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458 views253 pages

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josei201097
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_ Gearbox Instruction Manual Baw This Gearbox instruction manual contains specific design and operating data as well as ‘some general instructions for your gearbox. Description: Product identification number: Gearbox AMG 11 (44KV13) 2000 4463 + Instructions + Data Sheets + Spare Parts ‘2 see 15, PO, Box 720, 0X90 Frederchan, Danan “aphera“46 96 204 0, Tascopy +45 62040 9, phar. AMG 11-Gearbox MAN’ ‘Ww Preface ‘What does this book contain? This instruction manual provides general guidance regarding operation and. main- tenance and gives a desenption of the de sign ofthe gearbox. Its aso to be used as Felorence when ordering spare parts “The manual is divided ito. @ number of ‘chapters that correspond to the main com- ponents/unitsin he gearbex. Menumber of ‘each chaptoris desided byour PSP-eystem (product specification system) and is the foundation stone of our EDP-system Each chapter consiats of three main clement + Instructions (text concerning func: tionally, operation ard maintenance) + Data (clit, tightening torquos ote.) + Spare part plates (spare pat ilustra- tions and adaonal lets) Falease Preface Reliable and safe operation of the gearbox |sdopendenton correct operation andmain: tenance. tis therefore important that the en- gine personne is fully acquainted with the Contents ofthis book: “The equipment is dalivored including a war- ranty clause which has been contractual ‘agreed upon. Itis, ofcourse, a precondition forthe validity ‘of such a warranty that the equipments op- ‘erated in accordance with agreed require- ‘ments and recommendations. ‘Spare parts must be original spare parte purchased directly from MAN B&W Diesel ‘Alpha Diesel or from one of MAN B&W Die- sel's authorized workshops or agents, AMG 11-Gearbox Gearbox type code ‘The gearbox code shall be interpreted as follows: Example: AMG 8 - 39KVB ‘Alpha Module Gearbox (Gearbox flanged on engl Gearbox free standing [Approx permissible power {transmission ir kW/100 at en gine speed at MCR "152 Foloace Preface a [Approx permissible power lransmission ir KW/100 at en- gine speed at CR or 39 —_([Gear ratio x 1C kv-veraon AMG 11-Gearbox MAN How do | order spare parts? Spare part plates consist ofa drawing of the spare part and an accompanying list ofthe items shown onthe drawing The drawing may not be completely ide ical to your plant and may also show some items that are notincludedin your plant. The adltional isto tems, honever, is vay in ‘accordance with your spetifi pant. Note that some items on the spare part drawings may only be delvered as part of a kitor complete assembled component. Ths, however, is gonorally stato onthe drawing ‘When ordering spare parts (or reference is made in correspondence) he following data, must be spectied: Aelease Preface 1. Name of vessel (eg M/S Wannsee) 2. ‘Type of gear (eg AMG16) 8. Engine no or s-no If the engine is not MAN BRW Diesel (eg 17019 or S-no 6769) 4. Spare part plate no it edition no eg 2830-02 5, tem no (eg 12) Description of part and quantity re- ‘quired (eg 2 plain journal bearings) “These data are used in order to ensure cor- rect supply of spare pars for the individual propulsion plants sol, Table of Contents maw chapter 215 chapter 2 20 chapter 225 chapter 2 35 chapter 2 40 chapter 2 45 chapter 2 80 chapter 2 62 [ap Setey equipment chapter 2 86 Additional equipment chapter 2 90 AMG 11-Gearbox MAN Ww 05. Data Description Gearbox - design Operation of gearbox Checking procedures ‘Trouble shooting ‘Tightening instruction for screws. Data Sectional drawing ‘Sectional drawing - PTO ‘Technical data. ‘Tightening-up data. Maintenance programme Gear oll specification Release toa 205 page 05-2 page 05-3 page 05-5 page 05-6 page 05-7 drawing no 2 04 39 20-4 drawing no 2 03 09 90-1 drawing no 2 04 08 68-5 drawing no 2 05 75 64-7 drawing no 2 05 07 49-2 drawing no 2.06 09 43-6 page 05-1, AMG 11-Gearbox MAN Gearbox - design ‘The gearbox Is bullt up as a unit comprising: + Abydraulic operated disc clutch on the input shatt + Apinion and a wheelto reduce the en- gine rpm to propeller rom. The gear ‘wheel shaftsare beddedin sturdy side bearings. + Ahydraulic operatedsservo cylinder for propeller pitch conta, placed in centre of the lower gear wheel onpumo. + Acthiust bearing bul-on to the aft of the gearbox to absorb the propeller ‘thrust. + single oil pump to supply lubricating Gl pressure, clutch oil pressure and servo oil pressure, ‘The gearbox can be delivered with dtferent types of power takeoffs (PTO). Gear wht Seno piston z Gearbox - VO eease 2 0541-02 age 05-2 AMG 11-Gearbox MAN) Ww Operation of gearbox Before starting 1. The cltch on the input shaft of the gearbox must be declutched Check ol eve inthe gearbox. 3. Pre-lbrication of the gearbox is only necessary after more than 6 houte of Sandell Mirning The siand-by oil pump must be stopped be- fore starting up the engine. Tho stand-by ol pump must never be run- fing while the buit-on ol pump is running. For inital starting make sure that the mag: netic suction prefiter for the bull on oll ‘bump 2s well as forthe stand-by oll purnp is. filled with ci. Before the intial starting the oll level mustbe filled to approx 50 mm above the max mark ‘on the dipstick. Aer the inital of filing the ol level wll drop when the stand-by pump is started due to the cooler, pipes, servo cylinder etc being Plug Bracke for accumultor filed with oll The servo cylinder must be activated tobe filed with ol Further adding of oll must be done while the tengine is running and the propeller is en- (gaged. Add to the max mark onthe dipstick. \When the engine is stopped the correct oll level cannot be read on tne dipstick. Before clutching-in |When clutching inthe engine mustbe at ile speed and the pitch in neutral. Cluching in at @ higher speed is only permited with specially designed clutch, “To engage or disengage the clutch, a sole- noid valve on the gearbox can be operated, cethor manually or rom the remote contol system. ‘An oll accumulator with arubber membrane ‘is connoctedto the clutch in pipeline to con- trol the engagement of the clutch ‘The accumulator must be prefiled with 2.5 bar on the upperside of the membrane to ensure a smooth clutch-in Accumulator Fonse 2 0581-09 age 05-3, AMG 11-Gearbox RY In operation ‘When the engine is runring, oll can be added to the gearbox through the ai fling ‘ontop ofthe oll pump drive housing. \When the gearbox oll is warm and the en- ‘ine running at max rpm, the lubricating of pressure should be 1.5-2.5 bar, During ma- oeuvres, the pressure may drop momen- {atily to about 0.2 bar. Atide speed the lube ‘il pressure will be about! bar. “The lube oll temperature eter cooler should be approx 45-50°C. ‘At olltemperature below about 30°C, the ol ump may become noisy. starting up with very low lubricating oiltem- perature, tis