Gearbox SV-320-C PDF

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11/3
TECHNICAL MANUAL
GEARBOX DREDGE PUMP
BEAVER 1200
SV-320-C
Issue 1.0 March 2010

i
COMPLETE DESCRIPTION
TECHNICAL MANUAL
GEARBOX DREDGE PUMP
BEAVER 1200
SV-320-C
PARTS & SERVICES ORDER Nr: 009086
BEAVER DREDGERS Nr:
02759
In case of correspondence
please indicate above number.
COPYRIGHT
ALL RIGHTS RESERVED

THE CONTENTS OF THIS DOCUMENT MAY NOT BE PRINTED,
MICROFILMED, PHOTOCOPIED, DIGITALLY REPRODUCED AND/OR
PUBLISHED IN ANY FORM WITHOUT THE PRIOR WRITTEN AGREEMENT
OF IHC MERWEDE BV. THIS APPLIES TO THE ASSOCIATED
ILLUSTRATIONS AND PICTURES TOO.
IHC MERWEDE BV RESERVES THE RIGHT TO MAKE MODIFICATIONS TO
THIS MACHINE AT ANY TIME WITHOUT NOTICE.

ii
CONTENTS
COMPLETE DESCRIPTION ..................................................................................ii
COPYRIGHT ..........................................................................................................ii
CONTENTS ............................................................................................................. iii
LIST OF FIGURES ............................................................................................... vii
LIST OF TABLES ................................................................................................. vii
FOREWORD............................................................................................................ ix
PURPOSE MANUAL .............................................................................................ix
GENERAL CONDITIONS ......................................................................................ix
MANUAL........................................................................................................ix
OWNERSHIP..................................................................................................x
LIABILITY .......................................................................................................x
WARRANTY ..................................................................................................xi
WARNING SYMBOLS.......................................................................................... xii
CONTACT ADDRESS......................................................................................... xiii
1 | INTRODUCTION ............................................................................................. 1-1
1.1
| GENERAL DESCRIPTION GEARBOX................................................... 1-1

1.1.1| Gearbox Principle of Operation ......................................................... 1-1
1.1.2| Gearbox Construction ....................................................................... 1-1
1.2
| STRUCTURE MANUAL.......................................................................... 1-3
2 | SAFETY .......................................................................................................... 2-1

2.1
| SAFETY PRECAUTIONS DURING OPERATION .................................. 2-1
2.2
| SAFETY PRECAUTIONS DURING MAINTENANCE ............................. 2-2
3 | TRANSPORT / STORAGE AND INSTALLATION .......................................... 3-1

3.1
| DELIVERY.............................................................................................. 3-1
3.2
| HANDLING ............................................................................................. 3-1

3.2.1| Shipping ............................................................................................ 3-1
3.2.2| Loading/unloading............................................................................. 3-2

iii
3.3
| STORAGE .............................................................................................. 3-2
3.4
| INSTALLATION ...................................................................................... 3-3

3.4.1| General ............................................................................................. 3-3
3.4.2| Alignment of the gearbox .................................................................. 3-3
3.4.3| Coupling on input shaft...................................................................... 3-4
4 | START-UP ...................................................................................................... 4-1

4.1
| COMMISSIONING.................................................................................. 4-1
4.1.1| Lubrication ........................................................................................ 4-1
4.2
| START-UP.............................................................................................. 4-1
4.2.1| START-UP CONDITIONS DIAGRAM ............................................... 4-2
4.3
| SHUT-DOWN ......................................................................................... 4-2

4.3.1| Short period (2-4 months) ................................................................. 4-2
4.3.2| Long period (> 4 months) .................................................................. 4-3
5 | SPECIFIC DESCRIPTION MAIN PARTS ........................................................ 5-1

5.1
| Hydraulic clutch ...................................................................................... 5-1

5.1.1| Description ........................................................................................ 5-1
5.1.2| Technical information ........................................................................ 5-1
5.2
| Oil pump ................................................................................................. 5-3

5.2.1| Description ........................................................................................ 5-3
5.3
| Oil cooler ................................................................................................ 5-4

5.3.1| Description ........................................................................................ 5-4
5.4
| Oil filter ................................................................................................... 5-5

5.4.1| Description ........................................................................................ 5-5
5.5
| Manometer ............................................................................................. 5-7

5.5.1| Description ........................................................................................ 5-7
5.6
| Thermometer .......................................................................................... 5-8

iv
5.6.1| Description ........................................................................................ 5-8

5.7
Speed monitoring system ......................................................................... 5-9

5.7.1| Description ........................................................................................ 5-9
5.7.3| Adjusting preset value..................................................................... 5-11
5.7.4| Calculation preset value .................................................................. 5-11
5.8
| Pilot operated sequence valve .............................................................. 5-12

5.8.1| Description ...................................................................................... 5-12
5.8.2| Technical information ...................................................................... 5-12
5.9
| Electronic system.................................................................................. 5-14
6 | INSPECTION................................................................................................... 6-1
6.1
| REGULAR INSPECTION........................................................................ 6-1

6.1.1| Lubricating oil level............................................................................ 6-1
6.1.2| Lubricating oil pressure ..................................................................... 6-1
6.1.3| Oil temperature ................................................................................. 6-2
6.1.4| Condition of bearing .......................................................................... 6-2
6.1.5| Breathing .......................................................................................... 6-3
6.2
| PERIODICAL INSPECTION ................................................................... 6-4
6.3
| INSPECTION SCHEDULE ..................................................................... 6-5
7 | TROUBLESHOOTING AND ALARM SETTINGS ........................................... 7-1

8 | Maintenance................................................................................................... 8-1
8.1
| safety precautions................................................................................... 8-1
8.2
| prepare system for maintenance............................................................. 8-1
8.3
| Specific maintenance instructions on gearbox ........................................ 8-2

8.3.1| Replacement of lubricating oil ........................................................... 8-2
8.3.2| Maintenance hydraulic clutch ............................................................ 8-3
8.3.3| Maintenance oil cooler ...................................................................... 8-4
8.3.4| Maintenance oil filter ......................................................................... 8-7
8.3.5| Cleaning the outside of the gearbox .................................................. 8-8

v
Appendix A: After Sales Services .......................................................................... a

| Order address .............................................................................................. b
Appendix B: General Specification ........................................................................ c
Appendix C: Lubricants .......................................................................................... e
Appendix D: Parts List ............................................................................................ g
Appendix E: General Arrangement Drawings ...................................................... m
Appendix F: Lubrication system gear box ............................................................ o

vi
LIST OF FIGURES
Figure 1: Sketch hydraulic clutch............................................................................................ 5-1
Figure 2: Overview of important parts of an oil pump............................................................. 5-3
Figure 3: Overall dimension oil filter ....................................................................................... 5-6
Figure 4: Dimensions of manometer ...................................................................................... 5-7
Figure 5: Picture thermometer................................................................................................ 5-8
Figure 6: schematic layout of location inductive sensor on pump shaft ................................. 5-9
Figure 7: Inductive sensor .................................................................................................... 5-10
Figure 8: Circuit diagram speed monitoring system ............................................................. 5-10
Figure 9: Front panel ............................................................................................................ 5-11
Figure 10: Schematic layout pilot operated sequence valve ................................................ 5-12
Figure 11: Dimension sketch Pilot operated sequence valve .............................................. 5-13
Figure 12: Order Address .......................................................................................................... b
LIST OF TABLES
Table 1: Start-up conditions diagram...................................................................................... 4-2
Table 2: Parts of the hydraulic clutch ..................................................................................... 5-2
Table 3: Specification oil cooler.............................................................................................. 5-4
Table 4: Specification oil filter................................................................................................. 5-5
Table 5: Specification manometer .......................................................................................... 5-7
Table 6: Technical specification thermometer ........................................................................ 5-8
Table 7: Specification speed monitoring system .................................................................. 5-10
Table 8: Calculation preset value speed monitoring system ................................................ 5-11
Table 9: Specification pressure sequence valve .................................................................. 5-12
Table 10: Inspection schedule for gearbox ............................................................................ 6-5
Table 11: Troubleshooting and alarm settings ....................................................................... 7-2
Table 12: Example After Sales Order........................................................................................ b
Table 13: General Specification Gearbox ..................................................................................c

vii
FOREWORD
PURPOSE MANUAL
This manual relates to a gearbox for the application in dredging and contains useful
and important information relevant to the correct installation, operation and
maintenance of this product. The instructions in this manual are intended for
technicians, operating personnel and maintenance staff and those who are in charge
of ordering spare parts. It also contains important information on safety procedures
and precautions to be taken to prevent accidents to personnel and damage to the
equipment.
Read the instructions carefully before installation, operation or maintenance is done
on the equipment.
GENERAL CONDITIONS
MANUAL
THE INFORMATION IN THIS MANUAL HAS BEEN CHECKED CAREFULLY

