation of spare parts, IP55, Frame size 180 - 500
1 Sealing ring DS, outer or labyrinth seal

2 Bearing shield DS
3 Grease nipple
4 Compensating washer
5 Spring clip DS and shaft nut
6 Collar oiler DS
7 Bearing DS
8 Sealing ring DS, inner
9 Bearing cover DS, inner
10 Stator housing IM B3 with core and winding
11 Terminal box, complete
12 Rotor with plates and winding
13 Key
14 Bearing cover NS, inner
15 Sealing ring NS, inner
16 Bearing NS
17 Circlip for NS bearing
18 Collar oiler NS
19 Spring clip NS and shaft nut
20 Bearing shield NS
21 Bush
22 Lubricating pipe
23 Sealing ring NS, outer or labyrinth
24 Fan
25 Circlip for fan
26 Securing angle-plate
27 Fan hood
28 Flange bearing shield
29 Stator housing without mounting feet, complete
30 Fan hood with protective cover
B000396-e/004.00 – P 23
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IP55 motors
P 24
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chapter content
9 valves
B31495000-0 177/201
Pressure Limiting Valve SPVF

Operating Instructions
Contents
Safety 2
Identification of safety instructions 2
General Safety Instructions 2
The Documentation 3
Description of Operation 3
Installation of the Pressure Limiting Valve 3
Constructions and Spares 4
Commissioning 4
Adjustment 4
Venting 4
B000304-e/12.99 - P 1
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Safety
Identification of safety instructions
The safety instructions contained in these operating instructions are identified by the following
attention symbol:
If these instructions are not observed, danger to personnel and equipment can result.
General Safety Instructions

The operating safety of the equipment supplied is only guaranteed under the prescribed
conditions of use (see ”Description of Equipment”). The stated limiting values (see also
”Technical Data”) must not be exceeded under any circumstances.
Personnel who are responsible for the installation, operation and the repair of the pressure
limiting valve, must possess an appropriate qualification; this can have been obtained through
training or relevant instruction. Such personnel must be acquainted with the contents of this
instruction.
During all work, the prevailing national regulations relating to accident prevention and safety in
the work place and, where appropriate, internal regulations of the operator, must be adhered
to, even where these are not named in this introduction.
During all work and prior to installation, the connecting pipelines must be de-pressurised!
The operator must ensure that these operating instructions are accessible to the personnel
concerned at all times.
P2
B31495000-0 179/201
The Documentation
These operating instructions describe the adjustment and venting of the SPVF pressure limiting valve.
The valve is manufactured in various versions.
The designated version of a particular valve is given on the type reference plate.
Description of Operation
The directly controlled pressure limiting valves are used to protect low pressure circuits, up to a
maximum pressure of 20 bar (SPVF 10, p max 30 bar).
In a cast hydraulic housing 10, a valve spool 30 seals the pressure chamber P from the reservoir
connection T, when acted on by the the pressure spring 70. When the set pressure is reached, the
valve spool 30 opens to create a connection between P and T. As the pressure in P falls below the set
pressure value, the valve closes.
Installation of the Pressure Limiting Valve

The valve should preferably be installed in a vertical attitude, with the adjustment screw underneath.
Before installing the pressure limiting valve, the pipe work system must be cleaned to eliminate dirt,
scale, sand, swarf, etc. Welded tube, in particular, must be scoured or scavenged. Cotton rags must
not be used in the cleaning operation. The pipelines must be connected to the valve in an absolutely
stress-free condition.
The pipes and connections used must be those appropriate for the operating pressure range. The
pipe manufacturers specifications should be consulted!
On installation, care should be taken that no sealing material finds its way into the pipeline. Sealing
materials such as hemp and mastic are not permissible, since they can lead to soiling and hence
impair the function of the valve.
B000304-e/12.99 - Page 3
B31495000-0 180/201
Constructions and Spares
Item Description Item Description Item Description

10 Housing 50 Protecting cap 100 Vent (bleed)
20 Plug 70 Pressure cap 110 Flat seal
30 Valve spool 80 Threaded rod 120 O-Ring
40 Spring guide 90 Hexagonal nut
Commissioning
Adjustment
The pressure limiting valve is set to the pressure required by the customer. It may be necessary to
carry out a check on the pressure setting during commissioning, since different flow rates, oil
viscosities and pipe lengths can affect the response value. In such cases a manometer should be
connected directly to the valve oil pressure connection. Their characteristics are such, that each of the
four pressure springs available is only suitable for a limited range of setting pressures.
These pressure ranges are specified in the Spare Parts List 58 601/4.
The pressure setting adjustment is made by removing the protecting cap 50 and loosening the
hexagonal headed nut 90 on the threaded rod 80, by means of an internal hexagon ring spanner.
Rotation to the right increases the pressure setting, rotation to the left decreases the pressure.
On achieving the desired pressure setting, the hexagon headed nut 90 must be tightened and the
cap 50.
Venting
Pressure limiting valves only operate correctly when all the voids within the valve are filled with
hydraulic fluid. If the installed attitude is incorrect, air may collect in the spring chambers and lead to
hydraulic shock. In these circumstances the valve must be ventilated (bled). This is achieved by
unscrewing the vent screw 100 through one turn. Venting should occur at low pressure and is
complete when oil is discharged free of air bubbles. After venting, the vent screw is tightened again.
Servicing and adjustments to the pressure limiting valve which require it to be dismantled, are only to
. be carried out by trained and appropriately qualified personnel.
When dismantling the pressure limiting valve, the components must be directly protected from
damage and soiling.
Fluids emerging from the valve must be collected and disposed of in such a way that there is no
danger to personnel or to the environment. The currently applicable regulations must be observed.
P4
B31495000-0 181/201
chapter content
10 instruments
B31495000-0 182/201
Data sheet Pressure transmitters
MBS 5100 and 5150
Danfoss block
components
The block concept has been developed to The range contains pressure controls,
save space, weight, and costs. pressure transmitters, test valves and
The product is intended for use in many accessories.
applications, for example: monitoring, alarm
indication, shut-down, diagnosing on The concept meets the strict demands on ma-
equipment such as motors, gears, thrusters, rine equipment, including EU stipulations on
pumps, filters, compressors, etc. such products.
MBS 5100 and MBS 5150 MBS 5100 and MBS 5150 are block transmit- Advantages
block transmitters ters designed for use in the marine industry. • Compact design
MBS 5150 has a built-in pulse-snubber. • Low installation costs
The transmitters can be easily mounted • Fast and easy to operate
directly on the MBV 5000 block test valve or • Version with pulse-snubber (MBS 5150)
the threaded pressure connection can be used. • Zero point and span adjustment
• Ten ship approvals
• High accuracy and small thermal drift
Approvals • Lloyd’s Register of Shipping • Bureau Veritas