advisable notto run at full rpm ‘ntl the oil has reached aprox 30°C. “The degree offouing ofthe lube of ftercan bbe checked by means ofthe pressure difer- cent indicator on the side of the ‘iter covers. When, during running with a warm Felease 2058-09 {gearbox, the pins protrude more than 3 mm from the cover, the iter elements requirere- placement CCheok that the hydraulio pressure is in ao- cordance with that indicated on the "Techni- cal data" sheet The normal working temperature of the thrust and journal bearings is between 50° 0 60°C and must not exceed 70°C. Towing or sailing with one engine out of service (twin-screw plants) “The towing resistance can be reduced con- siderably providing the propeler is set to maximum pitch. In this setting, the water ‘tow will rotate the propeller and gears. ‘To ensure adequate lubricating ofthe bear- ings in the gearbox under these conditions, the gearbox stand-by lubricating oll pump must be running, page 05-4 AMG 11-Gearbox MAN Ww Checking procedures ‘The various components of the goarbox should beinspected as described belowand athe speciiod intervals 500 hours The tooth contact area must be inspected. Ifthe contact area has bean essentially ro- duced, compared with thair original form, alignment of propeller staft and goarbox should be checked, The fiter basket and the magnets nthe suc- tion fiter must be inspected regulary If any particles of steel or white metal are foundin the fiter basket thereasonhas tobe found, ‘Abnormal noise from the gearbox indicates a fault which must be located and corrected, Noise in the piping system can appear if there is a leak inthe suction line or ifthe oll Is cold 3000 hours ‘The double ol fiter should be cleaned and the filer element renewed, ‘The fiter housing can be cleaned and fiter cartridge renewed during operation of the ‘gearbox. The three-way change-over cock is used, to operate with one fiter unit at a time. Normally, both fiter units should be in ‘operation to provide longer service life ofthe filter cartridge. 12000 hours ‘The lubricating olln the gearbox must be re- ‘newed, The gearbox sume can be emptied, using a pump. Feloase 2050-02 Inspection of gearbox - 500 hours 1. The gear wheal teeth can be inspected through the aft side covers. 2. Check of bearing wear can be ob- served by examining the contact sur- {ace of the teeth on the gear wheels 3. The axial play in the guide bearing for the pinion shaft can be checked by means ofa dial gauge against the axial ‘guide face while moving the pinion Sha fore and aft by means of a bar. “The clearance must be between 0.2 ‘mm and 0.7 mm. 4. The thrust bearing forthe lower shaft ‘can be chekced in the same way. Max ‘mum play is 1.0 mm 5. The main and guide bearing of the Cuich shaft can be checked by removal (ofthe round end cover inthe at of the ‘gearbox centre lie and the cover on top cof the ol pump drive housing. The avial play can be checked by ‘means ofa dial gauge connected tothe fend of the clutch shaft in the aft and ‘move the shat fore and aft by means of aber Fagal play can be checked by iting the shaft by means ofa rod in the aft and a lal gauge connected to the top of the {gear whee! forthe pump drive, 6. Maximum radial clearance in the oll sleeve inthe aft ofthe clutch shatt and the forward end of the servo piston shaft is 1.5 mm, 7. Inteenal pipes and hoses have to be ‘checked for leakage. Operating the stand-by pump leakagos can be ob- served through the side covers. 8, ‘The Geislinger coupling between the ‘rank shatt and the cluch shaft has to be checked. See engine instruction manual page 05-5 AMG 11-Gearbox (03) Trouble shooting 1. Clutch slipping or pitch control fails: aus + Too low clutch ol pressure: Adjust pressure as described, see page 35-16, + Too low oil level in gearbox. + Failure of oil pump o” similar. + Suction titer blocked and requires cleaning + Leak in suction tin. + Ifthe ol pressure cannot be increased sufficiently to maintan the cluich en- ‘gaged, oF inthe evert of oll pump fail lure oF simlar, the screws for emerg- tency operation ofthe clutch should be tightened as cescrbed, see page 20-12. 2, Rising oll temperature: Cause: + Thrust bearing running hot. + Diy cooler. + Insuficient quantity cf cooling water. + Insufiiont quantity f ot 3. Falling oll tomperature: Cause: + Detect oll thermostat 4, Constant contamination of lubricating oll with water Cause: + Leaky cil cooter. ‘5. Inability of lube oil pump to self prime. caus + After emptying and cleaning suction fits, aismanting pump or folowing Feteaso 2 0501-02 long periods stopped and pumpis dry, suction mightprove dificult. Thopump may require hand priming, by remov- ing the cover of the suction fter and filing wath ol. + Leak in suction tine. 6. 011 pump failure ‘A. Reduction gearbox with stand-by pump: Cause: + Ifthe buit-on pump fails, the stand-by ;purnp must be used. Is piping system 's Independent ofthat of the bult-on ‘pump, andcanbe arranged for manual ‘or automatic starting, + The bult-on pump has to be ds rmantled. +The bult-on pump must never be run- ning together with the stand-by pump, because this may cause damages on both pumps, B. Reduction gearbox with adaitional spare ‘pump on board Cause: +The buit-on pump to be removed and replaced with ship's spare 7. Low lub oil pressure Cause: + The lub olf pressure will always de- ‘crease when reversing the propeller. (Often below the alarm limi). This ‘shor time dropping willnot reduce the IMotime of tho goar ‘+ Tho oll temperature is too high (see item "2." + Too high servo or clutch ol pressure. page 05-6 AMG 11-Gearbox Tightening instruction for screws “This instruction contains important informa- tion regarding tightening, lubricating and so. ‘curing of screw connections. ‘This information is necessary when instal- ling and overhauling the gear. The given in stustions have 10 be carefully followed ‘when tightening up the gear in order to en ‘sure a correct assembling of the equipment. Tightening procedure Ente Flange and bearing surlaces are to be leaned and free of damages. Flange sur- faces are to be degreased and bearing sur- faces to be olle. Tightening by torque wrench ‘Afior adjusting the torque wrench to the torque spectfiad under tightening data al the screws in the connection are cross tigh- tened, After this fist ightening of an assem- bly, each botthas to be completely loosened ‘and retightened, but only one (1) ata time, This second cross tightening is repeated untill the screwsin the connection ave tigh- toned, ‘Mark the screws both afterthe fist and sec- ‘ond tightening in order to make sure that all bolts are tightened correct, ‘ease 2. 