AND IS ASSUMED TO BE ENTIRELY RELIABLE. HOWEVER, IHC TAKES NO
RESPONSIBILITY FOR INACCURACIES.
IHC MERWEDE (OR ASSOCIATED COMPANY) RESERVES THE RIGHT TO
CHANGE SPECIFICATIONS OR DESIGN WITHOUT NOTICE.

ix
OWNERSHIP
THIS MANUAL IS INTENDED TO SERVE AS A GUIDE FOR THE

MAINTENANCE, SERVICING AND/OR REPAIR OF THE EQUIPMENT
DESCRIBED THEREIN, AND SHOULD ONLY BE USED BY QUALIFIED
PERSONNEL.
THE USE OF THIS MANUAL SHALL, UNDER ALL CIRCUMSTANCES,
REMAIN THE SOLE RESPONSIBILITY OF THE USER.
ON NO ACCOUNT IHC SHALL BE LIABLE FOR ANY OPERATIONAL
DELAYS OR DAMAGE, EITHER SPECIAL, INDIRECT, CONSEQUENTIAL OR
OTHERWISE.
LIABILITY
ALL INVENTIONS, TRADEMARKS, TECHNICAL DATA, DRAWINGS, PLANS,

MANUALS, TEST RESULTS AND OTHER MATERIAL PROVIDED BY IHC ARE
TO BE CONSIDERED CONFIDENTIAL INFORMATION AND SHALL REMAIN
THE EXCLUSIVE PROPERTY OF IHC. (EXCEPT WHEN PROVIDED FOR IN
CONTRACT)
ALL INFORMATION IS SUPPLIED SOLELY FOR THE OPERATION AND
MAINTENANCE OF THE DESIGNATED EQUIPMENT AND THE USER SHALL
NOT COPY SUCH MATERIAL, OR COMMUNICATE INFORMATION
CONCERNING SUCH MATERIAL TO THIRD PARTIES.

x
WARRANTY
EXCEPT WHEN OTHERWISE PROVIDED FOR IN CONTRACT, IHC

WARRANTS THEIR EQUIPMENT AGAINST ANY DEFECT OR FAULT,
ARISING FROM OR CAUSED BY FAULTY WORKMANSHIP, MATERIAL AND
PARTS FOR A PERIOD OF SIX MONTHS FROM THE DATE OF DELIVERY,
PROVIDED THAT JUSTIFIED CLAIMS IN WRITING ARE RECEIVED BY IHC
WITHIN THIS PERIOD OR AT THE LATEST WITHIN 15 DAYS AFTER THE
EXPIRY DATE THEREOF. THIS WARRANTY DOES NOT INCLUDE WEAR ON
EQUIPMENT.
THE LIABILITY OF IHC WILL BE LIMITED TO THE FREE REPAIR OR
REPLACEMENT OF ANY DEFECTIVE PARTS AT THEIR PREMISES. IF THE
REPAIR OR THE REPLACEMENT IS CARRIED OUT ELSEWHERE, IHCs
LIABILITY WILL BE LIMITED TO THE AMOUNT THE REPAIR OR
REPLACEMENT WOULD HAVE COST IF CARRIED OUT AT IHCs PREMISES
DURING NORMAL WORKING HOURS.
SUBJECT TO THE ABOVE STIPULATIONS OF GUARANTEE, IHC SHALL BE
RELEASED FROM ANY LIABILITY WHATSOEVER AND THE BUYER SHALL
PROTECT AND INDEMNIFY IHC IN RESPECT OF ANY DEMANDS, CLAIMS
OR ACTIONS, MADE BY THIRD PARTIES ON ACCOUNT OF DAMAGES
AND/OR INJURIES, CAUSED OR ALLEGED TO BE CAUSED BY ANY
DEFECT OF GOODS, SUPPLIED BY IHC.

xi
WARNING SYMBOLS
This manual contains symbols and text that refer to dangerous situations and
operations. These symbols and text may also appear on the machine. The symbols
mentioned below are being used in this manual and have the following meaning:
THIS SYMBOL INDICATES A SITUATION OR OPERATION
WHERE THERE IS POSSIBLE DANGER TO PERSONNEL.
CAUTION!
THIS SYMBOL INDICATES A SITUATION OR OPERATION
WHERE THERE IS A POSSIBLE DANGER TO BURNS
CAUTION!
THIS SYMBOL DRAWS ATTENTION TO OPERATING INSTRUCTIONS WHICH SHOULD BE ESPECIALLY OBSERVED.

xii
CONTACT ADDRESS
IHC PARTS & SERVICES B.V.

Smitweg 6, 2961 AW Kinderdijk
P.O. Box 50, 2960 AB Kinderdijk
The Netherlands
Telephone
+31 (0)78 - 6910430
Telefax
+31 (0)78 - 6910439
Internet
www.ihcmerwede.com
E-mail
info.ps@ihcmerwede.com

xiii
1 | INTRODUCTION
This introduction states a general description of the Gearbox Process and
Construction in paragraph 1.1. The structure of this manual is explained in paragraph
1.2
1.1
| GENERAL DESCRIPTION GEARBOX
This paragraph provides a general process and constructional description of the

gearbox.
1.1.1
| Gearbox Principle of Operation
The gearbox consists of a one-step gear wheel transmission. It is driven by a diesel

engine by means of a flexible clutch. The gearbox directly drives the dredge pump,
which is mounted to the housing of the gearbox. The forces which originate from the
dredge pump are transmitted via the gearbox towards the foundation plate.
The gearbox is equipped with a hydraulic clutch on the incoming shaft, which will be
excited when the diesel engine reaches 700 rpm. This enables the gearbox to startup in the idle running mode.
After the hydraulic clutch has been engaged the number of revolutions of the diesel
engine can be increased.
In case the number of revolutions of the diesel engine drops below 700 rpm, the
hydraulic clutch will be disengaged automatically. This means that the diesel engine
will be disconnected from the gearbox and the dredge pump.
1.1.2
| Gearbox Construction
The housing of the gearbox consists of nodular cast iron. The teeth of the main gear
wheel are made of case hardening steel. After the hardening the teeth are being
grinded according to DIN 3962 (quality 6). The shafts of the gearbox are supported
on roller bearings with a minimum lifetime of 30.000 operating hours.
The lubrication of the gearbox is carried out with a lubricator pump, which is driven by
the gearbox itself. The lubrication system consists also of a cooler and an oil filter.

1-1
The lubricant is also used for the hydraulic clutch. First the lubricator pump provides
the pressure, necessary for the engagement of the hydraulic clutch by means of a
special valve. After the clutch has been engaged, the oil pressure is relieved, but
remains high enough to lubricate the gearbox.
A more detailed description about the construction and most important parts of the
gearbox is given in chapter Specific Description Main Parts. The main design
parameters and specification for this gearbox are listed in Appendix General
Specification. A technical description of the complete lubrication system is given in
Appendix Lubrication system gear box.

1-2
1.2
| STRUCTURE MANUAL
This technical manual is divided in 8 chapters, supplemented with specifications,

drawings and schemes. The structure of this manual is explained below.
CONTENTS
The contents consist of a numbered index off all paragraphs in this manual including
a list of figures and a list of tables.
FOREWORD
Description of the purpose of this manual, the general conditions and warning
symbols used and the contact address.
1 | INTRODUCTION
General description of the gearbox process and construction
Overview of the structure of this manual.
2 | SAFETY
General safety instructions during operation and maintenance of this equipment.
3 | TRANSPORT / STORAGE AND INSTALLATION
Instructions for proper transporting, storing and installing this equipment.
4 | START-UP
Instructions for the start-up and shut-down of the equipment.
5 | SPECIFIC DESCRIPTION MAIN PARTS
General description of the main parts and options for this type of equipment.

