Inspection and repair on RHENANIA AWNG 45/50S gearbox

Scope of work:

We performed an inspection and repair on a gearbox RHENANIA AWNG 45/50S.

The conversion operations consists of:

• Disassembly on board
• All piping and electric connections were removed.
• Hydraulic pump for the rudder control was removed.
• The input shaft coupling was disconnected from the main engine.
• The propeller shaft bolts were removed.
• Foundation bolts were left in place for safety
• A hole was cut and the main engine exhaust was removed to make it possible to remove the gearbox by a mobile crane.


Inspections in our workshop
• The complete gearbox was dissambled, including the oil cooler and the hydraulic block.
• All bearings and seals were removed.
• Oil pipes were flushed thoroughly.
• The complete gearbox was cleaned to get a good overview of the condition of the gearbox.


Assembling in our workshop
• During assembly, all bearings and seals were renewed.
• End covers were machined to the required axial bearing play.
• Multiple parts were renewed: input shaft, pump gear, oil pump, astern shaft, clutch plates etc.


Test run in our workshop
• After assembly, a test rum was performed to check for leakages and adjust the lubrication pressure.


Assembling on board
• The input shaft coupling was re-assembled using new coupling rubbers.
• Hydraulic pump for the rudder control was re-assembled.
• Gearbox was re-aligned.
• The output shaft was connected, bolts were assembled with the use of Molykote.
• All piping and electrical components were re-assembled.
• The gearbox was filled up with oil.


Test run on board (trials)
• The main engine was started and gearbox was tested without clutching.
• Rudder control was checked for proper functioning.
• Low pressure alarm was adjusted according the gearbox manual.
• Clutching was tested both manually and with bridge control.
• Temperatures and lubrication pressure was recorded for four hours during sailing.
• The gearbox was filled up with oil.