0561-02 Lubricating of screws Bofore assembling a threaded joint the screw threads and contact faces have tobe cleaned and lubricated (respectively ofthe thread is with nylon lock oF not. ‘Allscrewsin an Aipha gearboxes have tobe lubricated with: Copasio ‘The copper grease has to be applied in a very thin ayer by use ofa brush. Securing of screws For Alpha gearboxes 2 iferent methods of ‘sorew securing are used i. + Wire securing + Nylon lock securing Be The screws have to be correctly tightened before securing. Do not overtighten or loosen screws in orderto geta correct align- ‘ment of wire holes, cross flats etc. Wire securing 1. Insert wire, dimension according to tightening data, grasp the upper end of ‘the wireand benditaround the head of the sorew, then under the other end of the wire. Be sure that the wire is tight around the head, 9 page 05-7 AMG 11-Gearbox MAN aw 2. Twist the wire clockwise unt it is just short of the hole in the second screw. ‘Keeping the wire under tension, twist it Lunt tight. When the wire is tight, the Wwire is to have apgroximately 7-10 ‘wists per 25 mm, 8. Insert the uppermost wire in the sec- ‘ond serew and pul tight. <8 4, Bend the lower wire around the sorew and under the one protruding from the screw. 8. Keeping the wire under tension, twstit min, 3 twists counter clockwise untl 7 Release 2.0561-02 6. During the final twisting mation, bend ‘the wire along the screw head. Cut off excess wire. ‘Any tendency ofthe screws toloosen willbe counteracted by a tightening of the locking wire, Do not secure more than four sorews ina soties, unless othorwise specifiod. Nylon lock securing Screws ate delivered from Alpha with the nylon lock mounted — however, when refit- ting screws we recommend to renew the nylon locks. ‘Thenew nyion lockis to be secured with loc- {ite type 242 or similar and after mounting to be grinded close tothe thread es shown on the above sketen, yon lok {Nylon locked serew &) noe The nyion material must be in quality PAG-6 oreimiar. page 05-8 fg i = —} = a= a iE [p02020-4 AMG 8.11.46 “ot (on) [WAN BAW Diesel AS |; RAKING FOR APPROVAL 3030990- 1 | ed ‘Assembling gearbox/engine AMG 11 Pate no 21540-03 MAN Baw PLATE NO | PROD IDENT (05.01.20/ «465 2rso-co | aKvis [ASSEMBLING ENGINEIGEARBOX: Tew WEIGHT Te PART DESCRIPTION. Weer ‘CYLINDRICAL PIN (O-RING, NER. 05.0x 01250 HEXAGON SCREW LockInG PLATE ‘SEALING FING HEX SOCKET CAP SCREW W NYLON LOCK SILICONE ELASTONER PASTE (CAF 780) DESCRIPTION ALPHA REDUCTION GEAR: AMG 11 VERTICAL OFFSET Bac Sides MED SS) Sil Denys NICS oe GLE ENOVE-m Tolerances bere Das as Sa Ja Dp Tapa fa aa 5 4 3 2 "79907026 | BIJ | SMAI Max, sao pressure changed 060 i 19960918 [TAM] SM o Sr nina: 2096056: [ieee es Sea See he on ma AMG 11 (01(02)_ |MAN BAW Diesel Avs| oe loan Ne TECHNICAL DATA SHEET 2040868-5 Fear Dar ETE | alae Dae Fd oe eR Copyright 6, 1907 WAN BE Diesel NS pes coret.n aay tla he Bi net ae ane Srvstt | sivort | swvoTr | SBVOTT [aavars SPECIFIC DESIGN DATA | rrr | Suva | sayy | sony | ans | une Sor a Sasa vast] ries] razs| avei| eno Fis np oq ‘aio “wa| “ae| “36 | "ras am hint oat 120 sas so. rsot200 Isnt | “on | GENERAL DESIGN DATA abl Seng ot pu Npe MPO OTT TRAE TAT SST RR IORPA hoa fe 7070176 Vue mol olin sea seam tl rahi VO be 20270. ive Raconmendad acy pup presse 2 Bar Faconmended sant Oy pang Sapcly 180 to se reteae et maneien 3 ig Nom ergot ater eS fee came ta Pea & 8 Non trp of ural bat SS teria tat eeautae et rom colon wom Mean howtteara coms eS ‘Adm tri ounaloeantgomoerre BS Paar ay aS ‘Si unt Wb ot pecs os “Bar Aor it dice bance i Be er pote ta ao i ‘tt Sea lange damear ee him Tat Searing toe tine pao rovers rete apn change prioss Goer atte oss wos 8m Saris onan 10078 tm See cae “tm Sete Bete, darwor oso REQUIREMENTS FOR INSTALLATION: Fes foundation bots sxoorncs fej oanate Sows “at Ses ote ait Pressure pipe, sane by BURP 548. 3:28 mm voure | svnee_| unr Si conent aaa Bo Orcoole ye par| poe + area 47 19 im foreved heat a mae. npt i| es | naam wenn sora soo | a0 a ‘OPERATING DATA Tao press 25] er Mins uct pressure 1538 | ber Nam sve ef ear incu! pressure rerease 33) Be ter sone Pe S| ef fencers &| be Neti ae St tsau 05s | Bm a a ee —— i ‘oestope-t es tsuneo mean ast oi i FA ann 02(02) _|MAN BAW Diesel WS TECHNICAL DATA 2040868-5 TE OOS rari 1 [aa Alpha gear MAN BAW Diesel A/S Tae era aT 3G0102 Bolt tightening data 2 05 75 64-7 a Taso Rie SAS Daie CM agME se | FENZIEm Tolerances oar ao a EAE Den Teena 7 ea 3 a 7 6 5 a 3S 2 20040625 _|NINIAl SMU AFP |Z5| ANG SSE aced ert t 20080001 _|MIMA|SMJ [AFP] = “res2a7 0 ns Drv as Recon enue has 2OKD365-A ‘This data sheet specifies the tghtening-up torque, whichis to be applied to the different sorews and ruts in Alpha reduction gears. To identify the screw in question, itis necessary to refer to the instruction manual, which contains the plates that are stated in the sheet Its important that the tightening-up procedures described in paragraph 2 O5E1 in the instruction ‘manual are followed when assambling the goar. For Alpha reduction gears the ‘llowing general tightening-up torque data are to be user Theadsze M [10] @]1e[ 0] -[o7[ ola] wel oe] © FTorque —_INmj_[25 | 80 | 100 [200 [300 [360] 400/500] 700 | 950 | 1500 For some individual gear types, the tightening-up data difer from the above: ANNES (Plats [Tem [Pcs [Descrpion rTrvead [Torque [Nm] 2 1540] 3 | 6 | Screw for flexible coupling M20 [250 22010] 6 | 8 | Seraw forelutch drum Nizo_| 250) [2010] 11 | 24 [Nut for servo cyinderigearwhosl M20 300) ANG 11, ANGTIEV Pats [Wem [Pos [Descripfon PTrvead [Torque [Nn] 21640] 3 | 8 _|Scrow for faible coupling 20 _[ 250) 22010 5 | 8 | Screw for elutcn drum N20 250) 22010] 7 | 48_| Nut for servo eylincer [gear whos] 20250) (230t0[ 31 [4 [Nut fortack box w20_| 300) 2057584:.1 Page 118) MAN B&W Diesel A'S ‘ANG 16, ANGTOEV Plato[Tem [Pos [Desorption Thread [Forave [Nm] [22010] 33_| 8 [Nut for ‘tet bor 20_[ 250 [2 2010| 26 | 8 [Screw for clutch shat Mie 120, [2 2010 | 44/46 | @6_ [Screw for clutch shat Mz0_[ 250 23010| 12 | 20_|Screw for servo cylinder M20_[ 250. 23010] 314 | Nut for clack box ‘Mzo_| 300, ANG 2 Prats [Tom —[Pos_[Descrgton (Thvead [Torque [Nr] | 2.1510| 31_| 4 [Screw trust bearing housing toprbotom | M30 | 500. [22025 | 18_|_3_|Screw for gearwheel for pump ative Mz0_| 109. [2.3010 | 19 | 18 | Screw for servo cylinder Mg3_| 850) 24515] 0/10 | 4 [Main bearing screw M30_[ 500) "RING 28, AMGZBETEV Prato [tem [Pos [Description Thread [Torque [Nr] | 21810] 31] 4 [Screw hrust bearing housing toprbotiom | M30 | 500 21510] 11] 10 | Screw for front end PTO goarbox. M30_|_ 700) 21510] 87_|_4 | Screw for front end PTO gearbox. Ma6_[ 815: 21510] 60_|~4_| Screw forhigh PTO top ‘M20_| 800. (22025 | 193 | Screw for goarwheel for pump dive | _M0_| 100 23010 19 | 18_| Screw for servo cylinder M33_| 550. [2.3010 | 28 [8 _[Nut for ack box Mi6_| 150 ANG 36,40 Prats [Tem _[Pos_[Descripton Thread [Torque [NT] 2 1535, 2 _|Serew for bearing at nput shaft M20 [300 21510 12_|Screw trust bearing housing/gear ‘Ma6_ [1200 21810 2 _| Screw hrust bearing housing ‘30_[ 500 22025 ‘6 [Screw for gsarwheel for pump drive: Mi6_| 150 23010 20__[ Screw for sarvo cyindor Maz | 1600 “ANG SEV Pate [Item [Pos_[Descripton Thread [Torque [Nm] 21510] 31] 2 |Screw for bearing suppor M30_[ 600 [21510] _47_|~4 | Screw for bearing support and top part_|Mi30_| ~~ 