1-3
6 | INSPECTION
Overview of the most important regular and periodical inspections on the equipment,
including an inspection schedule.
7 | TROUBLE-SHOOTING AND ALARM SETTINGS
Overview of the operating limits for this equipment.
Instructions on how to handle when these limits are exceeded
8 | MAINTENANCE
Maintenance instructions for the most important parts
APPENDICES
Here the general specification, technical drawings and additional information on
options of the equipment can be found, including instructions to order spare parts.

1-4
2 | SAFETY
This chapter provides general safety procedures and precautions that must be
obeyed on operation and maintenance of the gearbox. Specific precautions while
maintaining the installation are given in chapter Maintenance.
The purchaser and/or user must make sure all installation, operating and
maintenance personnel understand and obey all safety instructions.
2.1
| SAFETY PRECAUTIONS DURING OPERATION
Obey following safety precautions on operation of the gearbox:

1.
Only qualified personnel are allowed to operate the gearbox.
2.
This manual is to be read and understood by the operating staff.
3.
All personnel have to understand all emergency procedures and have to

know the location of all emergency equipment.
4.
Obey the instructions given.
5.
Use the gearbox for its designed purpose only.
6.
Before operating, make sure no maintenance is being performed on the

system.
7.
Report all defects immediately.

2-1
2.2
| SAFETY PRECAUTIONS DURING MAINTENANCE
Before maintaining the system, first read the following precautions carefully:
1
Turn off all the electrical and hydraulic activators.
Place sign:
DO NOT OPERATE
APPLY NO POWER
SYSTEM IS BEING MAINTAINED!
On all control units linked with the system, like the control desk on the bridge, but
also all main electrical and hydraulically switches.
3
Use electronically communication systems when working in remote areas.
Before working on the hydraulic system, make sure the pressure is down.
Obey all instructions given in this manual.
Only qualified personnel are allowed to work on the installation.
Always use suitable protective clothing.
Always use the correct tools and Genuine IHC Spare Parts.
Make sure the area is clear of unnecessary personnel, equipment, parts and
tools.
10 Never stand underneath heavy parts being lifted.

11 Do not start welding on the gearbox without consulting IHC Parts & Services.
12 Use special equipment before working on high wear-resistance materials.
13 Do not modify the system before written approval is given by the manufacturer.

2-2
3 | TRANSPORT / STORAGE AND INSTALLATION

3.1
| DELIVERY
Before leaving the factory the condition and operation of the gearbox is tested by
submitting the installation to running tests. After the tests are executed, the gearbox
is carefully cleaned. The shafts and gears are preserved with special oil. This
conservation oil will dissolve in the lubricating oil used during normal operation.
Each gearbox is provided with a nameplate showing the main design parameters.
These parameters are also listed in the appendix General Specification.
In order to keep full guarantee and maintaining the perfect condition of the gearbox
the following terms should be respected:
Unauthorised conversion and modifications on the gearbox are not
permitted;
Before disassembling the gearbox or any other part of the gearbox,
the manufacturer has to be notified.
3.2
3.2.1
| HANDLING
| Shipping
The gearbox is shipped in the assembled state. The method of shipping determines
the type of material used for packing the gearbox.
The contents of the shipment are listed in the shipping documents. The shipment
should be checked for completeness and possible damage immediately on receipt. If
necessary, the manufacturer should be consulted.

3-1
WHEN
HANDLING,
LOADING
AND
UNLOADING
THE
GEARBOX MAKE SURE NO EXCESSIVE FORCES ARE

APPLIED
CAUTION!
ON
DAMAGED
THE
GEARBOX,
GEARBOXES
MUST
TO
NOT
AVOID
BE
DAMAGE.
PUT
INTO
OPERATION.
3.2.2
| Loading/unloading
Loading or unloading of the gearbox is done best with the lifting eyes which are
located on the gearbox. The ones, which can be used for hoisting the gearbox, are
indicated on the general arrangement drawing. Lifting is carried out with at least three
of these eyes.
WHEN HOISTING: ALWAYS USE APPROPRIATE LIFTING
TOOLS. MAKE SURE NOBODY ENTERS THE HOISTED AREA.
WHEN LIFTING KEEP THE GEARBOX IN A HORIZONTAL
CAUTION!
3.3
POSITION
| STORAGE
The gearbox should be stored in a dry room with minimum temperature fluctuation.
The drive should be stored in a horizontal position free from the floor, preferably in its
original support frame.
Initially the gearbox is provided with internal preservation (see also paragraph 3.1). In
case of a prolonged storage (> 4 months) the preservation should be checked and if
necessary renewed (IHC Parts and Services may be consulted).

3-2
3.4
| INSTALLATION
3.4.1
| General
This chapter describes the method of installation of the gearbox.

NOTE: THE INSTALLATION OF THE GEARBOX SHOULD BE
CARRIED OUT BY SPECIALISTS ONLY AND THE INSTALLATION
PROCEDURE SHOULD BE EXECUTED WITH EXTREME ACCURACY.
3.4.2
| Alignment of the gearbox
The following procedure should be carried out for the proper alignment of the
gearbox:
1
The gearbox is to be levelled horizontal and mounted stress free. The foundation
bolts are kept loose;
The in- and output shafts of the gearbox must be aligned with great accuracy.
The driving and driven shafts should be aligned both vertical and horizontal. This
can be achieved by using shims and wedges. These are applied between the
foundation and the mounting plates of the gearbox, motor and driven unit.
Special attention must be paid to proper cleaning of the foundation and the
mounting plates of the gearbox and the motor as well as the driven units;
When the shafts have been aligned in both horizontal and vertical direction, the
deviation is measured. The maximum allowable deviation is not allowed to
exceed 0.05 mm. (The effect of the weight of the overhanging couplings on the
shaft may not be neglected!);
The thickness of the shims used is determined by measuring the height between
the foundation and the mounting plates of the gearbox. The shims are to be
made out of one piece and should be machined to the correct thickness;
Now the foundation bolts are tightened to the correct moment;
The alignment of the shafts is to be checked again. If the alignment is correct,

proceed with the next step, otherwise loosen the bolts again and the steps 2-5
have to be repeated;

3-3
The holes for the dowel pins are reamed and the pins are fitted;
Upon completion and before commissioning, the alignment is to be checked

again. If the deviation is too large, the above mentioned procedure is to be
repeated.
USE APPROPRIATE LIFTING TOOLS WHEN LIFTING THE
GEARBOX.
CAUTION!
3.4.3
| Coupling on input shaft
The connection between the input shaft of the gearbox and the driving shaft of the
engine is by means of a coupling. The type of coupling used, is a coupling with
sunken keys.

3-4
4 | START-UP
4.1
4.1.1
| COMMISSIONING
| Lubrication
Before commissioning, the gearbox should be topped up with lubricating oil. (For the
recommended lubricating oil, see Appendix Lubricants)
4.2
| START-UP
When the system is started, the gearbox should be operated first without any load.
During this test run the gearbox is being checked on proper functioning. The start-up
conditions are displayed in the start-up conditions diagram (Table 1). In case of a
possible defect consult chapter Troubleshooting and Alarm Settings.
After this load-free test run, the load should be gradually increased to the normal
level.

4-1
4.2.1
| START-UP CONDITIONS DIAGRAM
The start-up conditions diagram contains the most important conditions for the
lubrication system, which have to be met when starting up the gearbox.
Startup conditions
Parameter
Sensor
Condition
Lubricating oil temperature
Thermometer
> 15C
Lubricating oil level
Dipstick
Level at high mark on dipstick
Before start-up
Conditions before clutching the gearbox

Lubricating oil pressure
Manometer (0-6 bar)
> 0.5 bar
Thermometer
< 70C
Conditions after clutching the gearbox

Manometer (0-6 bar)
> 2.5 bar
Thermometer
< 70C
Table 1: Start-up conditions diagram
4.3
| SHUT-DOWN
4.3.1
| Short period (2-4 months)
In case the gearbox will not be used for a rather short period (2-4 months), the
following measures should be taken to preserve the gearbox:
The used lubricating oil should be replaced with fresh lubricating oil (see
paragraph 8.3.1);
The outer surface of the drive is cleaned (see paragraph 8.3.5);
It is recommended that the shafts will be rotated at least once a month in order to
lubricate all rotating parts of the gearbox.

