Service Manual of Marine Gearbox Model GW Series
Contents
1. input output casing weight with cooler gear model d I q k J P Q q F H h h L GWS GWK mm kg kg GW28 30 82 100 134 250 32 300 174 557 1050 300 450 1020 1370 100 235 968 1230 1130 GW30 32 85 105 149 270 32 320 191 680 1110 320 500 1070 1420 100 250 1143 1465 1300 GW32 35 95 115 147 290 35 340 190 718 1200 350 S60 1140 1480 120 260 1189 2035 1870 GW36 39 105 130 169 300 40 360 218 718 1330 390 600 1240 1580 120 290 1256 2245 2245 GW39 41 115 140 182 330 45 400 227 821 1400 410 650 1290 1630 130 320 1393 3230 2960 GW42 45 130 160 189 400 46 470 198 848 1460 455 700 1290 1630 140 335 1425 3960 3630 GW45 49 135 165 194 420 58 500 272 934 1590 490 710 1420 1860 150 410 1594 5275 3835 GW49 54 145 180 214 440 65 530 301 960 1750 540 870 1690 2130 170 470 1684 6900 6310 GW52 50 155 190 220 460 70 550 250 319 1036 1870 590 1080 1750 2320 180 480 2038 8920 8120 GW60 66 180 225 254 500 75 600 310 370 1146 2080 660 1200 1950 2520 200 500 2340 12100 11100 x _ 660 66 180 225 254 500 75 60 Dimensions and weights for gears with reduction above 4 1 are on request HANGZHOU ADVANCE GEARBOX GROUP CO LTD 64 Service Manual of Marine Gearbox Model GW Series Data for vibration calculation Each system including the auxiliary system driven by the power take off must be calculated regarding the torsional vibrations The following table contains all necessary data for GWC calculation for reference2. C3 9 gt version N version version P version Q 1 Rotations stated refer to ahead movement facing engine flywheel Available as special design for models GWK GWD GWS and GWH only HANGZHOU ADVANCE GEARBOX GROUP CO LTD 61 Service Manual of Marine Gearbox Model GW Series GWC reverse reduction gear GWL z reduction gear with clutch dimensions table i 2 1 up to 6 1 input output casing weight with cooler gear model d 1 k 1 Q q A B F H H h hy L GWC GWL mm kg kg GW28 30 100 125 102 250 32 300 179 607 800 450 840 950 100 250 1036 1230 1070 GW30 32 102 125 117 270 32 320 190 743 860 500 888 1298 100 260 1198 1465 1240 GW32 35 110 135 123 290 35 340 205 752 920 560 905 1315 120 260 1238 2035 1780 GW36 39 125 150 123 300 40 360 238 789 1060 600 1005 1500 120 300 1326 2450 2140 GW39 41 135 163 120 330 45 400 227 o 913 1010 650 1065 1425 130 320 1454 3245 2820 GW42 45 145 180 131 400 46 470 198 946 1180 700 1162 1650 140 335 1486 3975 3470 GW45 49 160 200 168 420 58 500 272 1015 1230 710 1280 1710 150 410 1688 5275 4600 GW49 54 165 205 172 440 65 530 301 1072 1340 870 1390 1925 170 430 1783 6954 6000 CW52 59 195 240 200 460 70 550 250 319 1151 1400 1080 1480 2015 180 450 2198 8920 7780 GW60 66 200 250 226 500 75 600 310 370 1280 1600 1200 1670 2215 200 500 2445 12100 10550 HANGZHOU ADVANCE GEARBOX GROUP CO LTD 62 Service Manual of Marine Gearbox Model GW
3. 3 0 770 3 950 0 060 3 250 1 050 3 680 0 440 0 211 28 36 1 130 12 38 5 720 50 24 135 115 37 200 e 3 5 0 880 3 950 0 060 2 660 1 400 3 680 0 440 0 211 28 36 1 130 12 38 5 720 50 24 135 115 37 200 c3 4 1 030 3 950 0 060 2 210 1 680 3 680 0 440 0 211 28 36 1 130 12 38 5 720 50 24 135 115 37 200 E 4 5 1 140 3 950 0 060 1 890 2 040 3 680 0 440 0 211 28 36 1 130 12 38 5 720 50 24 135 115 37 200 5 1 260 3 950 0 060 1 580 2 440 3 680 0 440 0 211 28 36 1 130 12 38 5 720 50 24 135 115 37 200 5 5 1 390 3 950 0 060 1 390 2 770 3 680 0 440 0 211 28 36 1 130 12 38 5 720 50 24 135 115 37 200 6 1 520 3 950 0 060 1 260 3 270 3 680 0 440 0 211 28 36 1 130 12 38 5 720 50 24 135 115 37 200 HANGZHOU ADVANCE GEARBOX GROUP CO LTD 66 Service Manual of Marine Gearbox Model GW Series Torsional rigidity CI 10 6Nm rad 1 ocoocoococ A amp RB a 0 1 2 3 4 953 4 414 5 398 6 7 9 861 861 861 Gear Ratio model il x i2 il 12 2 0 500 4 000 2 5 0 636 4 000 3 0 756 4 000 ES 3 5 0 895 4 000 N 4 1 000 4 000 E 4 5 1 18 4 000 o 5 1 250 4 000 5 5 1 400 4 000 6 1 483 4 000 2 0 500 3 947 2 5 0 625 3 947 3 3 0 733 3 947 p 3 5 0 857 3 947 4 1 000 3 947 4 5 1 108 3 947 5 1 229 3 947 5 5 1 364 3 94 6 1 516 3 947 2 0 489 3 952 2 5 0 622 3 952 d 3 0 738 3 952 3 5 0 872 3 952 be 4 1 000 3 952 E 4 5 1 147 3 952 o 5 1 242 3 952 5 5 1 387 3 952 6 1 517 3 952 2 0 490 3 950 2 5 0 630 3 950 B 3 0 750 3 950
4. GW30 32 1 9688 2 5185 2 9583 3 5238 4 000 GW32 35 2 000 2 5556 3 0000 3 5714 4 0526 GW36 39 2 0323 2 4815 2 9167 3 4762 3 9474 GW39 41 2 0000 2 5357 2 9600 3 5000 3 9500 GW42 45 1 9730 2 5484 2 9286 3 5833 4 0000 CWA45 49 2 0323 2 4815 3 0870 3 4762 3 9474 CW49 54 1 9714 2 4667 3 0000 3 5217 3 9524 GW52 59 1 9714 2 4667 3 0000 3 5217 3 9524 CW60 66 1 9722 2 4516 2 9630 3 4583 4 0952 SS 5 SE 7 HANGZHOU ADVANCE GEARBOX GROUP CO LTD 9 Class ABS Service Manual of Marine Gearbox Model GW Series Selection diagram GWC GWL 2 f PL p Eur Class GL BH d EU Reduction ratio i 3 4 5 Reduction ratio i 5 6 Reduction ratio i Class LROS Reduction ratio i HANGZHOU ADVANCE GEARBOX GROUP CO LTD Maximum permissible input speed Gear model reduction ratios 2 1 2 5 1 3 1 3 5 1 4 6 1 r min 28 30 36 39 900 1125 1350 1580 1800 39 41 42 45 800 1000 1200 1400 1600 45 49 700 875 1050 1230 1400 49 54 60 66 600 750 900 1050 1200 Remarks N rated power in HP metric n input speed in rpm The selection curves are based on following conditions the above mentioned input speeds are not to be exceeded special order on request inline engines with more than 5 cylinders Veeline engin
5. Oil capacities and cooling water requirement 60 5 Configurations and rotations 61 6 Incas o rio 62 HANGZHOU ADVANCE GEARBOX GROUP CO LTD 4 Service Manual of Marine Gearbox Model GW Series 7 Data for vibration calculation of GWC 65 I List of Technical Data General data Engine manufacturer Engine type Engine output kW Output speed n r min Direction of engine rotation facing the flywheel Classification society Shipyard Hull no 2 Gearbox data Product no Type and size Input speed Gear ratio Control type Oil grade SD CC30 or in summer of the torrid zone for 0 40 or SAE40 Lub Oil quantity Max lub Oil temperature 80 Cooling water inlet temperature lt 32 C Cooling water inlet pressure lt 0 6MPa HANGZHOU ADVANCE GEARBOX GROUP CO LTD 5 Service Manual of Marine Gearbox Model GW Series Cooling water requirement m3 h Reversing time t lt 15s Mechanical efficiency n 297 Rated propeller thrust Ps N Permissible angle of inclination Longitudinal 10 Transverse 15 Overhaul 10000h Net weight 1 3 Technical documents standard Service Manual Gertificate Assembling drawing Outlook and installation drawing Part list List of torque vibrational data Diagram for clutch thermal load limited
6. The gearbox selector is in the stop position The clutches 1 and 2 are connected via the gearbox selector connections A B with the return flow to the gearbox oil sump The connections C D of the 2 stage valve are also pressureless and connected via the clutch connections on the gearbox selector A B with R and the oil sump The same happens to connection E of the 2 stage valve Oil from the oil pump flows to the 2 stage valve via connection F to connection In this selector position the connections and E are pressureless and it is the spring assembly which is lightly stressed and produces the pre pressure After the 2 stage valve the oil comes into the lubrication oil circuit Engaging the gearbox Clutch engaged When operating the gearbox selector the connection or B is connected with the clutch 1 or 2 The connection C or D of the 2 stage valve is likewise with the connection A connected Thereby ol reaches the clutch and 2 stage valve at the same time The oil which enters connection C D moves the checking piston in the direction of connection D C The checking piston serves to separate the clutches 1 2 the function being like that of a double return valve The oil from connection D reaches the time adjustment The time adjustment consists of the receiving hole with jet needle and the chamber Screwing in the jet needle clockwise makes the press
