Service Manual of Marine Gearbox Model GW Series
Hangzhou Advance Gearbox Group Co.,Ltd (Hangzhou Gearbox Works)
2024/12/19 21:02:45
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-1, ratios 2:1～6:1 and rated transmission capacity (N/n1) 0.257～9.25 kW/r.min-1. 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 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.
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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.
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Service Manual of Marine Gearbox Model GW Series
Contents . List of Technical Data……………………………………………………………..( 5 ) . Description of Gearbox …………………………………………………………. ( 7 ) . Instructions ………………………………………………………………………. ( 10 ) 1. General Information ……………………………………………………….. ( 10 ) 2. Instructions …………………………………………………………………. ( 11 ) . Mounting ………………………………………………………………………….( 15 ) . Gearbox Alignment ………………………………………………………………( 18 ) . Gearbox control and Remote-Control …………………………………………( 21 ) 1. Control types ……………………………………………………………….. ( 21 ) 2. Requirements of the control system ………………………………………( 22 ) 3. Pneumatic remote control and design example …………………………( 24 ) 4. Elecricl remote control design example ………………………………….( 26 ) . Initial operation …………………………………………………………………( 27 ) . Lubrication and oil pressure instructions …………………………………… ( 28 ) 1. Lubrication oil specifications ………………………………………………( 28 ) 2. Rated values for oil pressure …………………………………………… .( 29 ) . Maintenance ……………………………………………………………………( 30 ) . Special Notes ……………………………………………………………………( 31 ) 1. Monitoring equipment ……………………………………………………….( 31 ) 2. Basic explanation of pumping unit motors ……………………………… ..( 31 ) 3. Replacement of the segment thrust pads, output end ……………………( 32 ) 4. Emergency control of the gearbox ………………………………………….( 33 ) 5. When taken in tow ……………………………………………………………( 33 ) 6. Sealing strips ………………………………………………………………….( 34 ) . Trouble-Shooting ……………………………………………………………….( 35 )
HANGZHOU ADVANCE GEARBOX GROUP CO.,LTD.
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Service Manual of Marine Gearbox Model GW Series 1. Overheating ……………………………………………………………………( 35 ) 2. Lack of oil pressure …………………………………………………………..( 36 ) 3. Oil leakage …………………………………………………………………….( 37 ) 4. The engine stalls during reversing ………………………………………….( 37 ) 5. The propeller does not reach the corresponding speed of the motor … .( 38 ) 6. The propeller does not stop turning in “Neutral” …………………………..( 38 ) 7. Gearbox noise …………………………………………………………………( 39 ) . Standard Accessories ………………………………………………………….( 40 ) 1. Filter and cooler ……………………………………………………………….( 40 ) 2. Geartype oil pump …………………………………………………………….( 41 ) 3. Filter for control oil circuit …………………………………………………….( 42 ) 4. Pneumatic controller ………………………………………………………….( 44 ) 5. Electrical controller ……………………………………………………………( 46 ) 6. 2-stage control valve ………………………………………………………….( 47 ) 7. Lub rication pressure regulator valve ……………………………………….( 52 ) 8. Oil filler neck with sieve ………………………………………………………( 52 ) 9. Dipstick …………………………………………………………………………( 53 ) 10.Pressure switch ………………………………………………………………( 53 ) 11.Temperature switch …………………………………………………………..( 54 ) 12.Clutch release valve ………………………………………………………….( 55 ) ⅫⅠ.Gear selection information ……………………………………………………( 55 ) 1. Gear selection and ordering ………………………………………………… ( 56 ) 2. Reduction ratio ……………………………………………………………….. ( 57 ) 3. Trans capacity diagram ……………………………………………………….( 58 ) 4. Oil capacities and cooling water requirement …………………………….,.( 60 ) 5. Configurations and rotations …………………………………………………( 61 ) 6. Dimension table ……………………………………………………………….( 62 ) HANGZHOU ADVANCE GEARBOX GROUP CO.,LTD.
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Service Manual of Marine Gearbox Model GW Series 7. Data for vibration calculation of GWC ………………………………………( 65 )
Ⅰ.
List of Technical Data
1. General data Engine manufacturer: Engine type: Engine output :
P=
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 SAE30 (in summer of the torrid zone for SD/CC40 or SAE40 Lub. Oil quantity: Max. lub. Oil temperature
80℃
Cooling water inlet temperature
≤32℃
Cooling water inlet pressure
≤0.6MPa
HANGZHOU ADVANCE GEARBOX GROUP CO.,LTD.
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Service Manual of Marine Gearbox Model GW Series Cooling water requirement
m3/h
Reversing time
t ≤15s
Mechanical efficiency
η≥97%
Rated propeller thrust
Ps =
Permissible angle of inclination:
Longitudinal 10°, Transverse 15°
Overhaul:
10000h
Net weight:
1
N
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 (Switching frequency) Maintenance Card
HANGZHOU ADVANCE GEARBOX GROUP CO.,LTD.
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Service Manual of Marine Gearbox Model GW Series
Ⅱ. 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.
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.
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.
HANGZHOU ADVANCE GEARBOX GROUP CO.,LTD.