• Det Norske Veritas • NKK, Nippon Kaiji Kyokai
• Germanischer Lloyd • Polski Rejestr Statków
• RINA, Registro Italiano Navale • MRS, Maritime Register of Shipping
• American Bureau of Shipping • Korean Register of Shipping
Dimensions
Plug Pg 13.5, DIN 43650 Plug Pg 9-11, DIN 43650
B00146-e/10.99 - P 1
B31495000-0 183/201
Data sheet Pressure transmitters MBS 5100 and MBS 5150
Technical data Performance

Accuracy (Incl. non-linearity, hysteresis and repeatability) ±0.1% FS (typ.)
±0.3% FS (max.)
Non-linearity (Best fit straight line) < ±0.2% FS
Hysteresis and repeatability ≤ ±0.1% FS
Thermal zero point shift ≤ ±0.1% FS/10K (typ.)
≤ ±0.2% FS/10K (max.)
Thermal sensitivity (span) shift ≤ ±0.01% FS/K (typ.)
≤ ±0.02% FS/K (max.)
Response time < 4 ms
Max. operating pressure See ordering table, page 4
Burst pressure See ordering table, page 4
Electrical specification
Rated output signal 4 to 20 mA
Supply voltage, Vsupply (polarity protected) 10 to 32 V d.c.
Voltage dependency < 0.01% FS/V
Current limitation (linear output signal up to 1.5 × nom range) 28 mA (typ.)
V supply − 10 V
Max. load, RL RL ≤ ____________ −10 [Ω]
0.02 A
Environmental conditions
Operating temperature range −40 to 85°C
Compensated temperature range 0 to 80°C
Transport temperature range −50 to 85°C
EMC - Emmission EN 50081-1
Air 8 kV EN 50082-1 (IEC 801-2)
Electrostatic discharge
Contact 4 kV EN 50082-1 (IEC 801-2)
field 10 V/m, 26 MHz - 1 GHz EN 50082-1 (IEC 801-3)
EMC - Immunity
RF conducted 3 Vrms, 150 kHz - 30 MHz EN 50082-1 (IEC 801-6)
conducted 1 Vrms, 10 kHz - 50 MHz RINA, Lloyds Reg.
LF conducted 3 Vrms, 50 Hz - 10 kHz RINA, Lloyds Reg.
burst 4 kV (CM), Clamp EN 50082-1 (IEC 801-4)
Transient
surge 1 kV (CM,DM) at Rg = 42Ω EN 50082-1 (IEC 801-5)
Insulation resistance > 100 MΩ at 100 V d.c.
Mains frequency 500 V, 50 Hz SEN 361503
Sinusoidal 20 g, 25 Hz - 2 kHz IEC 68-2-6
Vibration stability
Random 7,5 g rms, 5 Hz - 1 kHz IEC 68-2-34, IEC 68-2-36
Shock Shock 500 g / 1 ms IEC 68-2-27
resistance Free fall IEC 68-2-32
Enclosure IP 65 - IEC 529
Mechanical specification
Pressure connection G 1/4, ISO 228/1 or flange
Electrical connection DIN 43650 plug
versions without flange connection AISI 316L, W.no 1.4404
Pressure connection AISI 316L
Wetted parts,
Plug ETG 88 Zn 10F
material versions with flange connection
Plug gasket W.no. 1.0388 Sn5
O-ring for flange NBR
Housing material Anodized AIMgSiPb
Weight 0.4 kg
Electrical connection
2-wire, 4 - 20 mA
1. Supply +
2. Supply −
3. Function test
Connected to MBS transmitter enclosure
P2
B31495000-0 184/201
MBS 5150 with integrated MBS 5150 has an integrated pulse snubber
pulse snubber for protection of the sensor element against
extreme pressure peaks and pulsations. Such
conditions may be caused by pumps or fast
operating valves in both high and low pres-
sure plants.
The integrated pulse snubber is designed as