7. V via the control valve and pushes the controller moving left the working oil enters A ahead clutch is engaged Astern Compressed air comes into W and pushes the controller moving right the working oil enters astern clutch is engaged Hand control When without air pressure hand control is available to realize exchanging of ahead stop astern HANGZHOU ADVANCE GEARBOX GROUP CO LTD 45 Service Manual of Marine Gearbox Model GW Series Control air piping connections V to control air piping valve ahead M14 X 1 5 W to control air piping valve astern M14 X 1 5 Z to compressed air stop M14 X 1 5 5 Electrical controller The gearbox can also be controlled with electrical solenoid valve The valve is a 3 position and 4 way valve Voltage D C 24V The voltage permissible fluctuation lt 15 Imax 0 94 On the both sides of the valve there are mechanic hand bottoms which can be used for the emergency controlling in case of that electricity is cut off When the electrical control buttom tums to the Ahead or Astern position the relevant solenoid has electricity pushes the valve moving and makes the working oil enter the corresponding clutch for engaging When the control buttom is in the stop position both two solenoids have no electricity and the ahead and astern clutches are all disengaged HANGZHOU ADVANCE GEARBOX GROUP CO LTD 4 6 Service Manual of Marine Gearbox Mo
8. E in quad 35 2 Lack of oil pressure soe adven i dag lese peperit ique dei 36 37 4 The engine stalls during 5 e 37 5 The propeller does not reach the corresponding speed of the motor 38 6 The propeller does not stop turning in Neutral 38 Te GOatbaX MOISE Desa ee uia Paga 39 zotaldard ACCeSSOLBS c dx lie pe a aab t o da dd tesa 40 1 Fiter ANG CODEN 40 2 Geartype oil 41 3 Filter for control oil circuit 42 4 Pneumatic controller u caseo ceo ERA E Pati rod Euboea 44 5 Electrical controller ode ei da iA tO GONE e PR PASO tends dedu 46 6 2 stage control valve 47 7 Lub rication pressure regulator valve 52 8 Oil filler neck with sieve aprile te deckt 52 Emo d T 53 TOP resstire S ce DEEP ERR DG 53 11 Temperature switch s ocean Da etel n vt vite Re Re uy 54 12 Clutch release Valen iess ainnise vanier hot Fass abd acia 55 XI I Gear selBetionInfOITiatio 2 c c race rd e ma n cat eu sida 55 1 Gear selection and ordering sssseene 56 2 Reduction allo e sure iaa rh cubat eon Pope dae hs 57 3 Trans capacity 58 4
9. Series dimensions table i 2 1 up to 4 1 only Input shaft optionally left or right reverse reduction gear GWD input output casing weight with cooler gear model 4 I q k J P Q q A B E e F H H h h L mm kg GW28 30 82 100 102 250 32 300 179 607 800 265 140 450 840 950 100 250 971 1130 GW30 32 85 105 117 270 32 320 190 743 860 282 150 500 888 1298 100 260 1168 1345 GW32 35 95 115 123 290 35 340 205 752 920 310 1625 560 905 1315 120 260 1198 1870 GW36 39 105 130 113 300 40 360 238 789 1060 344 182 600 1005 1500 120 300 1251 2245 GW39 41 115 140 120 330 45 400 227 913 1010 360 195 650 1065 1425 130 320 1423 2960 GW42 45 130 160 131 400 46 470 198 946 1180 396 2125 700 1192 1625 140 335 1454 3630 GW45 49 135 165 168 420 58 500 272 1015 1230 435 225 710 1280 1710 150 410 1649 4835 GW49 54 145 180 172 440 65 530 301 1072 1340 480 2475 870 1390 1925 170 430 1756 6310 GW52 59 155 190 200 460 70 550 250 319 1151 1400 528 2625 1080 1480 2015 180 450 2341 8175 GW60 66 180 225 226 500 75 600 310 370 1280 1600 587 300 1200 1670 2215 200 500 2410 11100 Dimensions and weights for gears with reduction above 4 1 are on request 63 HANGZHOU ADVANCE GEARBOX GROUP CO LTD Service Manual of Marine Gearbox Model GW Series dimensions table i 2 1 up to 4 1only GWS reverse reduction gear GWK reduction gear with clutch
10. a suitable manner on the propeller shaft flange to ensure correct and true measurements Propeller shaft flange and gearbox flange are turned simultaneously so that the dial deflection can be read The required accuracy is 0 025mm i e 0 05mm deflection on the dial gauge Align gearbox and engine acc to the requirements of the highly flexible coupling Compensation for thermal expansion Since as a rule gearboxes are aligned when in cold condition the amount of vertical thermal expansion between the support and propeller flange center must be compensated for The following diagram shows the degree of compensation required for various types and sizes of the GW gearbox series With the help of the aligning screws on which the unit rests during aligning the gearbox is raised by the dimension indicated to bring it to the position which exists when the gearbox has reached its operating temperature The Compensation diagram considers not only the thermal expansion but also the bearing play HANGZHOU ADVANCE GEARBOX GROUP CO LTD 20 Service Manual of Marine Gearbox Model GW Series If tanks are to be found underneath the gearbox foundation which have varying temperatures during the ships operation the diagram is not suitable The Compensation diagram takes into account only the position changes of the gearbox shafts Deflections for the engine are to be observed Compensation diagram 900 65 15 800 700 5 c 0
11. appropriate 1 3 nominal rotation speed If the actual values differ from the rated values the Service Dept should immediately by informed IX Maintenance Daily Check oil level Turn gap type filter in the switch line 2 3 times Check the gearbox for leakages Check the oil pressures and temperatures Monthly Clean the gap type filter Clean the lubrication oil filter Check the remote control operation Check oil for water contact Yearly Check all exterior screw connections Check the protection covering of the sea water cooler if used Oil change Under normal service conditions the first oil change must be after approximately 250 working hours HANGZHOU ADVANCE GEARBOX GROUP CO LTD 30 Service Manual of Marine Gearbox Model GW Series Further oil changes must be completed after approximately 2000 service hours however not longer than 12 months In special conditions consult a mineral oil company Before filling with new oil in accordance with the enclosed lubricant specifications the gearbox must be cleaned with flushing oil X Special Notes 1 Monitoring equipment If monitoring equipment has been installed by the shipyard and maximum permissible value sensors pressure and temperature controls fitted then the following information must be observed When engaging the clutches the total oil quantity For a short period is required to fill the clutch cylinder This produces that for a short period there is no
12. is no reading on the gauges within one minute the engine should be stopped for inspecting running halt an hour a little more in winter then engage Ahead and Astern for a short period 4 Check the oil level The oil level can be taken from the dip stick The dip stick has marks for stationary and running When taking the oil level reading with a stationary gearbox the oil level must be between the marks stationary and with a running gearbox between the running marks HANGZHOU ADVANCE GEARBOX GROUP CO LTD 27 Service Manual of Marine Gearbox Model GW Series 5 The gearbox should be slowly run in until the operating temperature is reached under a partial loading Then all joints and connections of the oil pipelines should be checked for leakage and if necessary re tightened The cooling system must be adjusted so that the operating temperature is kept constant at a full load After a total 10 operating hours the foundation bolts must be checked and if required tightened All renewed pipe connections must also be checked VII Lubrication and Oil pressure instructions 1 Lubrication oil specifications Following lubrication oil are to the used API Classification CA CB CC Respectively MIL L 2104A Viscosity grade SAE30 This is mineral oil without an EP additive This oil brand specification must be strictly adhered to since GW family gear units incorporate also multiple plate friction clutches wh
13. is not exactly in the Adjust the remote control operation Ahead position Gearbox controller defect Replace controller Damaged propeller shaft bearings Replace worn bearings Linings of the clutch in the incorrect Mount the clutch plates correctly sequence Clutch plates broken Exchange damaged plates Sealing rings of the clutch damaged Replace with new sealing rings The splines of the clutch are worn Re work the teeth or renew the part Check the installation at critical speed ranges 6 The propeller does not stop turning In Neutral Possible cause Remedy The vessel is still moving Wait until it s at a complete standstill The propeller is being driven by a current Gearbox controller is not directly on the Adjust the remote operation HANGZHOU ADVANCE GEARBOX GROUP CO LTD 38 Service Manual of Marine Gearbox Model GW Series stop position Defect gearbox controller uncontrolled oil to one clutch Clutch plates broken Seal damaged sticking piston Splines of the clutch damaged Release springs not working 7 Gearbox noise Possible cause Idle speed is within a critical range Gearbox runs within the critical speed range The noise is not to be observed through out the whole speed range Input flange loose The oil level is too low Suction noise of the pump Suction pipe not tight Pump sucks in air Filter choked Excessive pump pressure Pump drive not in order Gearwheel damaged or loo