600 21510] —49_|~2 | Lifing tot ‘Mgo_ | 675 [21895 | 42/aB | 12 [Scrow twust cover, ‘N30 [3a Hiyeraulic [oar / KN) 2760 630" 21510| 11 | 8 |Nutforstay batt go x2| 27807 600 20575.68-7.1 Hiydraulie jack with diameter 094 mm Hydraulic Jack with diamete Pago 213) Tia eu omeal (223) FLEXSTAR PratoTem [Pos [Deseripion Thread [Torque [Nm] [23010] 1 | 12 [Fitted bots for mounting of spines, Ms 20 All contact faces are to be lubricated with COPASLIP (Cuppor Grease). When tightening torques ‘exc6d 400 Nm, the torque spanner should be used in connection with a geared head wrench All studs mounted in the gearbox housing must be screwed in with 60% of the torque indicated in the table and secured with LOCITITE 242. This will ensure that suds will not loosan by dismantling of the nuts late on zener Ta |e ee eR) eo lait Fy * ° St ee 3) Ts 4 : 3h OOBOSTAIMMAJAFPISWJ|* [ANG 65 added 2=B947| 1 10001 O24ISMJIAFPISMJI * 1 ol 4 |"Atohe mocule geor (AMS) [Of (01 )|MANBAWDiosol S|: Tolerances ond maintenance _|2050749-2) a MAN BAW Diesel A'S Aa Alpha Module Gear Tae Saino: ie We 360119. Gear Oil Specification 2 06 09 43-6 cE MOS Aap Dangle ECS om ag ENDIF Toeraneas sia aE i Ba] SE [aS rasan z Raped br Ve 3 8 T 3 5 4 3 2 7 00a T004_| SMI] AFP] SM] Trae 0 tern [Reina ar Oil used for the Alpha Module Gear must fulfil the requirements listed bel General information: For use in Alpha Module Gear for both the propeller servo system, the friction clutch system and for lubrication ofthe slide bearings and gaarwheols only single arade mineral oll is accepted, Viscosi “The kinematic viscosity at Gof the oll used must be BOEHEELcSt [mm/s] according to ISO 9448, 180 Viscosity Grade VG100 as wall as SAE 20 withthe above viscosity range are accopted, FZG Failure load stage: “The oll must obtain a FZG Fallure load stage of 12, according to DIN 1 354 -02 - A/8.3/80. Contamination Class: ‘Maximum recommendad contamination class for new oll added to the gear is 10 (NAS1638), 21/19/16 (18044061999) and 11 (SAE AS4059:D). Maximum allowed iatsiitontent is (2H Additives: Itis required that the oil contains addtives for foam reduction. Recommended al release capacity according to DIN 51 381 - 50 must be 10 minutas or better. ‘The oll must not contain adaltves for tiction reduction because of the builtin friction clutch. IMPORTANT: Thal mtbe chanced: oc A 920 IE whovr coms ft. n the contractual waranty poriod for he Aipha Module Goat, the ol used mus ul tho above specications, Any deviation wit onl be allowed provided MAN B&W Diesal A'S, Alpha has given a vmiten acceplance. Further we undertake no responsibly for cficulies that might be caused by the of set 200094940 age 12) MAN B&W Diesel A'S Recommended list of marine gear olls (VG100/SAE 30) for Alpha Module Gear (AMG Series) ‘Theol st below states recommended mineral based marine gear lubricants, which have ‘been used with good rsuitsin a number of Aipha Module Gears irom the ANG Series. ‘Other ol ypes that ful the requirements listed on the previous page can also be used, (403) Fim Name of ot Specific | Viscosity in eSt at | FZG faire donsly toad stage arise | are | tore | (woo) ‘ip (050 100 as | 100 | ana 32 BF Ena GAP 100 oso | a | na >a ‘aia Henin AWAD 0880 | io | 133 2 ees oss | 105 | 115 e Maine iD 153 oso | 103 | t15 2 Soamax Extra 153 oar | 106 | 115 2 Ey ISOLA W 015 oss | tio | 120 a ‘Kuna Paoium | G8 Mozan DP 30 eae | vo | at 72 ‘rel ‘Ome 00 ‘oars | 100 | a oe cine st oso | ioe | te 2 Gacinia At 30 oa | os | tts 2 Stato Masay 1300 e800 | ioe [tts 12 Tat Caner €P 100 a0 | 100 | 10 >a 298.0943.80, Page 20) AMG 11-Gearbox Baw 15. Gearbox Description Gearbox . . . + page 15-10 Spare part plates Gearbox with bearing caps 2.1... plata 21810 il pump housing «.. plate 2 1520 Bearings in gearbox... plate 2 1530 Covers on gear box plate 2 1535 Assembling gearboxlengire ..........- plate 2 1540 ‘Assembling gearboxlengire plate 2 1540 Release tor 215 AMG 11-Gearbox Gearbox “The gearboxis made of aston tconssts ‘ofa lowor, ntecmeclate and a upper pat. ‘The thrust bearing housing is bolted on to the gearbox housing The lower part ofthe geatbox contains the oil, An i guards instalodaround the lower part of the lower gear wheel to minimize foaming ofthe ol. “Tho boarings aro side bearings. “The thrust bearing is of the “ling pac” type ‘and consists of two identical two-parted cartior rings holding the slide blocks re- ‘spectively in front and aft ofthe thrust shaft cam, ‘The slide blocks can be inspected by dis- ‘mantiing the upper half ofthe thrust bearing housing. For inspection of bearings, see page 05-5. Upper part ease 2 1541-02 page 15-10 er | Fal ” LI d T| ke beet He i 1920 af ff 2 a0. y= fa aN ae . ‘1 ss20 a = te a gy — 2 NES i a Bh 60° LA Fare Geaitox wih bearing caps awa ir | 21610-08 MAN 4 | HEXAGON SocKETHEAD CaP SCREW 5 | HEXAGON SOCKETHEAD CAP SCREW 6 | TAPERED DROWE. 7. | HEXAGON SOCKETHEAD GAP SCREW | BEARING suPPORT, FORE (31.9KV1) 9 | stu 10 | SELF-LOCKING HEXAGON NUT 11 | GEAR HOUSING, INTERMEDIATE PART (@oKVI1)- 12 | HEX SOCKET CAP SCREW W NYLON LOCK 12 | Hexagon sour 14 | HEXAGON SOCKETHEAD GAP SCREW 15 | screw 18 | TAPERED DOWEL WITH THREAD THRUST BEARING HOUSING, INCL 19,1405,98 HEXAGON SOCKET HEAD GAP SCREW stu) ‘SELF-LOCKING HEXAGON NUT ‘TAPERED DOWEL WITH THREAD STUD FOR LOWER SEARING (31,39KV11) SSELF-LOCKING HEXAGON NUT TAPERED DOWEL WITH THREAD ‘STUD FOR LOWER SEARING (81,9KV11) ‘SELF-LOCKING HEXAGON NUT ‘TAPERED DOWEL WITH THREAD (GEAR 6X LOWER PART AMG 11 BEARING CAP, FORE (81,38KV11), BEARING CAP, AFT (3,S0KV13) (CYL DOWEL WITH HEAD/THREADED HOLE ‘BEARING SUPPORT, AFT (31,99KV'1) ‘TAPERED DOWEL WITH THREAD HEXAGON BOLT ‘TAPERED DOWEL WITH THREAD CYLINDRICAL GUIDE PIN HOUSING FOR SEALING AMG (CYUNDRICAL PIN HEXAGON SOCKET HEAD CAP SCREW HEX SOCKET SET SCREW WITH CUP POINT ‘TAPERED DOWEL WITH THREAD HEXAGON SCREW HEXAGON SCREW 2SSSISSSSRLBRESRRRTRENRVBSSs Baw PLATE NO [PROD IDENT 05.01.2074 | 2 1610-02 xvi (GEARBOX WITH BEARING CAPS Tew WeihT i PART DESCRIPTION waar | 1 | GEARBOKUPRER PART AGT View Ah 23 20 i pump housing AMG 11 Piste no 21820-01 MAN Baw PLATEWO | PROD IDENT 05:01-20/ 4469 2 1520-01 nv OL PUMP HOUSING TEM WEIGHT nah PART DESCRIPTION bry ‘ik PUMP HOUSING, UPPER PART = lL PUMP HOUSING, LOWER PART ~ HEXAGON SOCKETHEAD CAP SCREW HEXAGON SOCKETHEAD CAP SCREW ‘TAPERED DOWEL WITH THREAD HEXAGON SOCKET HEAD CAP SCREW ‘OIL PUNP HOUSING COMPLETE 208 | HEXAGON SOCKET HEAD CAP SCREW 208 | HexAGON 8oLT aoc | wasHER 21a | HEXAGON BOLT 218. | HEXAGON BOLT 22_ | TAPERED DOWEL WITH THREAD 23_| SILICONE ELASTOMER PASTE (CAF 720) (aa) sa aaa et, ot ea 80 ‘Only for em 4 | Ae a. = ° 2 » Paterno uct | 21530-02 Paes Nh Bearings in gearbox MAN Baw LATEWO [PROD IDENT (05.0207 4483 2isso-o2 | aaxvia BEARINGS IN GEARBOX: noel PART DESCRIPTION — 7 | THRUST WASHER WOT WAYS 2 | Lock rin | CYLINDRICAL PIN 4 | HEX SOCKET CAP SCREW W NYLON Lock 5 | JOURNAL BEARING INPUT SHAFT - GEAR 6 | SECURING WASHER 7 | HEX. SOCKET COUNTERSUNK HEAD SCREW 8 | JOURNAL BEARING 9 | HEX. SOCKET COUNTERSUNK HEAD SCREW to | SECURING WASHER 22 | SUPPORTING BEAANG 24 | HEXAGON SOCKETHEAD SHOULDER SCREW 27 | THRUST BEARING WITH PADS 30 | BEARING 31 | SLOTTED COUNTERSUNK HEAD SCREW 22_| LockINe wasHER Pia na 2.1835-02 Page 1(2) ANG 11 © Not included if Flexstaris part of propulsion plant [ony ter vo-gear boxes Covers on gear box MAN Baw RATE WO | PAOD ERT 0.020/ 48 prsvs.c2 | salons CCovERS ON GEARBOX Ten ART DESCRIPTION ween 3 | SLICORE ELASTONER PASTE (AF a0) — 17 | nererweoisTe PLAGE — «| Hexacon socKET HEAD caP SCREW | suirewo riren 10 | HEXAGON soKET HEAD CaP screw N#RRAH ITS SGeeSRBRSPUN sss esseeeg GASKET ‘COVER FOR OIL FILING ~ HEXAGON SOCKETHEAD CAP SCREW END COVER FOR PUMP HOUSING PLUG SCREW ‘GASKET HEXAGON SOCKETHEAD CAP SCREW ‘STOP FOR OIL SUPPLY SLEEVE GASKET HEX SOCKET CAP SCREW W NYLON LOCK HOLDER FOR OIL SUPPLY SLEEVE HEXAGON SOCKET HEAD CAP SCREW (OIL SEALING RING, SOFT SPLIT.0200 TENSION SPRING [ARROW FOR DIRECTION OF ROTATION ‘SoREW HEXAGON SOCKET HEAD CAP SCREW (CYLINDAICAL PIN [ALIGNMENT SCREW GASKET SIDE COVER, AFT HEXAGON SOCKET HEAD CAP SCREW stu HEXAGON NUT ALIGNMENT SOFEW, M24 Asker COVER, FORE HEXAGON SOCKET HEAD GAP SCREW covER HEXAGON SOCKET HEAD CAP SCREW GASKET DUMMY THERMOMETER BLIND FLANGE FORPUMP HOUSING stud 'SELF-LOCKING HEXAGON NUT HEXAGON SOCKET HEAD CAP SCREW a , AS Covers on gear box © Motinciied it lexstars part of propuision pant [ony tor vo-gear boxes MAN Baw PLATENS | PROD IDENT 501308 aise | aakvia__|_COVERS ON GEARBOK ne PART DESCRIPTION wean | PROTECTION COVER CASKET HEXAGON SOCKET HEAD CAP SCREW COVER FOR SEALING HOUSING HEXAGON SoREW | tes ‘Assembling gearbox/engine AMG 1t Piano 21540-02 MAN Baw PLATE WO | PRODIDENT 05.01.20/ 465} 2isio-o2 | aakvis [ASSEMBLING ENGINEIGEARGOX: ew = WEIGHT His PART DESCRIPTION tear 7 | HEXAGON SOCKET HEAD GAP SCREW | HEXAGON scREW HEXAGON SOCKET HEAD CAP SCREW 11_| SILICONE ELASTOMER PASTE (CAF 790) AMG 11~Gearbox (ead 20. Input shaft Description Input shatt with clutch Spare part plates Input shaft... Coupling shaft. Pinion Pump drive . Release toe_220 page 20-12 plate 2 2010 late 2 2015 plate 2 2020 late 2 2025 page 20-11 AMG 11-Gearbox Input shaft with clutch ‘The Inputshaftincorporates the clutch shatt, pinion, friction clutch and 3ear whee! drive for oll pump, The clutch consists of an outer clutch bow with inside toothing, a hydraulic operated piston, clutch discs and a toothing pinion shalt. “The outer clutch bow!and the gear whee! for the pump drive are bolted on to the clutch shaft. Tightening torque, #26 page 05-7. ‘Aiexible coupling (not shown) connects the ‘crankshaft tothe clutch shaft, This coupling is also a torsional vibration damper. For VO-gearsthe couplings piaced outside the gearbox and for KV-gears Inside the gearbox, In case of emergency the clutch can be locked by means of 4 screws with inside hexagon. Tightaning torque: 100 Nm. Note Ithe clutoh has been locked by means ofthe emergency screws the propeller cannot be ‘de-clutohed. 1 insufficient lubrication fs suppiedto the oll sleeve, on the end ofthe clutch shaft during ‘emergency operation, the ollsioeve mustbe removed and the pipe connections on the: ‘mounting plate forthe magnetic valve must be plugged using 1/2" BSP plugs. Olisleve Clich shat Friction eter Pion n Z tL ul Looking soos) \ Pump ave i Input shat wth clutch Foloase 2 2081-02 page 20-12 1017 04 42 4 44 45 ny fr VO-type Piao na Input shatt await | 22010-01 MAN Baw PLATE NO | PROD IDENT 22010-01 avis Ineur SHAFT (0501-207 485 Tew No" PART DESCRIPTION WeignT KILOS. BERBRRERBBsss ee END COVER OW SLEEVE DISC FOR GEAR WHEEL HEX. SOCKET CAP SOREWW NYLON LOCK CLUTCH BOWL, Ge. t1-XLC PISTON FING PISTON FOR COUPLING (CLUTCH PLATES, EXTERNAL TOOTHING (CLUTCH PLATES, INTERNAL TOOTHING. SECURING RING. CLUTCH DIS6, (1.99KV1) ‘THRUST RING AXIAL GUIDE, (31,394V11) HEX SOCKET GAP SCREW W NYLON LOCK FLANGE FOR CLUTCH SHAFT. HEX SOCKET CAP SCREW W NYLON LOCK HEX SOCKET SET SCREW WITH 006 POINT LockInG RING (CYLINDRICAL PIN PISTON FING DECLUTCHING FING HEX SOCKET CAP SCREW W NYLON LOCK PISTON FING PLUG SCREW PLATE FOR SHAFT HEX SOCKET CAP SCREW W NYLON LOCK PLUG SCREW SPRING PIN _ i aa fae ot i ' Alpha Coupng sat awa | 220%s-o1 MAN Baw PLATE WO | PROD IDENT 05:0.207 463 22016-01 aaevia LUTOH SHAFT | rem Weight hs PART DESCRIPTION wan ‘BUSH FOR COUPLING SHAFT 18 | COUPLING SHAFT, ROUGH MACHINED Alpha Pinion Awan Piste no 2.2020-01 MAN Baw PLATENO | PRODIDENT 05.01.20, 448 22020-01 aaevis |_ewson, Tew WEIGHT 7 PART DESCRIPTION a 1 [PINION aanvig mS Pump drive AMG Pie no 2.2025-01 (aaa) PLATE NO | PROD IDENT (05.01.20 468 2005-01 aaa PUMP DAIVE Te WEIGHT PART DESCRIPTION Wear MAN AMG 11-Gearbox 25. Intermediate shaft Not included inthe plant ease to_2 25 MAN) AMG 11-Gearbox 30. Output shaft Description Output shat + page 30-15 Spare part plates Output shat coscssseesses plate 2 8010 Geanwhee or output sha... : plate 2 3020 Felease toc 290 page 30-14 AMG 11-Gearbox MAN ‘Ww Output shaft ‘Tho output shaft consist ofa thrust shat, a servo cylinder anda forward shaft bolted io- ‘gethor with fitted bots. Tightening torque, ‘300 page 05-7, ‘A servo piston with forward andl at rod is inctalied in the serv cylinder. ‘Tho aft rod is connected tothe ptch control rod atthe propeler. Atthe fnwardend an ol sleove for pitch contalis installed. Shaft brake The main purpose of the shalt brake is to prevent the propeller causing damage to Piston al Shatt rake fishing tackle and ropes, resulting in pos- sible subsequent damage {0 the propeller, shafting, seals and reduction gear. Shaft brakes, mainly apply, onlyto fishing veseels, tugs, supply vessels etc. No special design requirements for the propeller shatting are necessary when installing shaft brakes. When a sha brake is required, the disc can be accommodated between any conveniont inboard coupling flange in the propeller hating “The braking power can be increased, by in- stalling an additonal pair of calipers. i Output shaft section Felease 2 2081-02 page 30-15 Patani ™. Baw ‘Soe plate 22020 ‘zp tom 26-32 1 1 2 118 wiz | 29 2 oe a a / a 4 Oe 8 4 9 88 16 95-96-97 18 19 a . 