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MARINE GEARBOXES

OPERATING MANUAL

Type: VA 4851 K41 B

Reduction: 4.500 : 1
Work no.: 76 643
Direction of rotation
Input: clockwise
Output: anticlockwise

Contents
Operating manual BV2179.en 2007-10

Appendix
0-104-83450 Drawing of installation
0-211-83684 Supervision plan

Gearbox preservation BV1945 2008-03


Lubrication chart BV1597/4

Service manual

Spare parts with index

REINTJES GMBH TELEPHONE +49 (5151) 104-0


31785 HAMELN TELEFAX +49 (5151) 104-300
GERMANY E-MAIL service@reintjes-gears.de
© REINTJES GmbH 2010

76643.en_T.doc
BV2179.en
MARINE GEARBOXES 2007-10

OPERATING MANUAL VA ... K41

1 General Information ........................................................................................................2


1.1 Introduction....................................................................................................................2
1.2 Maintaining the documentation......................................................................................2
1.3 Important Notes .............................................................................................................2
1.4 Safety Information .........................................................................................................3
1.5 Protective measures against fire and danger of explosion............................................5
1.6 Before-operation Checks...............................................................................................6
2 Installation and Alignment .............................................................................................7
2.1 Lifting Equipment...........................................................................................................7
2.2 Alignment.......................................................................................................................7
2.3 Marine Gear Installation and Alignment ........................................................................7
2.4 Connection to Engine ....................................................................................................8
2.5 Propeller Shaftline Check ..............................................................................................8
2.6 Seat Chocks and Foundation Bolts ...............................................................................9
2.7 Installation of Gearbox with Longitudinal Mounting Arrangement .................................9
2.8 Alignment Check .........................................................................................................10
3 Function and Operation................................................................................................11
3.1 General Information.....................................................................................................11
3.2 Name Plate Arrangement ............................................................................................11
3.3 Hydraulic System.........................................................................................................11
3.4 Function of Series VA .. K41 .......................................................................................12
3.5 Recommended Lubricants...........................................................................................12
3.6 Initial Operation ...........................................................................................................13
3.7 Operating Instructions .................................................................................................14
3.8 Trailing Operation, Engine STOP Propeller Rotating ..................................................14
4 Maintenance ..................................................................................................................15
4.1 Maintenance Recommendations .................................................................................15
4.2 Conversion Factors .....................................................................................................15
4.3 General Torque for Metric Fasteners ..........................................................................16
4.4 Maintenance Schedule ................................................................................................17
4.5 Maintenance Task Descriptions ..................................................................................19
4.6 Completed Maintenance..............................................................................................24
4.7 Troubleshooting...........................................................................................................25
4.8 Preservation of the Gearbox........................................................................................26

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REINTJES BV2179.en 2007-10

1 General Information

1.1 Introduction
In order for the unit to operate without fault as well as for any warranty claims to be
honoured, it is necessary to observe this documentation in its entirety.
Anyone responsible for transport, installation, operation or maintenance of this equipment
must adhere to the contents of this documentation.
Your safety as well as the safety of others depends on correctly operating this gearbox.
The best protection against possible accidents is for the party operating the equipment to
exercise caution.
REINTJES will accept no liability for damage or faults during operation if this documentation
is not observed.
Constant improvement and continued development may result in changes to your gearbox
that is not yet mentioned in these instructions.
Please address any questions about your gearbox or about this documentation to REINTJES
customer service:

service@reintjes-gears.de or on
working days: Phone (+49) 05151 104 0
In emergencies and on weekends: Phone (+49) 05151 104 237

1.2 Maintaining the documentation


• This documentation belongs to the gearbox.
• Please maintain the documentation for the entire service life of the gearbox.
• Please pass on the complete documentation to any later owner or user.

1.3 Important Notes


REINTJES will only accept warranty claims when:
⇒ You install, operate, monitor and maintain the gearbox in accordance with our
instructions.
⇒ Only the types of oil listed in the lubricant table are used.
⇒ You comply with the performance ratings and labelling stamped on the type plate.
No modifications may be made to the gearbox unless they have been approved by
REINTJES.
REINTJES, as supplier of one of the components of the complete propulsion system, will not
assume responsibility for any problems with vibration resulting from the system as a whole.
REINTJES will not therefore assume any liability for complaints or damage resulting from this
type of vibration.

Note!
REINTJES strongly recommends that you have a torsional vibration calculation
performed for the entire system.

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In any case, a whirling calculation must be done for any shaftlines connected to the
input or output shafts. We additionally recommend having an axial vibration
calculation done for propeller shaftlines. Torsional, axial and whirling can mutually
excite each another. In order to preclude this possibility, the results of the whirling
calculation, axial vibration calculation and torsional vibration calculation should be
compared with each other in order to rule out that any of the vibration types have the
same natural frequencies.

1.4 Safety Information

NOTE!
Incorrect operation, lubrication, maintenance or repair of this product can be
dangerous and may even lead to injury.

1.4.1 Requirements for assembly personnel


Assembly personnel must be trained in the use of transport aids and lifting equipment and
have a mastery of the tasks required in safely carrying out assembly. This includes skilled
use of the tools required.
In order to maintain safety during operation, and to avoid any damage to the gearbox, it is
necessary for you to carefully read and to understand the chapters "Transport, Storage and
Preservation" and "Installation and Assembly".
In order ensure your safety and the safety of others during assembly, utilise only tools,
procedures and methods of working in line with the most recently technology.
If the gearbox appears to require work not described in the documentation, please consult
the REINTJES service department or a REINTJES representative.
In addition to this documentation, please observe and follow applicable laws and any
other binding regulations governing accident prevention and environmental
protection!

1.4.2 General protective measures and personal protection in the machine room
The gearbox may be operated and maintained only by qualified staff knowledgeable in its
operation and maintenance.
⇒ Prior to the trial run, mount coverings over all openly accessible rotating parts.
⇒ Immediately repair any faults that pose a safety hazard!
⇒ Ensure that no foreign objects enter the inside of the gearbox during assembly.
⇒ Wear protective eyewear when cleaning with compressed air.
Danger of eye injuries due to dirt particles.
⇒ While the engine is running, wear ear protectors to prevent hearing impairments.
⇒ Do not wear long hair loosely or any loose clothing or jewelry, including rings, when
near the gearbox while in operation.
Danger of injury due to getting caught or drawn in!
⇒ Do not touch the gearbox while it is warm from operation.
Danger of burns!

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1.4.3 Safety information for assembly


The gearbox has been built in accordance with the most recent technology and with
recognized safety regulation standards. Yet, even when the gearbox is used appropriately,
due to its manner of functioning and depending on how it is installed, a danger of personal
injury or death to the user or other individuals may arise.
Observe the following procedures!

WARNING!
When working on the gearbox, prevent the engine from being switched on!
Danger of death due to rotating components!
Shut down the compressed air feed and bleed the air tubes.
Prior to any assembly work on the gearbox, place a sign reading "OUT OF ORDER" or
a similar warning sign on the start-up switch or starter button and on the remote
starter.
Make sure that the remote starter of the drive motor on the bridge is also disabled and
not functioning.

1.4.4 Safety prior to working on the gearbox


⇒ Before performing adjustments or repairs on the gearbox or on aggregates powered
by the gearbox, shut down the engine.
⇒ Secure the propeller and drive shafts against unchecked rotation.
⇒ Before loosening or dismantling any tubes or accessory parts in air, oil or water
circulating systems, first reduce the pressure.

WARNING!
Oil pipes on the gearbox are under pressure when in operation!
Any oil escaping as a result of cracks or other leakage can result in serious injury.
Avoid damaging piping during assembly.
Perform a daily sight check of the piping in order to recognize any leakage at any early
stage.

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1.5 Protective measures against fire and danger of explosion

1.5.1 General information


⇒ Immediately remove any oil residues completely.
⇒ Do not leave on the gearbox any rags or cloths used to wipe oil residues.

1.5.2 Pipes and tubes


⇒ Check all tubes and oil pipes daily for wear or damage.
⇒ Check to see that these have been laid, supported and fastened in accordance with
professional standards.
⇒ Tighten bolt joints only to the required torque.
⇒ Note that lubricants are flammable.
⇒ Never weld pipes or tubes carrying lubricants.
⇒ Do not straighten or bend any pipes or tubes under pressure during operation.
⇒ Immediately replace any bent or damaged pipes or tubes.
⇒ Do not replace steel pipes with copper ones.

1.5.3 Hoses
⇒ Do not damage hoses by subjecting them to mechanical force.
⇒ Check all hoses daily for any cracks forming or any mechanical damage.
⇒ Keep flames, acids and other corrosive or caustic liquids away from hoses.
⇒ Replace hoses no later than after 5 years.