14. oil pressure The warning or cut off system manufacturer has taken this particular feature into consideration An override mechanism is included in the warning or cut off system and conforms to the classification society for maneuver operations 2 Basic explanation of pumping unit motors Together the suction and pressure lines may contain no more than four 90 elbows The maximum suction pipeline length may not exceed 1 5 metres and the pressure line length 2 5 metres The electric motors have to be designed for long term operation and conform to the classification rules with consideration of the room temperature By an unknown room temperature 45 C is a good basis Isolation is of normal design HANGZHOU ADVANCE GEARBOX GROUP CO LTD 31 Service Manual of Marine Gearbox Model GW Series None of the motors has an explosions class The terminal box has the type of enclosure The motor is normally of construction spark suppression has not been provided for Content following is only valid for GW with Segment thrust bearings 3 Replacement of the segment thrust pads Output end After removing the bolts lift the bearing cover vertically Remove upper part of the radial bearing Lift the upper part of the supporting disk together with the thrust pads Tum the lower part of the supporting disk by means of the holes at the circumference and lift the disk Re assembling is in the reverse sequence When installing new pads take care of t
15. the shaft ends according to our assembly drawings When the couplings are fitted the hub must be HANGZHOU ADVANCE GEARBOX GROUP CO LTD 16 Service Manual of Marine Gearbox Model GW Series heated For this the temperature of the hubs has to be 40 higher than that of the shaft in the case of a taper fit Thus driving on shocks or impacts will be avoided and the gear wheels protected Gearbox is fixed to the foundation If the gearbox is fixed to the foundation with bolts then all bolts must be reamed bolts Mounting bolts The holes are pre bored and must have a larger clearance for together ream Use bolts of strength specification 8 8 Tensile strength 758N mm Aligning screws 7 8 Ductile strength 630N mm Foundation Drawing of Gearbox If the gearbox is mounted and fixed with stoppers against the foundation normal bolts can be used The sizes in the Assembly Drawing can Gearbox foundation be taken for clearance holes The bolts can Y Stop wedges after being tightened to now be chosen to fit 8 stoppers must be used the principle of which can be seen on the drawings The required chocks must conform to Stopper faces on gearbox the classification societies requirements HANGZHOU ADVANCE GEARBOX GROUP CO LTD 17 Service Manual of Marine Gearbox Model GW Series Stand by pump In the case of an installation with a separate stand by oil pump the oil mus
16. valve is adjusted by this ring Lengthening the ring raising pre pressure Shortening the ring lowering pre pressure 3 Adjustment washer The final pressure is adjusted by this washer Clutch control pressure is adjusted Normally no adjustment washer is provided Adding or strengthening of the washer produces a rise in the final pressure HANGZHOU ADVANCE GEARBOX GROUP CO LTD 50 Service Manual of Marine Gearbox Model GW Series Removing or making thinner respectively shortening the spring reduces the final pressure 4 Ascertain the control pressure at operating temperature and nominal speed Check when idling and with cold gearbox 5 For values see Control and Lubrication Oil Pressures 2 Stage Control Valve pressure adjustment d x AAE AZ DAP i k INN NK Qo NO 1000290 S us VAIN 4 HANGZHOU ADVANCE GEARBOX GROUP CO LTD 51 Service Manual of Marine Gearbox Model GW Series Pressure time relationship in the clutch control pipeline after the gearbox Engaging controller during engaging and disengaging phases The illustration shown is valid for operation at nominal speed and operating temperature 7 Lubrication pressure regulator valve Characteristics Sealing by a 90 cone sealing washer Y o 2 made
17. 3 5 0 890 3 950 1 4 1 000 3 950 4 5 1 120 3 950 o 5 1 260 3 950 5 5 1 370 3 950 6 1 500 3 950 173 173 728 728 0 728 0 728 0 728 0 728 0 728 1 absolute values not reduced 14 29 14 29 14 29 14 29 2 hollow shaft 313 HANGZHOU ADVANCE GEARBOX GROUP CO LTD C2 7 7 7 7 7 800 7 7 7 Shaft diameters 2 130 46 220 130 46 220 130 46 220 130 46 220 130 46 220 130 46 220 130 46 220 130 46 220 130 46 220 127 50 240 127 50 240 127 50 240 127 50 240 127 50 240 127 50 240 127 50 240 127 50 240 127 50 240 145 51 260 145 51 260 145 51 260 145 51 260 145 51 260 145 51 260 145 51 260 145 51 260 145 51 260 145 51 247 145 51 247 145 51 247 145 51 247 145 51 247 145 51 247 145 51 247 145 51 247 145 51 247 67
18. 4 1 60 5 m a 2 03 500 2 a 400 D 02 300 amp 20 01 3 2 E 100 2 10 20 30 40 50 60 Difference between temperature when installation and operation VI Gearbox Control and Remote Control 1 Control types A dependable remote control is of great importance for a ships drive system The gearboxes of the GW Family are supplied as standard with a pneumatic gearbox switch HANGZHOU ADVANCE GEARBOX GROUP CO LTD 21 Service Manual of Marine Gearbox Model GW Series Electrical gearbox controllers are available The gearbox controllers whichever type of operation have exactly the same base plate connections To this base plate are all pipelines connected The base plate is separately screwed to the gearbox housing Through having separate base plates the replacement of a controller can also mean changing the type of operation without having to change the pipe work system Pneumatic gearbox controller Gearbox controller Controller baseplate Gearbox housing 2 Requirements of the control system Even through the running of the motor governor gearbox coupling and if supplied shaft brake is difficult it is necessary to perform the following steps to check the system The switching sequence for all switching systems should conform to the following specifications Bridge control Controller positions Full Ahead onto Astern or Full A
19. 5 GW36 39 79 120 GW39 41 124 161 GW42 45 146 180 GW45 49 183 240 GW49 54 250 318 GW52 59 335 432 GW60 66 475 665 1 With GWS and GWK gears having ratios above 4 1 oil capacities are on request Cooling water requirements type GWC GWL GWD GWS GWK Gear model i 2 6 1 2 6 1 2 4 1 2 4 i 2 4 m h cooling water requirement in cbm h GW28 30 3 0 2 5 2 8 2 8 2 5 GW30 32 3 6 225 3 6 3 6 2 5 GW32 35 5 0 3 6 4 1 4 1 3 4 CW36 39 5 1 4 1 4 6 4 5 3 6 CW39 41 6 2 4 8 5 0 5 0 4 0 GW42 45 7 5 6 0 5 1 5 1 5 1 CW45 49 10 2 7 5 8 9 8 9 7 3 GW49 54 13 2 10 0 10 2 10 2 8 9 CW52 59 14 0 13 0 12 5 12 5 10 2 GW60 66 14 6 13 0 13 2 13 2 13 0 Cooler selection based on Water inlet temperature max 32 C Oil cooler inlet temperature max 65 HANGZHOU ADVANCE GEARBOX GROUP CO LTD 60 Service Manual of Marine Gearbox Model GW Series Water pressure at cooler inlet max 0 6 Configurations and rotations GWC GWL 11 m VES Q RE Fh zo ae 0 6 E version version B version C version D configurations and rotations GWD CWH ER 6 Q CE 4 4 sail P PR b W EE E TM Q E n REN nm version E version F version C version H Q Ju V n t r 01 n Va Q 38 Es E version T version K version L Vs M configurations and rotations GWS GWK KO FL gt CHRD
20. 5 0 739 0 073 0 033 5 425 0 298 2 872 1 551 12 16 100 79 31 130 6 1 472 4 050 0 015 0 203 0 683 0 739 0 073 0 033 5 425 0 298 2 872 1 551 12 16 100 79 31 130 2 0 508 4 000 0 022 2 089 0 103 1 217 0 162 0 045 8 110 0 369 3 986 1 621 17 14 102 82 31 150 2 5 0 638 4 000 0 022 1 735 0 189 1 217 0 162 0 045 8 110 0 369 3 986 1 621 17 14 102 82 31 150 3 0 759 4 000 0 022 1 329 0 292 1 217 0 162 0 045 8 110 0 369 3 986 1 621 17 14 102 82 31 150 3 5 0 880 4 000 0 022 0 994 0 421 1 217 0 162 0 045 8 110 0 369 3 986 1 621 17 14 102 82 31 150 i 4 1 000 4 000 0 022 0 792 0 511 1 217 0 162 0 045 8 110 0 369 3 986 1 621 17 14 102 82 31 150 E 4 5 1 136 4 000 0 022 0 601 0 699 1 217 0 162 0 045 8 110 0 369 3 986 1 621 17 14 102 82 31 150 o 5 1 262 4 000 0 022 0 484 0 833 1 217 0 162 0 045 8 110 0 369 3 986 1 621 17 14 102 82 31 150 5 5 1 410 4 000 0 022 0 367 0 943 1 217 0 162 0 045 8 110 0 369 3 986 1 621 17 14 102 82 31 150 6 1 514 4 000 0 022 0 293 1 041 1 217 0 162 0 045 8 110 0 369 3 986 1 621 17 14 102 82 31 150 2 0 508 4 052 0 030 2 712 0 149 1 699 0 194 0 087 13 05 0 434 6 550 2 238 23 58 110 87 31 160 2 5 0 627 4 052 0 030 2 176 0 276 1 699 0 194 0 087 13 05 0 434 6 550 2 238 23 58 10 87 31 160 3 0 745 4 052 0 030 1 468 0 422 1 699 0 194 0 087 13 05 0 434 6 550 2 238 23 58 110 87 31 160 n 3 5 0 882 4 052 0 030 1 288 0 617 1 699 0 194 0 087 13 05 0 434 6 550 2 238 23 58 110 87 31 160 4 1 000 4 052 0 030 1 020 0 803 1 699 0 194 0 087 13 05 0 434 6 5