3 rr Patera Alpha ‘Output shaft ANG 11 2:3010-06 MAN Baw ‘LATE NO] PROD IDENT Kvi9 ourpur sHagT 05.01.20/ «48 Trew No! PART DESCRIPTION WEIGHT KiLos: seSeeRReSBRNBRees ae “THRUST SHAFT WITH BUSHES RETAINING FING FOR BOING DISTANCE RING. INSIDE SEALING FOR THRUST SHAFT [BUSH FOR THRUST SHAFT FITTED BOLT FOR SERVO CYLINDER 'SELF-LOCKING HEXAGON NUT GUIDE PIN FOR SEAVO PISTON, PISTON RING 0985 FITTED BOLT FOR GEAR WHEEL SEALING RING RETANING FING FOR BORING ‘BUSH FOR SUPPORTING SHAFT SEALING RING ‘SUPPORTING SHAFT AMG 11 INTERMEDIATE RING. lt steeve END COVER HEX SOCKET GAP SCREW W NYLON Lock ‘SERVO PISTON CONPLETE ANGI FLANGE FOR SERVO PISTON RETAINING RING FOR BORING HOLDER FOR OIL SLEEVE, COMPLETE HEX SOCKET CAP SCREWW NYLON LOCK HEX SOCKET GAP SCREW W NYLON LOCK HOLDER FOR OIL SLEEVE, TOP PART. NER HEXAGON SOCKETHEAD CAP SCREW ‘BRACKET FOR OIL SLEEVE, BOTTOM PART TACHO WHEEL, 107 TEETH HEX SOCKET COUNTERSUNK HEAD SCREW GLUE LOCTITE exe Bust RETAINING FING FOR SHAFT SEALING RING FITTED BOLT FOR GEAR WHEEL ‘SERVO CYLINDER ANG 11 | sauna ra | BUSH FOR THRUST SHAFT Alpha Gearwhee! for output shatt aun Pater 23020-01, MAN Baw PLATENO | PROD IDENT 5.0120) 2000-01 aaiovia GEAR WHEEL FOR OUTPUT SHAFT TEM Welch ra PART DESCRIPTION wer 1 | GEAR WHEEL aaeNOTS ‘AMG 11-Gearbox Man 35. Oil system Description Hyeraulc ol system ~ mechanical pitch response page 35-17 Ludicatng ol system . page 35-19 Data Oi dagram - draing no 2.0995 67-7 Spare part plates il pump with pinion late 2.3515 it profitor plate 2.3520 Stand-by oll prefiter . plate 2 3522 Ol distributor late 2 3525 Lubricating ot fiter ceesersees plate 2 3530 Counter pressure valve cove plate 2.9545 Pitch control system plate 2 3860 ‘Actuator for clutch function plate 23555 Oil accumulator plate 2 2560 Dipatich «ssasssessssssseenss plate 2 3565 Internal pipes: ; ; plate 23570 Extomal pipes ...ee cece ; plato 2 2575 Lub. oll pipes for PTO... .[Link] plato 2 9580 Feease oo. 235 page 35-16 AMG 11-Gearbox (ed Hydraulic oil system - mechanical pitch response ‘The gearbox operates wih 8 different oll pressures, All supplied from the same pump: 1. Servo oll pressure 2. Clutch oll pressure 3. Lubricating oil pressure Oil distributor ‘Tho ol distributorhousing contains a double acting non-retumn valve, >ressure control valve for servo ol pressure and a pressure Contra valve for lutch ol pressure. Servo oil pressure The design ofthe pressure control valve for servo ol pressure will automatically in- crease the pressure as soon as a pitch change has been ordered, The surplus of oll released from this valve i lubricating allthe bearings. ‘The surplus of ol released to the lubricating oil system will drop as long as pitch change takes placo and consequently the lubricat- ing oil pressure will drop. Doube acting i actuator supply non-atr foretycn frompum —vaye SPOS Ajusiment ‘retuten a pressure onto ee ctuteh ‘ont pressure vaio va Pon Serve FO presse Ajusient Spot oto ha ob Pessoa: ! system a Oil distributor Peloase 2 9581-02 page 95-17, AMG 11-Gearbox Clutch oil pressure ‘The servo oll pressure is reduced to clutch oil pressure by means oft cluich ol pres- ‘sure control valve inthe oi distributor Suto The clutch oll pressure car never be higher than the servo oll pressure. A solenoid valve on top of the oi distributor will direct the clutch ol ether to clutch in or to alutoh out The solenoid valve can be operated man- wally. 2 Sotenotd valve for clutch function ‘At end of sore elder UE ge Uap onto at Fonvard ond of ‘servo oyinder Pitch control valve ‘The pitch control valve controls the cilfiow Into the servo cylinder for pitch contro, It ‘also controlles if the pressure has to in- ‘rease when the pitch has to be changed. ‘As long as the pitch contol valve is closed the servo oll pressure willbe at normal level ‘Two pipes connect the ol dstributor with the pitch control valve, The pressure in these {wo pipes is the same as long as the pitch Control valve is closed. This makes maxi- ‘mum cad against the spring forthe servo ol pressure control valve, ‘As s00n as the pitch contol valve fs moved to ahead or astern the pressure at the end Cf pressure control valve wil drop and the ‘servo oil pressure will Increase, ‘Connection to piston rod t Pot Seno of A tomat di- ' ‘ioutor Section of pitch control valve Release 2 51-02 page 35-18 MAN AMG 11-Gearbox Lubricating oil system ‘The surplus of ol rom the servo oll pressure ccontral valve isledtoa cooler anda fine filter before entering the gearbox for lubricating (of gear wheels and bearings. “The lubricating oll pressures adjusted on a pressure control valve, Pressure control valve Foioase 2.9581-02 page 35-19) Cl ont detvered a5 part of compote 50 Compt soing packet WG oi 2 i ia * Not spare part Mounting of ult ono pump ‘soon fom after be 3 € i & } - Forengine fuming eotntor ‘aockwie SS tung ceowise Alpha pump with pinion Piano 2:3515-08 MAN Baw TIRTEWO | PROD TENT 3501207 8 sosis-oa | aavia 1 puwe ne PART DESGRIPTION wear 1 | HSINGON SOCKET HERD CAF SCREW 2 | 1 pump countes cLocemse NProse a | oxsker «| stop sonew wmarioN Lock 3 |. «| pmion Fon o1 puve,eoe00 RPM 1 | DEEP GROOVE BALL BEARING | revannc rie 9 | stance rina 10 | enconna 11 | suPPoRTNG ING 2 [one 13 | oisraice ana | meraniwo ria 20 _| SEALING PACKET FOR WANG PUMP NETO ise no Pie it prefiter AMGR/I1/16 2.3520-03 MAN Baw PURE WO] PROD WENT 504.20 4468 2esoos | salois oot prerisen a PART DESCRIPTION weir 3 | RAGRETICFITER, COMPLETE a | exaaon sour x2 | Torcover aa | casker ne | FUTER HOUSING as | spur en as | spre aa | spre wo | euDE Bak aie | wacnene nop, ccurtere e_ | Hexagon nur ve | spur en avs | mren answer eee ys Stand-by ol prefiter ANG Piston 2.3522-05 PLATE WO | PROD IDENT zasee-os | aacvis SSTAND-8Y OIL PREFILTER, 05.01.20 4183 PART DESCRIPTION. WeignT KiLos. ‘BREFILTER WITH FLANGES HEXAGON NUT BOLT GASKET FLANGE GASKET BOLT GASKET pour nut cOvER HEXAGON SCREW FILTER ELEMENT Patt Complete ot trtor ‘Servo of pressure Far cuten ot Cutch prossure Suetetee “gether. Erekepcalad Ielodepelln oes eee caunnete’ "Can ottetwaur cennntite” "eat tr tomte etnate Geta cunntte e a ee ‘9 S708 Fp] Sas 4 BR § ‘ i qh -ee4 par Tobe placed onto ator 1617 18 \ Steno ot ctbutor Preesuresensiv snitch must avays be placed onthe tons ofthe ol tor il distibutor ANG 8 Plate no amar | 23525-02 ANGIE MAN Baw PLATE NO | PROD IDENT 29595-02 aacvis lL DISTRIBUTOR 05.01.20) «465 PART DESCRIPTION WEIGHT iLos' ‘OIL DISTRIBUTOR AVG 8.1.76 \VALVE CONE FOR OIL DISTRIBUTOR aus SLIDE VALVE ANGS4.11.16 ‘SPRING ‘TIGHTENING Disc ‘SEALING FING cover HEXAGON SOCKET HEAD CAP SCREW HEXAGON NUT HEX SOCKET SET SCREW WITH DOG POINT SPRING ‘SEALING FING ‘SLIDE VALVE ust asker HEXAGON SOCKET HEAD CAP SCREW FLANGE HEXAGON SOCKET HEAD CAP SCREW FLANGE HEX SOCKET SET SCREW WITH DOG POINT LOCKING PLATE Fo3 SLIDE BUSH HEXAGON SOCKET HEAD CAP SCREW SEALING FING PLuG SCREW lL DISTRIBUTOR AWGS.a.1.16 SEALING RING HEXAGON SCREW WITH NYLON Lock (a2) Piso no Awagiit/16| 23530-01 Lubricating ol fiter ; i MAN Baw PLATENO | PROD IDENT aaievis LOWMIGH PRESSURE FILTER (0501207 65 PART DESCRIPTION WEIGHT iLos' TUBRIGATING Oi FLTER, COMPLETE ‘VENTING SCREW GASKET FOR VENTING SCREW COVER COMPLETE ‘SEALING FING FILTER CARTRIDGE [Link] SEALING FING LAMP ‘QUIDE FOR FILTER NSERT PLU scREW AWE ‘SEALING FING ‘SEALING FING FILTER BASKET ‘SEALING FING ‘SEALING RING GASKET ‘SPING FOR [Link] PLUG SoREW suo, WASHER HEXAGON NUT stu SPRING (GUIDE cove ‘SEALING FING FITTED SCREW cuck Pus nur WASHER WASHER scrEW Pla a Alpha Counter pressure valve ANGST /I6: Piste na 2.3545-01 MAN Baw PLATEWO | PROD IDENT "05.05.20 4469) 2955-08 saevia [BACK PRESSURE VALVEVSAFETY VALVES. Tew WeiGHT BG, PART DESCRIPTION wera ‘SPRING 7 2 3 6 | sPrNa: 5 0 ‘SLIDE VALVE FLANGE FOR SPRING JACKET HEXAGON SOCKET HEAD CAP SCREW JIRCKET TIGHTENING O16 ‘SEALING FING HEXAGON NUT ‘GOUNTER- PRESSURE VALVE HOUSING HEXSOOKET SET