an 0.3 mm orifice mounted in the pressure
connection. The medium should not contain
particles which may clog up in the orifice. The
viscosity has only little effect on the response
time. Even at viscosities up to 100 Cst. the
response time will not exceed 4 msec.
Mechanical connection
Thread Flange
Adjustment
Span
–5 ... + 5 % FS
Zero
Pressure range Adjustment
0-1 to 0-10 bar –5 ... +20 % FS
0-16 to 0-40 bar –5 ... +10 % FS
0-60 to 0-600 bar –5 ... +2.5 % FS
B00146-e/10.99 - P 3
B31495000-0 185/201
Ordering of standard
MBS 5100 and MBS 5150
Relative pressure version, G 1⁄4 with flange connection, DIN 43650 Pg 11 plug, 4 - 20 mA output
Pressure Max. operating Min.burst MBS 5100 MBS 5150
range pressure pressure
bar bar2) bar1) Type no. Code no. Type no. Code no.
0 to 1 2 50 MBS 5100-1011-1DB04 060N1032 MBS 5150-1011-1DB04 060N1081
0 to 2,5 8 50 MBS 5100-1411-1DB04 060N1033 MBS 5150-1411-1DB04 060N1083
0 to 4 8 50 MBS 5100-1611-1DB04 060N1034 MBS 5150-1611-1DB04 060N1084
0 to 6 20 50 MBS 5100-1811-1DB04 060N1035 MBS 5150-1811-1DB04 060N1063
0 to 10 20 50 MBS 5100-2011-1DB04 060N1036 MBS 5150-2011-1DB04 060N1064
0 to 16 50 100 MBS 5100-2211-1DB04 060N1037 MBS 5150-2211-1DB04 060N1065
0 to 25 50 100 MBS 5100-2411-1DB04 060N1038 MBS 5150-2411-1DB04 060N1085
0 to 40 80 800 MBS 5100-2611-1DB04 060N1039 MBS 5150-2611-1DB04 060N1066
0 to 60 200 800 MBS 5100-2811-1DB04 060N1040 MBS 5150-2811-1DB04 060N1086
0 to 100 200 800 MBS 5100-3011-1DB04 060N1041 MBS 5150-3011-1DB04 060N1087
1)
200 bar for abs. pressure versions
2)
FS ≤ 300 bar min. 2 x FS; FS > 300 bar min. 1,5 x FS
Ordering of customized
types Type no: MBS 5100- xx x x- x xxxx
Type no: MBS 5150- xx x x- x xxxx
Measuring 0 - 1 bar 10 CA05 M 10 × 1 female Pressure

range 0 - 1.6 bar 12 CA07 M 12 × 1.5 female connection
0 - 2.5 bar 14 CB02 G 1/8 female
0 - 4 bar 16 CB04 G 1/4 female
0 - 6 bar 18 CC04 NPT 1/4 female
0 - 10 bar 20 DA05 M 10 × 1 female with flange
0 - 16 bar 22 DA07 M 12 × 1.5 female with flange
0 - 25 bar 24 DB02 G 1/8 female with flange connection
0 - 60 bar 28 DC04 NPT 1/4 female with flange connection
0 - 100 bar 30
0 - 160 bar 32
0 - 250 bar 34 0 No plug (DIN 43650 A) Electrical
0 - 400 bar 36 1 Pg 11 plug (DIN 43650 A) connection
0 - 600 bar 38 2 Pg 13.5 plug (DIN 43650 A)
Others xx 3 Pg 9 plug (DIN 43650 A)
Pressure Relative 1 1 4-20 mA Output

reference Absolute 2 signal
An order form has been worked out The order form with code no. 991L1099 can
PRESSURE SWITCH TYPE
Specification form
Order specification MBC5000 and MBC5100
DSC Contact person Customer
Order No. Order date Quantity
Code No. Type No. Delivery week

0 6 1 B M B C 5 0 0 - -
Approvals Pressure connection

No approvals ............................................. 0 C A 0 5 M10 x 1 female *
Ship-approvals .......................................... 1 C A 0 7 M12 x 1,5 female *
Other ** ..................................................... X C B 0 2 G1/8 female *
C B 0 4 G1/4 female
C C 0 4 NPT 1/4 female *
to facilitate specification of special be ordered from Danfoss.

Measuring range D A 0 5 M10 x 1 female with flange *
-1 - 1 bar ..................................................................... 1 0 D A 0 7 M12 x 1,5 female with flange *
-1 - 4 bar ..................................................................... 1 2 D B 0 2 G1/8 female with flange connection *
-1 - 10 bar ..................................................................... 1 4 D B 0 4 G1/4 female with flange connection
1-6 bar ..................................................................... 2 2 D C 0 4 NPT 1/4 female with flange connection *
1 - 10 bar ..................................................................... 2 4 X X X X Other **
5 - 20 bar ..................................................................... 3 2
5 - 30 bar ..................................................................... 3 4
5 - 40 bar ..................................................................... 3 6 Electrical connection
10 - 100 bar ..................................................................... 4 2 0 No plug (DIN 43650 A)
Other ** ........................................................................... X X 1 Standard plug (DIN 43650 A), PG11
2 GL approved plug (DIN 43650 A), PG13,5
X Other **
Type
Low pressure below (-1 - 10 bar) ............................................... 1
High pressure below (-1 - 30 bar) ............................................... 2
Low pressure diaphragm (1 - 20 bar) ......................................... 3 Microswitch
MBS block transmitters.

High pressure diaphragm (5 - 100 bar) ...................................... 4 1 0,1A, 250V (AC11); 12W, 125V (DC11)
Other ** ....................................................................................... X X Other **
* On request
** Please state below
Application Medium Medium temperature
Comments / special requirements

991L1100 udg. 12.94
For DN use only

OB-nr. Dato Bekræftet uge Prod. spec. udsendt dato NSP AG-S sign.
ISO 9001 quality approval

Danfoss A/S is certificated in accordance with international standard ISO 9001.
ISO This means that Danfoss fulfils the international standard in respect of product develop-
9001 ment, design, production and sale.
P4 Danfoss A/S AG-SP.JFB (kaa) 3-98

B31495000-0 186/201
Data sheet Pressure control
MBC 5000 and 5100
Danfoss block
components
The block concept has been developed to The range contains block pressure controls,
save space, weight, and costs. block pressure transmitters, block test valves
The product is intended for use in many and accessories.
Block pressure control MBC 5100 is a ship approved block pressure Advantages:
MBC 5000 and MBC 5100 control designed for use in the marine • Compact design
industries. MBC 5000 is designed for general • Light material
industrial application. The block pressure • Low installation costs
controls will withstand vibration up to 4 g, • Fast and easy to operate
shock up to 50 g as well as high media • Low differential
temperatures, and high pressure peaks. • Ten ship approvals (MBC 5100)
The pressure control can be easily mounted • High repeatability
direct on the block test valve MBV 5000 or the
threaded pressure connection can be used.
MBC 5100 approvals • Lloyd’s Register of Shipping • Bureau Veritas