21. 50 2 238 23 58 110 87 31 160 4 5 1 133 4 052 0 030 0 793 1 026 1 699 0 194 0 087 13 05 0 434 6 550 2 238 23 58 110 87 31 160 o 5 1 256 4 052 0 030 0 660 1 293 1 699 0 194 0 087 13 05 0 434 6 550 2 238 23 58 110 87 31 160 5 5 1 375 4 052 0 030 0 510 1 393 1 699 0 194 0 087 13 05 0 434 6 550 2 238 23 58 87 31 160 6 1 500 4 052 0 030 0 408 1 608 1 699 0 194 0 087 13 05 0 434 6 550 2 238 23 58 110 87 31 160 2 0 500 3 947 0 040 5 300 0 281 2 730 0 292 0 147 21 79 0 738 10 39 2 670 35 20 125 94 37 180 2 5 0 621 3 947 0 040 4 526 0 448 2 730 0 292 0 147 21 79 0 738 10 39 2 670 35 20 125 94 37 180 3 0 755 3 947 0 040 3 168 0 732 2 730 0 292 0 147 21 79 0 738 10 39 2 670 35 20 125 94 37 180 3 5 0 880 3 947 0 040 2 443 1 060 2 730 0 292 0 147 21 79 0 738 10 39 2 670 35 20 125 94 37 180 d 4 1 000 3 947 0 040 1 897 1 376 2 730 0 292 0 147 21 79 0 738 10 39 2 670 35 20 125 94 37 180 4 5 1 114 3 947 0 040 1 473 1 616 2 730 0 292 0 147 21 79 0 738 10 39 2 670 35 20 125 94 37 180 gt 5 1 268 3 947 0 040 1 105 2 042 2 730 0 292 0 147 21 79 0 738 10 39 2 670 35 20 125 94 37 180 5 5 1 385 3 947 0 040 0 859 2 371 2 730 0 292 0 147 21 79 0 738 10 39 2 670 35 20 125 94 37 180 6 1 513 3 947 0 040 0 715 2 738 2 730 0 292 0 147 21 79 0 738 10 39 2 670 35 20 125 94 37 180 2 0 500 3 950 0 060 6 420 0 390 3 680 0 440 0 211 28 36 1 130 12 38 5 720 50 24 135 115 37 200 2 5 0 630 3 950 0 060 4 680 0 710 3 680 0 440 0 211 28 36 1 130 12 38 5 720 50 24 135 115 37 200
22. Gearbox electrical To the gearbox controller 1 Stop 2 Ahead 3 Astern 4 Main selector 5 Erase link 6 Control lamp HANGZHOU ADVANCE GEARBOX GROUP CO LTD 26 Service Manual of Marine Gearbox Model GW Series VII Initial operation All gearboxes are given a test run and checked by the manufacturer in the workshops The control units and control valves are all adjusted in the workshops By delivery the gearbox is without oil and is internally protected by a preservation oil This oil has the quality to mix without any problem or detriment to the gearbox oil Turn the engine and propeller shaft with the unit in Neutral position The sequences of initial operation describe in brief as follows 1 Fill the gearbox with lub oil acc to oil specification table a meshed strainer should be used to avoid foreign matter entering into Check whether the lever of the filter is put to working position and the gauges as well as pipelines are correctly mounted 2 In the case of an installation with stand by pump at first turn on the stand by pump for reading on lub oil gauges If there is no reading on the gauges within one minute about the stand by pump should be stopped for inspecting running for half an hour a little more in winter then turn off the stand by pump and start the engine case of no stand by pump installation at first start the engine running at idling speed for reading on oil gauges If there
23. Oil filter Periodically clean the filter acc To the maintenance instructions 7 Pressure gauge Indicate working oil pressure 8 Oil temperature indicator Show the oil temperature 9 Pressure gauge Indicate lub Oil pressure 10 Temperature switch When oil temperature reaches 72 75 C the switch is on 11 Working oil filter HANGZHOU ADVANCE GEARBOX GROUP CO LTD 13 Service Manual of Marine Gearbox Model GW Series Be cleaned regularly acc to the maintenance instructions 12 Oil pump with pressure limiting valve 13 Input flange Special order acc To differential types of high flexible couplings 14 Oil filler neck with sleve Fill oil into gearbox from here 15 Dipstick Periodically check oil level acc to the maintenance instructions 16 Cooler 17 Water inlet 18 Water outlet 19 Controller Pneumatic or electrical controller are available in required 1 When use pneumatic controller the air pressure is 0 5 1MPa 2 When use electrical control the voltage D C 24V Permissible voltage fluctuation lt 15 20 2 stage control valve The valve regulates initial pressure working pressure pressure raising time 21 Non return valve From here to connect stand by pump set 22 Installation bracket 23 Pump suction 24 Drain plug 25 Stand by pump suction HANGZHOU ADVANCE GEARBOX GROUP CO LTD 14 26 27 28 29 30 3 32 33 Service Manual of Marine Gearbox Model Series Conn
24. Service Manual of Marine Gearbox Model GW Series Hangzhou Advance Gearbox Group Co Ltd Hangzhou Gearbox Works Service Manual of Marine Gearbox Model GW Series FOREWORD The marine gearbox GW series manufactured by Hangzhou Advance Gearbox Group Co Ltd The People s Republic of China has been approved by the classification societies such as ABS LR GL CCS etc with good selling at home abroad Thanks to their compact design and wide matching range GW gearboxes rated input speed is 400 1800r min ratios 2 1 6 1 and rated transmission capacity N n1 0 257 9 25 kW r min t GW gearboxes have 6 series each of which has 10 models The GWC GWD GWS and GWH have the function of reverse and reduction and the GWL and GWK without reversing function Input and output shafts can be arranged coaxial or offset vertically horizontally or diagonally The gearboxes have adapted to combined design and all running parts have been carefully designed and machined to the highest standards for less wasted fuel smooth operation which can be fitted to most engine models Gearbox controller can be selected pneumatical or electrical operation with manual emergency control device Gearbox and engine are connected by a highly flexible coupling which may be ordered on request In generally a stand by pump set should be prepared When fitting to the engine please refer to the main transmission data and the instructions in the manual For
25. Switching frequency Maintenance Card HANGZHOU ADVANCE GEARBOX GROUP CO LTD 6 Service Manual of Marine Gearbox Model GW Series Description of Gearbox Marine Gearbox GW series cover six models There are the GWC GWD GWH reverse reduction gears and the GWL and GWK reduction gears without reversing function The six models differ as follows GWC design The GWC reverse reduction gear has a primary stage a reduction stage and a reverse stage Input and output are coaxial and have same sense of rotation GWC GWD design The GWD reverse reduction gear has no primary stage but a reduction and a reverse stage either one of the clutch shafts is driven directly Input and output are diagonally offset and have opposite sense of rotation GWD GWS design As the GWD model the GWS reverse reduction gear has no primary stage but a reduction and a reverse stage Input and output are vertically offset and have opposite sense of rotation GWS HANGZHOU ADVANCE GEARBOX GROUP CO LTD 7 Service Manual of Marine Gearbox Model GW Series GWH design The GWH reverse reduction gear as GWD and GWS has a reduction and a reverse stage but no primary stage Input and output are horizontally offset and have opposite sense of rotation GWL design The GWL reduction gear without reverse function corresponds to the GWC model in that it has a primary and a reduction stage Input and output are coaxial and have the same
26. The data for other series and variations will be made awailable on request Vibration scheme of GWC marine gearbox Moments of inertia l part of input shaft without coupling l2 input wheel with part of input shaft Clutch wheel l4 turning wheel with clutch disks external Is clutch disks internal with part of pinion shaft ls shaft pinion l7 output wheel with part of shaft ls output flange with part of shaft Torsional rigidity C4 input shaft C shaft pinion output shaft HANGZHOU ADVANCE GEARBOX GROUP CO LTD 6 5 Service Manual of Marine Gearbox Model GW Series gear ratio moment of inertia torsional rigidity shaft diameters model 1 2 11 12 11 12 D I3 I5 16 I7 I8 C2 C3 dl 42 d3 kg nr2 10 6Nm rad mm 2 0 568 4 050 0 015 1 127 0 067 0 739 0 073 0 033 5 425 0 298 2 872 1 551 12 16 100 79 31 130 2 5 0 618 4 050 0 015 0 864 0 113 0 739 0 073 0 033 5 425 0 298 2 872 1 551 12 16 100 79 31 130 3 0 760 4 050 0 015 0 605 0 180 0 739 0 073 0 033 5 425 0 298 2 872 1 551 12 16 100 79 31 130 b 3 9 0 872 4 050 0 015 0 484 0 245 0 739 0 073 0 033 5 425 0 298 2 872 1 551 12 16 100 79 31 130 4 000 4 050 0 015 0 384 0 322 0 739 0 073 0 033 5 425 0 298 2 872 1 551 12 16 100 79 31 130 4 5 1 119 4 050 0 015 0 328 0 420 0 739 0 073 0 033 5 425 0 298 2 872 1 551 12 16 100 79 31 130 o 5 1 256 4 050 0 015 0 259 0 498 0 739 0 073 0 033 5 425 0 298 2 872 1 551 12 16 100 79 31 130 5 5 1 342 4 050 0 015 0 239 0 58