4-2
4.3.2
| Long period (> 4 months)
When the gearbox is taken out of operation for a longer period, the following
additional measures have to be taken:
Drain the lubricating oil and clean the gearbox with a similar type of lubricating oil;
Preserve the gearbox with a special type of preserving oil, which forms a
protective coating against corrosion;
Grease the in- and output shafts;
Close all openings with plugs.
The recommended lubricating oils are displayed in the Appendix Lubricants.

4-3
5 | SPECIFIC DESCRIPTION MAIN PARTS

This chapter provides a more specific description of the main parts of the gearbox.
5.1
5.1.1
| HYDRAULIC CLUTCH
| Description
The hydraulic clutch (425) inside the gearbox consists of a multi plate clutch. The
plates are pressed with lubricating oil by means of a piston. This results in a friction
connection between the outer housing and the hub of the clutch. When the pressure
is released the piston is pushed back by compression springs and the plates will be
separated from each other.
The hydraulic clutch is equipped with metal oil catchers. These oil catchers have a
very precise tolerance. Leakage is restricted to a minimum.
All external bolts on the hydraulic clutch are provided with Loctite bearing.
5.1.2
| Technical information
Figure 1: Sketch hydraulic clutch

5-1
Pos
Description
Pos
Description
Housing
External lamination
Housing piston
Internal lamination
Hub
Outer piston packing ring
Pressure plate
10
Inner piston packing ring
End plate
11
Pressure ring
Piston
12
Drive shaft
Table 2: Parts of the hydraulic clutch

5-2
5.2
5.2.1
| OIL PUMP
| Description
The lubricating system of the gearbox is equipped with an oil or lubricator pump (601)
for pumping the lubricating oil around in the system. The oil pump is mounted on the
gearbox and is directly driven by the diesel engine by means of a pinion wheel (303)
on the incoming shaft of the gearbox.
5.2.2
Figure 2: Overview of important parts of an oil pump

5-3
5.3
| OIL COOLER
5.3.1
| Description
While running, heat is developed inside the gearbox due to friction. This causes the
warm-up of the lubricating oil. The oil cooler is used to dissipate the developed heat
by cooling the lubricating oil with water to prevent the system from overheating. The
cooler is a shell and tube type heat exchanger. On the water side the cooler is
equipped with anodes to protect the cooler against corrosion.
5.3.2
Oil cooler type:

Process data
Unit
Type of fluid
[-]
Flow
Design pressure
Design temperature
Hot side
Cold side
Lubricating oil
water
[m /h]
4.2
[bar(g)]
16
10
[C]
120
80
Connection inlet
[-]
N1 (1 BSP)
N3 (1 BSP)
Connection outlet
[-]
N2 (1 BSP)
N4 (1 BSP)
Anode protection
[-]
no
yes
O-ring
[-]
NBR
NBR
Table 3: Specification oil cooler

5-4
5.4
5.4.1
| OIL FILTER
| Description
The gearbox is equipped with a pressure oil filter type DF160 MA. The filter is used
for filtering the lubricating oil. Table 4 displays the general specification of the filter.
5.4.2
Oil filter type: DF160MA

Description
Value
Unit
Filter Material
Stainless steel wire mesh
[-]
Size: filter and element
160
mm
Operating pressure
250
bar
Type of connection
2 mounting holes
[-]
Filtration rating in m
25
Type of clogging indicator
with steel blanking plug
[-]
Type Code
1 version with 1-piece bowl
[-]
Supplementary details
[-]
Temperature range
-30 to 100
Table 4: Specification oil filter

5-5
Figure 3: Overall dimension oil filter

5-6
5.5
| MANOMETER
5.5.1
| Description
Manometers are installed to measure the pressure of the lubricating system at

various places.
These meters are liquid filled manometers. The liquid inside the manometer absorbs
the vibrations in the measuring system caused by tremors, pressure drops and
pressure pulses. This results in a higher accuracy for the reading of the meter.
Another effect is the lubricating property of the liquid, which increases the life-time of
the manometer.
5.5.2
Figure 4: Dimensions of manometer

Description
Value
Unit
Type
63 Kl. 1.6
[-]
Connection
1/4 BSPP
[-]
Fluid in manometer
Glycerine
[-]
Operating temperature
0 to 60
[C]
Range
0 to 6 and
bar
0 to 40
Table 5: Specification manometer

5-7
5.6
5.6.1
| THERMOMETER
| Description
The thermometer on the gearbox is installed to measure the outgoing temperature of

the lubricating oil of the oil cooler.
5.6.2
Figure 5: Picture thermometer

Description
Value
Unit
Type of thermometer
Glass tube (straight)
Scale range
0 to 120
[C]
Connection
BSPP
[-]
Accuracy according to
DIN16184, 16188, 16193
[-]
Insert
Brass
Max. Pressure
16
[-]
bar
Table 6: Technical specification thermometer

5-8
5.7
5.7.1
SPEED MONITORING SYSTEM

| Description
The speed monitoring system consists of an inductive sensor and a monitoring

system. The sensor is positioned on the cover of the outgoing shaft. In the outgoing
shaft a number of holes are present. During operation of the gearbox the sensor
counts the number of holes and sends a signal to the monitoring system. The
monitoring system records the measurements of the sensor and converts these
signals into the speed of the outgoing shaft. This measured speed is compared with
the preset value. If the measured value drops below this preset value the gearbox is
shut-down automatically.
During the start-up procedure of the gearbox the monitoring has a fixed time lag to
prevent that the system is shut down premature before it even reaches the preset
value. The preset value is already set by the manufacturer.
5.7.2
Pos.
Description
Inductive sensor
Cover output shaft
Hole 6x
Output shaft
Figure 6: schematic layout of location inductive sensor on pump shaft

5-9
Figure 7: Inductive sensor

Type of speed monitor
MS24-R
Function
Under speed detection
Speed range
0.6.100.000 min-1 or 0.01.1660 Hz
Fixed time lag
0.5.30 s (adjusting screw)
INPUT CIRCUIT:
NAMUR according to EN50227
Sensors
3-wire pnp
OUTPUT CIRCUIT
2 relay outputs; 1 pulse output
LED-indications
Power (2-color LED)
Power ON: green / FAULT: red
Output excitation
Yellow
Input pulse
Yellow
Table 7: Specification speed monitoring system
Figure 8: Circuit diagram speed monitoring system

5-10
5.7.3
| Adjusting preset value
Figure 9 displays the front panel of the monitoring system. By means of adjusting
screws the preset value can be altered. The general specification and ranges of the
monitoring system are displayed in Table 7.
Figure 9: Front panel
5.7.4
| Calculation preset value
Pos.
Description
Formula/Unit
Value
(a)
Disengage value clutch
[rpm]
224
(b)
No. of holes in output shaft
[-]
(c)
Switching frequency
(a) x (b) / 60
22.4 Hz.
(d)
Setting value frequency
[mHz]
100
(e)
Setting value disengage clutch
(c) : (d)
224
Table 8: Calculation preset value speed monitoring system

5-11
5.8
| PILOT OPERATED SEQUENCE VALVE
5.8.1
| Description
The pilot operated sequence valve is a pressure relief valve with which the required
pressure to operate the clutch can be adjusted. The set pressure can be read from
the manometer. The sequence valve consists of an internal pilot and an external
drain. The hysteresis is limited to a minimum of 1%.
5.8.2
Figure 10: Schematic layout pilot operated sequence valve
pilot operated sequence valve type:
RSHC-LAN
Description
Value
Unit
Adjustment range
2 to 25
bar
Standard set pressure
14
bar
Typical response time
10
ms
Control
Standard screw adjustment
Type of seals
Buna-N
Table 9: Specification pressure sequence valve

5-12
Figure 11: Dimension sketch Pilot operated sequence valve

5-13
5.9
| ELECTRONIC SYSTEM
The connection scheme for the electronic system can be found in appendix E
General Arrangement Drawings.
In case of an electronic failure IHC Parts & Services may be consulted.
NOTE: The electronic system of the gearbox is already pre-installed
and connected by the manufacturer. It is not allowed to change
anything on the electronic system without permission of IHC Parts &
Services.

