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propeller gearboxes

marine reduction gearboxes


PGV / PGVC
Oktober 2011

contents

- history

- arrangements

- technical specification

- standard gearbox PGV / PGH

- selection diagram

- main dimensions PGV

8 + 9

- gearbox PGVC with integrated multi disc clutch

10 + 11

- main dimensions PGVC with secondary PTO

12 + 13

- main dimensions PGVC with primary PTO

14 + 15

- twin in / single out reduction gearbox PGHC-2A

16

- examples

17

- references

18

- service

19

history
An innovative enterprise in drive
technique

Jahnel-Kestermann

Since the early sixties, the company Jahnel-Kestermann, formerly Jahnel and after
1981 Jahnel-Kestermann, has been one of
the leading enterprises in technology for
the drive technique. Operations underwater and on board, loosening and transport
of sand and stones under most difficult
conditions around the world, JahnelKestermann is your experienced partner
for the drive technique.
Decades of experience in the dredging
field, up-to-date calculation programs and
fabrication methods being optimal and related to the products offer safety and grant
reliability for your plants. Competent engineers advise you on site by planning and
realization of your special drives. Our experiences are the result of decades of
close cooperation with the famous shipyards and engineering companies as well
as the criticism by the great international
companies.
Therefore, already decades ago JahnelKestermann had the task to develop cutter-head gearboxes and have had it up to
the current
Hard-Rock-Cutter-Suction
Dredgers of highest power. These gearboxes, designed for extreme load, have integrated axial-thrust bearings for absorption of the axial load from cutter head.

Jahnel-Kestermanns highest priorities are


special solutions for the customers, reliability of operation and our proverbial service.
No wonder, that Jahnel-Kestermann gets
orders to design and manufacture the propeller, generator, jet- and dredgepump
gearboxes as well as cutter drives for the
largest dredgers.
In the field of offshore technique Ja)(Kes
gearboxes are in operation for deep-sea
cutter, pipe fitter and oil platforms. Great
crane ships lift their loads by means of
Ja)(Kes gearboxes.
Many years of experience flow into toothing design, selection of bearings, construction of casing and sealing of high-stress
gearboxes. We make a point of our service availability e. g. the inspection of axial-thrust pads. Here, a check is possible
without essential gearbox disassembly.
Calculation methods according to the latest state of engineering, torsional-vibration
simulations and FEM analysis have been
executed in our workshop. Thus, constructional influences regarding torsional deflection and stress concentration may be
identified at a very early state. For
Ja)(Kes engineers it is important to know
not only the gearbox but also the complete
ambient conditions, consequently, to know
all working conditions of the vessel.
We offer these experiences for the selection of gearboxes and couplings of any
kind.

Already in 1970 we delivered the propeller


and pump gearbox for the ship Humber
River with a hopper capacity of 10,000
m. This hopper dredger was a milestone
in further development!
Meanwhile,
Jahnel-Kestermann
has
equipped a great variety of cutter-suction,
cutter-wheel and hopper-suction dredgers
with gearboxes and couplings for operation underwater and on board, and according to the regulations and standards of
Classification Societies including ice class.

arrangements

shafts
The gearbox output shaft has a forged-on flange for connection to the propeller shaft. The shaft is
bored with mounting face for c.p.p. oil distribution box. The gearbox input shaft with cylindrical
shaft end is adapted to the flexible coupling.
housing
The gearbox casing is designed as torsion-proof welded steel construction, suitable for accepting
the outer forces and leading them to the basement. The internal rips are optimized due to vibrational properties and carrying-off of heat.
bearings
Bearing types are dependent on selected gear type. The pinion shaft can be equipped either with
roller or plain bearings while the PTO-shaft is normally fitted with roller bearings. The propeller
thrust is absorbed via thrust bearing collar seated in axial thrust pads, completely surrounded by
oil. The relevant flange is forged to the shaft. The thrust pads can be inspected and replaced via
inspection cover without dismantling the gearbox casing.
gearing
The pinion is made of case hardened steel while the bull wheel can be made of case hardened or
through hardened steel.
The pinion and the wheel have single helical and precision-ground teeth with optimum corrections
to ensure long lifetime and low structure born noise level.
lubrication and control system
Gearing and all bearing points are lubricated with forced oil by means of a mounted lubrication oil
device.
Oil circulating system is completely built-on, including stand-by pump.
Monitoring system acc. to classification rules including switchboard and interface.
clutch
The input and PTO shaft can be equipped with hydraulic operated multi disc clutches. The clutch is
operated and lubricated by the hydraulic system of the gearbox.