27. age can burst Remove the plate r with filter cartridge p then remove the nut 5 and the filter cartridge The filter can be a multi baged one of which consists of several round disc or a HANGZHOU ADVANCE GEARBOX GROUP CO LTD 40 Service Manual of Marine Gearbox Model GW Series star sieve cartridge The filter web is to be rinsed in an acetone bath and blown out with compressed air Care must be taken not to damage the web After cleaning re assemble the filter on the plate and mount into the filter housing Generally the filter has to be cleaned when the machine set is stopped In special cases it is allowed for cleaning the filter during the set is running firstly switch the lever to the u position for oil flows directly into the cooler then clean the filter cartridge After cleaning the lever must be switched to the t position Cleaning of tube bundle Water side After cutting off the water and oil flow the oil should be emptied at the bottom chamber socket cover After the removal of the reverse covers the cooling tubes are to be cleaned by means of wire or nylon brushes and the remains blown out with compressed air The covers can now be re assembled 2 Geartype oil pump Type Plate Filling Normally when putting into operation the filling of the pumps is not necessary but dry operation must be avoided HANGZHOU ADVANCE GEARBOX GROUP CO LTD 41 Service Manual of Marine G
28. del GW Series 6 2 stage control valve Control and lubrication oil circuit Control ail tothe quick drain piston Regulator piston t Az SSS LL LE GY ES A lt lt ZZ AR fA NS Lr RS Regulator piston damping HANGZHOU ADVANCE GEARBOX GROUP CO LTD Bs Service Manual of Marine Gearbox Model GW Series aunssaid uoneonqn Ow IN 9A PA aunssaid ow IN s r uonesugn Buueeg u51As aunsseid ounssaud 5 9 002 E et 9 5 gt is 1 HL c jr z E E Q WADO jo 2 Stage control valve Yo IMs duie c C 5 e 5 3 E E a 1 l 5 5 amp yana Z uoy s enssejd eseajay m o YOUMS 2JhnssoJd jo E 5 r eli 9A unoum L m JPA uinjei UON role BABA Ajajes air Control nuo xoqiper uie cred LJUnja1 UON MEN Aq pues Service Manual of Marine Gearbox Model GW Series 2 stage Control valve description Idling of the gearbox Clutch not engaged
29. earbox Model GW Series Direction of rotation Pumps must only rotate in the given direction but it is possible to alter the direction of rotation To check the direction of rotation the motor can be switched on and off for short periods only so long as the pump is filled and has no load Pressure limited The pump and hydraulic system have to be protected by the pressure Limiting valve when ex works the valve discharge pressure set of 2 5MPa normally without re adjustable Temperature After having reached the operating values the temperature of the units especially that of the bearings and shaft seals has to be checked Bearing temperatures taken on the surface may exceed the oil temperature by 10 3 Filter for control oil circuit View in direction P HANGZHOU ADVANCE GEARBOX GROUP CO LTD 42 Service Manual of Marine Gearbox Model GW Series Mode of operation and maintenance The liquid to be cleaned flows from the outside towards the inside of the filter element whereby the dirt particles are left on the element Dirt collects on the filter element and by means of a special unit operated by turning the T handle or setting in motion the electrical or hydraulic spindle drive is scraped off and allowed to drop into the sediment chamber This must from time to time be drained No other maintenance of any kind is necessary Cleaning instructions 1 According to operating conditions the filer must be cleaned regularly I
30. ect to stand by pump pipes Back pressure valve Regulate lub Oil pressure Working oil pipe ahead Spare adapter M14 X 1 5 Spare adapter M10 X 1 Working oil pipe astern Spare adapter M14 X 1 5 Spare adapter M10 X 1 drain plug for cooler IV Mounting HANGZHOU ADVANCE GEARBOX GROUP CO LTD 15 Service Manual of Marine Gearbox Model GW Series Transportation The gearbox is suitably suspended on cables for transportation Therefore all cables taking the gearbox weight should be clear of the fittings Slowly lift the gearbox and place in position The lifting lugs on the upper part of the gearbox serve only to remove the upper section To lift the complete gearbox the transportation lugs are to be used To avoid accidents cables are to be used with shackles Installation in the engine room The aligning screws are to be inserted into the tapped holes in the mounting bracket Via the aligning screws the gearbox rests on the top plates Maximum permissible permanent installation angle fore and aft 5 The foundation In order to facilitate the changing of oil and washing out of the gearbox the foundation has been constructed so that there is sufficient space for the installation of an oil collector below the drain plug The fitting of couplings If couplings have to be fitted onto the gearbox input shafts the calibers of the bore holes in the coupling hubs have to be adapted to the diameters of
31. ection is eliminated for gearbox alignment A roller block is placed underneath the end flange of the propeller shaft and raised by the amount of deflection ascertained There are however cases where the free end of the propeller shaft due to additional loads is bent more than is required by natural deflection In this case an additional dial gauge can be installed near the bearing which indicates the amount of lift required at the shaft end to ensure that the shaft in the bearing is evenly raised The reading thus taken at the shaft flange dial gauge is twice the value of the actual deflection Raising the roller block by half of this value corrects exactly the position of the propeller shaft flange Aligning the gearbox axial parallelism The illustration shows how this is to be done with the help of gauge feeler gauges It is important for this measurement that the shafts be turned in one direction only The accuracy of axial parallelism should be no more than 0 01mm for 100mm of flange diameter HANGZHOU ADVANCE GEARBOX GROUP CO LTD 19 Service Manual of Marine Gearbox Model GW Series Aligning the gearbox axial displacement When the gearbox is arranged parallel to the propeller flange the axial displacement is to be aligned In the illustration it shows the procedure to be followed turning must also be in one direction only A dial gauge can as well be mounted in
32. es with more than 6 cylinders engine and gearbox to connected by hihgly elastic coupling In case of different conditiones Please contact us 58 Service Manual of Marine Gearbox Model GW Series Selection diagram GWD GWS GWK GWH Ciass ABS Reduction ratio i Class GL 2 Reduction ratio i Maximum permissible input speeds Class BV gear models r min 28 30 1800 30 32 1800 32 35 1800 36 39 1800 39 41 1600 42 45 1600 45 49 1400 49 54 1200 52 59 1200 60 66 1200 Reduction ratio i Class LROS Remarks Reduction ratio i HANGZHOU ADVANCE GEARBOX GROUP CO LTD rated power in metric n input speed in rpm The selection curves are based on following conditions the above mentioned input speeds are not to be exceeded special order on request inline engines with more than 5 cylinders and vee engines with more than 6 cylinders engine gearbox be connected by hihgly elastic coupling In case of different conditiones Please contact us 59 Service Manual of Marine Gearbox Model GW Series Cil capacities Type Gear model GWC GWL GWD GWS GWK 1 2 6 1 2 4 Oil capacity in ltrs GW28 30 40 56 GW30 32 57 80 GW32 35 61 9
33. from rubber Restricted stroke therefore ensures free opening shock absorbing and silent Opening pressure Approximately 0 1Mpa 8 Oil filler neck with sieve Sieve as above measurements with 3 Amm mesh size HANGZHOU ADVANCE GEARBOX GROUP CO LTD 52 Service Manual of Marine Gearbox Model GW Series 9 Dipstick Screwed into housing __ When the gearbox is at a standstill Stationary Oil level with running C gearbox running 7 7 min This marker shows the oil level at 6096 to 10096 of rated speed of the engaged gearbox wthout standby pump operation 10 Pressure Switch YWK50 aluminum casting case water resistant untivibration acc standard 101 GB5010 85 Wiring Double pole mini switch working process Terminal 1 2 and 3 When the pressure lowers to the HANGZHOU ADVANCE GEARBOX GROUP CO LTD 33 Service Manual of Marine Gearbox Model GW Series shift point terminal 1 has connected with terminal 3 and terminal 1 and terminal 2 are disconnected Electrical cable 12 marine class or 7 5 3 core Shift point Ahead 1 5Mpa Astern 1 5Mpa Lubrication oil 0 04Mpa 11 Temperature Switch Type JWC K A M22X1 5 1 Working Voltage D C 27 110V 2 Charge on the contact point 2A resistance 3 Shift temp regulated value 72 75 C 4 Wri