5-14
6 | INSPECTION
6.1
6.1.1
| REGULAR INSPECTION
| Lubricating oil level
Before the gearbox is started up, the lubricating oil level should be checked. The oil
level is measured by means of a dipstick. This dipstick is provided with an upper and
a lower mark. 2 hours after each operation the oil level should be at the high mark.
WHEN CHECKING OIL LEVEL WITH DIPSTICK, MAKE SURE

THE
GEARBOX
IS
SECURED
TO
PREVENT
FROM
ACCIDENTAL START-UP. AFFIX LOCK OR NOTICE AT THE
CAUTION!
6.1.2
SWITCH-ON LOCATION.
| Lubricating oil pressure
When the pressure in the piping is lower than 0.5 bar , the system must shut down
the whole installation, after the discharge pipeline is free of sand. (See chapter
Troubleshooting and Alarm Settings for possible causes, IHC Parts & Services may
be consulted in this case). The pressure can be read from one of the manometers
installed on the gearbox.

6-1
6.1.3
| Oil temperature
The temperature of the lubricating oil will be around 55C under normal operations.
The temperature of the lubricating oil may rise temporarily as high as 60C due to an
increased load on the gearbox. This should not cause any damage to the system.
When the temperature exceeds 70C, the clutch has to be disengaged.
The cause of this high temperature must be found in any case. Assistance from IHC
Parts & Services may be consulted for detecting the cause. (See also chapter
Troubleshooting and Alarm Settings)
6.1.4
| Condition of bearing
Bearings should be in good condition for optimal performance of the installation.

Therefore the condition of all bearings should be checked regularly.
The bearings should be checked also in the following events during operation:
The housing temperature close to the bearing exceeds 60C;
The gearbox makes an abnormal noise;
Abnormal vibrations from the gearbox occur.
WHEN CHECKING BEARINGS, MAKE SURE THE GEARBOX IS

SECURED TO PREVENT FROM ACCIDENTAL START-UP.
CAUTION!
AFFIX LOCK OR NOTICE AT THE SWITCH-ON LOCATION.
WHEN CHECKING BEARINGS, WEAR PROTECTION GLOVES

TO PREVENT AGAINST BURNS, BEARINGS CAN BE HOT!
CAUTION!

6-2
6.1.5
| Breathing
During normal operation, the air inside the gearbox is heated up due to friction
energy. This causes a certain amount of overpressure. A high overpressure could
cause oil leakage through the seals. Breathing caps are installed on the gearbox,
which will open automatically when the pressure is too high. These breathing caps
should be checked regularly on clogging and they should be cleaned when
necessary.
WHEN CHECKING BREATHING CAPS, MAKE SURE THE
GEARBOX IS SECURED TO PREVENT FROM ACCIDENTAL
START-UP. AFFIX LOCK OR NOTICE AT THE SWITCH-ON
CAUTION!
LOCATION.

6-3
6.2
| PERIODICAL INSPECTION
Every 5000 hours of operation or at least once a year, the gearbox needs to be
inspected carefully. The following procedure is carried out:
1. The gearbox is shut off and prevented from accidental start-up;
2. The inspection cover(s) is/are removed to allow inspection inside the gearbox;
3. When necessary the oil is changed (see paragraph 8.3.1);
4. The breathing caps are checked for clogging;
5. The tooth flanks are checked visually or by marking the teeth with Talbot Blue
again;
6. Bolts and nuts are checked for tightness. If necessary, they are tightened to the
correct moment.
After 30.000 or 40.000 hours of operation, or when necessary, it is recommended to
submit the gearbox to a major overhaul. For this overhaul, IHC Parts & Services may
be consulted.
BEFORE STARTING PERIODICAL INSPECTION, MAKE SURE
THE
GEARBOX
IS
SECURED
TO
PREVENT
FROM
ACCIDENTAL START-UP. AFFIX LOCK OR NOTICE AT THE
CAUTION!
SWITCH-ON LOCATION.

6-4
6.3
| INSPECTION SCHEDULE
Type of inspection
Frequency
Remedy
Observe/check oil level
Daily, before start-up
paragraph 6.1.1
Visual check for oil leakage
Daily, during operation
Observe/check oil
paragraph 6.1.2
temperature
Observe/check oil pressure
Check bearing failure
paragraph 6.1.4
Check breathing cap
At least once a week
paragraph 6.1.5
Check seals visually
At least once a week
Initial oil change after start-
After 500 operating hours
paragraph 8.3.1
up
Take lubrication oil sample
At least once a month
to check contamination
Check lubricating oil filter
At least once a month
paragraph 8.3.4
Every 5000 operating hours
paragraph 8.3.1
for contamination
Subsequent oil change
or once a year
Complete inspection of all
parts
or once a year
Check all bolts and nuts for
tightness
or once a year
Major overhaul of whole
Every
Gearbox
operating hours
30.000
to
40.000
Table 10: Inspection schedule for gearbox

6-5
paragraph 6.2
paragraph 6.2
paragraph 6.2
7 | TROUBLESHOOTING AND ALARM SETTINGS

PROBLEM
POSSIBLE CAUSE(S)
Gearbox does not
start running or
starts with great
Break of motor is not
REMEDY
Release break
released
difficulty
External loading on
Check if pump is
output shaft too high.
blocked
Pump may be blocked
Viscosity of lubricating oil
Change lubricating oil
is too high
Excessive operating
temperature gearbox
(T>70C)
with fresh oil
Lubricating oil level too
high in gearbox
Lubricating oil is
check oil level and drain

the oil if necessary
Check if oil pump is
contaminated or old
Low lubricating oil
Oil pump defect
pressure (P<0,5 bar)
running
Oil level too low
Check oil level and refill

if necessary
Abnormal noises in
Bearing is defect
Consult IHC Parts &
gearbox while
Services when
running
replacing
Visible leakage of
Oil catcher is defect
lubricating oil
Check oil catcher;

replace if necessary
Seals are mounted
Check mounted of seals
Check breathing caps,
wrongly
Breathing caps are

clogged
clean if necessary
Accumulation of dirt
around seals

7-1
Remove dirt from seals

and surroundings
PROBLEM
POSSIBLE CAUSE(S)
Large vibrations in
gearbox
Mounting of gearbox has
REMEDY
loosened
Check bolts and nuts on

loosening; tighten if
necessary
Clutch slips while
running and
connects not entirely
too low
Check oil level; refill if

necessary
Stroke of piston too large
as a result of worn plates
The multi-plates need to

be replaced (consult
IHC Parts & Services)
Viscosity lubricating oil
Check oil level; refill if
too high
Increased noise level
Low oil level in gearbox
oil pump
necessary
De-aerate whole
too high
Increase in
volumetric losses
Thermal

too low
Accumulation of air
performance oil
inside cooler and/or
cooler too low
network of pipes
Oil cooler is
cooling system.
contaminated
Table 11: Troubleshooting and alarm settings

7-2
Clean oil cooler
8 | Maintenance
This chapter gives information about maintenance of the main parts that are
described in chapter 1.
8.1
| SAFETY PRECAUTIONS
OBEY THE GENERAL SAFETY PRECAUTIONS STATED IN
CHAPTER 2 AND THE SPECIFIC SAFETY PRECAUTIONS
GIVEN IN THIS CHAPTER BEFORE WORKING ON THE
CAUTION!
8.2
SYSTEM! NEGLECTING THIS CAN RESULT IN SEVERE

PERSONAL INJURIES AND/OR DAMAGE.
| PREPARE SYSTEM FOR MAINTENANCE
Place sign:
DO NOT OPERATE
APPLY NO POWER
SYSTEM IS BEING MAINTAINED!
On all control units linked with the system, like the control desk on the bridge, but
also all main electrical and hydraulically switches.