• Det Norske Veritas • NKK, Nippon Kaiji Kyokai
• Germanischer Lloyd • Polski Rejestr Statków
• RINA, Registro Italiano Navale • MRS, Maritime Register of Shipping
• American Bureau of Shipping • Korean Register of Shipping
Dimensions
B00148-e/10.99 - P 1
B31495000-0 187/201
Data sheet Pressure control MBC 5000 and 5100

Bellows version ±0.2% FS (typ.)
Repeatability ±0.5% FS (max.)
±0.5% FS (typ.)
Diaphragm version ±1.0% FS (max.)
Response time < 4 ms
Max. switch frequency 10/min (0.16 Hz)
Life Mechanical > 400,000
Electrical (max. contact load) > 100,000
Low pressure bellows Max. operating pressure
Min. burst pressure
15 bar
30 bar
Pressure High pressure bellows Max. operating pressure
Min. burst pressure
45 bar
90 bar
Diaphragm Max. operating pressure 150 bar
Min. burst pressure 300 bar
Fixed differential
High presure diaphragm

Differential [bar]
Low pressure diaphragm
High pressure bellows
Low pressure bellows
Cut-in point
Electrical specification
Switch Microswitch SPDT
AC 15 0.1 A 250 V
Contact load DC 13 12 W 125 V
Mechanical specification
Pressure connection G 1/4, ISO 228/1 or flange
Electrical connection DIN 43650 plug
Housing Anodized AIMgSi1
Wetted parts, material Bellows 1.4306 (18/8)
Diaphragm NBR
O ring NBR
Housing material Anodized AIMgSiPb
Weight 0.4 kg
Environmental conditions
Bellows versions −40 to 85°C
Operation Diaphragm versions −10 to 85°C
Temperature
Bellows versions −50 to 85°C
Transport Diaphragm versions −50 to 85°C
Enclosure IP 65
Vibration stability Sinusoidal 4 g / 25 Hz - 100 Hz
Shock resistance Shock 50 g / 6 ms IEC 68-2-27
Free fall IEC 68-2-32
P2
B31495000-0 188/201
Input
Normally closed (NC)
Normally open (NO)
Connected to enclosure
of pressure control
Mechanical connection
Thread Flange
Adjustment
Mechanical difference
B00148-e/10.99 - P 3
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Ordering of standard types Electrical connection: DIN 43650 Pg 11 plug. Pressure connection: G 1⁄4 with flange
Pressure range Type no. Description Code no.
bar
MBC 5100-1011-1DB04 061B0005
-1 to 1 MBC 5000-1011-1DB04 Low pressure bellows 061B2005
MBC 5000-1211-1DB04 061B2004
MBC 5000-1411-1DB04 061B2002
MBC 5100-2431-1DB04 061B1004
1 to 10 MBC 5000-2431-1DB04 Low pressure diaphragm 061B3004
5 to 20 MBC 5100-3231-1DB04 Low pressure diaphragm 061B1002
MBC 5000-3231-1DB04 061B3002
5 to 30 MBC 5100-3421-1DB04 High pressure bellows 061B0003
MBC 5000-3421-1DB04 061B2003
MBC 5100-3641-1DB04 061B1005
5 to 40 MBC 5000-3641-1DB04 High pressure diaphragm 061B3005
10 to 100 MBC 5100-4241-1DB04 High pressure diaphragm 061B1003
MBC 5000-4241-1DB04 061B3003
Ordering of customized Type no: MBC 5000- xx x x- x xxxx

types Type no: MBC 5100- xx x x- x xxxx
Setting −1 - 1 bar 10 CA05 M10 × 1 female Pressure

range −1 - 4 bar 12 CA07 M12 × 1,5 female connection
−1 - 10 bar 14 CB02 G 1/8 female
1 - 6 bar 22 CB04 G 1/4 female
1 - 10 bar 24 CC04 NPT 1/4 female
5 - 20 bar 32 DA05 M10 × 1 female with flange connection
5 - 30 bar 34 DA07 M12 × 1,5 female with flange connection
Others xx DC04 NPT 1/4 female with flange connection
xxxx Others
Type Low pressure bellows

(–1 to 10 bar) 1
High pressure bellows
(1 to 30 bar) 2 0 No plug (DIN 43650 A) Electrical
Low pressure diaphragm 1 Pg 11 plug (DIN 43650 A) connection
(1 to 20 bar) 3 2 Pg 13.5 plug (DIN 43650 A)
High pressure diaphragm x Others
(5 to 100 bar) 4
Others x
1 0,1A, 250 V (AC 15); Microswitch
12 W, 125 V (DC 13)
x Others
An order form has been worked out The order form with code no. 991L1100 can
PRESSURE SWITCH TYPE
Specification form
Order specification MBC5000 and MBC5100
DSC Contact person Customer
Order No. Order date Quantity
Code No. Type No. Delivery week

0 6 1 B M B C 5 0 0 - -
Approvals Pressure connection

No approvals ............................................. 0 C A 0 5 M10 x 1 female *
Ship-approvals .......................................... 1 C A 0 7 M12 x 1,5 female *
Other ** ..................................................... X C B 0 2 G1/8 female *
C B 0 4 G1/4 female
C C 0 4 NPT 1/4 female *
to facilitate specification of special be ordered from Danfoss.