pK

control oil pressure

pKv

pilot oil pressure

T1

filling time
ascertained at JAKE test-run

T2

slipping time

T3

pressure holding time


ascertained at JAKE test-run
and adjusted at time relay

synchronisation point

soft clutch device

miscellaneous
Gearbox outside painting RAL 5010 or according to customers requirements.
Spare parts according to classification requirements.

PGV / PGH
SELECTION DIAGRAM
MARINE REDUCTION GEARS TYPE PGV(H) - SIZE 710 - 1250

50

Example :
1180-590

rating factor = engine power (mcr) P / engine speed n1 [kW / rpm]

40

30

1120-590

P
= 8000 kW
n engine = 500 rpm

1060-530

P/n

1000-530

= 16

n engine = 500 rpm


n propeller = 143 rpm

950-475

1250-590

ratio u = 3,49

20
900-475
1120-530

850-425

15

gearbox size PGV-950-475

800-425
750-375

1000-475

10
710-375

9
8

900-425

7
6
800-375

4
2

reduction ratio u = engine speed n1 / propeller speed n2 [rpm / rpm]

PTO rating factors


GEARBOX
TYP PGV
SIZE
710 - 375
750 - 375
800 - 375
800 - 425
850 - 425
900 - 425
900 - 475
950 - 475
1000 - 475
1000 - 530
1060 - 530
1120 - 530
1120 - 590
1180 - 590
1250 - 590

RATING
P / N1
KW / RPM
1,8
1,8
1,8
2,4
2,4
2,4
3,3
3,3
3,3
4,6
4,6
4,6
6,4
6,4
6,4

GEARBOX
TYP PGVC
secondary PTO

710 - 375
750 - 375
800 - 375
800 - 425
850 - 425
900 - 425
900 - 475
950 - 475
1000 - 475
1000 - 530
1060 - 530
1120 - 530
1120 - 590
1180 - 590
1250 - 590

RATING
P / N1
KW / RPM
1,8
1,8
1,8
2,4
2,4
2,4
3,3
3,3
3,3
4,6
4,6
4,6
6,4
6,4
6,4

GEARBOX
TYP PGVC
primary PTO

710 - 480 P
750 - 535 P
800 - 480 P
800 - 535 P
850 - 600 P
900 - 535 P
900 - 600 P
950 - 675 P
1000 - 600 P
1000 - 675 P
1060 - 750 P
1120 - 675 P
1120 - 750 P
1180 - 825 P
1250 - 750 P

RATING
P / N1
KW / RPM
1,9
2,1
1,9
2,4
2,7
2,4
3,2
3,6
3,2
4,4
4,9
4,4
6,0
6,7
6,0

NOTE
1) Rating factor P / n1 = generator power / engine speed [kW / rpm]
2) Higher rating factors on request

PGV

Standard gearbox type PGV / PGH

- single in / single out design


- main shafts in plain bearings
- PTO shaft in roller bearings
- output shaft equipped with thrust bearing located on engine side
- gearbox with secondary PTO (running together with output shaft)
- gearbox also in horizontal offset available ( PGH )

PGV
PGV
l3

L3

L1

l1

d3

H6

H2

3
d1

H1

H7

H4

d2

H3

H5

l2

B4

L5
L2

B2

L4

11

EQUIPMENT

1 1

11

B3

L6
L7

B1

1
2
3
4
5
6
7

Machined faces for stopper


Connection face for O. D. Box
Main lube oil pump
Stand-by motor lube oil pump
Double filter
Oil cooler
Supervision unit
(temperature and pressure
monitoring device with terminal box)