8-1
8.3
8.3.1
| SPECIFIC MAINTENANCE INSTRUCTIONS ON GEARBOX

| Replacement of lubricating oil
The lubricating oil needs to be replaced after the first 500 operating hours. After this,
every 5000 operating hours or once a year replacing the lubricating oil has to be
carried out.
The following procedure is carried out for changing the oil:
1.
The gearbox is shut down by shutting down the drive unit and the gearbox is
being prepared for maintenance;
2.
A suitable receptacle is placed underneath the oil drain plug (110) of the
gearbox housing;
3.
The vent plug (111) on top of the gearbox housing is unscrewed;
4.
The oil drain plug is unscrewed and the lubricating oil is drained;
5.
The gearbox is flushed with the same type of oil or special flushing oil which is
heated up to 50C. This is to remove residues of old oil and abraded particles.
(Due to the composition of fresh lubricating oil the gearbox should not be
flushed with gas oil or paraffin.);
6.
The oil drain plug is screwed in;
7.
The gearbox is refilled with fresh lubricating oil through the filling filter plug.
(During refilling, make sure no dirt or water is entering the gearbox). The
recommended type and quantity of lubricating oil are given in Appendix
Lubricants;
8.
The oil level is checked (see paragraph 6.1.1).

NOTE: THE LUBRICATING OIL IN THE GEARBOX IS TO BE DRAINED
OFF DIRECTLY AFTER SHUTDOWN, WHILE THE OIL IS STILL
WARM;

8-2
MAKE SURE THE DRIVE UNIT IS SECURED TO PREVENT

FROM ACCIDENTAL START-UP. AFFIX NOTICE AT THE
CONTROL DESK.
CAUTION!
WHEN
CHANGING
OIL
ALWAYS
WEAR
PROTECTION
GLOVES AND CLOTHING, HOT OIL CAN CAUSE BURNS ON

THE SKIN.
CAUTION!
8.3.2
| Maintenance hydraulic clutch
Adjustment of the stroke of the piston:

The adjustment of the stroke of the piston is not necessary, because the piston
automatically corrects for any wear on the multi-plate package.
In case the stroke of the piston is close to the maximum stroke as a result of wear,
the multi-plates package needs to be replaced. Consult IHC Parts & Services on
replacing the multi-plate package.

8-3
8.3.3
| Maintenance oil cooler
8.3.3.1 | Inspection of the cooler:

The accumulation of dirt inside the cooler depends to a great extent on the operating
conditions. It is recommended by the manufacturer that the cooler is inspected
regularly on dirt:
Every three months the coil of the cooler
Every half year the shell of the cooler
Together with the inspection of the coil the anodic protection is to be inspected also.
In case the anodic protection is not sufficient anymore, IHC Parts & Services may be
consulted.

8-4

CONTROL DESK.
CAUTION!
8.3.3.2 | Cleaning of the cooler
Removing dirt inside the cooler can be carried out in two ways:
1)
The coil inside the cooler can be cleaned by means of special brushes. Use
only this special type of brush, otherwise the protecting layer on the tubes
might be damaged.
2)
The tubes and shell can also be cleaned with a chemical solution, which is
flushed through the cooler or the coil is taken and put into a tank with the
chemical solution. In the latter case the plastic dams on the shell side of the
cooler are being removed.
CONTROL DESK.
CAUTION!
8.3.3.3 | De-aeration of the cooler
In case air has been accumulating inside the cooler, the cooler needs to be deaerated. The cooler is equipped with two air relief valves: One for the lubricating oil
side (N5) and one for the coolant side (N6). These air relief valves have to be opened
one at the time for de-aerating the system
De-aeration is carried out during normal operation of the gearbox.
CAUTION!
8-5
WHEN DE-AERATING THE COOLING SYSTEM BEWARE OF OVERPRESSURE

INSIDE THE SYSTEM. HOT GASSES AND FLUIDS MAY CAUSE SEVERE BURNS
ON EXPOSED BODYPARTS
8.3.3.4 | Putting out of service:

In case the oil cooler is put out of service for more than one week, the cooler has to
be drained entirely and dried with heated compressed air.
8.3.3.5 | Anodes of the cooler

The oil cooler have two anodes which are screwed on both sides. These anodes
must be checked every month.
Anode 1: a new one, Anode 2: should be replaced if a high consumption of the

anodes has been determined, Anode 3: need to be replaced immediately, Anode 4:
need to be replaced immediately.
Please note that above example is indicative only, the user still remains responsible
for the estimation, when anodes need to be replaced.

8-6
8.3.4
| Maintenance oil filter
The oil filter has to be cleaned regularly. 24 hours after commissioning the gearbox,
the oil filter must be checked for the first time. This is then to be repeated every 500
operating hours or at least once a month.
Cleaning is carried out by taking the filter element out of the filter and cleaning the
element. This can be carried out only a limited number of times. When the element
cannot be cleaned properly anymore, the filter element should be replaced.
The maximum mesh width of the filter is 25 micron. In case the mesh with exceeds
the maximum value it should be replaced.
CONTROL DESK.
CAUTION!

8-7
8.3.5
| Cleaning the outside of the gearbox
Keep the gearbox free from dirt and dust to guarantee sufficient dissipation of heat.
NOTE: IT IS NOT PERMISSIBLE TO CLEAN THE GEARBOX WITH A
HIGH-PRESSURE SPRAYER OR SHARP-EDGED TOOLS

CONTROL DESK.
CAUTION!

8-8
Appendix A: After Sales Services

To maintain the high quality level of the Gearbox constructed by IHC, Genuine IHC
Spare Parts should be used.
The IHC products are fully tested before delivery and guaranteed for the performance
and quality of materials.
IHC strongly recommends using these original spare parts in its products, because
they are designed to meet their specific demands. Using non-genuine parts can
result in reduced performance, damage and limited liability.
The high grade of standardisation of the parts guarantees the interchange-ability of
any subsequently delivered part of IHC components.
To be sure that the correct spare parts will be supplied in the most efficient way, it is
necessary to supply the following information of the desired part in each order:
The Reference Number of the Manual where the part is described;
This number can be found on the front page of this manual.
The full description of the part,
The Item Number of the desired part from the Manual;
The Quantity of parts needed.

a
Example:
ITEM
QTY
DESCRIPTION
212
BUSH
210
PIN
Table 12: Example After Sales Order
| Order address
Orders for Spare Parts should be addressed to:
IHC PARTS & SERVICES B.V.

Smitweg 6, 2961 AW Kinderdijk
P.O. Box 50, 2960 AB Kinderdijk
The Netherlands
Telephone
+31 (0)78 - 6910430
Telefax
+31 (0)78 - 6910439
Internet
www.ihcmerwede.com
E-mail
info.ps@ihcmerwede.com
Figure 12: Order Address

b
Appendix B: General Specification

Below are the most important design parameters of the gearbox listed. These are
also displayed on the nameplate.
DESIGN PARAMETER
VALUE
UNIT
Rated Power :
638
kW
Input speed :
1800
rpm
Output speed :
577
rpm
Gear rating :
1 :3.12
[-]
Input shaft connected to
Diesel Engine
[-]
Output shaft connected to
Dredge Pump
[-]
Lifetime Bearings
30000
hrs
Type of lubricating oil
ISO VG 100
[-]
130
litres
Total weight installation
1800
kg
IHC P & S Order number
009086
[-]
Year of Manufacturing
2010
[-]
Amount of lubricating oil to be used

1
Table 13: General Specification Gearbox
Lubricant not included

c
Appendix C: Lubricants
It is recommended by IHC Parts & Services to use one of the below listed lubricants
for the lubrication of the gearbox
LUBRICATING OIL
IN ACCORDANCE WITH
DIN 51502
MINERAL OIL
VISCOSITY CLASS
CLP ISO VG100

NUTO H100
Mobil DTE OIL 27
Tellus T100
BP energol HLP 100

Renolin CPL 100
Castrol HYSPIN
AWH100
Further suitable lubricants of the brands ADDINOL, OMV, STATOIL, TEXACO,

TUNAP and VALVOLINE we are pleased to nominate on request at one of our
Service Addresses.