Measuring range D A 0 5 M10 x 1 female with flange *
-1 - 1 bar ..................................................................... 1 0 D A 0 7 M12 x 1,5 female with flange *
-1 - 4 bar ..................................................................... 1 2 D B 0 2 G1/8 female with flange connection *
-1 - 10 bar ..................................................................... 1 4 D B 0 4 G1/4 female with flange connection
1-6 bar ..................................................................... 2 2 D C 0 4 NPT 1/4 female with flange connection *
1 - 10 bar ..................................................................... 2 4 X X X X Other **
5 - 20 bar ..................................................................... 3 2
5 - 30 bar ..................................................................... 3 4
5 - 40 bar ..................................................................... 3 6 Electrical connection
10 - 100 bar ..................................................................... 4 2 0 No plug (DIN 43650 A)
Other ** ........................................................................... X X 1 Standard plug (DIN 43650 A), PG11
2 GL approved plug (DIN 43650 A), PG13,5
X Other **
Type
Low pressure below (-1 - 10 bar) ............................................... 1
High pressure below (-1 - 30 bar) ............................................... 2
Low pressure diaphragm (1 - 20 bar) ......................................... 3 Microswitch
MBC block pressure controls.

High pressure diaphragm (5 - 100 bar) ...................................... 4 1 0,1A, 250V (AC11); 12W, 125V (DC11)
Other ** ....................................................................................... X X Other **
* On request
** Please state below
Application Medium Medium temperature
Comments / special requirements

991L1100 udg. 12.94
For DN use only

OB-nr. Dato Bekræftet uge Prod. spec. udsendt dato NSP AG-S sign.
ISO 9001 quality approval

Danfoss A/S is certificated in accordance with international standard ISO 9001.
ISO This means that Danfoss fulfils the international standard in respect of product
9001 development, design, production and sale.
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material.
Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such
alterations can be made without subsequential changes being necessary in specifications already agreed.
P4 Danfoss A/S AG-SP.ER 5.95 CCB

B31495000-0 190/201
Data sheet
Pressure test valve
MBV 5000
Danfoss block
components
The block concept has been developed to The range contains block pressure controls,
save space, weight, and costs. block pressure transmitters, block test valves
The product is intended for use in many and accessories.
Block valve MBV 5000 MBV 5000 is a block valve designed in many Advantages
different configurations for use in the marine • Compact design
industry. • Light material
The valve meets demands for fast installation, • Many configuration possibilities
simple isolation, and easy test pressure • Low installation costs
connection. • Fast and easy to operate
Dimensions Test valve
Outputs 1 2 3 4 5
L1 36 mm 76 mm 116 mm 156 mm 196 mm
Adapters
Angleway Straightway
Cover adapter adapter
August 2000 DKACT.PD.P15.B1.02

520B0383
B31495000-0 191/201
Data sheet Pressure test valve MBV 5000

Overload pressure 180 bar
Pressure Burst pressure 250 bar
Operating pressure 0 to 120 bar
Operating temperature –20 to 120°C
Temperature Ambient temperature –20 to 120°C
Temperature of medium –20 to 120°C
Mechanical
Housing Anodized AIMgSi1
Nipple AIMgSi1
Material Ball 1.4571
Gasket PEEK/FPM
Input G 1 /4
Pressure connection Output Flange / M5 × 8
Specification and code Pressure connection: G 1⁄4 . Test pressure connection: M16 × 2
numbers for standard Output Weight Length Height Width
types Symbol Type Type no. Code no.
no. kg mm mm mm
Output
×1 0.4 36 80 40 MBV5000-1111 061B7000
×2 0.8 76 80 40 MBV5000-1211 061B7001
1 ×3 1.2 116 80 40 MBV5000-1311 061B7002
×4 1.6 156 80 40 MBV5000-1411 061B7003
×5 2.0 196 80 40 MBV5000-1511 061B7004
Input
Output
×2 0.8 76 80 40 MBV5000-2211 061B7005
×3 1.2 116 80 40 MBV5000-2311 061B7006
2
×4 1.6 156 80 40 MBV5000-2411 061B7007
×5 2.0 196 80 40 MBV5000-2511 061B7008
Input
Output
×2 0.7 76 80 40 MBV5000-3211 061B7009
Test pressure connection ×3 1.0 116 80 40 MBV5000-3311 061B7010
3
×4 1.3 156 80 40 MBV5000-3411 061B7011
Shut-off valve
×5 1.6 196 80 40 MBV5000-3511 061B7012
Input
Code numbers for standard Description Code no.

flange → G 1⁄ 8 adapters Cover 061B7200
Angleway adapter 061B7201
Straightway adapter 061B7202
Ordering special versions Type no: MBV 5000- x x x x

Type Pressure connection
Separate inputs and separate test functions 1 1 G 1/ 4
Common input and separate test functions 2 2 M10 × 1
Common input and common test function 3 x Other
Other X
Number of outputs (n) Test pressure connection
1 Output (only for type 1) 1 0 Hole plug G 1 /4
2 Outputs 2 1 Pressure gauge connection M16 × 2
3 Outputs 3 X Other
4 Outputs 4
5 Outputs 5
Other X
2 DKACT.PD.P15.B1.02 Danfoss A/S AG-SP.ER 08-2000 CCB

B31495000-0 192/201
Temperature sensor with

interchangeable measuring insert
type MBT 5252
MBT 5252
• For measuring and regulating temperature in
Features and applicatio piping systems and refrigeration piant on ships -
or at all points where reliable, robust and
accurate equipment is required.
• Gaseous or liquid media temperatures, e.g. air,

water or oil.
• Up to +200°C media temperatures.
• Pt 100 resistance element.
• Available with built-in transmitter.