34. he direction of rotation sketch C p propeller anti clockwise rotation C p propeller clockwise rotation Fixed propeller Fixed propeller C p propeller and anti clockwise rotation clockwise rotation reversible engine HANGZHOU ADVANCE GEARBOX GROUP CO LTD 32 Service Manual of Marine Gearbox Model Series 4 Emergency control of the gearbox Inspection cover _ If for any reason the hydraulic control of the gearbox is not possible then there is always the possibility to block the clutch mechanically Remove the inspection hole cover part 141 of the upper section of the iE SS _ KSS EM ER Se er housing Remove the locking device the emergency screw and firmly tighten Fix the inspection hole cover by means of the screws The gearbox is now ready for emergency operation Leave the gearbox switch in the stop position when in emergency operation When emergency switching pay attention Put the gearbox selector in the stop position after the unit stands still Add filling with lub oil the oil level must be the mark stationary The engine speed is at 60 or less of the rated speed Regularly inspect the temperature on housing surfaces where the hearings were fixed inside 5 When taken in tow When the ship is being towed and therefore the gearbox is being driven by the propeller the lub oil supply must be assu
35. ich in addition to the gearwheels take part in power transmission Extreme pressure additives negatively effect the functioning of these clutches Preferred lubrication oils Mineral oils of group SOU 63 or HQ 10 GB485 72 HC 11 SY1152 71 china are to be used for the running in and later operations Oil group SOU O II s without additives influencing friction and wear Viscosity group 63 HANGZHOU ADVANCE GEARBOX GROUP CO LTD 28 Service Manual of Marine Gearbox Model GW Series Viscosity from 50 to 80 cSt corresponding to 6 6 to 10 5 by 50 C Firma Oil Type FINA FINA Dorano 30 FINA Dilano 30 FINA Stellano 30 FINA Cirkan 100 FINA Solna 30 FINA Purfinaol 30 Fuchs Renolin LTA 30 Renolin 20B Mobil Mobil D T E Oil Heary Shell Shell Tellus OIC100 Shell Turbo OIT100 Shell Vitrea 01100 Texaco Regal Oil R amp 0 150 Ursa Oil P 100 2 Rated Values for oil pressure Switching oil pressure MPa Starting Gearbox oil temperature 15 30 Idling Pre Pressure 0357 Switch pressure 1 875 Rated speed Pre pressure 0 6 HANGZHOU ADVANCE GEARBOX GROUP CO LTD Normal running 40 60 0 15 0 2 0 05 1 855 40 15 0 65 Service Manual of Marine Gearbox Model GW Series 403 02 Switch pressure 2 01 2 01 Lubrication pressure MPa Idling min 0 04 0 04 Max 0 25 0 15 Rated speed min 0 1 0 1 Max 0 4 0 3 Switching time of the 2 stage valve 2 5 3 5 sec 1 5 2 5 sec
36. itching rate per minute Engagement speed is the switching is initiated A copy of the diagram must be available at the bridge 3 Pneumatic remote control and design example When the gearbox is equipped with the standard controller the remote control is via pneumatics When planning the remote control system attention should be payed to The engine speed when reversing should not amount to more than 60 of the motor rated speed An agreement between the supplier of the control system and Hangzhou Gearbox Works must be made for the requirements of the Crash Stop man oeuvre design Design example for the pneumatic control of the ships drive 1 Pressure reducing station 2 Air reservoir 4 Stopcock HANGZHOU ADVANCE GEARBOX GROUP CO LTD 24 Service Manual of Marine Gearbox Model GW Series 6 Control valve 13 Pressure reducing valve 14 Double non return valve 15 Double non return valve for oil 16 Non retum choke valve 17 3 way valves 19 3 way valve adjustable 24 Multi way valve hydraulic pneumatic 27 Control unit Circuit diagrams for systems with multiple control points as for ships with multiple systems can be provided Description for a design example of a pneumatic ships propulsion control The example shows the pneumatic remote operation consisting of motor reversing gearbox and fixed propeller within the ships drive system With the single lever operation of the control valve 6 the de
37. l pressure Possible cause Wrong direction of rotation Filter obstructed Cil level too low The viscosity of the oil is too low Oil temperature too high Suction pipe obstructed 2 stage valve is defective Pump drive is defective Pump wear Selector position is not correct Wear of the oil supply Quick release valve does not close Regulate operating pressure see 2 stage valve Clean the filter Installation of end covers or seal covers in such a way that the oil can flow back Replace damaged bearings Loosen Remedy After engine rotation or gearbox rotation direction clean filter Refill with oil and trace cause of oil loss Change to an oil conforming to the recommended lubricants See Excessive gearbox temperature Clean suction pipe Replace defective parts or the complete valve Renew the pump drive Install new pump Adjust remote control operation Renew oil supply Clean quick release valve HANGZHOU ADVANCE GEARBOX GROUP CO LTD 3 6 Service Manual of Marine Gearbox Model GW Series 3 Oil leakage Possible cause Drain plug is not tight Dipstick connector not tight High pressure system leaking Oil loss through the air vent Mating faces of the housings are not sealed Leakage of the shaft seals Oil cooler is leaking 4 The engine stalls during reversing Remedy Replace the gasket and tighten drain plug Replace dipstick gasket and tighten Tighten all fittings Install a pla
38. ng type normally open When the temperature reaches at 72 75 the switch is on HANGZHOU ADVANCE GEARBOX GROUP CO LTD 54 Service Manual of Marine Gearbox Model GW Series 12 Clutch release valve The release valve has the task of putting the clutch into a renewed working phase as quickly as possible after being disengaged After the disengagement of the clutch the retaining pressure on the piston is removed and by centrifugal and spring force the piston is put into the limiting position The clutch space is then discharged into the gearbox 2 AAA S a dizi Piston in draining position Oil feed LAL 4 a Wl Discharge 13 Notes If the structure or type of these standard accessories should be modified the manual will be corrected in new issue HANGZHOU ADVANCE GEARBOX GROUP CO LTD 55 Service Manual of Marine Gearbox Model GW Series Vil Gear selection information Gear selection The gear model selection based on rating input speed and required radio is made from rating diagrams on the manual Ordering date When ordering please state gear specification reduction ratio design number i e Marine reverse reduction gear GWC42 45 reduction ratio i 3 design No B02 and the following data Engine maker Engine type Engine output Input speed Engine speed Output speed Propeller speed Direction of engine rotation facing flywheel Direction of p
39. nnections etc to the gearbox which have to be installed modified or renewed after having left our works must be carefully acidified and cleaned off any obstructions before they are mounted The direction of rotation is shown by an arrow Intermediate Storage If the gearbox is stored outside it must be protected from the atmospheric conditions by a protective cover or canopy Our liability is invalid when the gearbox is opened without our authorization HANGZHOU ADVANCE GEARBOX GROUP CO LTD 10 Service Manual of Marine Gearbox Model GW Series 2 Instruction HANGZHOU hs Service Manual of Marine Gearbox Model GW Series 27 28 29 30 31 32 33 HAN Service Manual of Marine Gearbox Model GW Series 1 Output shaft Align the gearbox acc to the requirements then fasten the output flange and the propulsion flange with reamer bolts 2 Pressure switch When the lub Oil pressure reduces to 0 04MPa the switch is on 3 Pressure switch for ahead When the working oil pressure reduces to 1 5MPa the switch is on 4 Pressure switch for ahead When the working oil pressure reduces to 1 5MPa the switch on 5 Shift handle for lub Oil filter 1 When gearbox running the handle is placed horizontally 2 It is necessary to turn the handle 90 clockwise while the gearbox is running continuely the oil flows directly into the system After cleaning the filter be sure to return the handle in horizontal position 6 Lub