e
Mineral base gear oils in accordance with designation CLP as per DIN 51 502.
These oils comply with the minimum requirements as specified in DIN 51 517 Part 3.
They are suitable for the following operating temperatures:
CLP ISO VG 100: 5C ... +90C
The maximum temperatures can be exceeded by 10K for a short time.
STORAGE OIL
IN ACCORDANCE WITH
DIN 51502
STORAGE OIL
VISCOSITY CLASS
CLP ISO VG100
SHELL VSI 8235

f
Appendix D: Parts List
Posnr Quantity
Description
101
GEARBOX HOUSING
102
BOLT
103
BOLT
104
BOLT
105
18
BOLT
106
DOWEL PIN
107
NUT
108
STRETCHING PIN
109
BOLT
110
PLUG WITH INT. HEXAGON
111
DE-AERATION
112
BOLT
114
INSPECTION COVER
115
INSPECTION COVER
116
28
BOLT
118
COVER
119
BOLT
121
COVER
122
16
BOLT
123
DOWEL PIN
127
COVER
128
BOLT
130
COVER
131
10
BOLT
113
117
120
132

g
133
NAMEPLATE
134
CYLINDER HEAD SCREW
135
V-RING
136
V-RING
137
COVER
138
BOLT
139
SPACING RING
140
COVER
141
TAPBOLT
142
RING
143
SPRING
144
STRETCHING PIN
146
KEY
147
SCREW
150
OIL DIPSTICK
151
O-RING
153
TURNING ROD
301
PINION SHAFT
302
GEARWHEEL
303
PINION
304
GEARWHEEL
401
INPUT SHAFT
402
SPACING RING
403
KEY
404
SAFETY RING
405
SAFETY RING
406
OUTPUT SHAFT
407
SHRUNK-RING
408
RING
409
RING
410
OIL SUPPLY RING
411
O-RING

h
412
SAFETY BOLT
414
END-JOURNAL
415
KEY
416
KEY
417
KEY
418
KEY
419
RETAINING RING
420
BOLT WITH INTERNAL HEXAGON
421
DOWEL PIN
423
SAFETY RING
425
HYDR COUPLING
426
COUPLING
427
SCREW
501
SPHERICAL ROLLER BEARING
502
503
504
505
506
CYLINDER BEARING
507
GROOVE BALL BEARING
508
GROOVE BALL BEARING
601
GEARPUMP
602
OIL COOLER
603
CONNECTION BLOCK
604
THROTTLE
605
THROTTLE
606
THROTTLE
607
THROTTLE
608
BOLT
610
DELIVERY PIPELINE
611
BOLT
609

i
613
SUCTION PIPELINE
614
SUCTION PIPELINE
615
BOLT
618
FRAME
619
BOLT
620
BOLT
621
10
NUT
622
BOLT
701
CONNECTION BOX
702
INSPECTION COVER
703
12
SCREW
704
INSPECTION COVER
705
END PIECE
706
63
CONNECTING PIECE
707
12
DIVIDING PIECE
708
NAME STRIP
709
NAME STRIP
710
NAME STRIP
711
SPEED COUNTER
712
ROTATION SPEED MONITOR
713
BUSHING
714
SEAL PLATE
715
SEAL PLATE
616

j
1.00
MANIFOLD
1.01
PRESSURE LINE FILTER
1.02
PRESSURE GAUGE
1.03
PRESSURE RELIEF VALVE
1.04
DIRECTION CONTROL VALVE
1.05
PRESSURE GAUGE
1.06
NON RETURN VALVE
1.08
PRESSURE GAUGE
1.09
TEMPERATURE GAUGE
1.10
MEASURING POINT

k
Appendix E: General Arrangement Drawings

The following drawings are enclosed in this technical manual:
DESCRIPTION
DRAWING NO.
ASSEMBLY
5483892
ARRANGEMENT
50403540
OIL CIRCUIT SCHEME
50410780
LIFTING
50410782
CONNECTION SCHEME
50401180

m
Appendix F: Lubrication system gear box

Technical description lubrication system gear box.
The purpose of the hydraulic manifold is to merge the following functions:
1.
2.
3.
4.
5.
Filtration
Clutch in/ out
Pressure sequence
System pressure relief
Gauging of pressures and temperature
Technical description according diagram 1.
Diagram 1.

o
Filtration:
The lubrication pump connected on the P port of the manifold delivers the oil for the
system. The incoming oil is getting filtered by the high pressure filter (1.01) with a
fineness of 25 m. The pump pressure can be gauged at measuring connection
(1.10) (MP1).
Clutch switching:
With the pressure sequence valve (1.03) the required pressure to operate the clutch
can be adjusted. Pressure gauge (1.02) (MP2) indicates the set pressure. Directional
valve (1.04) operates the gear box clutch. In de-energized position the clutch is
clutched out and energized the clutch is in.
The switching time of the clutch is regulated with the fixed orifice (1.11) in the
directional valve. Pressure to the clutch is indicated on the pressure gauge (1.05)
(MPC)
Lubrication:
Between ports C1 and C2 the oil cooler is installed. 8 Threaded ports are available
for connection of piping to the several lubrication ports of the gear box. Orifices in the
couplings on the gear box are regulating the oil flow.
The system is protected against overpressure by a spring loaded check valve (1.06).
Pressure gauge (1.08) indicates the pressure in the system.
Temperature gauge (1.09) indicates the temperature in the system.

p
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
ENGINEERING CHANGES
Rev. Zone Description
B
Sign.
Drawing in SE
Date
13-10-2009
505 143 142
147 604
302
111
112
605
146
C
104
106 107
105
103
119 108
407
118
604
131
502
303
406
102
130
712
604
136
108
501
138
144
DETAIL A
402
412
404
135
128
401
127
411
416
137
410
507
J
405
141 108
403
140 606
139
605
504
608 601
427 426
417
DETAIL A
1:2
M
M
420
114 115
110
116
RECOMMENDED TORQUES
IN Nm, FOR METRIC BOLTS
122
121
110
101
508
304
418
150
415
503
605
408
301
409
M10
M12
M14
M16
M18
M20
M24
M27
M30
M33
M36
M39
M42
123
425
419
414
151
506
109
108
607
610
423
711
1049
1422
1932
2481
3226
3991
RELEASED
FOR
PRODUCTION
NS
HB
IHC Parts & Services B.V.

www.ihcmerwede.com
JvH
10
11
12
13
14
15
16
17
18
19
20
Model number:
Drawing number:
ASSEMBLY
13-10-2009
Revision:
Scale:
1:2,5
Projection method:
SV-320-C
16-12-2009
This document remains the property of IHC Parts & Services B.V. All rights reserved. This document or any part thereof may not be made Units:
public or disclosed, copied or otherwise reproduced or used in any form or by any means, including but not limited to use hereof for the design
mm
16-12-2009
and manufacturing of identical or similar parts or products, without prior permission in writing from IHC Parts & Services B.V.
21
Mass:
5483892
Derived from:
Description:
Released for production:
1660.0 kg
Title:
Checked:
12.9
85
147
235
358
490
696
1196
1775
2403
3266
4197
5442
6727
Material(spec):
LOCK BY PENNING
Author:
10.9
71
122
194
299
412
579
1000
1481
2010
2716
3491
4432
5609
ALL THREAD CONNECTIONS

LOCK WITH LOCTITE 242
611
421
8.8
50
87
138
211
289
412
22
23
Sheet:
1/1
24
Size:
A0
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
ENGINEERING CHANGES
B
Sign.
Drawing in SE
Date
09-11-2009
DETAIL A
1:1
11 -+0,1
0 ,1
2,04
+0,05
-0,05
R 10
R 2
1168
332 0,5
125
150
150
150
150
168
267
65
2,3
8
60
R 4
R 10
O 124 h9
O 140,4 h9
O 124 h9
O 151,5 h9
O 165 f6
O 95 r6
10
1050
O 200 n6
O 179
O 164,7
R 6
3 x 15v
10
10,4
83
+0,2
0
F
155
20
140
35
60
25
46
4 x M24
6 x O33
4 x O32 H7 AT ASSEMBLING ON SHIP

(PRE-DRILLED O31)
680
H
610 0,2
516
553,3
305 0,05
448,5
112
798
442,7
J
PIPE O 42
OUT
100,7
BREATHER
287
90
531,5
WATER CONECTION
OIL COOLER
90
IN BSP 1"
40
77
172,5 0,02
350
8 x O26
230
700
57,5 57,5
M
230
PULSE TRANSMITTER
320
1507
6 x O25
KEY ACCORDING TO DIN.6885
1220
172,5 0,02
350
455
4 x O25 H7 AT ASSEMBLING WITH PUMP