• Approvals
- Lloyds Register of Shipping, LR
1) MBT 5252
Measuring insert type MBT 152
- Germanischer Lloyd, GL
2) with Pt100 - Bureau Veritas, BV
3) with temperature transmitter 1) 2) 3) - Det Norske Veritas, DNV
- Nippon Kaiji Kyokai, ClassNK
- Registro Italiano Navale, RINA
- American Bureau of Shipping, ABS
Dimensions
Insertion length Extension length
Union nut
Welded
Protection tube
Process connection
Process Width across

Transmitter type connection flats
MBT 9110, as terminal block
Connection head, type B
G 1/2 A HEX 27
PG 16 G 3/4 A HEX 32
All dimensions in millimeters
Technical data Response times

Indicative response times
according to VDI/VDE 3522
Protection tube Water Air
0.2 m/s 1 m/s
t0.5 t0.9 t0.5 t0.9
Æ11 ´ 2.5 14 s 37 s 77 s 198 s
B00150-e/10.99 - P 1
B31495000-0 193/201
Data sheet Temperature sensor type MBT 5252
Weight
Process connection
Insertion length Electrical connection Transmitter setting G 1 /2 A G 3 /4 A
[mm] Weight [g] Weight [g]
50 430 480
100 Sensors are 460 510
2-wire, 3 terminals
150 without transmitter 490 540
200 520 570
50 420 470
100 4 - 20 mA, 2-wire universal 450 500
0 ® +100°C
150 temperature transmitter 480 530
200 510 560
Max. load on protection tube according to DIN 43763

G 1/2 A
G 3/4 A
Protection tube Æ11 ´ 2.5

Max. tightening torque 50 Nm
Air 25 m/s
Permissible Steam 25 m/s
media velocity
Water 3 m/s
Materials
Protection tube in contact with media W. no. 1.4571 (AISI 316 Ti)
Process connection in contact with media W. no. 1.4571 (AISI 316 Ti)
Extension length W. no. 1.4571 (AISI 316 Ti)
Union nut Nickel plated brass
Connection head Die cast aluminium
Mechanical and environmental specifications

Max. temperature 1) Ambient: 90°C for sensors without temperature transmitter
Transmitter: 85°C for sensors with temperature transmitter
Sensor tolerance EN 60751 Class B: ± (0.3 + 0.005 ´ t) t = temperature of medium,
numerical value
Vibration stability Shock: 100 g in 6 ms
Vibrations: 4g sine function 2 - 100 Hz, measured acc. to IEC 68-2-6
Enclosure IP 65 according to IEC 529
Cable entry PG 16
Temperature transmitter Supply voltage: 8 - 35V d.c.
MBT 9110 Output: 4 - 20 mA
1)
The temperature of the temperature transmitter is influenced by media temperature, ambient temperature and
ventilation in the engine room. If the temperature of the temperature transmitter exceeds the max. allowed
temperature the temperature transmitter must be placed in a separated enclosure, as described in the separate data
sheet for MBT 9110.
P2
B31495000-0 194/201
Without temperature transmitter With temperature transmitter
Pt100 2-wire, 3 terminals 2-wire universal
B00150-e/10.99 - P 3
B31495000-0 195/201
Ordering - · Measuring range: –50 to +200°C

Standard programme · Resistance value: 1 ´ Pt100
· Protection tube: Æ11 ´ 2.5 mm, W. no. 1.4571 (AISI 316 Ti)
· Extension length: 50 mm
· Connection head: Type B
· Tolerance: EN 60751, Class B
Process connection
Insertion length Electrical connection Transmitter setting G 1 /2 A G 3 /4 A
[mm] Code no. Code no.
50 084Z8210 084Z8230
100 Sensors are 084Z8211 084Z8231
2-wire, 3 terminals
150 without transmitter 084Z8212 084Z8232
200 084Z8213 084Z8233
50 084Z8214 084Z8234
100 4 - 20 mA, 2-wire universal 084Z8215 084Z8235
0 ® +100°C
150 temperature transmitter 084Z8216 084Z8236
200 084Z8217 084Z8237
P4
B31495000-0 196/201
Data sheet Thermostats type MBC 8000 and MBC 8100
Introduction
MBC 8100
MBC thermostats are temperature controlled The MBC thermostats is part of the Danfoss
switches designed for use in severe industrial block controls programme consisting of MBC
environments. It consists of the standard pressure controls and thermostats, MBS
series MBC 8000 and the special series MBC pressure transmitters and MBV test valves.
8100 with ship approvals. In MBC thermostats The thermostats are suitable for use in
special attention has been given to meeting monitoring and alarm systems in factories,
demands for: diesel plant, compressors, power stations
compact design and on board ship.
a high level of enclosure
robust and reliable construction
resistance to shock and vibration
low differential and high repeatability
Standard types
Setting Fixed Max. Well/Sensor Cap. Capillary tube Armoured capillary tube Rigid sensor
range diff. sensor pocket see length
temp. accessories
Type Code no. Type Type

C° C° C° mm m Code no. Code no.
MBC 8100 MBC 8100 MBC 8100
-10 - 30 3 80 65 75 110 160 2 061B8201 1221-1A02000 061B8101 1231-1A02000
20 - 60 3 130 65 75 110 160 2 061B8202 1421-1A02000 061B8102 1431-1A02000
20 - 60 3 130 75 110 160 061B8002 1411-1A00075
50 - 100 4 200 65 75 110 160 2 061B8203 2221-1A02000 061B8103 2231-1A02000
50 - 100 4 200 75 110 160 061B8003 2211-1A00075
70 - 120 5 220 65 75 110 160 2 061B8204 2421-1A02000 061B8104 2431-1A02000
70 - 120 5 220 75 110 160 061B8004 2411-1A00075
60 - 150 6 250 65 75 110 160 2 061B8205 2621-1A02000 061B8105 2631-1A02000
60 - 150 6 250 75 110 160 061B8005 2611-1A00075
100 - 200 7 300 65 75 110 160 2 061B8206 2821-1A02000 061B8106 2831-1A02000
Approvals CE marked acc. to EN 60 947-5-1 Bureau Veritas, France