SCREW WITH DOG POINT 18 | HEXAGON SOCKET HEAD CAP SCREW tr | COUNTER-PRESSURE VALVE, COMPLETE a | asker 12 | cover 4 | stud 15. | Hexacon nut 16 | Gasker 18 | casker we | FLANGE ao | sus: at_| HEXAGON NUT | m2 “6 <4 L at 64 6% et 45 d < View A-A Ue ea \ 930 39.94 ou 2 fo a 2 . ve 9895 7778 42 37 387578 5 z Plas no Alph ich contra system Await | 23550-01 Page 1 (2) MAN Baw PLATE WO] PROD IDENT anes PITCH CONTROL SYSTEM (050.207 «485 ew No’ ‘PART DESCRIPTION WEIGHT KiLos' ZSSSSERRERESSRSRRREK ‘ELEGTRO-MEOHANGAL ACTUATOR stu 'SELF-LOCKING HEXAGON NUT BRACKET FOR ACTURATOR, STE. SPRING PI BAKELITE BALL PIN FOR HANDLE HEXSOOKET SET SCREW WITH CUP POINT SSNAP-LOCK FORK FOR CROSSHEAD HEXAGON SOCKET HEAD CAP SCREW INTERMEDIATE PART HEXAGON SOCKET 4EAD CAP SCREW HEX SOCKET COUNTERSUNK HEAD SCREW coven HEXAGON SOCKET 4EAD CAP SCREW SIGN NO 272 scREW SIGN NO 269 SCREW HOLDER FOR SIGN POINTER HEXAGON SOCKET _OW HEAD CAP SCREW CROSSHEAD WIPER SEAL HOLDER FOR TELESCOPE ROD HEX. SOCKET CAP SCREW W NYLON LOCK ANGLE BALL JOINT WITH NUT. PINBOLT maxas HEXAGON NUT GUIDE FOR FORKE® ARM FORKED ARM HEXAGON NUT PIN FOR REVERSING SDE BALL JOINT WITH EXTERNAL THREAD M10 ‘SLIDE VALVE HOUSING FOR REVERSING SUDE/BUSH AMG,16,2920 594 LOCKING PLATE FOR SUDE BUSH LOCKING PLATE WITH TAB AND WING HEX. SOCKET CAP SCREW W NYLON LOCK MAN) Ww ale 4 a Ne Plano Alpha Pe conta tom men | 2355001 Page 2 (2) MAN Baw PLATE NO 29550-01 PITCH CONTROL SYSTEM (050.207 446 Trew No" PART DESCRIPTION WEIGHT KiLos’ SeeIeueegrgsesseres yyesegeaeare aadaasa ‘SEALING ING PLUG SCREW RETAINING RING FOR SHAFT ‘CONNECTING LINK REVERSING SLEEVE INTERMEDIATE PIECE SPRING WASHER RETAINING ING FOR BORING HEXAGON SOCKET HEAD GAP SCREW SECURING FOR SHAFT PIN FORK FOR GROSSHEAD PIN FOR CROSSHEAD [ARM FOR CROSSHEAD BAKELITE BALL PIN FOR HANDLE SPRING PIN SPRING Pitt HOLDER FOR HANDLE SHAFT FOR EMERGENCY RUNNING HEX. SOCKET COUNTERSUNK HEAD SCREW BEARING BUSH, 018% 15, SECURING WASHER PIN FOR REVERSING SLIDE ‘COVER BY CROSSHEAD HOUSING ‘COVER ‘CROSSHEAD HOUSING HEXAGON SOCKET 4EAD CAP SCREW HEXAGON SOCKET 4EAD CAP SCREW [GUARD FOR ACUTACOR, stu HEXAGON NUT ‘CABLE TIES, NYLON 40x68 SLEEVE BUSHING FOR SLIDE VALVE SLIDE FOR REVERSNG ‘GASKET PLUG ScREW ater ‘Actuator for clutch function AMG anins Piero 2.3555-04 PLATE NO (050.207 4465 2.9655-04 ACTUATOR FOR CLUTCH FUNCTION TEM Weight Be PART DESCRIPTION Pa "ANGLE CONNECTOR SEALING RING BUTTON FOR SOLENOID VALVE COMPLETE SEALING RING Coll. FOR SOLENOID VALVE FLOW REDUCTION VALVE. HEXAGON SOCKET 4EAD CAP SCREW SOLENOID VALVE, COMPLETE Section A-A, ll accumulator ANIGBIIT/N6 Paaero 23560-05, MAN Baw PLATE NO | PRODIDENT (05.0.20/ 4465 29560-05 | aacvis OL ACCUMULATOR Tew Weigh BS PART DESCRIPTION waar HEXAGON SOGKET HEAD CAP SCREW HOLDER FOR ACOLMULATOR, PART 1 ‘SELF-LOCKING HEXAGON NU it [BRACKET FOR ACCJMULATOR ACCUMULATOR 1.4 ITER HEXAGON SOCKET HEAD CAP SCREW WASHER [ADAPTER FOR ACCJMULATOR PRESSURE GAUGE, 0-40 BAR, Patera Front end section Dipstick AMG tt Patera 2.3565-01, MAN Baw PLATE NO (0501.20/ 4465 2605-01 ppsrick Tew WeiGhT BS PART DESCRIPTION weer 1 | PIPE FOR DIPSTIOK 2 | piestick 3 [pws pean jacinta 418 1617 1819 2021 BBM 2s \ ones aI - a Heeb — l 7 mig 7e5 4 3 2 Not used when Flostar mountas & see Plas Alpha teal os auc | 2357006 MAN Baw PLATE WO [PROD IDENT acuta OL PIPES, INTERNAL 05.01. 20/ «465 PART DESCRIPTION ‘WEIGHT KiLos. eeteuesene ‘GASKET ‘SUCTION PIPE WITH BRACKET stu LUB OI. DISTRIBUTION PIPE SILICONE ELASTOMER PASTE (CAF 730) ‘GASKET HEXAGON BOLT BANIO COUPLING ‘SEAMLESS HYDRALUC PIPE, 012 15 [STRAIGHT MALE STUD COUPLING GASKET NIPPLE ‘SEALING FING HEX. SOCKET GAP SCREW W NYLON LOCK SILICONE ELASTOMER PASTE (CAF 720) FLANGE SEALING FING SPAING PIN ‘SILICONE ELASTOMER PASTE (CAF 730) FLANGE HEXAGON HEAD PLUG SCREW NIPPLE NIPPLE GASKET HIGH PRESSURE HOSE 1/2" COMPLETE HOSECONECTION FOR AV. SLIDE SEAMLESS HYDRALUIC PIPE, 12% 15 [BRACKET FOR HOSE, COMPLETE = —Luticatng a sere of == +08 auction “Only for AMG 8 ‘Included in item 5 for AMG 8 & 11 eee — popsssaet= es} wae | al som OF | 3 \ | | sac ol seat ae | Lh hs eal ee A cel fous pal an (Oit distributor ‘Plach control Alpha External pipes AMG 811,16 ky Piano 23575-08 MAN Baw FRENS —| PROOENT 0120/5463 pomsco | saris OL Pres. ETERNAL ew PART DESCRIPTION wear 7 PES: GEARGOKSRERITERS an | Puan seawess set pe, om.ax29 48 | Pe senos, cone te | pance rom pnerTen 10 | SeancronPrenten {| Hexagon sockeT HEAD caP sonew tr | rercoue Fusion to. | Seana ronnrenEDiATe FLANGE 4 | nexacon nur 11 | pe cusne 1 | Hexacon sur te | ruane ron cenrsox tt_| Seana ron GEAraOx tit | sexacon 300 fn | Hexacon nur to. | FLANGE Fon aeanaox 6T-09 {P| SEAING FOR G=Ar8Ox 1-8) ta. | Hexacon wor in | Pipe sorrow 0051 mn | PPE FROM Ol. PREFLIER TO PUN 2x. | PUAN SeaMtess STE IPE, enx29 2e_| Pie BeNos, 90060, 20 | LANGE FOR OIL PLM 20 | SeALNG FORO Pune e_| nexacon 80.r a | rexconnur 23. | puanoe ron [Link] Di_| Seas Fonrenten a | rexcon screw 9. | PPE -PuMP TO ou OSTREUTOR KY sx | PUAN seanurssoreL ripe omnes sa | pire aeno, so DEGrers, «8x20 so. | rexscon sour e_| rexacon wor a | Seana ron ou pve 6. | wetons sox x20 ot_| STRAIGHT MALE sTu0 COUPLING 3 | strwexr couPins ‘+ | O1LPPE Fnow [Link] cooLER sh | PLAN Seas SEL PPE, ond ax26 == Lutratina of sere of = = +0 suction joni torawa Back prosaue ‘ave My MN P im I g. tame | 2 ) wl teh Foch Aston] | Anes | 10 ‘OF debe L Pech cool tom ‘eke I | ° I ! I = | included in item 5 for AMG 8 & 11 Alpha External pipes AMG 811,16 Piano 2.3575-08, MAN Baw PERFEWO—|-PRODIDENT osora07 8 renre-oo | sacra OAL PPES. TERNAL = PART DEscnPTION aT “| PPE BEN oO DEGREEE IKE wt 4e_ | Raat Fomon cooLEn ‘o | seainaronot coouen te | nexcon screw a | wexacon or fa. | Hewaon nur ‘| peevowen owns «| Hexacon screw 4 | ust ron ot osmauron sic_| SeaLne Fonot osrmpuToR 4 | exaaon sooxerHeaD car sonew | pe rrow [Link] PLTERE PALE sh | ruaniseamess sexi PPE. omaxae 2 | PREEND,@oD¢REES. 8x20 se. nrerwepure FLANGE 8 SEALING FORIVTERMEDITE FLANGE se | AWE FOROILFLTER se | nexacon sot sa | Pre [Link], 0483 S| HExAaoN socKeT HEAD CaP Sc=EW BeseRee@BGRSRaFo fe Rea HEXAGON SCREW HEXAGON SOCKET HEAD GAP SCREW HEXAGON NUT PIPE CLAMP. HEXAGON BOUT OIL PIPE F [Link] FILTER T GEAREOX PLAIN SEAMLESS STEEL PIPE, 049.9x2.6 PIPE BEND, 90 DEGREES, aa.3X2.6 Mt FLANGE FOR OI FITTER HEXAGON BOLT WELDING SOCKET, 63/4% 20 HEXAGON HEAD PLUG SCREW SEALING FOR PLUGEF WELDING SOCKET FOR THERMOMETER ‘THERMOMETER POCKET WITH SCREW SEALING FOR THERMOMETER, WELDING SocKET HEXAGON HEAD PLUG SCREW SEALING FOR PLUG EL WELDING socKEr FLANGE FOR GEARBOX = —Lutricatng ot sen of = = + Oi suction Bul on ‘ceypultor utes Jovten her oa Aster | Anood On detnbutce ‘teh corral ‘book I I ‘ SS * Only for AMG 8 ** Included in item 5 for AMG 8 & 11 ata waa) Pa Alph tera pes alte | asso i KV MAN Baw PLATE NO ‘PROD IDENT (05.01.20 / 4468 29575-08, 44Kv19 OL PIPES. EXTERNAL on PART DESCRIPTION ee @ | SEALING FOR GEARBOX 60 | HEXAGON BOLT 7 | O1PF [Link] FILTER T THBEARING 7A _| SEAMLESS HYDRALUC PIPE, 015 X 2 78 | BANJO COUPLING 70. | PIPE HOLDER HALF-PART, 15 Mh 7. | WELDING-ON PLATE 7@ | HEXAGON SOCKET HEAD CAP SCREW TF | ADJUSTABLE ELBOW COUPLING 9 | [Link] F DISTRIB. READJ SLIDE 94 | SEAMLESS HYDRALLIC PIPE, 018 x2 98 | BANJOCOUPLING 2 | PIPE GLAMIP WITH FUBBER 980 | HEXAGON SOCKETHEAD CAP SCREW 10 | [Link] F DISTAB.T SUDE 104 | SEAMLESS HYDRALLC PIPE, 010% 1 108 | ADJUSTABLE ELBOW COUPLING CoMPL. 