PGV
PGV
GEARBOX
SIZE
PGV
710 - 375
750 - 375
800 - 375
800 - 425
850 - 425
900 - 425
900 - 475
950 - 475
1000 - 475
1000 - 530
1060 - 530
1120 - 530
1120 - 590
1180 - 590
1250 - 590

L1
630
630
630
710
710
710
795
795
795
885
885
885
990
990
990

MAIN DIMENSIONS [mm]


LONGITUDINAL DIRECTION 1)
VERTICAL DIRECTION
L2
L3
L4
L5
L6
L7
H1
H2 H3 H4 H5 H6
745 665 800 1095 547,5 1285 710 375 200 53 675 420
745 665 800 1095 547,5 1285 750 375 200 53 675 420
745 665 800 1095 547,5 1285 800 375 200 53 675 420
840 750 900 1235 617,5 1440 800 425 225 60 775 445
840 750 900 1235 617,5 1440 850 425 225 60 775 540
840 750 900 1235 617,5 1440 900 425 225 60 775 445
940 835 1010 1385 692,5 1610 900 475 250 67 860 565
940 835 1010 1385 692,5 1610 950 475 250 67 860 565
940 835 1010 1385 692,5 1610 1000 475 250 67 860 465
1050 950 1130 1535 767,5 1780 1000 530 280 75 960 590
1050 950 1130 1535 767,5 1780 1060 530 280 75 960 590
1050 950 1130 1535 767,5 1780 1120 530 280 75 960 590
1175 1050 1265 1735 867,5 1995 1120 590 315 85 1065 620
1175 1050 1265 1735 867,5 1995 1180 590 315 85 1065 620
1175 1050 1265 1735 867,5 1995 1250 590 315 85 1065 620

H7
2380
2420
2470
2670
2815
2770
3050
3100
3050
3360
3420
3480
3710
3770
3840

THRUST
GEARBOX
SIZE
PGV
710 - 375
750 - 375
800 - 375
800 - 425
850 - 425
900 - 425
900 - 475
950 - 475
1000 - 475
1000 - 530
1060 - 530
1120 - 530
1120 - 590
1180 - 590
1250 - 590

MAIN DIMENSIONS [mm]


WEIGHT
LATERAL
INPUT, OUTPUT AND P.T.O.
DIRECTION
SHAFT 2)
DRY
B1
B2
B3
B4
d1
l1
d2
l2
d3
l3
[kg]
1760 1382 1140 1020 235 300 560
60
95 120
9050
1760 1382 1140 1020 250 315 600
63
95 120
9500
1760 1382 1140 1020 235 300 600
63
95 120
9850
1960 1550 1290 1135 265 335 630
67 100 125 12800
1960 1550 1290 1135 280 355 670
71 100 125 13600
1960 1550 1290 1135 265 335 670
71 100 125 13850
2180 1730 1450 1269 300 375 710
75 110 140 18100
2180 1730 1450 1269 315 400 750
80 110 140 18950
2180 1730 1450 1269 300 375 750
80 110 140 19100
2430 1938 1640 1424 335 425 800
85 125 155 24800
2430 1938 1640 1424 355 450 850
90 125 155 26300
2430 1938 1640 1424 335 425 850
90 125 155 26800
2700 2158 1840 1587 375 475 900
95 140 175 34800
2700 2158 1840 1587 400 500 950 100 140 175 36300
2700 2158 1840 1587 375 475 950 100 140 175 37100

3)

MAX.
[kN]
663
733
707
836
921
887
1090
1200
1160
1370
1500
1460
1690
1840
1800

NOTE
1) Distance L1 is the minimum length and will be increase in depending from the type and size
of the attached oil distributi
distribution box for c. p. propeller installation.
2) Dimensions for input, output and p. t. o. sshaft (d1, l1, d2, l2, d3, l3) are preliminary and
depending from the design of the appropriate coupling.
3) Propeller thrust is valid for ahead condition at highest rating factor of reduction gear. The
permissible thrust for astern condition is appr. 75% of the ahead thrust as stated before.