1.5.4 Drained oil


⇒ Collect drained oil in a used oil collector.
⇒ Collect any rags soiled with oil in containers intended for this purpose.

Store all lubricants in appropriately labelled containers. Dispose of filter elements and
used oil either as recyclable substances or as hazardous wastes.

1.5.5 Cables connected to the gearbox


⇒ Make sure that all cables are maintained in an undamaged condition.
⇒ Check to see that all cables are laid properly and cannot be damaged by abrasion.
⇒ Immediately after connecting any cables to the gearbox, remove any leftover pieces
of cable or refuse.
⇒ Use only wires and cables having the required diameter and type of insulation.
⇒ Protect cabling on the board side by means of fuses in front of them in circuits.

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1.5.6 Foreign substances in the gearbox


⇒ Ensure that no used parts, dirt or foreign substances are in or near the gearbox.

1.6 Before-operation Checks


⇒ Ensure that all protective guards and covers are correctly installed.
⇒ To prevent accidents, always exercise extreme care when working around rotating
components. Check the marine gear frequently for potential hazards.
⇒ Do not, under any circumstances, start an engine or operate the controls when a
warning notice is attached.
⇒ Prior to starting the engine and operating the marine gear, ensure that no work is in
progress within the immediate vicinity.

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2 Installation and Alignment


2.1 Lifting Equipment

The gear dry weight (without oil but with special accessories) is stamped onto the name
plate. The lifting rig must be attached to the lifting eyes provided by means of shackles.
Under no circumstances must lifting equipment be attached to shaft ends, pipework
or other externally-mounted equipment. The lifting equipment must be secured
against tilting.

2.2 Alignment

A basic prerequisite for trouble free operation of a propulsion plant is careful alignment of
engine and gearbox to the propeller shaft. Accurate alignment to the engine is also
necessary if torsionally elastic couplings are used, since every alignment error has a
disadvantageous effect on the service life of the driving elements or accesories. Only high
flexible couplings must be used.
On request, REINTJES will supply all data required for alignment calculation (such as
temperature expansion curve, mass and stiffness distribution of the gearbox output shaft and
allowable bearing loads).
If the customer, or shipyard, is in possession of an alignment calculation for the complete
propulsion plant, then plant alignment must be completed in accordance with such
calculation. A copy of the alignment calculation should, however, be submitted to REINTJES
for information.
Propulsion plant alignment diagrams are generated by superimposing the fullload
temperature characteristics of the engine crankshaft, the gearbox input and output shafts and
the propeller shaftline.
These full-load temperature shaft-displacement characteristic curves permit precision cold-
state alignment for optimized fullload operating conditions.
If alignment calculation for the complete propulsion plant has not been made, it is mandatory
to comply with REINTJES instructions when aligning the marine gear.

2.3 Marine Gear Installation and Alignment

During gearbox installation it is essential to ensure that sufficient free space provided for
disassembly of housings, shafts, etc during later maintenance. The gearbox has to be
installed onto an adequate strengthened foundation so that no housing distortion can occur.
The installation, or foundation, drawing includes all necessary marine gear mounting face
dimensions. Application-specific deviations must be confirmed in consultation with the
factory.
For propulsion plant alignment, it is mandatory that the vessel be afloat with
absolutely noground-contact with the sea bed.
Alignment of the gear output shaft-to-propeller shaftline connection, the engine PTO to the
gear input shaft and the auxiliary units to the additional gearbox (PTO) shafts must be made
in compliance with manufacturer's instructions.
Vertical alignment of gearbox to propeller or intermediate shaft is effected by alignment
screws located in the gearbox seating. For horizontal alignment we recommend to fix
alignment screws on the foundation.

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2.4 Connection to Engine

Engine power transmission from the engine to the marine gear must be via a torsionally
resilient coupling. Based on our experience we recommend that, when selecting a torsionally
resilient coupling for the propulsion plant, the torsional resilience factor chosen be such as to
ensure that the resonance speed, of the 1. grade vibrational form exited by the main
rotational harmonics of the engine, is so far below the lowest specified operational speed
that it is only transgressed during engine startup and shutdown. Alternatively care must be
taken to ensure that, within reasonably acceptable limits, the plant operating range be kept
free of torsionally-critical speeds.
Selection of the torsionally resilient coupling is generally made by the engine manufacturer.
The gearbox data required for torsional vibration calculation is supplied by REINTJES
together with the associated order-referenced torsional vibration diagram.
If the coupling is specified by the engine manufacturer or the shipyard and is supplied
assembled with the marine gear; then REINTJES cannot accept responsibility for the
suitability or durability of the torsionally resilient coupling. Compliance with the appropriate
instructions is mandatory for assembly / dismantling of the coupling flange (hub).
The propulsion engine is normally resiliently mounted; the gearbox may be rigidly or
resiliently mounted onto the foundation. The torsionally resilient coupling used must also be
capable of accommodating the the axial misalignment between the engine and gearbox
shafts at the specified operating speeds.
Referenced to the gearbox, the flexibility of the resilient engine mounts must be such as to
allow engine-to-gearbox alignment accuracy which ensures that there is no possibility of
appreciable reactive forces at the bearings of the connected gearbox shafts when operating
temperatures prevail.

2.5 Propeller Shaftline Check

Radial and axial run-out


A prerequisite for correct propeller shaftline-to- marine gear connection is that the propeller
and/or intermediate shaft does not "sag" and is in the operational position.
Radial and axial run-out must not exceed 0.05 mm.

Radial and Angular Misalignment


For these checks the coupling flange centering recesses must be disengaged. Secure the
dial gauge carrier to the gear flange so that the stylus of one gauge is in radial contact with
the periphery of the blocked propeller, or intermediate shaft flange and that of the 2nd gauge
is in axial contact with the flange face.
With the plant at operating temperature and under full-load operating conditions, the
maximum permissible deviations of both flanges towards each other are as follows:
Radial misalignment 0.05 mm (centerline run-out 0.025 mm)
Angular misalignment 0.05, referenced to 300 mm flange diameter.
Order-specific instructions are applicable to universal shaft alignment.

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2.6 Seat Chocks and Foundation Bolts

Seat Chocks
Rectangular seat chocks must be used only. Round discs or shim plates arranged one
upon the other are not permissible.
Seat chocks must be adequately dismensioned and closely fitted. They are to be made in
accordance with the rules of the classification societies.

Fitting Bolts
The fitting bolts used must be of tensile strength 8.8 in accordance with ISO 898.
The fitting bolt bores are pre-drilled.

Through Bolts
Through bolts must be of the same tensile strength as the fitting bolts.
The foundation bolts must comply with application- specific requirements and be tightened to
the specified torque.

2.7 Installation of Gearbox with Longitudinal Mounting Arrangement

On completion of alignment, the gear must be attached to the foundation in such a manner
that it is secured against displacement and that the propeller thrust is transmitted and led into
the foundation.

Foundation with Steel Seat Chocks


There are various combination possibilities which may be used for the attachment of marine
gears with side mounting faces (longitudinal foundation):
1. Seat chocks with fitting screws and collision chocks.
2. Seat chocks with fitting screws, without collision chocks.
3. Seat chocks with collision chocks and foundation screws constructed as through screws.

Foundation with Cast Resin


If cast-resin seat chocks are used, collision chocks will be necessary to transfer the propeller
thrust to the ship´s frame. In this case, the foundation bolts have to be through bolts. If no
thrust is to be transfered, through bolts and at least 2 fitted bolts will be sufficient.
Other possibilities for transfering the propeller thrust must be approved by REINTJES.
After the thermosetting of cast-resin curing, the alignment screws must be backed-off
out of contact, with the foundation.

Important
Planning, calculation and installation of cast-resin foundation should only be carried out by
an authorized company which is also in a position to submit the necessary drawings,
calculations and materials to the Classification Societies for approval.

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2.8 Alignment Check

On completion of alignment and after the engine and marine gear foundation bolts have been
finally tightened to specified torque, a check of the mating accuracy of both marine gear
flanges is recommended whereby the flange securing screws must be removed.
We accept no claims under warranty arising from exceeding alignment tolerances of
both gearbox connecting flanges.

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3 Function and Operation


3.1 General Information

REINTJES marine reduction gearboxes of type VA are vertically offset, single stage spur
wheel gearboxes.
The direction of rotation marked on the name plate is the direction of rotation of input and
output shaft looking in the direction of AHEAD travel.
The gearbox output shaft is turning in the opposite direction to the input shaft.
The service life of the gearbox depends upon the correct completion of the recommended
operating and maintenance services and the use of recommended lubricants.

3.2 Name Plate Arrangement

The name plate is attached to the gear housing.