11 | ENGAGEMPIPE F DSTRIB.T PUMP HOUS, 110 | SEAMLESS HYDRALLIC PIPE, 0152 11D. | BANJO COUPLING ‘16 | MALE STUD L-couPLINe 12 | DISENGAGEMENT PPE 120 | SEAMLESS HYDRALLIC PIPE, 0152 120 | BANJO COUPUNG 13. | ENGAGEMENT PIPE 194 | SEANILESS HYDRALLIC PIPE, 0152 198 | BANJO COUPLING 19¢__| WELDING sockET 130 | PLUG scREW 1s | GASKET 14 | OILPIPE FOR STAND-BY PUMP 14a _| PLAIN SEAMLESS STEEL PIPE, 048.9x2.6 140. | FLANGE FOR OIL DISTRIBUTOR 140 | HEXAGON NUT Me | HEXAGON SOCKET 4EAD CAP SCREW 14F | SEALING RING FOROIL DISTRIBUTOR 14G__ | PIPE BOTTOM, 080 1 mM 14H | FLANGE FOR STAND-BY PIPE 141_| PIPE HOLDER, 48.8 " Alpha Lub. oll pipes for PTO Amant Pie no 2.3580-02 MAN Baw ATEN] PROD ENT 05.0 297 48 2aseo.c2 | sia [Link] Pipes FoR PTO be PART DESCRIPTION Wear Gt_| SEAMLESS HYORALUGPIPE B10X1 22 | panvo couruna 29_| REDUCING ADAPTOR, MALEIFEMALE eee (sen) 40. Pitch indicator Des Pich indicator os. ecesesseeee page 40-21 Spare part plates, Piich indicator plate 2 4010 Pitch indicator arrangement plate 2.4015 Peles oe. 2 40 page 40-20 ‘AMG 11-Gearbox MAN Pitch indicator “The purpose of the pitch idicator is to give The potentiometers mounted in a housing incication ofthe actual prpelior pitch. ftted on the gearbox intermediate par. ‘The arrangementincludes.a potentiometer, The potentiometer is directly connected to connected indirectly to theservo piston rod. one or more analog pitch indicator instru: ments. Pitch indicator mounted on gearbox - seen from above Felease 2 4aa1-22 page 40-21 (23) 4 2 18 1p at 7 y6 ts we \ Plas no Pitch indicator AMG 2 4010-01 MAN Baw PLATEWO | PROD IDENT aaevis PITCH INDICATOR "0501.20, 4463 PART DESCRIPTION ‘WEIGHT KILOS. PLUG SCREW RETAINING RING FOR SHAFT HOLLOW-POINT SCREW WITHNYLON Lock \RE WHEEL FOR FOTENTIONETER BUSHING ‘SHAFT FOR POTENTIONETER ‘SEALING FING SEALING FING HEXSOOKET SET SCREW WITH CUP POINT SEALING FING CONTACT DISC ‘CABLE CONNECTOR POTENTIOMETER WITH WIRES. WASHER HEXAGON SOCKET HEAD CAP SCREW ‘TERMINAL ROW SLOTTED CHEESE HEAD SCREW HOUSING FOR POTENTIOMETER DISTANCE PIPE [BLIND PLUG SCREW icRo-swrrci ‘BLIND PLUG SCREW HEXAGON SOCKET HEAD CAP SCREW PITCH INDICATOR MAN Baw PLATENO | PROD IDENT (0501-207 a6 2aois-o2 | aakvis PITCH INDIGATOR ARRANGEMENT. Trew ma peaen WEIGHT HS DESCRIPTION bi SPRING TIPLE WITH SCREW PIN SCREW M12 SPEC. T 2 3 4 | wire Lock 5 | BRACKET FOR TURNBUCKLER 6 8 9 | HOLDER FOR WIRE 10 | HEX SOCKET GAP SCREW W NYLON LOCK 1 | serine PIN FOUNDATION FOR PIPE HOLDER HEXAGON SOCKET HEAD CAP SCREW STEEL WIRE, 01.6 Mi 12 | BRACKET FOR TUAVBUCKLER 60 | GUIDEPIN FoR SLIDING SLEEVE AMG 11-Gearbox Baw 45. Power take-off Description Power take-off sess page 45-23 Data PTO arrangement drawing no 2 05 68 03-9 ‘Spare part plates Power take-off seeteerieeeeeeeneeseeseess plata 24515 ‘Shaft for power take-off coeseteeees late 2.4525 Folease foo 245 page 45-22 ‘AMG 11-Gearbox Man Power take-off ‘The power take-off shaft is placed in two for oll pump drive on the clutch shaft. PTO. slide bearings. The gearwheelonthepower shaft speed will normally be either 1500 oF ‘take-off shaftisinmeshwith the gearwheel 1800 rpm. Power take-off AMG 8/11/16- section Fiolease 2 4541-02 page 45-23 Ker according te Or 6805 ; AB0r1 2x1 25. i anor PTO arrangement 2056803-9] Power take-off AMG Amant Piston 24515-04 MAN Baw (05.0120/ 4485 PLATE NO POWER TAKE OFF “WEIGHT | PART DESCRIPTION weer jSHING FORPTO [ABT BEARING SUPPORT COVER FOR POWER TAKE-OFF HEXAGON SOCKET HEAD CAP SCREW SILICONE ELASTOMER PASTE (CAF 730) HEXAGON SOCKET HEAD CAP SCREW OIL SEALING ING. ‘STRAIGHT MALE STUD COUPLING PLUG SCREW Pian Baw i i fi i i awe Piso no ‘Shaft for power take-off AMG | 2.4525-04 MAN Baw BLRTEWO | PROD IDENT 0501.07 4463 zasasoe | sais SHAFT FOR POWER TAKE-OFF TEM PART DESCRIPTION PTO SHAFT se6/000 ANG WeichT KiLos: AMG 11-Gearbox Baw 80. Instrumentation Description Instrument panel... : . + page 80-25 Spare part plates BM tacho sensor plate 2 8015 Thermometer plate 2 8020 Feleasetoo_280 page 80-24 MAN AMG 11-Gearbox Instrument panel With the VO gearbox type, the instument With the KV gearbox type, close coupled panos placed on the gearbox. with the engine, the gearbox instumenta- Itispossbletomake addtonalconnections 80" is located on the engine instrument for instruments located in the control room —_PaNel. and on the bridge. Example of an instrument pane! Foioaso 28041-02 page 80-25 MAN Baw BBM tacho sensor Awan Pate 0 2.8015-01 MAN Baw PLATEWO | PROD IDENT (05.01.20/ 4465 | 20015-01 aaevia TACHOMETER Tew ‘weignr i PART DESCRIPTION Sarr NIPPLE B-TAGHO SENSOR SPAING PIN ‘CONNECTION FOR FLEXIBLE CONDUIT FLEXIBLE CONDUIT HEX. SOCKET CAP SCREW W NYLON LOCK BACKET FOR TACHO PROBE 2.8020-01, AMG ‘Themometer MAN) Baw PLATEWO | PROD IDENT (05.0120, 4463 20020-01 aanvia “THERMOMETER Tew WEIGHT A PART DESCRIPTION a TA | THERMOMETER 0-100CS2-210F Nur RUBBER CAP THERMOMETER PIPE 0-toocis2-212F ‘THERMOMETER HOUSING 0-100C/32-210F RUBBER FING. RUBBER FING WASHER ‘THERMOMETER STEM BULB MAN’ AMG 11-Gearbox 82. Remote control equipment Description Actuator for adjustment of propeller pitch ............6.+.++ page 82-27 Emergency operation of propelie pitch... Copyright ©, 1997 MAN BaW Diesel AIS rar ‘Sensor no: Specifies all alarms and sensors used for tne propulsion plant acco rang to a separate sensor specification ist. Placed: Refers to the location ofthe alarm/sensor. Following capital letors are used: A= Onengine B= On gear C= In remote control system = In tacho converter = On separately supplied alarm panel In safety unit H.= Soparataly installed/supplied Group alarm: Indicates the alam group in which the alarm is classified “The folowing numbers are used ‘Stop main engine 2= Reduce load General alarm 4 = Failure in manoouvre systom Main engine stopped Insome cases 1 and § are trealed as interchangeable alarm groups, and therefore classified as group alarm 1 omarks: Used for various explanations. "This mark indicates one ofthe following: * Pressure is measured between the main pump and the double non-retum valve ‘= Ananalog sensor =m a a se 79940377 [Sw Fate atone ied zea 2 eae he ra ‘A4| _ Monitoring- and safety equipment_| _02(02) _ | MAN B&W Diesel avs| Ti cast aa Terminolog) 2.01 45 70-8 I Copyright ©, 1907 WAN BAW Discol A/S (aan) ‘parvo mom thse bean suite wat 98m lee! A. mare ki ow ‘SENSOR SPECIFICATION LIST - ABSTRACT ‘The sensor specification lists the list of the sensors Alpha Diesel use with our monitoring and safely system. ‘The list contains information apout make, type and characteristic values for the sensor. 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