PGVC
PGVC
with built- in clutch and secondary PTO

- single in / single out design


- main shafts in plain bearings
- PTO shaft in roller bearings
- output shaft equipped with thrust bearing located on engine side
- input shaft with built- in multi disc clutch to disengage the Diesel from the
propeller shaft
- gearbox with secondary PTO (running together with output shaft)
- gearbox also in horizontal offset available

10

PGVC
PGVC
with built- in clutch and primary PTO

- single in / single out design


- main shafts in plain bearings
- PTO shaft in roller bearings
- output shaft equipped with thrust bearing located on engine side
- input shaft with built- in multi disc clutch to disengage the Diesel from the
propeller shaft
- gearbox with primary PTO (PTO running also during propeller standstill)
- gearbox also in horizontal offset available

11

PGVC secondary PTO


PGVC
5
L3

L1

l1

H2

d3

H6

l3

H1
H7

d1

3.2

H3

H4

d2

3.1

H5

l2

L5
L2

B4
L4

B2

B3
B1

EQUIPMENT

L6
L7

12

1 Machined faces for stopper


2 Connection face for O. D. Box
3 Main lube oil pumps
(3.1 prim. and 3.2 sec. driven)
4 Stand-by motor lube oil pump
5 Double filter
6 Oil cooler
7 Selector valve (not drawn)
8 Supervision unit
(temperature and pressure monitoring device with terminal box)

PGVC secondary PTO


Type PGVC with secondary PTO

GETRIEBEGROESSE
PGVC
710 - 375
750 - 375
800 - 375
800 - 425
850 - 425
900 - 425
900 - 475
950 - 475
1000 - 475
1000 - 530
1060 - 530
1120 - 530
1120 - 590
1180 - 590
1250 - 590
GETRIEBEGROESSE
PGVC
710 - 375
750 - 375
800 - 375
800 - 425
850 - 425
900 - 425
900 - 475
950 - 475
1000 - 475
1000 - 530
1060 - 530
1120 - 530
1120 - 590
1180 - 590
1250 - 590

L1
1370
1420
1370
1530
1580
1530
1705
1755
1705
1880
1955
1880
2105
2185
2105

MAIN DIMENSIONS [MM]


LONGITUDINAL DIRECTION 1)
VERTICAL DIRECTION
L2
L3
L4
L5
L6
L7
H1
H2
H3
H4
H5
H6
745
665
800 1095 547,5 1285 710
375
200
53
675
420
745
665
800 1095 547,5 1285 750
375
200
53
675
420
745
665
800 1095 547,5 1285 800
375
200
53
675
420
840
750
900 1235 617,5 1440 800
425
225
60
775
445
840
750
900 1235 617,5 1440 850
425
225
60
775
540
840
750
900 1235 617,5 1440 900
425
225
60
775
445
940
835 1010 1385 692,5 1610 900
475
250
67
860
565
940
835 1010 1385 692,5 1610 950
475
250
67
860
565
940
835 1010 1385 692,5 1610 1000 475
250
67
860
465
1050 950 1130 1535 767,5 1780 1000 530
280
75
960
590
1050 950 1130 1535 767,5 1780 1060 530
280
75
960
590
1050 950 1130 1535 767,5 1780 1120 530
280
75
960
590
1175 1050 1265 1735 867,5 1995 1120 590
315
85
1065 620
1175 1050 1265 1735 867,5 1995 1180 590
315
85
1065 620
1175 1050 1265 1735 867,5 1995 1250 590
315
85
1065 620

MAIN DIMENSIONS [MM]


LATERAL DIRECTION
INPUT, OUTPUT AND P.T.O. SHAFT 2)
B1
B2
B3
B4
d1
l1
d2
l2
d3
l3
1760 1382 1140 1020 235
300
560
60
95
120
1760 1382 1140 1020 250
315
600
63
95
120
1760 1382 1140 1020 235
300
600
63
95
120
1960 1550 1290 1135 265
335
630
67
100
125
1960 1550 1290 1135 280
355
670
71
100
125
1960 1550 1290 1135 265
335
670
71
100
125
2180 1730 1450 1269 300
375
710
75
110
140
2180 1730 1450 1269 315
400
750
80
110
140
2180 1730 1450 1269 300
375
750
80
110
140
2430 1938 1640 1424 335
425
800
85
125
155
2430 1938 1640 1424 355
450
850
90
125
155
2430 1938 1640 1424 335
425
850
90
125
155
2700 2158 1840 1587 375
475
900
95
140
175
2700 2158 1840 1587 400
500
950
100
140
175
2700 2158 1840 1587 375
475
950
100
140
175