For parts ordering or other inquiries in respect of your marine gear, the following
information is required from the name plate:
Gearbox No.
Type
Input power
Input speed

3.3 Hydraulic System

The hydraulic system comprises a geartype pump, an oil filter, heat exchanger, pressure
limiting valve, and lubrication oil system.
Oil supplied by the pump is filtered and cooled, so that the oil temperature does not rise
above the normal operating temperature. The cooling water flows through the tube bundle
and the oil flows between the tube bundle and the outer housing. The cooling water
connections can be reciprocally used for inlet, outlet resp.

Pressure Limiting Valve


The operating pressure is regulated by a spring- loaded pressure limiting valve and set by
adjustment screw V13. For readjustment purposes, nut V12 must be slackened off. Pressure
is increased by turning adjustment screw V13 clockwise and decreased by turning it
anticlockwise.

Warning
The adjustment screw is not secured against turning out of the valve block and must not be
removed by screwing it out anticlockwise. Oil will leak out if screw V13 is removed while oil is
under pressure (engine STOP)!
The setting screw should only be screwed in until the top is even with the lock nut, so
that the valve is not blocked. (At valves with hexagon screw, the screw can be turning
in so that the hexagon head is against the lock nut).

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Hot oil can cause personal injury. Do not allow hot oil or hot parts to contact skin.
Before a re-setting of the pressure limiting valve is intended due to changed pressure
readings, possible causes must be checked carefully.
The pressure gauge on the gearbox indicates the operating pressure. At nominal engine
speed and the gearbox at operating temperature, the normal operating pressure is approx. 5
bar.

3.4 Function of Series VA .. K41

The engine power is transmitted to the input shaft via the engine-to-marine gear coupling.
When the input shaft rotates, the oil pump provides oil pressure for gearbox lubrication.
The output shaft and propeller shaft are turning in the opposite direction to the input shaft.
The path of drive is from input pinion shaft R1 via gear R2 to output shaft P1 connected with
the propeller shaft. These parts are turning as soon as the input shaft is force locked
engaged to the running engine.

Power Take-Off K41 (PTO non - controllable)


Above the input shaft a non-controllable power take- off is build-in. When the engine is
running and the gearbox input shaft turning the PTO can be used.
The sense of rotation is opposite to the engine rotation.
The path of drive is from input pinion shaft R1 via gear R57 to PTO-pinion shaft R118
(or gear R118 mounted on PTO-shaft W241).

3.5 Recommended Lubricants

The oil companies are responsible for determination of the oil types stated in the lubrication
chart.
REINTJES is not liable for correctness of these data nor for any amendments occuring.
REINTJES does not accept responsibility for any damages due to the use of unsuitable oils.

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3.6 Initial Operation

Oil Filling
Prior to shipment, the marine gear is preserved internally. In the case of units which have
been hermetically sealed, the sealing plug must be removed and the venting filter (supplied
loose) must be installed. The preservation oil must be drained, minor oil residues will mix
with the service oil.
The amount of oil required is stamped into the name plate. Fill oil as specified into the marine
gear until the upper mark on the dipstick is reached. The oil level can only be checked with
the plant shut down and using the dipstick.
After installation check and prior to sea trial a short test run under limited load must be
carried out. As the hydraulic system will be filled with oil then, the oil level must be re-
checked on the dipstick and if necessary oil must be filled up.

Dipstick markings
The dipstick for the gear unit has 3 markings:
• The top mark shows the maximum oil level when the gear unit is stationary.
• The centre mark shows the minimum oil level when the gear unit is stationary.
• The bottom mark shows the minimum level when the gear unit is running.
Refer also to the adhesive label "Dipstick markings" near the dipstick.

Installation Check
In the course of the last check prior to initial operation, it is essential to ensure that all
necessary connections have been made as specified. All necessary data must be recorded
on the "Alignment Certificate" which must be signed.
Having confirmed that the gearbox is in an operationally safe condition and that the
propulsion plant is ready for service, initial operation may be done.
On completion of the test-run the propulsion plant alignment should be checked and the
foundation bolts must be checked for tight fit.

Use of the Gearbox within the European Union


In case the operation has to comply with the safety regulations stipulated by the European
Union, the manufacturer of the complete plant will be responsible for the CE-certification.

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3.7 Operating Instructions

Safety and maintenance are prerequisites for troublefree operation, maximum performance
and a long service life.
Safety is, initially, an abstract definition and can not, in all cases, be defined by regulations.
The necessary safety measures can normally be determined by experience and intelligence.
Be alert at all times.
Observe possible danger sources.
Take all necessary precautions.
Safety is EVERYBODY'S business.
This Operation Manual includes descriptions of maintenance services which have to be
completed periodically. Familiarize yourself with the "Maintenance" chapter.
Periodic supervision and registration of measured parameters provides a duty profile for the
engine and marine gear. If certain conditions change then a changed display may indicate a
potential problem. The necessary repairs can be laid down before an actual failure occurs
with resultant non-scheduled down time.

3.8 Trailing Operation, Engine STOP Propeller Rotating

This condition covers all operating conditions in which the propulsion plant is shut
down and the propeller, the shaftline and the gearbox shafts are caused to rotate by
entrained water.

Restricted Trailing Operation


With the standard marine gear without an additional trailing oil pump, this is possible without
any special precautions.
Should this condition last longer than 12 hours all marine gear lubrication points must be
lubricated for at least 5 minutes.
This can be achieved by starting the propulsion engine or by activating the electric stand-by
pump.
If the above-mentioned short-term lubrication is not possible, the propeller shaft must be
locked.

Unrestricted Trailing Operation


In this case the marine gear must be equipped with a trailing oil pump.
The trailing oil pump is mounted at (or in) the marine gear housing, depending on the
operating conditions and marine gear version. The trailing oil pump is driven by the gearbox
output shaft. Irrespective of the direction of rotation, this pump always forces oil into the
system in the same direction and thus ensures the marine gear lubrication oil supply.
Another possibility is the installation of an electric pump to supply the gearbox lubrication oil
system.

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4 Maintenance
Operational safety, reliability and low maintenance costs can only be achieved by
maintenance and care in compliance with our instructions. Furthermore, only trained
maintenance personnel, should work on the gearbox, and only correct tools, original spare
parts and lubricants in accordance with our recommendation should be used.
Filter elements and waste oil must be disposed of as recyclable material or special
waste.
If required, our Service Department is available at all times to provide advice and assistance.

4.1 Maintenance Recommendations

Has the "Function and Operation" chapter been read and understood?
Operator alertness provides the best protection against possible dangers.
The operator must comply with safety instructions and be familiar with all precautionary
measures. Run a maintenance log book. Regular registration of recorded data can provide
indication of internal changes. Rectify minor faults before they can develop into major
repairs.
Keep the marine gear clean and dry at all times, this facilitates early recognition of any
possible leaks thus preventing subsequent extensive damage. As a matter of principle, never
use chemical detergents to clean rubber or synthetic components. Wipe with a dry cloth only.

4.2 Conversion Factors

Approximate Conversion Factors


Multiply By To Get
mm 0,03937 inch
inch 25,4 mm
kg 2,2 lb
lb 0,454 kg
kPa 0,145 psi
psi 6,89 kPa
psi 0,0689 bar
bar 14,5 psi
Nm 0,74 lb ft
lb ft 1,36 Nm
Nm 8,9 lb in
lb in 0,113 Nm
Liter 0,26 U.S.Gal.
U.S.Gal 3,79 Liter
U.S.Gal. 0,833 Imp. Gal.
Temperatur conversions
°C = (°F - 32) : 1,8
°F = (°C x 1,8) + 32

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4.3 General Torque for Metric Fasteners

Be very careful never to mix metric with customary (standard) fasteners.


Mismatched or incorrect fasteners will cause marine gear damage or malfunction and may
even result in personal injury.
Original fasteners removed from the marine gear should be saved for reassembly whenever
possible. If new fasteners are needed, they must be of the same size and grade as the ones
that are being replaced.
The material strength identification is usually shown on the bolt head by numbers (8.8, 10.9
etc.). The following chart gives general torques for bolts and nuts with Grade 8.8 and 10.9.