40. red The stand by pump must be running and the oil pressure existing HANGZHOU ADVANCE GEARBOX GROUP CO LTD 33 Service Manual of Marine Gearbox Model GW Series In case of no stand by pump installation make the intermediate shaft disengaged by means of brake installed on boat tailshaft or other measures 6 Sealing strips 1 General Information It is absolutely necessary to observe that the colour marking on the side of the sealing strip lies on the bottom of the sealing strip groove When the sealing strip is incorrectly inserted with the fabric side to the shaft can this fabric sealing strip be damaged thus is the sealing inoperative If there is no colour coding then the assembly is arbitrary To cut the sealing strip a good sharp knife is required The cut must be at right angles to the length 2 Measuring and fitting The measurement of the sealing strip must be done with great care There must exist a slight compression between the two butting ends so as to give a good seal When the sealing strip is measured for separable parts the amount that stands Proud of the joining surfaces must be equal The amount that the sealing strip is compressed can be seen in previous notes 3 Running in conditions The sealing area of the sealing strip must be lubricated before the first run It must be continuously lubricated to avoid the strip drying up When systems have an adjustable speed the running in of the sealing strip mus
41. ropeller rotation facing flywheel Control valve type Cooling water temperature inlet Classification society Kind of survey Shipyard Yard no Special order contact the maker HANGZHOU ADVANCE GEARBOX GROUP CO LTD 956 Service Manual of Marine Gearbox Model GW Series Precise reduction ratios GWC GWL i JM Y o nominal reduction ratios eit model 2 265 3 3 5 4 4 5 5 3 5 6 precise reduction ratios CW28 30 2 0607 2 5053 3 0800 3 5353 4 0526 4 6457 5 0917 5 5861 6 1369 CW30 32 2 0317 2 5517 3 0370 3 5200 4 0000 4 5455 5 0476 5 6410 6 054 GW32 35 2 0585 2 5414 3 0210 3 5760 4 0526 4 5930 5 0893 5 5723 6 0789 GW36 39 1 9737 2 4502 2 9791 3 4737 3 9474 4 3958 5 0065 5 4656 5 9744 GW39 41 1 9750 2 5339 3 0632 3 5206 4 0420 4 5280 5 0935 5 5960 6 1573 GW42 45 2 0000 2 5454 3 0244 3 5788 4 0000 4 4706 5 0000 5 6000 5 9310 GWAS 49 1 9737 2 4671 2 8947 3 3835 3 9474 4 3741 4 8496 5 3828 5 9847 CW49 54 1 9359 2 4592 2 9173 3 4457 3 9524 4 5336 4 9105 5 4824 5 9966 GWS52 59 1 9343 2 4817 2 9643 3 5251 3 9524 4 4314 4 9725 5 4017 5 9286 GW60 66 2 0476 2 6061 3 0714 3 5833 4 0952 4 6804 5 1190 5 6040 6 1428 TAX S LE URL e VE c eius pude nr rede MM coc Mte Tu Precise reduction ratios GWD GWS GWK GWH i H ee nominal reduction ratios gear model 2 25 3 3 5 4 precise reduction ratios GW28 30 2 0000 2 5556 3 0000 3 5714 4 0526
42. se Extreme bearings damaged Gearbox bearings damaged Gear wheels are damaged by foreign matter Replace gearbox controller Renew clutch plates Renew seal Re work the teeth or renew the part Clean clutch and if required replace springs Remedy Increase idling speed Avoid running the gearbox continuously in the critical range Tighten the flange or replace when damaged Correct oil level Tighten all fittings on the suction line Clean filter Repair damaged parts or replace Re align The whole installation Renew damaged bearings Grind damaged area and if necessary replace the gear wheel The gear rims are loosened by overloading Re tighten the gear rims HANGZHOU ADVANCE GEARBOX GROUP CO LTD 39 Service Manual of Marine Gearbox Model GW Series Gear wheels are loose on the shaft due to Re tighten the wheels overloading Propeller damaged Re set propeller and eventually repair Output flange is loose Re tighten the flange and replace if damaged Extreme misalignment on the output side Realign installation of the gearbox Standard Accessories 1 Filter and cooler water in water out Cleaning of the filter After approx 200 300 hours of operation the filter package has to be removed and cleaned With a large dirt accumulation and when on the first run the filter must be more frequently cleaned Differential pressure may not exceed 0 2MPa as otherwise the filter pack
43. sense of rotation GWK design The GWK reduction gear has no reverse function and is of single stage design Input and output are vertically offset and have opposite sense of rotation HANGZHOU ADVANCE GEARBOX GROUP CO LTD GWH GWL GWK Service Manual of Marine Gearbox Model GW Series Power flow and shaft rotations for GWC Fold out section Power flow and shaft rotations for GWL Fold out section Power flow and shaft rotations for GWD Fold out section direction of rotation Va 4 f Hak RR wk Woe Se SS i direction of rotation direction of rotation HANGZHOU ADVANCE GEARBOX GROUP CO LTD ta ey Pd p m EY n k i SEU R direction of rotation direction of rotation direction of rotation Service Manual of Marine Gearbox Model GW Series IIL Instructions 1 General Information The gearbox is delivered without oil The gearbox is protected internally with preservation oil effective against corrosion for a period of six months when the gearbox is stored in a dry area at an even temperature The gearbox is painted externally Flanges shaft ends and flanging surfaces outside the gearbox have a preservation paint The connections for the air pipes oil tubes and water pipes to be assembled at the site are sealed by means of blanking flanges or blugs Pipelines pipe co
44. sired value for the motor speed and the directional rotation of the propeller wiz be given The control air supply is via a pressure reducing station 1 whereby the doubled supply of air is filtered and from 3 MPa to the operating pressure of 0 6 MPa is reduced In the air reservoir 2 the air is stored and if necessary the water drained off The control air desired value is over control valve 6 which then goes to control unit 27 and then the pneumatically mechanically multi way valve 24 for the motor and gearbox to be adjusted into the required operating condition Also dependent on the switching oil pressure of the clutches can only be changed at a low motor speed The motor speed is raised slightly by the combination of units 18 17 19 and 14 when the HANGZHOU ADVANCE GEARBOX GROUP CO LTD 25 Service Manual of Marine Gearbox Model GW Series gearbox is in a reversed procedure so that the motor governs the propeller inertia 4 Electrical remote control design example When the gearbox is equipped with the electrical controller the remote control is via electrical system When planning the remote control system attention should be payed to The engine speed when reversing should not amount to more then 60 of the motor rated speed An agreement between the supplier of the control system and HC must be made for requirements of the Crash Stop manoeuvre design Wiring diagram of the main operating position Main operating position
45. special requirements contact with sales and design departments A thorough understanding of this manual will result in lengthy and satisfactory service from the gearbox please carefully read the manual before putting the gearbox into operation and install operate and maintain according to stipulated requirements in the manual HANGZHOU ADVANCE GEARBOX GROUP CO LTD 1 Service Manual of Marine Gearbox Model GW Series Important Note The gearbox can not be held responsible for torsional problems arising from the drive system We therefore recommend that a calculation and adjustment for the vibrational data of the ship s entire drive system should be performed including the torsional compatibility of the gearbox No liability is accepted for the gearbox damage arising from wrong matching operating or other parts of the drive system caused by such vibrations The manual is applicable to the standard gearbox version Variations are possible on special customer requirements Technical modifications revised HANGZHOU ADVANCE GEARBOX GROUP CO LTD 2 Service Manual of Marine Gearbox Model GW Series Contents sLISEO Technical Data roe oe od Er Dt im e oe M 5 Description OF GBatDOX Poets de tot EO retra Esau doa 7 c M 10 1 General sesen Teves induct ae 10 2 11 tae PROS toi AR NIS teas