H7
2380
2420
2470
2670
2815
2770
3050
3100
3050
3360
3420
3480
3710
3770
3840

WEIGHT
DRY
[KG]

THRUST 3)
MAX.
[KN]

11100
11900
11700
15600
16900
16400
21800
23600
22700
30000
32500
31600
41800
44700
43700

663
733
707
836
921
887
1090
1200
1160
1370
1500
1460
1690
1840
1800

NOTE
1) Distance L1 is the minimum length and can be increase in depending from the type and size of the attached
oil distribution box for c. p. propeller installation.
2) Dimensions for input, out
output
put and p. t. o. shaft (d1, l1, d2, l2, d3, l3) are preliminary and depending from the
design of th
the
e appropriate coupling.
3) Propeller thrust is valid for ahead condition at highest rating factor of reduction gear. The permissible thrust
for astern condition is appr. 75
75%
% of the ahead thrust as stated before.

13

PGVC primary PTO


5
l3

PTO outline of PGVC - P

L3

l1

L1

3.2

3.1
2

l2

L5
L2

B4
B2

L4

1
EQUIPMENT

L6
L7

14

1 Machined faces for stopper


2 Connection face for O. D. Box
3 Main lube oil pumps
(3.1 prim. and 3.2 sec. driven)
4 Stand-by motor lube oil pump
5 Double filter
6 Oil cooler
7 Selector valve (not drawn)
8 Supervision unit
(temperature and pressure monitoring device with terminal box)

PGVC primary PTO


Type PGVC with primary PTO (PGVC-P)

GETRIEBEGROESSE
PGVC - P
710 - 480
750 - 535
800 - 480
800 - 535
850 - 600
900 - 535
900 - 600
950 - 675
1000 - 600
1000 - 675
1060 - 750
1120 - 675
1120 - 750
1180 - 825
1250 - 750

MAIN DIMENSIONS [MM]


LONGITUDINAL DIRECTION 1)
VERTICAL DIRECTION
L2
L3
L4
L5
L6
L7
H1
H2
H3
H4
H5
H6
745 665 800 1095 547,5 1285 710 480 200
53
675 420
745 665 800 1095 547,5 1285 750 535 200
53
675 420
745 665 800 1095 547,5 1285 800 480 200
53
675 420
840 750 900 1235 617,5 1440 800 535 225
60
775 540
840 750 900 1235 617,5 1440 850 600 225
60
775 540
840 750 900 1235 617,5 1440 900 535 225
60
775 445
940 835 1010 1385 692,5 1610 900
600 250
67
860 565
940 835 1010 1385 692,5 1610 950
675 250
67
860 565
940 835 1010 1385 692,5 1610 1000 600
250
67
860 565
1050 950 1130 1535 767,5 1780 1000 675 280
75
960 590
1050 950 1130 1535 767,5 1780 1060 750 280
75
960 590
1050 950 1130 1535 767,5 1780 1120 675 280
75
960 590
1175 1050 1265 1735 867,5 1995 1120 750
315
85 1065 620
1175 1050 1265 1735 867,5 1995 1180 825
315
85 1065 620
1175 1050 1265 1735 867,5 1995 1250 750
315
85 1065 620

L1
1370
1420
1370
1530
1580
1530
1705
1755
1705
1880
1955
1880
2105
2185
2105

GETRIEBEGROESSE
PGVC - P
710 - 480
750 - 535
800 - 480
800 - 535
850 - 600
900 - 535
900 - 600
950 - 675
1000 - 600
1000 - 675
1060 - 750
1120 - 675
1120 - 750
1180 - 825
1250 - 750

MAIN DIMENSIONS [MM]