Registro Italiano Navale, Italy
Ship approvals, Det norske Veritas, Norway MRS, Maritime Register of Shipping, Russia
MBC 8100 only American Bureau of Shipping Nippon Kaiji Kyokai, Japan
Lloyds Register of Shipping, UK KRS, Korean Register of Shipping
Germanischer Lloyd, Federal Republic of
Germany (FRG)
October 2001 DKACT.PD.P10.J1.02

520B1060
B31495000-0 197/201
Ordering of customized
types
MBC - -
Type Length
Industrial Thermostat ...................... 8000 02000 ........ Capillary tube length [mm]
Ship Approved Thermostat ............. 8100 00065 ........ Rigid sensor length in [mm]
xxxxx ........ Other
Setting range Temperature connection

-10 - 30°C ................................................................. 1 2 A ............................................. M18 x 1.5
20 - 60°C ................................................................. 1 4 x ............................................. Other
50 - 100°C ............................................................... 2 2
70 - 120°C ............................................................... 2 4 Electrical connection
60 - 150°C ............................................................... 2 6 0 ..................................................... No plug
100 - 200°C ............................................................... 2 8 1 ..................................................... Pg 11 plug (DIN 43650)
Others ......................................................................... x x 2 ..................................................... Pg 13.5 plug (DIN 43650)
3 ..................................................... Pg 9 plug (DIN 43650)
x ..................................................... Other
Type
Rigid sensor ................................................................................ 1
Capillary tube .............................................................................. 2
Armoured capillary tube ............................................................. 3 Microswitch
1 .............................................................. 0.5 A, 250 V (AC 15)
12 W, 125 V (DC 13)
x .............................................................. Other
Technical data Contact load (Alternating current): Enclosure

Inductive: 0.5 A, 250 V, AC15 IP 65 to IEC 529 and DIN 40050. Anodized
Direct current: 12 W, 125V, DC 13 Al Mg Si 1.
Ambient temperature –40 to +70 °C Electrical connection

DIN 43650 plug, Pg 9, Pg 11, Pg 13.5
Shock resistance:
50 g / 6 ms, 500 g / 1ms Switch
acc. to IEC 68-2-27 Single-pole changeover switch (SPDT).
Free fall acc. to IEC 68-2-32
Vibration resistance
Sin 20 g, 25Hz ® 2 kHz acc. to IEC 68-2-6.
Properties acc. to EN 60947

Wire dimensions
Solid/stranded 0.2 - 1.5 mm2
Flexible, w/out ferrules 0.2 - 1.5 mm2
Flexible, with ferrules 0.2 - 1 mm2
Tightening torque max. 1.2 Nm
Rated Impuls voltage 4 kV
Pollution degree 3
Short circuit protection, fuse 2 Amp
Insulation 250 V
IP-index 65
2 DKACT.PD.P10.J1.02 ã Danfoss A/S, 10-2001

B31495000-0 198/201
Accessories: Sensor pockets Sensor A Thread Code no. Sensor A Thread Code no.
for MBC thermostats pocket mm B pocket mm B
1
75 /2 NPT 060L3264 Steel 18/8 75 G 1/2 A 060L3267
75 G 1/2 A 060L3262
Brass 75 G 3/4 A 060L3266
75 G 1/2 A (ISO 228/1) 060L3281
75 G 3/4 A (ISO 228/1) 060L3404
1
110 /2 NPT 060L3270 Steel 18/8 110 G 1/2 A 060L3268
110 G 1/2 A 060L3271 110 1
/2 NPT 060L3270
Brass 1
110 G /2 A (ISO 228/1) 060L3406
110 G 3/4 A (ISO 228/1) 060L3403
160 G 1/2 A 060L3263 Steel 18/8 160 G 1/2 A 060L3269
Supplied without gland nut, Brass 160 G 1/2 A (ISO 228/1) 060L3407
gaskets and washer 160 G 3/4 A (ISO 228/1) 060L3405
Part Description No. of per unit Code no.
Clamping band For thermostats with remote sensor (L = 392 mm) X 017-4204
For thermostats with sensor fitted in a sensor pocket.

Heat-conductive
Compound for filling sensor pocket to improve heat transfer
compound As required 41E0110
between pocket and sensor. Application range for compound:
(4.5 cm2 tube)
–20 to +150 °C, momentarily up to 220°C.
Dimensions
Rigid sensor Cap. tube version
ã Danfoss A/S, 10-2001 DKACT.PD.P10.J1.01 3

B31495000-0 199/201
Installation Installation right angles to the direction of flow. The

MBC thermostats are designed to withstand active part of the sensor is Æ13 mm x 50 mm
the shocks that occur, e.g. in ships, on long on thermostats with rigid sensors and
compressors and in large machine installa- 2 m capillary tube.
tions. MBC thermostats with remote sensor
are fitted with 5 mm screws to bulkheads or Brass Stainless steel
similar. See fig. 2
MBC thermostats with rigid sensor are self-
supporting from the sensor pocket.
For permissible media pressure see fig. 3.
Fig. 3. Permissible media pressure on the

sensor pocket as a function of temperature
Setting
When the top cover screw at the thermostat
is removed, the range can be set with the
setting screw. The differential is non-adjust-
Fig. 2 able.
Resistance to media
Material specifications for sensor pockets:
Sensor pocket, brass

The tube is made of Ms 72 to DIN 17660, the
threaded portion of So Ms 58Pb to DIN
17661.
Sensor pocket, stainless steel 18/8