46. stern onto Ahead or Full Ahead onto Full Astern HANGZHOU ADVANCE GEARBOX GROUP CO LTD 22 Service Manual of Marine Gearbox Model GW Series or Full Astern onto Full Ahead Sequence 1 Control unit onto low speed Let the propeller shaft speed drop to a minimum of 60 of the rated speed 2 Coupling in zero position 2 1 Propeller shaft brake engages 2 2 Propeller shaft stops 2 3 Open propeller shaft brake In case without brake the controller should be retained at zero position for approx 2 3 sec 3 Engage coupling 4 Retain switch position for approx 1 sec In case without brake the controller should be retained at engaging position for approx 1 5 2 sec then increase speed 5 Increase speed The control system must be carefully maintained Any faults must be immediately repaired The control units must be handled very carefully Switching rate of the Gearbox When the switching rate is high and or if engine speed is high when switching the diagram Engagement speed Number of Engagements must be considered The diagram is based on the heat regenerating ability of the multiple disc clutch and determined according to the service condition as specified in the order It shows the admissible number of engagements in relation to the engagement speed HANGZHOU ADVANCE GEARBOX GROUP CO LTD 23 Service Manual of Marine Gearbox Model GW Series The Number of engagements minute is to be understood to be a uniformly divided sw
47. t be pumped through the system for approximately 2 hours before the first start For this a close meshed strainer must be inserted at the oil inlet to the gearbox in order to catch dirt particles coming from the pipeline system installed after delivery If the diameter of the pipe exceeds NW 25 1 the strainer has to be supported by a perforated disc of Moet y chier Stand by bu mp set wath safety valve special order 2mm thickness with holes of approximately 8mm diameter in order to prevent the strainer from being crushed and getting into the interior pipeline system which may happen if the dirt accumulation is too heavy During this pump test the exterior pipeline system can be checked for leaks V Gearbox Alignment The propulsion unit shall only be aligned when the vessel is afloat and it is gt definitely ensured that it is not in contact with the ground VU Shaft bending o The completely assembled propeller shaft shows a deflection between the supporting bearing and the flange The 1000 2000 mm 3000 extent of the deflection in relation to the shaft sari pvernang HANGZHOU ADVANCE GEARBOX GROUP CO LTD 18 Service Manual of Marine Gearbox Model GW Series overhang and diameter can be seen in the diagram This deflection is to be compensated Bending checking on the propeller shaft The right illustration shows how the defl
48. t always be at the lowest possible speed 4 Treatment of Sealing Strips Store in a cool room HANGZHOU ADVANCE GEARBOX GROUP CO LTD 34 Service Manual of Marine Gearbox Model GW Series During storage the strips must not be exposed to a highly humid atmosphere nor must they come into contact with any kind of liquid If the sealing strip is wound then the beginning of the winding must be located away from the shaft The start of the winding can be determined by the frontal cut edge With plaited sealing strips the assembly is arbitrary i of Winding Sealing Strip Apply oil to the slideway of the sealing strip prior to installation Press the sealing strip uniformly into the receiving groove suing the handle of a hammer After pressing in the sealing strip cut off the ends at the joint leaving 1 5 2mm proud The special notes of the manufacturers are to be observed XI Trouble Shooting 1 Overheating Possible cause Remedy Oil level is too high Correct oil level Lubricating oil pressure too low Re set operating oil pressure to the insufficient cooled oil lowest permitted value Gearbox is overloaded Reduce input power HANGZHOU ADVANCE GEARBOX GROUP CO LTD 35 Service Manual of Marine Gearbox Model GW Series Operating oil pressure is too low clutch is slipping Excessive pump pressure Cil does not flow back from the outer bearing sides Bearings damaged Seal too tight 2 Lack of oi
49. t is advisable to clean the filter when new liquid is to be renewed The pictures show the cleaning procedure 2 Shut off feed release the sediment drain plug A and allow the sediment to flow out Take care of sealing washer D 3 Undo the fixing nuts F and remove the washers 4 Lift the filter element carfully from the housing L and take care of seal HANGZHOU ADVANCE GEARBOX GROUP CO LTD 43 Service Manual of Marine Gearbox Model Series 5 Clean the filter element J in washing petrol and dry with compressed air Do not damage the coil or cleaning brushes 4 Pneumatic controller Gearbox controller with by air return device stop astern ahead M14 Xx1 5 M14x 1 5 190 HANGZHOU ADVANCE GEARBOX GROUP CO LTD 44 Service Manual of Marine Gearbox Model GW Series Pneumatic controller is a 3 position and 4 way valve its control air pressure is 0 5 1MPa The connection 7 is always with air pressure and the connections V and W are connected with the valve which set in control air piping Control principing Stop position The V W are opened into the atmosphere via the control valve With the air pressure acting Z the pneumatic controller is in the neutral position and the working oil is cut off with T are connected with oil sump Both ahead and astern clutches are disengaged Ahead position Compressed air comes into
50. te 15 Gearbox Alignment eM qm a uit 18 Gearbox control and 21 Te lt Control DES i hod ba ora EM b d ad 21 2 Requirements of the control system 22 Pneumatic remote control and design example 24 4 Elecricl remote control design example 26 27 Lubrication and oil pressure instructions 28 1 Lubrication oil specifications oct rte Eth ea 28 2 Rated values for oil pressure 29 EP une 30 OG TA NOLO ue T 31 1 Monitoring PE CR CR P bre 31 2 Basic explanation of pumping unit motors 81 3 Replacement of the segment thrust pads output end 32 4 Emergency control of the gearbox 33 5 Wherr taken MiTo scene TTE ERE ERR Eos PE CO EU bot CUP RS eR 33 6 Sealing telitnn 34 Tro ble Shooting s vasco 35 HANGZHOU ADVANCE GEARBOX GROUP CO LTD 3 Service Manual of Marine Gearbox Model GW Series T Overhead soo tone rn a D ao OQ HIER NU
51. te under the air vent Seal with new compound and tighten all bolts Renew seals b Install sealing cover in such a manner that the passage is free from the outer bearing side Replace the cooler stem When switching over the engine threatens to stall at this manoeuvre the engine must be caught by fuel admission so that the power taken from the propeller will not be larger than the engine power at this moment Possible cause The idling speed is too low The operating pressure is too high therefore engagement is too quick The gearbox controller is defect uncon trolled at flow to one clutch Clutch plates are damaged The splines of the clutch are damaged Remedy Increase the idling speed Reduce the operating pressure to normal value Replace gearbox controller Replace damaged clutch plates Re work the splines or renew the part check at critical speed ranges HANGZHOU ADVANCE GEARBOX GROUP CO LTD 37 Service Manual of Marine Gearbox Model GW Series The release springs do not work Clean the clutch Replace the springs if necessary Pistons of the clutch are jammed seals Renew damaged seal damaged 5 The propeller does not reach the corresponding speed of the motor Possible cause Remedy Pressure gauge defect higher pressure Change pressure gauge and re adjust oil shown than in reality pressure Control oil pressure too low 1 Clean filter 2 Check the control operation Gearbox controller
52. ure build up time longer Unscrewing the jet needle ant clockwise shortens the pressure build up time Attention See control times The given control time must be adhered to Not HANGZHOU ADVANCE GEARBOX GROUP CO LTD 49 Service Manual of Marine Gearbox Model GW Series conforming to these times can lead to multiple plate damage The oil that flows via the time adjustment into the chamber actuates the pressure raising piston which the spring assembly strongly stresses Through this measure the pressure rises before the regulator piston and therefore in the complete clutch operating system At the same time the remaining oil at the time adjustment H flows via the connection K passed the quick drain piston and thereby blocking return flow E Disengaging the clutch The connections are the same as in idling of the Gearbox However draining of the chamber is additionally required Through cessation of the pressure at connection K the quick drain piston is not held in position Because of the return force of the spring assembly via the pressure raising piston on the oil in the chamber the quick drain piston rises and the oil flows to the oil sump Because of this the 2 stage valve is also suitable for high control frequencies Drain period max 1 sec Pressure adjustment 1 The 2 stage control valve is adjusted in the works A re adjustment is normally not necessary 2 Adjustment ring The pre pressure of the
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