LATERAL DIRECTION
INPUT, OUTPUT AND P.T.O. SHAFT 2)
B1
B2
B3
B4
d1
l1
d2
l2
d3
l3
1760 1382 1140 1020 235 300 560
60
95
120
1760 1382 1140 1020 250 315 600
63
95
120
1760 1382 1140 1020 235 300 600
63
95
120
1960 1550 1290 1135 265 335 630
67
100 125
1960 1550 1290 1135 280 355 670
71
100 125
1960 1550 1290 1135 265 335 670
71
100 125
2180 1730 1450 1269 300 375 710
75
110 140
2180 1730 1450 1269 315 400 750
80
110 140
2180 1730 1450 1269 300 375
750
80
110 140
2430 1938 1640 1424 335 425
800
85
125 155
2430 1938 1640 1424 355 450
850
90
125 155
2430 1938 1640 1424 335 425
850
90
125 155
2700 2158 1840 1587 375 475
900
95
140 175
2700 2158 1840 1587 400 500 950 100 140 175
2700 2158 1840 1587 375 475 950 100 140 175

WEIGHT
DRY
[KG]
11700
12600
12300
16400
17800
17200
22900
24800
23800
31500
34300
33200
44100
47200
45900

H7
2485
2580
2575
2875
2990
2880
3175
3300
3275
3505
3640
3625
3870
4005
4000

THRUST 3)
MAX.
[KN]
663
733
707
836
921
887
1090
1200
1160
1370
1500
1460
1690
1840
1800

NOTE
1) Distance L1 is the minimum length and can be increase in depending from the type and size of the attached
oil distribution box for c. p. propeller installation.
2) Dimensions for input, output and p. t. o. shaft (d1, l1, d2, l2, d3, l3) are preliminary and depending from the
design of the
e appropriate coupling.
3) Propeller thrust is valid for ahea
ahead
d condition at highest rating factor of reduction gear. The permissible thrust
for astern condition is appr. 75%
75% of the ahead thrust as stated before.

15

PGHC 2A twin in / single out

twin in / single out reduction gearbox


type PGHC-2A
- horizontal offset
- input shafts with multi disc clutch
- roller or plain bearings on input
shaft
- plain bearings on output shaft
- thrust bearing on engine side
- housing in welded construction
- optional : secondary or primary
PTO
power rating from
2x 1.500 kW up to
2x 20.000 kW

16

The gearbox size mainly depends on the available


engine center distance.
Some examples for the engine center distance :
1000, 1120, 1400, 1600, 1800, 2000, 2250 [mm]
Other dimensions as well as size of multi disc
clutches results from input power and gearbox ratio

examples

17

references of equipped vessels

fast ferry Hammerodde

chemical tanker Harbour Pioneer

tanker Ruth Theresa

cargo vessel Erria Vietnam

18

container vessel Anne Sibum

cargo vessel Arklow Meadow

hopper dredger Wang Qing Sha

multi role vessel Canterbury

service
Thats service
at any time - In all places - under guarantee
As specialists in special gears and transmission
technology, we follow innovative methods, utilise latest technology, find solutions which are
forward-looking, economical and safe.
Our most powerful drive is our experience.
Ja)(Ke-drives are installed worldwide for use
under the hardest of conditions such as in the

fields of mining, chemical industry, shipbuilding and general industry (steel and rolling mill
construction, cement, wind, sugar, rubber and
synthetic industries). In order to secure flawless operation at all times in all places and to
prevent down-time, we have improved our
already well-known service still further.

We offer you :
1.

Preventive maintenance
to ensure availability

2.

Operation plan for our specialists


within 48 hours our service specialists are
on the spot throughout Europe.

3.

Spare part supply


supply of spare parts for both Ja)(Ke and
other manufacturers gears illustrates our
broad spectrum.

4.

6-months minimum guarantee on repaired gears


following guidelines given by us

5.

Performance and quality guarantee


we modernise your gears according to
latest technology.

19

In case of any questions please contact


phone: +49 234 339 238
fax:
+49 234 339 200
email: sales@jake-gear.com

Jahnel Kestermann
Getriebewerke GmbH
Hunscheidtstrasse 116 44789 Bochum, Germany

www.jake-gear.com

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