(PRE-DRILLED O24)
N
218
N
DIPSTICK
350
INSPECTION COVER
50
OIL LEVEL
OIL PUMP
130
200
OIL DRAIN
124
776,6
50
171
INPUT RATING
INPUT SPEED
OUTPUT SPEED
RATIO
WEIGHT
OIL QUANTITY
OIL VISCOSITY
130
40
570
840
140
750
DIMENSION FOR DISASSEMBLY
880
1150
130
P=634 kW
n1=1800 rpm.
n2=576,9 rpm.
i=3,12
m= 1770 kg
130 L
ISO VG 100
OIL DRAIN
Material(spec):
RELEASED
FOR
PRODUCTION
AF
HB
Drawing number:
ARRANGEMENT
09-11-2009
Checked:
10
11
12
13
14
15
16
17
18
19
20
Revision:
Scale:
1:5
Projection method:
SV-320-C
16-12-2009
16-12-2009
mm
21
Mass:
50403540
Derived from:
Description:
JvH
Model number:
1779.5 kg
Title:
Author:

www.ihcmerwede.com
22
23
Sheet:
1/1
24
Size:
A0
10
11
12
ENGINEERING CHANGES
A
Sign.
Drawing in SE
Date
10-11-2009
1 1/2" BSP
(2x)
42x3
42x3
1 1/2"
BSP
1 1/2"
BSP
04.02.00
15 kW
04.01.05
0-40 bar
MPC
1/4"
BSP
04.01.08
0-6 bar
04.01.09
0-100C
MTC
1/4"
BSP
1/2"
BSP
MC2
1/2"
BSP
1/2"
BSP
1/2"
BSP
1/2"
BSP
1/2"
BSP
1/2"
BSP
1/2"
BSP
C2
1 1/4"
BSP
1/2"
BSP
04.01.03
8,8 bar
30
2
04.01.02
0-40 bar
T 04.01.04
NG06
04.01.12
9,3 l/min
1/2"
BSP
04.01.01
1 mm
4 mm
31
MP2
1/4"
BSP
1/4"
BSP
D
32
2 mm
40
PC
1/2"
BSP
43
2 mm
41
42
1,5 mm
C1
1 1/4"
BSP
1,5 mm
50
2 mm
1,5 mm
8x 2 mm
04.01.06
20
2 bar
1
04.01.10
04.01.00
MP1
1/4"
BSP
P
1 1/4" SAE
6000 PSI
T
3/4"
BSP
T3-048115-100
T3-048115-010
38x2
T
3/4"
BSP
10
Description of the hydraulic system of the gearbox
04.03.03
1. Start of the gearbox from 0 to idle speed
04.03.01
04.03.02
1.1 Start driving motor
F
Gear pump (Kracht)
Type : KF 50 RF1
Speed : 1409 rpm
Oil flow : 68 l/min
10
2. Speed variants during operation
20
Oil filter (Hydac)

Type : Df-W\HC-160-M-A-25-A-01
Filter element : metal mesh
Siev mesh size MV = 25 um nominal
30
Sequence valve (Sun)

Type : RSJC-LEN
Max. flow capacity : 40 l/min
Pressure setting range : 0,5 -30 bar
Pressure set to : 8,8 bar
Directional control valve

(Parker Denison)
Type : 4D01-3151-0101-C1GOQ
31
32
Non return valve (Sun)

Type : CXID-XCN
Operating pressure : 2 bar
40
Pressure gauge (Hydroflex)

Type : 1151-063-0040
63 mm, BSP1/4"
0 - 40 bar
41

Type : 1151-063-0040
63 mm, BSP1/4"
0 - 40 bar
42
43
Temperature gauge (Econosto)

40 mm, BSP1/2"
0 - 120 C
50
Oil/water cooler (Bloksma)

Type : P13-2P-L=600 MV
Cooling power : 15 kW
2.1 The gearbox lubrication will be done by the

mechanical lub oil pump at all operating speeds
3. Stop of gearbox
3.1 Stop driving motor
G
Material(spec):
RELEASED
FOR
PRODUCTION
AF
HB
OIL CIRCUIT SCHEME
10-11-2009
Checked:
Model number:
Mass:
Drawing number:
Revision:
50410780
Derived from:
Description:
16-12-2009
mm
Scale:
A
Projection method:
SV-320-C
16-12-2009
JvH
Title:
Author:

Type : 1151-063-0006
63 mm, BSP1/4"
0 - 6 bar

www.ihcmerwede.com
10
11
Sheet:
1/1
12
Size:
A2
10
11
12
ENGINEERING CHANGES
A
700
Sign.
Drawing in SE
Date
13-11-2009
108
B
1140
E
APROX. 1580
SPECIFICATIONS:
MASS OF 1 GEARBOX: 1,7 Ton
NO FORKLIFTS ALLOWED
LENGTH OF THE CABLE: MAX 1 m

Material(spec):
RELEASED
FOR
PRODUCTION
NS
HB
LIFTING
13-11-2009
Checked:
Mass:
Drawing number:
Revision:
50410782
Derived from:
Description:
16-12-2009
mm
Scale:
1:10
Projection method:
SV-320-C
16-12-2009
JvH
Model number:
Title:
Author:

www.ihcmerwede.com
10
11
Sheet:
1/1
12
Size:
A2

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20.

Issue 1.0 March 2010

ALL RIGHTS RESERVED

Issue 1.0 March 2010

| GENERAL DESCRIPTION GEARBOX................................................... 1-1

| STRUCTURE MANUAL.......................................................................... 1-3

2 | SAFETY .......................................................................................................... 2-1

| SAFETY PRECAUTIONS DURING OPERATION .................................. 2-1

| SAFETY PRECAUTIONS DURING MAINTENANCE ............................. 2-2

3 | TRANSPORT / STORAGE AND INSTALLATION .......................................... 3-1

| HANDLING ............................................................................................. 3-1

Issue 1.0 March 2010

| STORAGE .............................................................................................. 3-2

| INSTALLATION ...................................................................................... 3-3

4 | START-UP ...................................................................................................... 4-1

| SHUT-DOWN ......................................................................................... 4-2

5 | SPECIFIC DESCRIPTION MAIN PARTS ........................................................ 5-1

| Hydraulic clutch ...................................................................................... 5-1

| Oil pump ................................................................................................. 5-3

| Oil cooler ................................................................................................ 5-4

| Oil filter ................................................................................................... 5-5

| Manometer ............................................................................................. 5-7

| Thermometer .......................................................................................... 5-8

Issue 1.0 March 2010

5.6.1| Description ........................................................................................ 5-8

Speed monitoring system ......................................................................... 5-9

| Pilot operated sequence valve .............................................................. 5-12

| Electronic system.................................................................................. 5-14

| REGULAR INSPECTION........................................................................ 6-1

| PERIODICAL INSPECTION ................................................................... 6-4

| INSPECTION SCHEDULE ..................................................................... 6-5

7 | TROUBLESHOOTING AND ALARM SETTINGS ........................................... 7-1

| safety precautions................................................................................... 8-1

| prepare system for maintenance............................................................. 8-1

| Specific maintenance instructions on gearbox ........................................ 8-2

Issue 1.0 March 2010

Appendix A: After Sales Services .......................................................................... a

Issue 1.0 March 2010

Issue 1.0 March 2010

THE INFORMATION IN THIS MANUAL HAS BEEN CHECKED CAREFULLY

Issue 1.0 March 2010

THIS MANUAL IS INTENDED TO SERVE AS A GUIDE FOR THE

ALL INVENTIONS, TRADEMARKS, TECHNICAL DATA, DRAWINGS, PLANS,

Issue 1.0 March 2010

EXCEPT WHEN OTHERWISE PROVIDED FOR IN CONTRACT, IHC

Issue 1.0 March 2010

Issue 1.0 March 2010

IHC PARTS & SERVICES B.V.

+31 (0)78 - 6910430

+31 (0)78 - 6910439

Issue 1.0 March 2010

| GENERAL DESCRIPTION GEARBOX

This paragraph provides a general process and constructional description of the

| Gearbox Principle of Operation

The gearbox consists of a one-step gear wheel transmission. It is driven by a diesel

Issue 1.0 March 2010

Issue 1.0 March 2010

This technical manual is divided in 8 chapters, supplemented with specifications,

Issue 1.0 March 2010

Issue 1.0 March 2010

| SAFETY PRECAUTIONS DURING OPERATION

Obey following safety precautions on operation of the gearbox: