Kumera Norgear 6FGC 335 Installation and Maintenance Manual PDF

INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
Total number of pages: 11
6FGC-335
FRONT-END GEAR
SERIAL NUMBER(S):
N98015
N98016
N98017
N98018
Shipyard:
NA
Hull number:
NA
Norgear Gearbox with clutch 1

MANUFACTURER
Kumera AS
Gneisveien 11
P.O.Box 2043
3202 Sandefjord
NORWAY
Tel: +47 33 48 54 54
Fax: +47 33 48 54 55
E-mail: sales@kumera.no
Web: www.kumera.no
MANUAL APPROVED
Date of manual: 05.12.2016 Issue no.: 1
Approved by KUMERA AS 05.12.2016 Engineer: JH
TABLE OF CONTENTS Page No.

1. General data 3
2. Technical data 3
3. General description 4
4. Installation 4
5. Hydraulic system 5
6. Control and alarm systems 7
7. Operating instructions 7
8. Maintenance routines 9
9. Spare part kits 10
10. Service 11
11. Storage 11
12. Warranty 11
13. Appendix 12
This manual should be considered as part of the gearbox.

Please keep it in a safe place!
Please make the manual available to any subsequent user.

1 GENERAL DATA
Gearbox serial number(s) N98015 N98016
N98017 N98018
Gearbox model 6FGC-335
Year built 2016
Classification society -
EXW delivery 38 & 42 - 2016
2 TECHNICAL DATA
Part list N401791A
Assembly drawing N1-02062
Dimension drawing N2-91378A Rotation CCW
Torsional data N2-91378A
Hydraulic diagram N3-04807
Control valve block drawing N3-05029
Total admissible input torque [Nm] 6685

Driven machinery Hyd.pumpx5
Specific input power [kW] 140x5
Max. input speed n 1 [rpm] 1000
Output speed n2 [rpm] 1200
Ratio [n2/n1] 1,20
Clutch type/ Max torque [Nm] NKH-7500
Clutch engagement speed [rpm] 600
Nominal clutch oil pressure [bar] 24
Clutch cooling oil flow [lpm] 0,3
Clutch oil alarm setting [bar] 20
High oil temp. alarm setting [°C] 80
System oil alarm setting [bar] 18
Start STBY p. alarm setting [bar] -
Clutch engaged alarm setting [bar] -
-
-
Clutch solenoid power supply 24 VDC El. oil pump power supply -
Cooling water type Fresh/Sea-water Oil group ISO VG 68
Cooling water inlet temp. [°C] 38 Oil quantity [liters] 50
Required cooling water flow [lpm] 39 Gearbox net. weight [kg] 1140
Max. water flow through cooler [lpm] 45 - -
Cooling water max. pressure [bar] 16 - -
Correct orifice size [mm] for max water flow through oil cooler:

3 GENERAL DESCRIPTION
This NORGEAR gearbox is designed as a front-end PTO drive with one or

more output shafts to power hydraulic pumps, fire pumps or electrical
generators.
The gear case sections are manufactured in grey cast iron. Gearwheels are
single helical case hardened steel with ground tooth flanks.
The built-in clutch is an oil operated multi disc type, sized to transmit the
rated torque continuously. The clutch plate sets are made up of alternate
steel and highly wear resistant sintered metal. The clutch is self-adjusting to
the limits of wear on the clutch plates.
All bearings are anti-friction type supplied from leading manufacturers.
The gearbox has been built to the Rules and under Survey of the
Classification Society indicated in Section 1.
4 INSTALLATION
Adjustable units (i.e. pressure limiting valves and lubrication control valves)
have been set for the specified pressure and oil flows during the Works test.
The gearbox is delivered with lifting eyebolts in place.
The gearbox seating should have a machined top surface and machined
supporting chocks should be used. “Chock fast” or other approved resin
compounds may be used if accepted by the surveyor. It is imperative that the
gearbox seating bearers are fully supported on their entire surface area
before the foundation bolts are tightened down. If not, the casing may be
distorted and gear tooth contact will suffer.
To simplify the alignment, the bearers are provided with threaded boltholes
for jacking screws at each corner.
Round discs or shim plates arranged one upon the other must not be used
as fitted pieces. The gearbox must be secured on the foundation against
displacement by four fitted bolts at the corners. When tightened all bolts
must be secured.
When a flexible coupling is fitted, alignment must be within the limits set by
the coupling manufacturer. If in doubt, please contact Kumera AS technical
department. This also applies to the output shaft and the connection to the
driven equipment.
If the driven equipment is mounted to the gearbox by a spigoted flange, the

correct alignment is ensured by our machining tolerances. Pump couplings /
spline sleeves should be greased with an NLGI 2 grease with long fibres.
No axial loads are allowed on input or output shafts.
Norgear Gearbox With Clutch 4

Installation also includes connection of cooling water supply to the oil cooler.
When installing a seawater cooling system it is required to install a good
filtration system ensuring not to clog the oil cooler. Ensure to install correct
orifice on water outlet side.
In addition installation includes electrical power to the clutch control solenoid
valve. Please refer to Section 2 for the required information on the above-
mentioned points.
The total oil charge is contained within the gear case. Oil filling and
breathing connections are provided. The oil grade and quantity will be found
in Section 2 and on the identification plate attached to the gear case.
5 HYDRAULIC SYSTEM
While running, all bearings and gear mesh are lubricated and cooled by the
mechanical driven oil pump and/ or an electrical motor driven oil pump.
The hydraulic system of the gearbox provides pressure oil to the hydraulic
clutch and lubrication oil to the gears and clutch. The system comprises an
oil pump, cooler, filter, valve block and distribution ring.
Clutch
The built-in clutch is a hydraulically operated multi-disc type. It has DNV type
approval.
The clutch plates are made of steel and sintered bronze. Normally the clutch
does not need any readjustment as the length of the piston stroke
automatically compensates wear of the discs. If this distance exceeds 9 - 10
mm, new clutch plates will have to be fitted.
Pump
The mechanical oil pump is usually assembled on the end of the input shaft
but another continuously running shaft may be used in special situations.
Oil cooler
The tubular oil cooler is placed on the pressure side of the oil pump. It is
mounted on the gear case and must have a continuous water supply. An
orifice ring must be fitted to control the water flow within the design limits of
the cooler. It is recommended to mount this on the outlet side of the cooler.
Filter
The oil filter includes a fibreglass cartridge, relief valve and a mechanical
indicator that shows when the cartridge must be replaced. The cartridge is
disposable - do not try to wash and re-use it.
Hydraulic valve
The electrically controlled valve block includes a solenoid valve (6) for
engagement and disengagement of the clutch, and a pilot valve (3) that
regulates the oil pressure in the clutch and also in the complete oil system.
The clutch cooling oil flow is adjusted to the correct amount by using a
needle valve on the clutch cooling oil flow meter.

The valve block has been set correctly during the test run at our Works.
However, if adjustment is necessary, use the following procedure:
1) Clutch cooling oil

This is set with the clutch in the disengaged position. The gearbox oil
distribution sleeve at the front of the gearbox housing has two pipes
leading to it. The one for the clutch cooling oil is going through the
flow meter.
When the engine is running at nearly full speed, turn the needle
valve on the base of the flow meter until it shows correct flow
according to Section 2, do not exceed or drop below this amount.
The flow will vary with the speed but this is quite acceptable.
2) Clutch pressure
The clutch pressure control is a pilot valve (3) adjusted by an Allen
screw with locknut, see control valve block diagram listed in Section
2.
Clutch pressure at normal running temperature is shown in Section 2.

To re-set follow this procedure:
a) Run the engine at the rated speed.

b) Engage the clutch.
c) Adjust the control valve (3) to give the specified clutch pressure
allowing + 1 bar with cold oil.
d) Lock the control valve (3)
e) If necessary, the clutch pressure must be re-adjusted at normal
operating temperature and nominal speed.
Pump test
If there is any reason to suspect that the cause of oil pressure loss comes
before the valve block in the system, it can be checked as follows
(ref. to control valve block diagram - see Section 2):
a) Check and replace the filter cartridge.

b) Unlock the pilot valve (3) and unscrew the valve.
c) Plug port B on the valve block (pressure oil to clutch).
d) Set the solenoid valve (6) to clutch engaged position.
e) Start the engine. Try to raise the clutch pressure to 25 - 30 bar by
turning valve (3) inwards.
f) If it is not possible to reach this pressure, the trouble source is
either the oil pump or a connection on the suction side.
g) If this pressure is attained, reset the pilot valve (3) at the pressure
given in Section 2 and re-connect the pressure pipe to port B.
Distribution ring
The distribution ring is on the free end of the input shaft and through it, the
pressure oil and cooling oil are lead to the clutch. The clearance between
the shaft and the bore of the ring when new is 0.04 - 0.08 mm. Clearance
greater than 0.15 mm may cause a pressure loss in the system because of
oil leakage. In this case the distribution ring must be changed.

6 CONTROL AND ALARM SYSTEM
The clutch engagement / disengagement is controlled by an electro-

hydraulic valve block to allow remote operation. Please see the Section 2 for
the correct electrical supply to the solenoid incorporated in the valve block.
Local manual operation is provided on the valve block to allow clutch
engagement in the event of electrical power loss and is a useful feature
when adjusting the clutch pressure setting.
Local reading gauges are provided for:

§ System oil pressure
§ Clutch oil pressure
§ System oil temperature
Alarm switches are provided for:

§ Low system oil pressure
§ Low clutch oil pressure
§ High system oil temperature
For alarm set points - please see Section 2.
The control solenoid and alarm sensors are wired out to a terminal box
mounted on the gear case. See Section 2.
7 OPERATING INSTRUCTIONS
Clutch
Do not engage the clutch at a lower speed than “Clutch engagement speed”.
Avoid clutching in at lower speed, as the clutch oil pressure may be too low.
It should also be avoided to clutch in at higher speed as this may load the
clutch unnecessarily.
When the gearbox is driving pumps with low resistance, for example fire
fighting pumps, the inner friction in the hydraulic operated clutch may be
higher than the resistance in the pump, causing the output shaft to rotate
when the clutch is disconnected. This is no functional fault.
Oil level
The gearbox is not filled with oil when delivered. The oil level can be
checked by means of the dipstick when the gearbox is stationary.
Approximate quantity is specified on the identification plate on the gear case
and also the recommended grade of oil. It is essential that the clutch does
not touch the oil because that may generate additional heat.
Lubricating oil circulation

The gearbox lubrication oil spray from the internal nozzles may be observed
through the inspection windows.
Cooling water
Check that the cooling water is passing through the oil cooler at the required
rate of flow. The water inlet and outlet connections on the cooler are
interchangeable on a two-pass cooler.

Lubricant recommendation
1. Lubrication oil
A high quality mineral gear oil with EP additives, having good anti wear
performance with low corrosion, oxidation and foaming properties must be
used. The oil must meet the FZG A/8,3/90 load stage 12+. In addition the
oil must have a flash point not lower than 150°C.
The oils listed below have been used with good experience. If you wish to
use other equivalent gear oils, contact your oil supplier, ensuring the
mentioned requirements are met.
Note: Any extra additives must not be used. In such case our warranty will
not be valid.
Typical oils for NORGEAR gearbox with built-in clutch
BP Energol GR-XP 68
Castrol Alpha SP 68
Esso Spartan EP 68
ExxonMobil Mobilgear 600 XP 68
Shell Omala oil 68
Texaco Meropa 68
Statoil LoadWay EP 68
Synthetic oil grades meeting the above requirements in addition to be

compatible with mineral oils may be used. Contact your oil supplier for
recommended grade.
2. Lubrication grease
A grease of type NLGI 2 grease with long fibres should be used for re-
greasing all pump couplings and spline sleeves.
Oil temperature
Normal oil temperature in the gearbox sump will range from 40 - 70 deg. C.
The temperature switch is set at 80 deg. C and it will initiate an alarm at
higher temperatures.

8 MAINTENANCE ROUTINES
Daily
Check of oil level prior to start, and status on oil filter indicator, oil pressures
and temperatures during operation.
Monthly
External control for oil leakages and fixture of built on components.
Quarterly
Oil samples to be sent for analysis. In case offer anodes are installed
replacement at 50 % corrosion. With higher corrosion more frequent checks
are required.
Annually
Change oil and replace oil filter elements. Grease all splined shafts and shaft
seals. Demount oil pump and lubricate splined oil pump drive shaft. Inspect
gearbox inside for possible wear and damages by removing inspection
cover. In gearboxes with built in hydraulic clutch it must be checked that
clutch discs moves freely by using a screw driver through inspection holes at
clutch housing outer rim.
Every 2-3 years

Perform alignment control, check for abnormal vibrations and check for
unusual noise level. Control of gear mesh flank contact and condition of oil
cooler and all built in components including pipes and pipe fittings. Function
control of alarm system and measure oil pressures and temperatures.
(Authorized Kumera service personnel are recommended)
Every 5 year
Complete gearbox overhaul.

Recommended actions with reference to operational hours:
300 hours:
First oil change and replacement of lubrication Oil filter element.
2500 hours:
Replacement of lubrication Oil filter element and sample of lubrication oil for
oil analysis.
5000 hours:
Regular change of lubrication oil.
10000 hours:
Perform alignment control, check for abnormal vibrations and check for
unusual noise level. Control of gear mesh flank contact and condition of oil
cooler and all built in components including pipes and pipe fittings. Function
control of alarm system and measure oil pressures and temperatures.
20000 hours:
Complete gearbox overhaul.
9 SPARE PART KIT
We strongly recommend you keep in stock onboard basic spare parts to

avoid any shutdown during operation.
Such parts should include:
n Oil filter elements – on board vessel

n Oil cooler – onshore at local site
n Oil pump – onshore at local site
n Solenoid valve – on board vessel
n Flow meter – on board vessel
n Pressure gauge – on board vessel
n Temperature gauge – on board vessel
n Pressure switch – on board vessel
n Temperature switch – on board vessel
n Bearing set – onshore at local site
n Shaft seals – onshore at local site
n Clutch plates, seals & springs – onshore at local site
Only original spare parts must be used. Please contact our After Sales department to
ensure original spare parts are being supplied.

10 SERVICE
Kumera AS offers worldwide service and planned inspections. Please do

contact our After Sales department if you need assistance.
Tel. switchboard: +47 33 48 54 54

24 hours service: +47 95 24 64 60
E-mail: service@kumera.no
11 STORAGE
The inside of the housing is anti-corrosion protected only intended for short
time protection during transportation and a short storage time if stored in a
covered dry place.
All bright parts, i.e. flanges and drive shafts, are coated with a preservative
before shipment from Kumera AS, intended for short time protection only
during transportation and short time storage in a covered dry place.
Connections i.e. oil and water, which cannot be completed until the unit has
been installed are closed with plugs at our Works. Any connections or pipes
that must be modified in the course of installation should definitely be
acidified and cleaned before use.
If the gearbox cannot be installed immediately on delivery to the shipyard, it

should be stored in a dry and temperate place. Ensure protection of both
inner and outer parts. For long time storage the unit should be filled
completely with oil, the breathing plug sealed, and the shafts must be turned
every second month so all shafts rotates minimum a half turn. Other
additives intended for long time storage may be used.
12 WARRANTY
Please see the Contract for the particular gearbox regarding terms and
conditions.
Following additional Kumera AS terms are always part of our deliveries:

Warranty covers replaced parts only.
Warranty covers working hours used by Kumera AS service
personnel only.
Warranty does not cover travel expenses, hotel, daily allowance and
other related costs.
Warranty does not cover any indirect loss, loss of profit and/ or any
consequential damage.
Any modifications and/ or work done on the unit by unauthorised personnel

without a written consent of Kumera AS will make the warranty invalid.
Kumera AS shall have copy of aligning data together with a report after
start up of the system for the warranty to be fully valid.
For the warranty to be valid, all instructions in this manual must be
followed!

Manufacturing part list Part List # N401791A
6FGC‐335
Kumera Sales Order #: SO02359 Date 05.03.2014

CLIENT PO. #: 30000124 Revision
Assembly Drawing N1-02062 Create JH
Dimension drawing, Port N2-91378A Check SS
Dimension drawing, Stbd - Approve J.H.
Hydraulic/Electric drawing N3-04807 CLASS -
Item no. Pos. Qty. Item name Notes
N300384 1 1,0 HOUSING MACHINED 6FGC‐335

N401920 2 1,0 SHAFT CLUTCHED
N401921 3 3,0 SHAFT FIXED
N401922 4 1,0 GEAR WHEEL CLUTCHED
N401923 5 3,0 GEAR WHEEL FIXED
N300012 6 1,0 CLUTCH HYDRAULIC NKH‐7500
N2002038 7 1,0 TOOTHED RIM
N101150 8 1,0 SPLINE SLEEVE
N401924 9 6,0 SPLINE SLEEVE
N2016551 10 1,0 OIL DISTRIBUTION BRACKET
N100976 11 1,0 OIL DISTRIBUTION SLEEVE
N2087863 12 6,0 PUMP BRACKET
N2073030 13 6,0 COVER BLIND
N2016548 14 1,0 COVER SEALED
N2087860 15 3,0 SPACER
N2058527 16 1,0 SPACER
N2016545 17 1,0 SPACER
N2016544 18 1,0 SPACER
N102006 19 1,0 SPHERICAL ROLLER BEARING
N101385 22 2,0 DEEP GROOVE BALL BEARING
N2033042 23 1,0 RECTANGULAR KEY
N100478 26 6,0 HEX.HEAD SCREW
N100309 33 6,0 CAP SCREW
N100216 34 36,0 CAP SCREW
N100311 35 36,0 CAP SCREW
N100320 36 6,0 CAP SCREW Mv = 333 Nm
N100327 37 8,0 CAP SCREW
N100775 38 6,0 DOWEL PIN
N100728 39 18,0 DOWEL PIN
N100704 40 2,0 DOWEL PIN
N100687 41 2,0 DOWEL PIN
N100855 42 2,0 TAPER PIN
N100881 43 4,0 EYE BOLT
N2000072 44 1,0 PLUG
N401791 - SO02359.xls 1 of 2
N101067 45 1,0 DIP STICK PLUG
N101070 46 1,0 BREATHER PLUG
N2000074 47 1,0 FITTING
N400245 48 2,0 OIL SEAL
N2000075 49 1,0 COVER INSPECTION
N2005236 50 2,0 COVER INSPECTION
N102813 51 2,0 O‐RING
N102285 52 1,0 CIRCLIP. SEEGER
N101028 53 1,0 TEST VALVE
N401945 54 1,0 HYDRAULIC VALVE BLOCK Rev. A
N101054 55 1,0 FLOW METER
N101060 56 1,0 TEMPERATURE SWITCH
N103284 57 1,0 TEMPERATURE GAUGE
N101017 58 2,0 PRESSURE SWITCH
N101052 59 2,0 PRESSURE GAUGE
N100909 60 1,0 OIL FILTER
N102565 61 1,0 OIL PUMP
N101112 62 1,0 OIL COOLER Max Ø=128 mm
N104730 63 1,0 EKM ZINC ANODE
N2000176 64 1,0 TERMINAL BOX
N401791 - SO02359.xls 2 of 2
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Data sheet
Pressure Test Valve MBV 5000

Danfoss block components
The block concept has been developed to save The range contains block pressure controls, block
space, weight and costs. pressure transmitters, block test valves and
The product is intended for use in many applications, accessories.
for example: monitoring, alarm indication,
shut-down, diagnosing on equipment such as The concept meets the strict demands on marine
motors, gears, thrusters, pumps, filters, equipment, including EU stipulations on such
compressors, etc. products.
Block valve MBV 5000 MBV 5000 is a block valve designed in many different Advantages
configurations for use in the marine industry. • Compact design
The valve meets demands for fast installation, simple • Light material
isolation and easy test pressure connection. • Many configuration possibilities
• Low installation costs
• Fast and easy to operate
Technical data Performance

Burst pressure 720 bar
Pressure
Operating pressure 0 to 180 bar
Operating temperature −20ºC to 120ºC
Temperature Ambient temperature −20ºC to 120ºC
Temperature of medium −20ºC to 120ºC
Mechanical
Housing Anodized AlMgSi1
Nipple AlMgSi1
Material
Ball 1.4404
Gasket PEEK/FPM
Input G¼
Pressure connection
Output Flange / M5 x 8
Data sheet Pressure Test Valve MBV 5000
Specification and code Pressure connection: G 1e4. Test pressure connection: M16 u 2
numbers for standard types Symbol Type Output Weight Length Height Width Type no. Code no.
no. kg mm mm mm
Output
x1 0.4 36 MBV5000-1111 061B7000
x2 0.8 76 MBV5000-1211 061B7001
1 x3 1.2 116 80 40 MBV5000-1311 061B7002
x4 1.6 156 MBV5000-1411 061B7003
x5 2.0 196 MBV5000-1511 061B7004
Input
Output
x2 0.8 76 MBV5000-2211 061B7005
x3 1.2 116 MBV5000-2311 061B7006
2 80 40
x4 1.6 156 MBV5000-2411 061B7007
x5 2.0 196 MBV5000-2511 061B7008
Input
Output
Test pressure connection x2 0.7 76 MBV5000-3211 061B7009
x3 1.0 116 MBV5000-3311 061B7010
3 80 40
Shut-off valve x4 1.3 156 MBV5000-3411 061B7011
x5 1.6 196 MBV5000-3511 061B7012
Input
Code numbers for standard Description Code no.

flange o G 1e8 adapters Cover 061B720001
Angleway adapter 061B720101
Straightway adapter 061B720201
Ordering special versions Type no: MBV 5000- x x x x

Type Pressure connection
Separate inputs and separate test functions 1 1 G 1/4
Common input and separate test functions 2 2 M10 u1
Common input and common test function 3 x Other
Other X
Number of outputs (n) Test pressure connection
1 Output (only for type 1) 1 0 Hole plug G 1/4
2 Outputs 2 1 Pressure gauge connection M16 u2
3 Outputs 3 X Other
4 Outputs 4
5 Outputs 5
Other X
Dimensions
Test valve
Outputs 1 2 3 4 5
L1 36 mm 76 mm 116 mm 156 mm 196 mm
Adapters
Angleway Straightway
Cover adapter adapter
Data sheet
Heavy duty pressure controls

MBC 5000 and MBC 5100
Features x Designed for use in severe industrial
environments
x High vibration stability
x Part of the block system, consisting of
MBC pressure controls, MBS pressure transmitters
and MBV test valves
x MBC 5100 with all major ship approvals
x High repeatability
x Optimal compact design for machine
building purposes
x Intended for alarm indication, shut down,
control and diagnostics in many
applications - motors, gears, thrusters,
pumps, filters, compressors etc.
Ship approvals Lloyd’s Register of Shipping BV, Bureau Veritas

MBC 5100 Germanischer Lloyd American Bureau of Shipping
RINA, Registro Italiano Navale KRS, Korean Register of Shipping
NKK, Nippon Kaiji Kyokai RMRS, Russian Maritime Register of Shipping
DNV, Det Norske Veritas
Approvals EN 60947-4-1 CCC, China Compulsory Certificate

EN 60947-5-1
Technical data Performance

± 0.2 % FS (typ.)
Repeatability Bellows versions ± 0.5 % FS (max.)
Diaphragm versions ± 0.5 % FS (typ.)
± 1 % FS (max.)
Piston versions ± 1 % FS (typ.)
± 1 % FS (max.)
Response time < 4 ms
Max. switch frequency 10/min (0.16 Hz)
Differential see page 3
Permissible operating pressure see page 3
Burst pressure see page 3
Mechanical for diaphragm and bellows > 400,000 cycles
Life time Mechanical for piston type >1 million cycles
Electrical at max. contact load > 100,000 cycles
Electrical specifications
Switch SPDT
AC 1 10 A, 250 V AC 15 0.5A, 250 V
Contact load
AC 3 3A, 250 V DC 13 12 W, 125 V
Environmental conditions
Bellows versions -40 to +85 °C
Operation
Temperature Diaphragm versions -10 to +85 °C
Piston versions -40 to +85 °C
Bellows versions -50 to +85 °C
Transport Diaphragm versions -50 to +85 °C
Piston versions -40 to +85 °C
Enclosure IP 65, IEC 529
20 g, 25 Hz - 2 kHz IEC 68-2-6
Vibration stability Sinusoidal
piston type 4.4g, 25-200 Hz
IEC 60068-2-27
INDUSTRIAL CONTROLS IC.PD.P10.A2.02- 520B2217

Data sheet Pressure controls, types MBC 5000 and MBC 5100
Technical data Mechanical characteristics

(continued) Pressure connection Standard G 1/4 female (ISO 228/1) or flange
Option see specification form, page 3
Electrical connection Plug DIN 43650, Pg 9 / Pg 11 / Pg 13.5
Housing Anodized AIMgSi1
Bellows Stainless steel 1.4306 (18/8)
Wetted parts material Diaphragm Viton
Piston Stainless steel 1.4028 (3H13)
O-ring NBR
Housing AIMgSi1
Enclosure material Plug fixture Glass filled polyamid, PA 6.6
Contact system Silver (AG) microprofile
Weight 0.4 kg
Electrical connection
Adjustment
Mechanical difference
One full turn (360°) of MBC setting screw is approx. equal to 7% of the setting range
Mechanical connection
Thread Flange connection
on MBV Test Valve
Not applicable for piston type
2 IC.PD.P10.A2.02- 520B2217
How to choose To achieve the best operating conditions for MBC pressure controls, it is recommended to apply the
following rules of thumb:
Choose: • the MBC type/types which meet the demands for the operating pressure
• the MBC version with the lowest possible setting range
• a diaphragm type, if pressure peaks and pulsations occur in the system
(if possible)
• bellows types, if low differential is needed
• piston type for high pressure
Ordering
standard types
Type: Setting Fixed Permissible Min. Type MBC 5100 MBC 5000
LP = Low pressure range differential operating burst designation Ship approved Standard
HP = High Pressure Pe [bar] Pe [bar] pressure pressure MBC 5000-/
(typ) Pe [bar] Pe [bar] MBC 5100- Code no. Code no.
LP bellows -0.2 to 1 0.15 to 0.451) 15 30 1011-1DB04 061B000566 061B200566
LP bellows -0.2 to 4 0.15 to 0.451) 15 30 1211-1DB04 061B0004662) 061B200466
LP bellows -0.2 to 10 0.15 to 0.601) 15 30 1411-1DB04 061B0002662) 061B200266
LP bellows -0.2 to 10 0.15 to 0.601) 15 30 1411-1CB04 061B000066 061B200066
LP bellows 0.5 to 3 0.15 to 0.301) 15 30 2011-1DB04 061B002966
LP bellows 1 to 6 0.15 to 0.451) 15 30 2211-1DB04 061B000766
HP bellows 5 to 30 0.40 to 1.51) 45 90 3421-1DB04 061B0003662) 061B200366
LP diaphragm 0.5 to 3 0.25 to 0.801) 150 300 2031-1DB04 061B101766
LP diaphragm 1 to 6 0.30 to 2.01) 150 300 2231-1DB04 061B100966
LP diaphragm 1 to 10 0.30 to 2.01) 150 300 2431-1DB04 061B1004662) 061B300466
LP diaphragm 5 to 20 0.4 to 2.51) 150 300 3231-1DB04 061B1002662) 061B300266
LP diaphragm 5 to 25 0.4 to 2.51) 150 300 3331-1DB04 061B102466
HP diaphragm 5 to 40 1.0 to 7.01) 150 300 3641-1DB04 061B1005662) 061B300566
HP diaphragm 10 to 100 1.7 to 141) 150 300 4241-1DB04 061B1003662) 061B300366
HP piston 16 to 160 12 to 301) 600 1200 5251-1CB04 061B510066 061B500266
Lowest differential at min. setting range, highest differential at max. setting range
1)
Preferred versions
2)
Ordering MBC 5000- -

customized types
MBC 5100- -
Pressure connection
Setting range C A 0 5 ............... M10x1 female
-0.2 - 1 bar ..................................................................... 1 0 C B 0 4 ............... G 1/4 female
-0.2 - 4 bar ..................................................................... 1 2 D A 0 5 ............... M10x1 female with flange connection
-0.2 - 10 bar................................................................... 1 4 D B 0 4 ............... G 1/4 female with flange connection
0.5 - 3 bar ..................................................................... 2 0 x x x x ............... Others
1 - 6 bar ..................................................................... 2 2
1 - 10 bar................................................................... 2 4 Electrical connection
2 - 6 bar ..................................................................... 2 6 0 ........................................................ No plug (DIN 43650 A)
5 - 20 bar................................................................... 3 2 1 ........................................................ Pg 11 plug (DIN 43650 A)
5 - 25 bar................................................................... 3 3 2 ........................................................ Pg 13.5 plug (DIN 43650 A)
5 - 30 bar................................................................... 3 4 3 ........................................................ Pg 9 plug (DIN 43650 A)
5 - 40 bar................................................................... 3 6 x ........................................................ Others
10 - 100 bar ................................................................ 4 2
16 - 160 bar ................................................................ 5 2 Microswitch
25 - 250 bar ................................................................ 5 4 1 ....................................................................... 0.5 A, 250 V (AC 15)
40 - 400 bar ................................................................ 5 6 ....................................................................... 12 W, 125 V (DC 13)
Others ................................................................................. x x x ....................................................................... Others
Type
Low pressure bellows (-0,2 to 10 bar) ............................................. 1
High pressure bellows (2 to 30 bar) ................................................. 2
Low pressure diaphragm (0.5 to 25 bar) ........................................ 3
High pressure diaphragm (5 to 100 bar) ........................................ 4
High pressure piston (40 to 400 bar) ............................................... 5
IC.PD.P10.A2.02- 520B2217 3
Dimensions
4 IC.PD.P10.A2.02- 520B2217
Data sheet
Thermostats type MBC 8000 and MBC 8100
Description MBC thermostats are temperature controlled

switches designed for use in severe industrial
environments. It consists of the standard series
MBC 8000 and the special series MBC 8100 with
ship approvals. In MBC thermostats special
attention has been given to meeting demands
for:
• compact design
• a high level of enclosure
• robust and reliable construction
• resistance to shock and vibration
• low differential and high repeatability
The MBC thermostats is part of the block
controls programme consisting of MBC
pressure controls and thermostats, MBS pressure
transmitters and MBV test valves.
The thermostats are suitable for use in monitoring
and alarm systems in factories, diesel plant,
compressors, power stations and on board ship.
Approvals CE marked acc. to EN 60 947-5-1

CCC, China Compulsory Certificate
Ship approvals, Bureau Veritas, France
MBC 8100 only Det norske Veritas, Norway Registro Italiano Navale, Italy
American Bureau of Shipping Nippon Kaiji Kyokai, Japan
Lloyds Register of Shipping, UK KRS, Korean Register of Shipping
Germanischer Lloyd, Germany RMRS, Russian Maritime Register of Shipping
Standard types
Setting Fixed Max. Cap.- Capillary tube Armoured capillary tube Sensor Rigid sensor
range diff. sensor length pocket
temp.
Type Type Type

C° C° C° m Code no. Code no. mm Code no.
MBC 8100 MBC 8100 MBC 8100
−10 - 30 3 80 2 061B820166 1221-1A02000 061B810166 1231-1A02000
20 - 60 3 130 2 061B810266 1431-1A02000
20 - 60 3 130 75 061B800266 1411-1A00075
50 - 100 4 200 2 061B820366 2221-1A02000 061B810366 2231-1A02000
50 - 100 4 200 75 061B800366 2211-1A00075
70 - 120 5 220 2 061B810466 2431-1A02000
70 - 120 5 220 75 061B800466 2411-1A00075
60 - 150 6 250 2 061B820566 2621-1A02000 061B810566 2631-1A02000
60 - 150 6 250 75 061B800566 2611-1A00075
INDUSTRIAL CONTROLS IC.PD.P10.D2.02-520B2392

Data sheet Thermostats type MBC 8000 and MBC 8100
Ordering of customized
types
MBC - -
Length
Type 02000 .............Capillary tube length [mm]
Industrial Thermostat................................... 8000 00075 .............Rigid sensor - pocket length in [mm]
Ship Approved Thermostat........................ 8100
xxxxx .............Other
Setting range Temperature connection

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

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

DIN 43650 plug, Pg 9, Pg 11, Pg 13.5
Shock resistance:
50 g / 6 ms, 500 g / 1ms Switch
acc. to IEC 68-2-27 Single-pole changeover switch (SPDT).
Free fall acc. to IEC 68-2-32
Vibration resistance
Sin 4 g, 5Hz o200 Hz acc. to IEC 68-2-6. *)
Properties acc. to EN 60947
Wire dimensions
Solid/stranded 0.2 - 1.5 mm2
Flexible, w/out ferrules 0.2 - 1.5 mm2
Flexible, with ferrules 0.2 - 1 mm2
Tightening torque max. 1.2 Nm
Rated Impuls voltage 4 kV
Pollution degree 3
Short circuit protection, fuse 2 Amp
Insulation 250 V
IP-index 65
*) If higher vibrations are present in the system/installation, thermostats with capillary tube or
armoured capillary tube are recommended.
2 IC.PD.P10.D2.02-520B2392
Accessories: Sensor pockets Sensor A Thread Code no. Sensor A Thread Code no.
for MBC thermostats pocket mm B pocket mm B
1
75 /2 NPT 060L326466 Steel 18/8 75 G 1/2 A 060L326766
75 G 1/ 2 A 060L326266
Brass 75 G 3/ 4 A 060L326666
75 G 1/2 A (ISO 228/1) 060L328166
1
110 /2 NPT 060L327066 Steel 18/8 110 G 1/2 A 060L326866
110 G 1/ 2 A 060L327166 110 1
/2 NPT 060L327066
Brass
110 G 1/2 A (ISO 228/1) 060L340666
110 G 3/4 A (ISO 228/1) 060L340366
Supplied without gland nut, 160 G 1/ 2 A 060L326366 Steel 18/8 160 G 1/2 A 060L326966
Brass 160 G 3/4 A (ISO 228/1) 060L340566
gaskets and washer
Part Description Code no.
017-420466
Clamping band For thermostats with remote sensor (L = 392 mm)
For thermostats with sensor fitted in a sensor pocket.

Heat -conductive Compound for filling sensor pocket to improve heat
compound transfer between pocket and sensor. Application 041E0114
(4.5 cm3 tube) range for compound:
–20 to +150 °C, momentarily up to 220°C.
Gasket set
For MBC thermostats without armoured capillary tubes 060L327366
Gasket set For MBC thermostats with armoured capillary tubes 060L036666
Dimensions
Rigid sensor Cap. tube version
IC.PD.P10.D2.02-520B2392 3
Setting point correction The sensor on MBC 8100 thermostats contains an

adsorption charge. Therefore its function is not Factor for setting
affected whether the sensor is placed warmer or point deviation
colder than the remaining part of the thermo-
static element (bellows and capillary tube). How-
ever, such a charge is to some extent sensitive to
changes in the temperature of the bellows and
capillary tube. Under normal conditions this is of
no importance, but if the thermostat is to be used Relative
in extreme ambient temperatures the setting scale
point might change. setting
in %
The deviation can be compensated for as follows:
Setting point correction = Z x a
Z can be found from fig. 1, while a is the

correction factor from the table below.
Regulation Correction factor a for thermostats

range with 2 and 5 m Fig. 1
°C with rigid sensor
capillary tube
-10 o+30 1.1
20 o 50 1.0 1.4
50 o100 1.5 2.2
70 o120 1.7 2.4
60 o150 3.7
100 o200 6.2
Example Relative setting:

A MBC 8100 with capillary tube length 2 m and
range 50 o 100°C must cut out at 75°C in 70°C Factor for setting point deviation Z (fig. 1).
ambient temperature. At which cut out tempera- Z - 1.2
ture should this thermostat be set at in 20°C ambi- Correction factor a (table under fig. 1) a = 2.2
ent temperature?
Setting point correction Z x a = 1.2. x 2.2 = 2.6°C
The relative setting Z can be calculated from the
following formula: The MBC must be set at 75 + 2.6 = 77.6°C in
20°C ambient temperature in order to cut out
Setting value min. range at 75°C ambient temperature.
x 100%
max. range - min. range
Relative setting: 75 - 50 x 100 = 50%

100 - 50
4 IC.PD.P10.D2.02-520B2392
Installation Installation Sensor position

MBC thermostats are designed to withstand the As far as possible the sensor should be positioned
shocks that occur, e.g. in ships, on compressors and so that its longitudinal axis is at right angles to the
in large machine installations. MBC thermostats direction of flow. The active part of the sensor is
with remote sensor are fitted with 5 mm screws to 13 mm x 50 mm long on thermostats with rigid
bulkheads or similar. See fig. 2 sensors and 2 m capillary tube.
MBC thermostats with rigid sensor are self-support-
ing from the sensor pocket.
For permissible media pressure see fig. 3.
Brass Stainless steel
Fig. 3. Permissible media pressure on the sensor

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

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

Material designation 1.4305 to DIN 17440.
Mech. diff.
Fig. 4
IC.PD.P10.D2.02-520B2392 ® Danfoss A/S 11-2005 IC-MC/mr

Form C-701 rev.0
Quality System Technical Data - Test Run Report
Etablished by: A. Enge Published date: 12.05.2014 Page 1 of 1

Approved by: Publisher: F. Kvamme
Revison Create JH Check SS Approve JH Classification society -
KUMERA AS SALES Gearbox serial Shipyard hull

- - - Certificate number
ORDER number number
SO02359 N98015 -
CUSTOMER Austral Group S.A.A
SHIPYARD TBA
Gearbox model 6FGC-335 Verified

Driven machinery Hyd.pumpx5 Input shaft rotation CCW X
Total input power [kW] 700 Lube oil pump rotation CCW X
Input speed n1 [rpm] 1000 Part list N401791A
Output speed n2 [rpm] 1200 Dimension dwg N2-91378A
Ratio [n2/n1] 1,2 - -
Clutch type/ Max torque [Nm] NKH-7500 Hydraulic/Electric dwg N3-04807
Nominal clutch oil pressure [bar] 24 Control valve block N3-05029
Nominal lube. Oil flow [lpm] 0,3
Clutch solenoid power supply 24 VDC
- -
- -
Ambient temperature [°C] Measured speed n1 / n2… [rpm] Oil amount [liters] Dip stick marks (max/min) Weight [kg]
20 1000 50 40,5 - 42,5 1140
Running time [hours] 0,5 1 1,5 2
Bearing temperatures [°C] A B A B A B A B
shaft no. 1 41 37 55 52 64 60 68 64
shaft no. 2 33 33 49 49 57 57 62 63
shaft no. 3 37 35 50 52 62 50 65 62
shaft no. 4 36 34 53 49 60 58 65 62
shaft no. 5
Shaft no. 6
Position Measured Adjusted
Lube oil temperature [°C] 42 56 64 70
Lube oil pressure [bar] 26 26 26 26 24,5
Lube oil flow [lpm] 0,5 0,5 0,5 0,5 0,3
Clutch oil pressure [lpm] 26 26 26 26 24

Assembler Ø
Remarks: System oil pressure tested to 36 Bar.Tested 3 hour
Test operator: Sander Kopstad Surveyor: Place and date: 02.09.2016
Signature: Signature:
Kumera AS Telephone: E-mail:

P.O. Box 2043 (+47) 33 48 54 54 kumera@kumera.no
N-3202 Sandefjord
Form C-701 rev.0


ORDER number number
SO02359 N98016 -
SHIPYARD TBA

Driven machinery Hyd.pumpx5 Input shaft rotation CCW x
Total input power [kW] 700 Lube oil pump rotation CCW x
Ratio [n2/n1] 1,2 - -
- -
- -
20 1000 50 40,1 - 42,5 1140
shaft no. 1 35 36 45 43 52 51 53 57
shaft no. 2 34 34 45 44 53 51 57 56
shaft no. 3 35 35 45 44 53 51 57 56
shaft no. 4 36 34 48 43 53 50 56 58
shaft no. 5
Shaft no. 6
Lube oil pressure [bar] 27 27 27 27 24,5
Lube oil flow [lpm] 0,5 0,5 0,5 0,5 0,3

Assembler Ø
Remarks: System oil pressure tested to 36 Bar. Tested 3 hour
Test operator: Sander Kopstad Surveyor: Place and date:13.09.2016

N-3202 Sandefjord
Form C-701 rev.0


ORDER number number
SO02359 N98017 -
SHIPYARD TBA

Driven machinery Hyd.pumpx5 Input shaft rotation CCW x
Total input power [kW] 700 Lube oil pump rotation CCW x
Ratio [n2/n1] 1,2 - -
- -
- -
20 1000 50 40,5 - 42,5 1140
shaft no. 1 40 38 50 50 58 54 62 60
shaft no. 2 36 35 47 47 54 55 61 61
shaft no. 3 39 37 50 50 56 58 63 62
shaft no. 4 36 37 50 50 58 57 62 60
shaft no. 5
Shaft no. 6
Lube oil pressure [bar] 27 27 27 27 25
Lube oil flow [lpm] 0,5 0,5 0,5 0,5 0,3

Assembler Ø
Test operator: Sander Kopsad Surveyor: Place and date:Sandefjord.12.09.2016

N-3202 Sandefjord
Form C-701 rev.0


ORDER number number
SO02359 N98018 -
SHIPYARD TBA

Driven machinery Hyd.pumpx5 Input shaft rotation CCW X
Total input power [kW] 700 Lube oil pump rotation CCW X
Ratio [n2/n1] 1,2 - -
- -
- -
20 1000 50 40,5 - 42,5 1140
shaft no. 1 44 42 59 55 64 53 71 67
shaft no. 2 39 44 53 58 60 63 64 67
shaft no. 3 43 40 56 55 63 62 67 69
shaft no. 4 45 41 59 52 64 59 69 70
shaft no. 5
Shaft no. 6
Lube oil pressure [bar] 26 26,5 26,5 26,5 24,5
Lube oil flow [lpm] 0,5 0,5 0,5 0,5 0,3

Assembler Ø
Test operator: Sander Kopstad Surveyor: Place and date:02.09.2016

N-3202 Sandefjord

Kumera Norgear 6FGC 335 Installation and Maintenance Manual PDF

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INSTALLATION, OPERATION AND

Total number of pages: 11

Norgear Gearbox with clutch 1

Date of manual: 05.12.2016 Issue no.: 1

Approved by KUMERA AS 05.12.2016 Engineer: JH

TABLE OF CONTENTS Page No.

This manual should be considered as part of the gearbox.

Norgear Gearbox with clutch 2

Total admissible input torque [Nm] 6685

Norgear Gearbox with clutch 3

This NORGEAR gearbox is designed as a front-end PTO drive with one or

All bearings are anti-friction type supplied from leading manufacturers.

The gearbox is delivered with lifting eyebolts in place.

If the driven equipment is mounted to the gearbox by a spigoted flange, the

No axial loads are allowed on input or output shafts.

Norgear Gearbox With Clutch 4

Norgear Gearbox With Clutch 5

1) Clutch cooling oil

Clutch pressure at normal running temperature is shown in Section 2.

a) Run the engine at the rated speed.

a) Check and replace the filter cartridge.

Norgear Gearbox With Clutch 6

The clutch engagement / disengagement is controlled by an electro-

Local reading gauges are provided for:

Alarm switches are provided for:

For alarm set points - please see Section 2.

Lubricating oil circulation

Norgear Gearbox With Clutch 7

Typical oils for NORGEAR gearbox with built-in clutch

Synthetic oil grades meeting the above requirements in addition to be

Norgear Gearbox With Clutch 8

Every 2-3 years

(Authorized Kumera service personnel are recommended)

(Authorized Kumera service personnel are recommended)

Norgear Gearbox With Clutch 9

(Authorized Kumera service personnel are recommended)

(Authorized Kumera service personnel are recommended)

9 SPARE PART KIT

We strongly recommend you keep in stock onboard basic spare parts to

Such parts should include:

n Oil filter elements – on board vessel

Norgear Gearbox With Clutch 10

Kumera AS offers worldwide service and planned inspections. Please do

Tel. switchboard: +47 33 48 54 54

If the gearbox cannot be installed immediately on delivery to the shipyard, it

Following additional Kumera AS terms are always part of our deliveries:

Any modifications and/ or work done on the unit by unauthorised personnel

Norgear Gearbox With Clutch 11

Kumera Sales Order #: SO02359 Date 05.03.2014

Item no. Pos. Qty. Item name Notes

N300384 1 1,0 HOUSING MACHINED 6FGC‐335

Pressure Test Valve MBV 5000

Technical data Performance

Code numbers for standard Description Code no.

Ordering special versions Type no: MBV 5000- x x x x

Heavy duty pressure controls

Ship approvals Lloyd’s Register of Shipping BV, Bureau Veritas

Approvals EN 60947-4-1 CCC, China Compulsory Certificate

Technical data Performance

INDUSTRIAL CONTROLS IC.PD.P10.A2.02- 520B2217

Technical data Mechanical characteristics

Not applicable for piston type

Ordering MBC 5000- -