Metric ISO-Thread 2) Metric ISO-Thread 2)

Thread Size Grade 8.8 Standard Torque Thread Size Grade 10.9 Standard Torque
Metric Nm )
1
lb ft Metric N m 1) lb ft

M5 5+1 4+1 M5 7+1 5+1


M6 9+1 7+1 M6 13+1 10+1
M8 21+2 16+2 M8 30+3 22+2
M10 41+4 30+3 M10 60+6 44+4
M12 71+7 52+5 M12 104+10 77+8
M14 113+12 84+8 M14 165+16 122+12
M16 170+20 126+13 M16 250+25 185+19
M18 245+25 181+18 M18 350+35 259+26
M20 350+35 259+26 M20 490+50 363+36
M22 470+47 348+35 M22 670+67 496+50
M24 600+60 444+44 M24 850+85 630+63
M27 880+90 650+65 M27 1250+125 925+93
M30 1190+120 880+90 M30 1700+170 1260+126
M36 2100+210 1550+155 M36 3000+300 2210+221
M39 2700+270 1990+199 M39 3800+380 2800+280
M42 3300+330 2442+244 M42 4700+470 3478+348
M45 4100+410 3034+303 M45 5800+580 4292+429
M48 5000+500 3700+370 M48 7000+700 5180+518

1) Newton meter (N m) is approximately the same


as 0,1 mkg.
2
) ISO= International Standard Organization

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4.4 Maintenance Schedule

The Maintenance Schedule summarizes the maintenance services which are sub-divided
into Maintenance Stages.
Particularly arduous service conditions may require modification of the Maintenance
Schedule (reduced intervals).
Maintenance Stage 1 Daily
• Check oil level (lower dipstick marking -- operation oil level)
Maintenance Stage 2 Daily with engine running, check:
• operating pressure,
• oil temperature,
• heat exchanger temp cooling water,
• duplex filter contamination indicator,
• visual checks and running noises
• Ball valve (oil sucking) for tightness
Maintenance Stage 3 After first 300 operating hours:
• Perform an oil analysis, acc. to this result possible oil cleaning or oil
change.
• Replace filter element
• Check threaded connections incl. foundation, check connection to
engine and propeller and bolts of intermediate housing
• Tighten swivel nuts and banjo bolts of threaded pipe connections in
case of leakage
• Check heat exchanger for leakage
Maintenance Stage 4 After each operating period of 3000 hours or 6 months:
• Change oil
• Replace filter elements
Maintenance Stage 5 After each operating period of 6000 hours or 1 year:
• Check threaded connections incl. foundation, connection to engine
and propeller and bolts of intermediate housing
• Check heat exchanger for leakage and replace seals, if necessary,
check control valve actuation
Maintenance Stage 6 After each operating period of 60000 hours or 10 years or in
conjunction with an engine major overhaul
Check:
• shafts for run-out
• bearing seats for damage
• carriers
• gear and pinion teeth
• annular piston carrier
• pins oil distributor
• pressure gauge
• Ball valve (oil sucking) for tightness

Replace:
• clutch discs
• rectangular rings, screws and return springs for annular piston
• O-rings, snap rings,

17 / 26
REINTJES BV2179.en 2007-10

• all clutch housing screws *8


• anti-friction bearings
• thrust bearing screws and springs
• shaft seals and bushes
• oil filter elements and seals
• oil pump
• inspection cover gaskets
• o-rings for pressure limiting valve, flexible hoses
• clean the complete gearbox,

18 / 26
REINTJES BV2179.en 2007-10

4.5 Maintenance Task Descriptions

Maintenance stage 1
4.5.1 Daily before engine start

Oil Level Check The dipstick for the gear unit has 3 markings:
• The top mark shows the maximum oil level when the gear unit is
stationary.
• The centre mark shows the minimum oil level when the gear unit is
stationary.
• The bottom mark shows the minimum level when the gear unit is
running.
• Refer also to the adhesive label "Dipstick markings" near the
dipstick.
• The oil level must be between the marks on the dipstick.
• If the oil level is low, fill up suitable oil until the level reaches the
upper mark on the dipstick.
• Determine and rectify the cause of oil loss.
• For filling in the oil screw out the venting filter marked OEL (OIL).

Maintenance stage 2
4.5.2 Daily with engine running

Operating Pressure • With the engine running and clutch engaged, the maximum
Check operating pressure is indicated on the gearbox-mounted pressure
gauge.
• Oil viscosity, operating temperature and different delivery rates of
the oil pump, due to varying engine speeds, have only a minor affect
on the operating pressure.
Oil Temperature • The normal operating oil temperature after the heat exchanger will
Check be in the range of approx. 40 - 60 °C and can be read off at the
thermometer.
• If the oil temperature is higher than the normal operating
temperature, determine the possible cause and initiate the
appropriate remedial measures.
Cooling Water • Normally the cooling water temperature difference across the oil
Temperature heat exchanger should be 3 to 5 °C (5 to 9°F).
• An increase of the cooling water temperature difference indicates
contamination of the water side of the oil heat exchanger or an
insufficient cooling water flow rate.
Oil Filter • Experience has shown that the contamination indicator must be
Contamination closely observed during the first 100 operating hours.
indicator
• With high viscosity or cold oil a high pressure difference may be
effective during the warm-up phase. This can lead to a temporary,

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REINTJES BV2179.en 2007-10

false alarm indication.


• If the NC contact of the transmitter opens and a prolonged electrical
audio alarm signal is initiated, the filter element is contaminated.
• The change over lever must be set to the other side to direct the oil
flow through the alternative filter bowl.
• The filter element must be replaced as described under
"Maintenance Stage 4".
Visual check and • Check the gear assembly for leaks and insecure parts. Ensure that
running noise only normal running noises are audible.
• Changes may indicate possible faults or malfunctions which can
include, among others, misalignment between engine-gear-propeller
shaft.
• Investigate all malfunctions. Where possible, rectify all faults
immediately or after shutting down the engine.
• Be alert!
• Beware of danger!

Maintenance stage 3
4.5.3 After first 300 operating hours

This oil change with changing filter elements is to be firstly carried out on all new or
completely overhauled gearboxes. All following oil changes are to be completed at the
intervals specified for Maintenance Stage 4.
Oil check • The first oil check or cleaning professionally of the oil (e.g. by a
separator) must be carried out after 300 operation hours.
• We recommend to have carried out an oil analysis and to clean
professionally or to replace the oil if required according to the
results.
• The intervals apply to the further regular oil changes to servicing
step 4.
• We independently of the oil change intervals recommend a monthly
check of the Hose lines on crack formation and mechanical
damages.

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REINTJES BV2179.en 2007-10

Maintenance Stage 4
4.5.4 After each operating period of 3000 hours or 6 months

This maintenance stage determines the Standard intervals of oil change and oil filter
element replacement. Adhering to these intervals the oil sludge must be checked for
metallic residues.
Oil Change • Change the oil when engine is shut down and the oil is warm
(cooled down from operating temperature).

Caution! • Hot oil or components can cause injury. Avoid skin contact with hot
oil and components.
Oil change cont. • Remove the oil drain plug and allow oil to drain into a suitable
container or pump the oil from the gearbox into the container. Clean
the drain plug and reinstall it with a new sealing ring. Tighten plug to
specified torque.
• Refill recommended oil into the gearbox until the oil level reaches
the upper mark on the dipstick. The oil capacity is indicated on the
gearbox name plate.
• Replace the oil filter elements.
• On completion of all maintenance tasks, start the engine and run for
5 to 10 min. Shut down the engine and recheck the oil level. The
level must remain at the upper mark on the dipstick. Do not overfill
the gearbox.
• Compliance with the oil change intervals specified in the
Maintenance Schedule is mandatory; especially the first,(or initial)
oil change. Prolongation of the oil change intervals is only
permissible when regular and reliable analyses are carried out.
• In addition to ageing checks the lubricating capability must be
checked.
• The above mentioned intervals rely on a operating temperature after
the heat exchanger of approx. 60°C. If these temperatures are
exceeded, the oil change intervals are reduced and must be
determined in consultation with REINTJES.
• Independent of the oil change intervals we recommend to check the
flexible hoses monthly for cracks and damage.

21 / 26
REINTJES BV2179.en 2007-10

Filter Element • Prior to carrying out the following maintenance tasks, the filter
Replacement element to be replaced must be taken out of service. The change
over lever is at the side of the filter element which is in operation.
• Direct the oil flow to the currently inoperative filter by moving the
lever away from the filter element to be replaced.
• Slowly release the vent screw and allow all pressure to escape.
Remove the vent screw and O-ring.
• Remove the drain plug and O-ring from the filter housing. Allow the
oil and contaminant deposits to drain from the filter housing.
• Remove the cover securing screws. Turn the cover through 45° and
carefully remove the cover and O-ring.
• Remove the filter element and contaminant strainer. Remove the
filter element out of the housing by turning it clockwise. The
contaminant strainer will become loose and remain in the housing
when lifting out the element by turning it anticlockwise.
• Clean the filter housing, contaminant strainer and drain plug.
• Prior to filter system re-assembly, check all O-rings for damage;
replace damaged O-rings.
• Install the drain plug and O-ring.
• Install the new filter element with O-ring and the contamination
strainer. Take care not to damage the O-ring. Install the filter cover
and O-ring. Ensure that the O- ring is correctly seated. Insert the
vent screw with O-ring loosely.
• With the vent screw loose, move the change-over lever approx. 10°
towards the centre; in this position the filter housing will be filled with
oil. Hold the lever in this position until bubble-free oil is discharged
at the vent screw.
• Tighten the vent screw to specified torque and set the change over
lever for single-filter operation.

Maintenance stage 5
4.5.5 After each operating period of 6000 hours or 1 year

Threaded • The screw tightening torques should be checked with the gear cold.
Connections Particular attention must be paid to the following connections:
• Engine - flexible coupling – gearbox,
• Gearbox output shaft flange - propeller shaft,
• Gearbox mountings - foundation.
• Swivel nuts and banjo bolts of threaded pipe connections.
• Check the rubber elements of the flexible coupling for porosity,
cracking or other signs of damage.
• Check the heat exchanger for leakage and replace the seals, if
necessary.

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REINTJES BV2179.en 2007-10

Maintenance stage 6
4.5.6 After each operating period of 60000 hours or 10 years
or in conjunction with engine major overhaul

Matching to the engine maintenance intervals is permissible provided that the operating
hours specified are not excessively exceeded.
Part Checks - Shafts for run-out,
- Bearing seats for damage,
(and replacement - Carriers,
as necessary):
- carrier pins for annular piston,
- Gear and pinion teeth,
- Oil distributor,
- Pressure gauge.
Replace - Rectangular rings,
- screws and return springs for annular piston,
- O-rings,
- Snap rings,
- All clutch housing screws
- Anti-friction bearings,
- Thrust bearing screws and springs,
- Shaft seals and bushes,
- Oil filter elements and seals,
- Oil pump,
- Inspection cover gaskets,
- O-rings for pressure limiting valve,
- Flexible hoses,
thoroughly clean the gear housing, vent filter and all other parts which are to be reused.
Our Service Department is available at all times, to answer any questions you may have:
Email service@reintjes-gears.de Tel. +0049 5151 104-0

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REINTJES BV2179.en 2007-10

4.6 Completed Maintenance

Gearbox No.
Type

Operating hours Maintenance stage Date Sign

24 / 26
REINTJES BV2179.en 2007-10

4.7 Troubleshooting

4.7.1 Disturbance

Probable Cause Remedial Action


Gear noise

Idle speed in critical range Raise idle speed

Anti-friction bearing damaged


Check gear security and alignment inspect gear
(possibility of metallic residues in filter)
(replace bearings)

Hydraulic noise, pump sucks in air see Pump sucks in air


Pump sucks in air
Oil level in gearbox too low Determine and rectify cause of oil loss, top-up oil
to max. mark

Suction line leaking Tighten threaded connection, or flange, replace


seals or pipe
Oil loss
Shaft seals (normal wear) Replace
Pipework Rectify leak
Housing cover Clean mating faces, renew gaskets
Plugs, oil drain plug Tighten, replace sealing ring
Heat exchanger leaking Replace sealings
Gear temperature too high
Oil level too high Rectify
Cooling water flow rate too low Adjust to correct rate
Heat exchanger contaminated Clean
Anti-friction bearing damaged (possibility of Inspect (replace bearings)
metallic residues in filter)
Gear overload Reduce input load
Clutch slipping, operating pressure too low see Operating pressure too low
Operating pressure too low, fluctuating
Pump sucks in air see Pump sucks in air
Pump drive or pump defective Repair or replace (wear)
Pressure limiting valve blocked Repair or replace
Non-return valve to electric pump Clean or replace defective
Incorrect brand oil Check viscosity, change oil
Operating pressure too high
Pressure limiting valve blocked Repair or replace
or defective
Oil cold Carry out gear warm-up procedure
Incorrect brand oil Check viscosity, change oil

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REINTJES BV2179.en 2007-10

4.8 Preservation of the Gearbox

Preservation Measures
From outside the gearbox is protected from corrosion by adequate packaging for
transportation and the storage period stated in the contract.
All openings of the gearbox are sealed.
For preservation of the inner parts the gearbox is operated with preservation oil during the
test run. After the test run BRANOROL (VCI preservation oil) is filled into the gearbox. This is
indicated by the plate on the gearbox:

Gearbox preserved with BRANOROL.


For initial operation drain off BRANOROL, fill in oil and
screw in venting filter.

The instructions on the plate must be strictly observed!


Before putting the gearbox into operation, the preservation oil must be drained (residual
quantities may remain in the gearbox). The gearbox must then be filled with the indicated
quantity of operating oil.
Never clean the interior of the gearbox with water or other chemicals.

Packaging, Storage, Standstill Periods


The effectiveness of the preservation measures depends on the packaging and the storage
conditions.
Defective packaging and unfavourable storage conditions, e.g. high atmospheric humidity,
saliferous air or extremely changing temperatures etc., will have a negative effect on the
permissible storage period.
On reception the gearbox packaging has to be checked for transport damages immediately.
In the period after removal of the original packaging and before initial operation adequate
measures have to be taken to ensure optimum protection of the gearbox from environmental
influences and external damage.
All openings of the gearbox have to be kept sealed.

Additional anticorrosion measures according to BV 1945 are necessary,


if the packaging has been damaged or is taken off several weeks before initial
operation,
if the gearbox is to be stored longer or under less favourable conditions than stated in
the contract or
if installed gearboxes are to be taken out of service for a longer period.

REINTJES Customer Service will provide further information upon request.


Email service@reintjes-gears.de Tel. +0049 5151 104-0

26 / 26
0 1 2 3 4 5 6 7 8 9

Eugen - Reintjes - Strasse 7


D-31875 Hameln
www.reintjes-gears.de
Phone. +49 (0)5151 - 104 - 0
Fax +49 (0)5151 - 104 - 300

Drawing number 0-211- 83684 General Remark

"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
Gearbox VA 4851 K41
Classification GL AUT

Engine producer MAN

Control voltage 24VDC Designation ENGLISH

Working pressure
Project agent ROT
Commission Created on 16.04.2010
Instructions by
Number of pages 13

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Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Cover sheet
0-211- 83684 +
Page
F1
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9

Table of contents
Page Page description supplementary page field
1 Cover sheet
2 Table of contents
3 Hydraulic diagram
4 Pressure switches
5 Pressure switches / Oil level controller
6 Temperature after oil cooler
7 Temperature Thrust bearing
8 Terminal diagram =+-X000
9 Terminal diagram =+-X000
10 Measuring points list
11 Monitor list
12 Terminal box
13 Pressure test valve

"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
=
Ed.
Appr
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DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Table of contents
0-211- 83684 +
Page
F2
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9

/13.2 /4.0 /4.3 /4.5 /4.7


-A35 -A103 -A105 -A461 -A125
P P P P

-A113
/6.3 /13.1
-A480 -A55
T
Oil cooler

/7.3
-A490
T

Oil filter

"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
-A43.1 P P -A43.2
/5.1 Δ Δ /5.2

Stand by pump

Gearbox pump Lubrication -Tooth mesh Lubrication -Bearings


3~

-A10 -A11 /5.7


Dipstick
-A57

=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Hydraulic diagram
0-211- 83684 +
Page
F3
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9

Pressure switches
1-2 Pressure low
1-3 Pressure high

Lube oil pressure too low - Alarm Start - Stand by pump Main engine slow down Main engine shut down

-A103 -A105 -A461 -A125


/3.6 /3.6 /3.7 /3.7
/13.2 P /13.3 P /13.3 P /13.3 P

1 2 3 1 2 3 1 2 3 1 2 3

1 2 3 1 2 3 1 2 3 1 2 3

-R1 -R2
24k 24k

-W103 BN BU -W105 BN BU -W461 BN BU -W125 BN BU

"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
-X000 1 2 3 4 5 6 7 8

wiring by yard wiring by yard wiring by yard wiring by yard

-AS -SP -MAN X58:3 X58:4 -MAN X58:1 X58:2

Alarm system Starter - Stand by pump Engine safety system cabinet Engine safety system cabinet

=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Pressure switches
0-211- 83684 +
Page
F4
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9

Pressure switch Pressure switch


1-2 ready 1-2 ready BN-BK Oil level ready
1-3 contaminated 1-3 contaminated BN-GY Oil level too low

Filter element 1 - contaminated Filter element 2 - contaminated Oil level too low

-A43.1 -A43.2 -A57


/3.1 /3.2 /3.8
P P
Δ Δ
1 2 3 1 2 3

BN GY(BU) BK
1 2 3 1 2 3

-W43.1 BK BN BU -W43.2 BK BN BU -W57 BN BU BK

"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
-X000 9 10 11 12 13 14 15 16 17 18 19

wiring by yard wiring by yard wiring by yard

-AS -AS -AS


Alarm system Alarm system Alarm system

=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Pressure switches /
Oil level controller 0-211- 83684 +
Page
F5
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9

Sensor_Lube oil temperature after cooler


-A480
/3.3

-A480.2
-A480.1
2L / 2x Pt100 Θ Θ

Pt100
Pt100
1 3 2 4

-W480 BN BU WH BK

"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
-X000 20 21 22 23 -X000 24 25 26 27

wiring by yard wiring by yard

-AS -MAN X59:8 X59:9 X59:10 X59:11

Alarm system Engine safety system cabinet

Main engine slow down

=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Temperature after oil cooler
0-211- 83684 +
Page
F6
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9

Sensor_Thrust bearing temperature


-A490
/3.9

-A490.2
-A490.1
2L / 2x Pt100 Θ Θ

Pt100
Pt100
1 3 2 4

-W490 BN BU WH BK

"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
-X000 28 29 -X000 30 31 32 33 -X000 34 35 36 37 38 39 40

wiring by yard wiring by yard

-AS -MAN X59:4 X59:5 X59:6 X59:7

Alarm system Engine safety system cabinet

Main engine slow down

=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Temperature Thrust bearing
0-211- 83684 +
Page
F7
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9

Terminal diagram

-W103

-W105

-W461

-W125

-W43.1

-W43.2

-W57

-W480
Strip

Cable name

Cable name
=+-X000

Page / column
Connection
Connection

cable type
cable type

terminal

jumper

point
point
Function text Target designation Target designation
Lube oil pressure too low - Alarm -AS 1 -A103 1 BN /4.0
= -AS 2 -A103 3 BU /4.1
Start stand by pump -SP 3 -A105 1 BN /4.3
= -SP 4 -A105 2 BU /4.3
Main engine slow down -MAN X58:3 5 -A461 1 BN /4.5
= -MAN X58:4 6 -A461 2 BU /4.6
Main engine shut down -MAN X58:1 7 -A125 1 BN /4.8
= -MAN X58:2 8 -A125 2 BU /4.8
Filter element 1 -AS 9 -A43.1 1 BK /5.1
Filter element 1 - ready -AS 10 -A43.1 2 BN /5.1
Filter element 1 - contaminated -AS 11 -A43.1 3 BU /5.1
Filter element 2 -AS 12 -A43.2 1 BK /5.2
Filter element 2 - ready -AS 13 -A43.2 2 BN /5.3
Filter element 2 - contaminated -AS 14 -A43.2 3 BU /5.3

"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
Oil level -AS 15 -A57 BN BN /5.7
Oil level too low - Alarm -AS 16 -A57 GY(BU) BU /5.7
Oil level ready -AS 17 -A57 BK BK /5.7
18 /5.8
19 /5.9
Lube oil temperature -Alarm (Pt100) -AS 20 -A480 1 BN /6.3
= -AS 21 -A480 3 BU /6.3
Lube oil temperature -Engine slow down (Pt100) -MAN X59:9 22 -A480 2 WH /6.5
-MAN X59:8
Lube oil temperature -Engine slow down (Pt100) -MAN X59:10 23 -A480 4 BK /6.6
-MAN X59:11
24 /6.8
25 /6.9
26 /6.9
27 /6.9

=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Terminal diagram =+-X000
0-211- 83684 +
Page
F8
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9

Terminal diagram

-W490
Strip

Cable name

Cable name
=+-X000

Page / column
Connection
Connection

cable type
cable type

terminal

jumper

point
point
Function text Target designation Target designation
28 /7.1
29 /7.1
Thrust bearing temperature -Alarm (Pt100) -AS 30 -A490 1 BN /7.3
= -AS 31 -A490 3 BU /7.3
Thrust bearing temp. -Engine slow down (Pt100) -MAN X59:5 32 -A490 2 WH /7.5
-MAN X59:4
Thrust bearing temp. -Engine slow down (Pt100) -MAN X59:6 33 -A490 4 BK /7.6
-MAN X59:7
34 /7.8
35 /7.8
36 /7.8
37 /7.8
38 /7.8
39 /7.8

"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
40 /7.9

=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Terminal diagram =+-X000
0-211- 83684 +
Page
F9
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9

Measuring points list Note XX = sequence alarm Time delays are not supplied by Reintjes

Pos. Measuring point Abbre. Responding value Function Function Function Alarm value Time delay Comment Function text
Low High Alarm slow down shut down
-A10 Pressure suction pipe P connection 1 -for gauge
-A11 Pressure suction pipe P connection 2 -for gauge
-A35 Operating pressure P Visual indication at gearbox 0 - 10bar Manometer_Operating pressure
-A43.1 Differential pressure PDAH X X DP > 5bar Filter element 1 - contaminated
-A43.2 Differential pressure PDAH X X DP > 5bar Filter element 2 - contaminated
-A55 Oil temperature T Visual indication at gearbox 0 - 100°C Temperature after oil cooler
-A57 Oil level NW X X 10sec Oil level too low
-A103 Oil pressure low PAL X X P < 1bar Lube oil pressure too low - Alarm
-A105 Oil pressure low PAL X XX P < 1.2bar Start - Stand by pump
-A125 Oil pressure low PALL X X P < 0.6bar Main engine shut down
-A461 Oil pressure low PAL X X P < 0.8bar Main engine slow down
-A480-A480.1 Oil temperature TAH X X T > 65°C Lube oil temperature -Alarm (Pt100)
-A480-A480.2 Oil temperature TAHH X X T > 70C° Lube oil temperature -Main engine slow down (Pt100)
-A490-A490.1 Oil temperature TAH X X T > 90°C Thrust bearing temperature -Alarm (Pt100)
-A490-A490.2 Oil temperature TAHH X X T > 95C° Thrust bearing temperature -Main engine slow down (Pt100)

"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Measuring points list
0-211- 83684 +
Page
F 10
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9

Monitor list
Pos. Manufacturer Designation Type number Measuring range Degree of protection

-A35 VDO Pressure gauge 63/0-10bar (0-145PSI) 0-10bar (0-145PSi)


-A43.1 Hydac Difference pressure switch VD5 C.0/-TA Δ-P 5bar IP 65
-A43.2 Hydac Difference pressure switch VD5 C.0/-TA Δ-P 5bar IP 65
-A55 Wika Thermometer 0-100°C
-A57 Kübler Level switch ABVU-GL IP 64
-A103 Danfoss Pressure switch MBC 5100-2031-1DB04 0.5-3 bar IP 65
-A105 Danfoss Pressure switch MBC 5100-2031-1DB04 0.5-3 bar IP 65
-A125 Danfoss Pressure switch MBC 5100-2031-1DB04 0.5-3 bar IP 65
-A461 Danfoss Pressure switch MBC 5100-2031-1DB04 0.5-3 bar IP 65
-A480 Noris Temperature sensor 2TP81-1-55 0-120°C IP 67
-A490 Noris Temperature sensor 2TP81-1-55 0-120°C IP 67

"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Monitor list
0-211- 83684 +
Page
F
11
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9

360 mm

160 mm
Cover

-A120

91 mm (Gesamthöhe)

-A21

"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
Box

-A119

=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Terminal box
0-211- 83684 +
Page
F
12
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9

Lube oil pressure too low - Alarm


Manometer_Operating pressure

Main engine slow down

Main engine shut down


Start - Stand by pump
/3.6 /4.0 /4.3 /4.5 /4.7
-A35 -A103 -A105 -A461 -A125

BAR

-A113
/3.6

"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
Pressure test valve

=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Pressure test valve
0-211- 83684 +
Page
F
13
Modification Date Name Original Replaced by Replaced by Supervision Page 13
BV1945.en
MARINE GEARBOXES 2008-03

Gearbox Preservation

1 Safety Information
• The established safety rules have to be observed when handling operating and auxiliary
materials!
• Check all lines, hoses and threaded connections for leakage before putting the gearbox into
operation!
• Smoking is generally prohibited when working with inflammable operating materials!
• Be careful when handling oil and fuel vapors! There is high risk of fire!
• Be careful when handling hot or caustic operating and auxiliary materials!
There is risk of getting burned or scalded!
• Be careful with liquids coming out under high pressure! Risk of injury!
• Relieve pressure from all operating materials systems and pressure lines according to
manufacturer's instructions before starting work!
• Let gearbox cool down before commencing maintenance work! For cleaning of gearbox use
only non-flammable cleansing liquid or liquid with flash point over 65°C!
Use only operating and auxiliary materials recommended by the manufacturer!