Material designation 1.4305 to DIN 17440.
Sensor position
As far as possible the sensor should be
positioned so that its longitudinal axis is at Fig. 4
DKACT.PD.P10.J1.02 ã Danfoss A/S(AC-TMP/mr), 10-2001

B31495000-0 200/201
Denomination:Float switches
1. Function Description
All UNIMESS float switches work according to the principle shown on picture 1.
A float equipped with magnets moves variably with the changing liquid level.
The magnetic field actuates a reed switch which is positioned inside the sliding tube at a pre- destinated place
and with this closes respectively interrupts the current circuit.
2. In s ta lla tio n
UNIMESS float switches are installed through the upper side of tank respectively the tank bottom. The units
should be mounted vertically if possible. However, the troublefree function is guaranteed up to 30° inclination.
3. Contact Protection
The indicated values for power, voltage and capacity are valid for purely resistive loads. Quite frequently
though, the loads are covered with inductive and capacitative components. Very often lamps loads must be
switched. In this case protection of the reed switch against voltage and power peaks must be considered.
4. Mounting
4.1 The sliding tube of the float switch may not be bent or exposed to hard impacts, as otherwise the protective
gas contacts (reed contacts) will be damaged.
4.2 Existing adjusting rings, gripping rings or clamping brackets may not be removed, as otherwise the
switching function opener, closer or changer no longer is guaranteed.
4.3 The maximum switching capacity as per leaflet for float switches with a 12 mm sliding tube, for one closer
resp. opener is 100 VA
for a switch-over contact 60 VA.
With short circuit the switching contact is immediate destroyed.
4.4 Long cables take a high capacitive loading current during switching on. This loading current can be built-in
into the connecting housing approx. 20 to 30 Ohm (1 W).
4.5 When switching direct voltages as spark killer a diode in locking direction + against + is to be parallely
switched to inductive consumers like relays, magnetic valves etc.
4.6 Cable screwing of float switches should be examined regarding to firmness at the connecting housing as
well as at the float switch,so that no spray water can penetrate. possibly seal be means of filler.
5. Maintenance
Maintenance works are not necessary except of possible cleaning of the guide tube from
medium residues.
Pic. 1 Sectional drawing Float switch
B00206-e/11.99 – P 1
B31495000-0 201/201
P2

Renk RSV 1120c

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This file is build out of different separate files.

For inquiry calls please use the RENK commisioning no.

Example: RENK document no.

Kunde MAN B&W Diesel AG

Schutzvermerk ISO 16016 beachten

Refer to protection notice ISO 16016

Dokument in PDM B131831-1 Seite/page 2

Ausfertigung der technischen Dokumentation

Ausgabe Adresse Anzahl Sprache Datum Abt. / Name

Dokument in PDM B131831-1 Seite/page 3

Pos.-Nr. Beschreibung Hersteller Dokument Sprache Dok. nr.

0.1 technical information RSV-1120C RENK DS D-E B131831

Pos.-Nr. Beschreibung Hersteller Dokument Sprache Dok. nr.

10.3 pressure test valve MBV 5000 Danfoss DS E B014390

HB = Handbuch / handbook *1): Pos.Nr. bzgl. Hydraulikplan

Schiffsgetriebe Type: Drehschwingungsschema Nr.:

Kupplung zwischen Motor und Getriebe:

Konstruktion Abt. RTKM

Dokument in PDM B087923-3

Technische Daten / technical datas

Lube oil cooler

Dokument in PDM B087974-1

‚Observe Copyright acc. to ISO 16016’

This operation manual is applicable for the following basic

RENK AG is certified according to DIN ISO 9001 / EN 29001.

B032423 – 2 / 01.2009 – Page 3

1.1 Introduction ....................................................................................................................... 7

1.2 Copyright and Patent Rights ........................................................................................... 7

1.3 Reference to Classification Societies ............................................................................. 7

1.4 Important Notes for the User ........................................................................................... 8

1.5 Instruction/ Training ......................................................................................................... 8

2.2 Symbols and Signs........................................................................................................... 9

2.3 Safety Instructions for the Operating Personnel ......................................................... 10

2.4 Operation of the Gearbox............................................................................................... 11

2.5 Gearbox Repair and Troubleshooting .......................................................................... 12

2.6 Instructions on Particular Hazards ............................................................................... 13

3.1 Intended Application ...................................................................................................... 15

3.2 Residual Risk .................................................................................................................. 15

3.3 Symbols and Signs......................................................................................................... 18

4.1 Function Description ...................................................................................................... 19

4.2 Product Description........................................................................................................ 19

4.3 Protective Devices .......................................................................................................... 23

5 TRANSPORT, STORAGE AND INSTALLATION ................................................... 25

5.1 Scope of Delivery ............................................................................................................ 25

5.2 Gearbox Connection Dimensions.................................................................................. 25

5.3 Transport ......................................................................................................................... 27

5.4 Storage and Corrosion Protection................................................................................. 29

5.5 Installation and Control of Installation.......................................................................... 30

5.6 Connection of the hydraulic system ............................................................................. 38

5.7 Connection of the electrical control .............................................................................. 38

6 COMMISSIONING AND OPERATION .................................................................... 39

6.1 Filling Up Lube Oil .......................................................................................................... 39

6.2 Operation ......................................................................................................................... 40

6.3 Special Operation Modes ............................................................................................... 42

7 OPERATION FAULTS ............................................................................................ 45

7.1 Introduction ..................................................................................................................... 45

7.2 Operation Faults and their Correction .......................................................................... 45

7.3 Monitoring System .......................................................................................................... 47

B032423 – 2 / 01.2009 – Page 5

8.1 Introduction ..................................................................................................................... 49

8.2 Maintenance Schedules ................................................................................................. 51

8.3 Maintenance Work .......................................................................................................... 54