2 General Information
Preservation is the protective treatment of sliding and bright metal parts against corrosion.
After the test run the gearbox undergoes specific preservation before being shipped to the
customer. The preservation measures to be taken depend on the period until initial operation, the
storage conditions and special wishes on the part of the customer.

For tropical climates the preservation has to be adjusted to the local conditions. Specific
preservation measures become also necessary for the gearbox and its auxiliary units, if they are
taken out of service for a longer period.
As a matter of course, all spare part shipments and gearbox accessories underwent adequate
preservation.

First preservation measures are taken by the manufacturer based on the provisions of the contract.
If the instructions and measures described in this document are not observed, REINTJES will not
accept responsibility for corrosion and resulting damages.

3 First Preservation
For preservation of the interior the gearbox is operated with preservation oil during the test run at
the factory. After the test run a VCI preservation oil (VCI = volatile corrosion inhibitor) is filled into
the gearbox. VCI inhibitors are agents which evaporate very slowly and in enclosed space settle
down on bright metal surfaces as an invisible film. Due to their polarity they interrupt electro-
chemical corrosion reactions.

BV1945.en_2008-03.doc Page 1 / 5
REINTJES BV1945.en 2008-03

In order to ensure that the VCI inhibitors are effective as long as possible all openings of the
gearbox are closed and the shafts are sealed with acid-free grease.

During transportation and, in addition, for the storage period stated in the contract the gearbox is
corrosion-protected from outside through preservatives forming a wax-like film after evaporation of
the solvent, as well as through adequate packaging.

4 Instructions for Packaging and Storage


The preservation measures taken at the factory have been designed for a limited period of time
under defined storage conditions according to the customer's specification or REINTJES factory
standard. It is taken for granted that REINTJES gearboxes are stored in enclosed space with
avoidance of extreme temperature changes and water contact (e.g. through rain).

If the gearboxes are to be stored longer than stated or under different conditions, additional
measures will have to be taken in order to guarantee sufficient corrosion protection.
If storage will be continued upon expiration of the guaranteed conservation time, the condition of
the packaging respectively the condition of the gear has to be checked by a company specialized
in long duration packaging. These checks and measures have to be discussed with REINTJES in
each single case.

The effectiveness of the preservation measures depends on the packaging, the storage conditions
and the storage period.
Damages to the packaging, which must also be avoided during storage, and unfavorable storage
conditions, e.g. high atmospheric humidity, saliferous or polluted air, extremely changing
temperatures etc., will have a negative effect on the permissible storage period. Generally, the
gearbox must not be stored in the open.
High-quality packaging with sufficient drying agent and storage in air-conditioned space with low
atmospheric humidity will have a positive effect on corrosion protection. The better the gearbox is
sealed, the less humidity can penetrate and the longer the VCI agents can protect the interior of
the gearbox against corrosion.

The period after removal of the original packaging and before initial operation has to be kept as
short as possible. During this period adequate measures have to be taken to ensure optimum
protection of the gearbox from environmental influences and external damage.

Generally, all openings of the gearbox have to be kept sealed until initial operation. If, however,
prior opening of the gearbox cannot be avoided, afterwards all openings will have to be
hermetically sealed again. In addition, further measures described in Section 5 will become
necessary.

5 Anti-corrosion Measures during Storage


5.1 General Information

The measures described in the following sections represent general instructions for certain
conditions. In case of doubt, it is recommended to agree on the measures to be taken with
REINTJES.

If corrosion damages are found during checks or maintenance REINTJES Customer Service will
have to be informed immediately.
On reception the gearbox packaging has to be checked for transport damages immediately.

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REINTJES BV1945.en 2008-03

5.2 Damaged Packaging

If the packaging is damaged, water and harmful environmental influences can act directly on the
gearbox. Due to changing temperatures more humidity can penetrate the interior of the gearbox.

Measures:
• Dry gearbox, if necessary
• Check and, if necessary, replace drying agent
• Check and, if necessary, restore preservation at shaft ends
• Repair packaging, better: take off old foil and shrink-wrap gearbox with drying agents again in
foil of comparable quality
• Regular outward check of packaging and, if possible, drying agents
Check intervals: European climatic zone every 4 weeks, tropical climate every 2 weeks

5.3 Storage without Packaging

The packaging will have to be taken off, if


a) the packaging has been so seriously damaged that it cannot be repaired or
b) the gearbox is put on board a ship and installed or
c) the storage period stated in the contract has been exceeded by more than 20%.

Immediately after removing the original packaging additional preservation measures will become
necessary in order to ensure sufficient corrosion protection for the gearbox.

Measures:
• Provide best possible protection of the gearbox against water and harmful environmental
influences. When covering the gearbox with awnings make sure that there is a distance to the
gearbox, they must not become steam domes.
• At regular intervals check gearbox for corrosion damages from outside, check and, if
necessary, restore preservation and sealing of shaft ends (for check intervals see 5.2)
• At regular intervals top up VCI preservation oil Branorol;
The time for the first topping-up is dependent on the storage conditions. The standard
calculation says that by removing the packaging the remaining, agreed storage period is
halved. However, the period until the first topping-up must not exceed 12 weeks (Europe) and
8 weeks (tropics).

Further topping-ups at intervals of 12 weeks (Europe) and 8 weeks (tropics)


Quantity: about 1% of operating oil volume, at least 1 liter;
IMPORTANT: After topping-up seal gearbox hermetically again

The above mentioned measures will have to be taken correspondingly, if the agreed storage
period of unpacked gearboxes (only European climatic zone) expired.

5.4 Opening the Gearbox

When the gearbox is opened, the VCI agents of the preservation oil escape. Whether a protective
agent atmosphere can develop again after the gearbox has been sealed anew, depends on the
residual quantity of VCI agents in the preservation oil, the quantity of humidity which penetrated
and the quality of the subsequent sealing of the gearbox.
Measures: top up preservation oil Branorol; for quantity and further service intervals see 5.3

Page 3 / 5
REINTJES BV1945.en 2008-03

6 Anti-corrosion Measures after Initial Operation


6.1 Initial Operation

Prior to initial operation drain off VCI preservation oil, residual quantities may mix with the
operating oil.
After that fill in the quantity of operating oil indicated on the name plate and replace the plug screw
with the supplied venting filter (see also Operating Manual).

Fill up the system and lubricate the gear by shortly starting the engine or by the electrical oil pump.
Stop the pump or the engine.
Check the oil level again and top up oil up to the upper mark of the dip stick.

IMPORTANT: Foreign substances must not get into the interior! For this reason never clean the
gearbox with water or chemicals inside or outside.
Remove the preservative from the functional surfaces of the shaft ends with the help of plastic
scrapers, cloths, brushes and adequate solvents. Do not damage the functional surfaces.

6.2 Prolonged Standstill

If the ship is to be taken out of service for several weeks, anti-corrosion measures will become
necessary for the gearbox. If these measures are not taken, corrosion damages may occur on the
gearbox.
The type and extent of the measures to be carried out is dependent on the possibilities available.
Anti-corrosion measures will have to be taken not later than after a standstill of
4 weeks in the European climatic zone and 2 weeks in the tropical zone.

The following measures are adequate for protecting the gearbox against corrosion:

Type A Flushing with anti-corrosion oil Valvoline 6


• Drain off operating oil
• Fill in anti-corrosion oil Valvoline 6; quantity: about 0.8 x operating volume
• Flush gearbox 15 minutes by means of pump
• Seal gearbox: replace venting filter with plug screw,
seal housing at shafts with acid-free grease
• After max. 12 weeks (Europe) and 8 weeks (tropics) repeat flushing process

Type B Filling VCI preservation oil Branorol into gearbox


• Drain off operating oil
• Fill in VCI preservation oil Branorol;
Quantity: series SVAL, DLG and DLGF approx 2% of operating oil volume.
Other gearbox types approx 1% of operating oil volume, however at least 1 litre.
service intervals see 5.3
• Seal gearbox: replace venting filter with plug screw,
seal housing at shafts with acid-free grease

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REINTJES BV1945.en 2008-03

Type C Flushing with operating oil


• Flush gearbox 15 minutes
• Seal gearbox: replace venting filter with plug screw
• Repeat flushing process at weekly intervals

Important: If the gearbox is turned in the meantime, for types A and B the sealing of the housing at
the shaft sealings will have to be restored after turning.

Remark: When draining off the operating oil residual quantities may remain in the gearbox. The
effectiveness of the anti-corrosion measures taken subsequently will not suffer from this.
Conversely, residual quantities of the anti-corrosion oils may mix with the operating oil when the
gearbox is put into operation again.

Note: If a heat exchanger is installed, its water circuit should be drained and flushed according to
Operating Manual BV 1758. Then the heat exchanger should be filled with fresh water containing
an anti-corrosion additive. The sort of additive is dependent on the cooling system.

7 Product Specification for Anti-corrosion Oils


• VALVOLINE ROSTSCHUTZ 6, Valvoline, Hamburg
full-power anti-corrosion oil for gearboxes
• BRANOROL 32/10, Brangs & Heinrich, Hannover
VCI anti-corrosion oil based on mineral oil

Page 5 / 5
Schmierstofftabelle / Lubrication Chart BV 1597/4
2010-06
Schiffsgetriebe ohne eingebauter Lamellenkupplung / Marine Gears without disc clutch

Schmierstoffart / Type of Lubricant Anforderungen / Requirements

Schiffsdieselmotorenöl - Marine Diesel Engine Oil - SAE 40 (ISO VG 150)


Getriebeöle - Gear Oils - FZG > 11

Energol DS-3 154 Castrol MLC 40* Delo 1000 Marine 40 Mobil DTE 19M
Energol DL-MP 40 Castrol MHP 154 Taro 16 XD 40 Mobilgear 600 XP 150
Vanellus C3-40 Castrol HLX 40 Taro 20 DP 40 Mobil Delvac 1640
Energol HPDX 40 Rivermax SX 40* Meropa 150* Mobilgard ADL 40
Energol GR-XP 150 Castrol Alpha SP 150 Pinnacle EP 150# Mobil SHC 629#
Hyspin AWH-M 150* Gear Compound EP 150* Mobilgear XMP 150*
Castrol MPX 40 Mobilgear SHC XMP 150*#
Mobilgard 412

Titan Universal HD 40 Shell Gadinia AL 40 TOTAL CAPRANO TD 40 DISOLA M 4015


Titan Universal XT 40 Shell Rimula X 40 RUBIA S 40 DISOLA M 4020
Renolin CLP 150 Shell Sirius 40 RUBIA FP 40 AURELIA XL 4030
Shell Argina S 40 CARTER EP 150 AURELIA XL 4040
Shell Omala S 2 G 150
(Shell Omala 150) EPONA Z 150
Shell Omala F 150 *
Shell Omala S 4 GX 150 *#
(Shell Omala HD 150 *#)
Shell Argina T 40

# synthetisches Öl (nur PAO Basis) / synthetic oil (PAO only)


* Öl mit Grauflecken-Tragfähigkeit (GFT) "hoch" / Oil with Greystaining Test result "high"

Reintjes GmbH
D-31785 Hameln
Phone: +49 (0)5151 104 0
Fax: +49 (0)5151 104 300
www.reintjes-gears.de

Bitte beachten Sie auch die Hinweise auf der Rückseite / Please see remarks on the backside
Für die Ölauswahl in REINTJES- To be observed in selecting oil for
Getrieben ist zu beachten: use in REINTJES gears:
1. Eine Öltemperatur unter 1. If oil temperature is lower than
+ 10 °C / 50 °F (SAE 30) + 10 °C / 50 °F (SAE 30)
+ 15 °C / 59 °F (SAE 40)erfordert eine + 15 °C / 59 °F (SAE 40)a sump heating
Sumpfheizung im Getriebe installation is required
(Sonderausstattung). (special equipment must be fitted to the gearbox).

2. Von REINTJES freigegebene Schmierstoffe 2. Lubricants approved by REINTJES have all


verfügen über alle notwendige Eigenschaften, eine necessary properties, further additives are
Zugabe von weiteren Additiven ist überflüssig und therefore superfluous and may even be harmful.
kann möglicherweise schädlich sein.

3. Hochalkalisch eingestellte Motorenöle (TBN > 20) 3. Highly alkaline engine oils (TBN > 20) must not
dürfen bei eingebauter Lamellenkupplung nicht be used.
verwendet werden.

Für den Ölwechsel ist zu beachten: To be observed when changing oil:


1. Die in der Betriebsanleitung vorgeschriebenen 1. Oil change intervals, oil analysis resp. as
Ölwechselzeiten bzw. Ölanalysen sind einzuhalten. specified in the operating manual must be
adhered to.

2. Beim Ölwechsel sind die Ölfilter-Elemente 2. Filter elements must be replaced when changing
auszutauschen. Der Entlüftungsfilter ist sorgfältig zu oil. The air filter (venting filter) should be carefully
reinigen. Erste Verschmutzungskontrolle ca. 12 cleaned. First check for contamination should be
Stunden nach Inbetriebnahme. made approx. 12 hours after starting up.

3. Der Ölstand muss zwischen den Markierungen des 3. The oil level must be between the dipstick
Peilstabes liegen. Die auf dem Typenschild markings. The oil quantity indicated on the name
angegebene Ölmenge ist ein Anhaltswert. plate is a reference value.

4. Erforderliche Getriebespülungen möglichst mit dem 4. For flushing and cleaning of the gearbox the
Betriebsschmierstoff vornehmen. Das Spülöl ist operating lubricant should be used. Remove
weitgehend aus Getriebe, Filter und Wärmetauscher cleansing oil from gearbox, filter and heat
zu entfernen. exchanger as thoroughly as possible

5. Das Getriebe ist im Anlieferungszustand konserviert 5. The gearbox will be delivered in preserved state
(Konservierungsmittel ablassen). Reste des (corrosion preventive). Residual corrosion
Konservierungsmittels sind im Betriebsöl mischbar. preventive may be mixed with oil used in the
gearbox.

Achtung ! Attention!

• Die in der Schmierstofftabelle aufgeführten • The oil types listed in the lubrication chart
Ölsorten werden von den Ölgesellschaften are defined by the responsibility of the oil
verantwortlich festgelegt. Die Öle sind für den companies. The oils are suitable for the
Gebrauch in Getrieben geeignet und entsprechen use in gearboxes and are in accordance
der REINTJES Spezifikation. Für die Einhaltung with the REINTJES specification.
der der Empfehlung zu Grunde liegenden The oil companies are responsible to keep
Spezifikation des Produktes ist der the compositions of the oils are identical
Mineralölhersteller verantwortlich. as specified for this oil chart.
• REINTJES übernimmt keine Haftung für die • REINTJES is neither liable for correctness
Richtigkeit dieser Angaben sowie aller of these data nor for any amendments
eintretenden Änderungen. occurring.
• Bei Verwendung anderer Schmieröle ist vor dem • If other lubrication oil shall be used please
Einsatz Rücksprache mit REINTJES zu halten. contact REINTJES first.
• Für alle Schäden, die durch die Verwendung nicht • REINTJES does not accept responsibility
geeigneter Öle entstehen, übernimmt REINTJES for any damages due to use of unsuitable
keine Haftung. oils.
Änderungen vorbehalten Subjects to alterations
MARINE GEARBOXES
WARTUNGSHANDBUCH
SERVICE MANUAL

Typ / Type: VA 4851 K41 B


Getr.-Nr. / Work no.: 76 643

Inhalt
Contents
BV1755.de 2001-05 Allgemeine Hinweise / Schraubensicherung
BV1755.en 2001-05 General information / screw locking

BV1778.de 2001-05 Geklebte Verbindung


Antriebswelle - Kupplungsgehäuse
BV1778.en 2001-05 Glued connection
Input shaft - Clutch housing

BV1174.de 2001-05 Montage und Demontagevorschrift für


Kegelpreßverbände mit Kegel 1:30
BV1174.en 2001-05 Assembly and dismantling instructions for
taper press hub with 1:30 taper

BV1758.de 2003-04 Wartungsempfehlungen für Wärmetauscher


des Fabrikats BLOKSMA
BV1758.en 2003-04 Recommended maintenance procedures for
heat exchangers of Bloksma make

BV1756.de 2008-02 Technische Daten


BV1756.en 2008-02 Technical Data

76643.de-en_W.doc 1/2
REINTJES WARTUNGSHANDBUCH / SERVICE MANUAL

Typ / Type: VA 4851 K41 B


Getr.-Nr. / Work no.: 76 643

0-102-67836 Antriebswelle
Input shaft

0-102-66700 Abtriebswelle
Output shaft

0-102-61342 PTO-Welle
PTO-Shaft

Service Reparatur Sätze


Service repair kits

A1 Wärmetauscher Typ P130


A1 Heat Exchanger Typ P130

A3 Doppelschaltfilter Typ RFLD


A3 Duplex Filter Typ RFLD

E19 Ölpumpe Typ KF 3/..


E19 Oil Pump Typ KF 3/..

V8 Druckbegrenzungsventil
V8 Pressure limiting valve

Technische Änderungen vorbehalten


Subject to alterations

REINTJES GMBH TELEPHONE +49 (5151) 104-0


31785 HAMELN TELEFAX +49 (5151) 104-300
GERMANY E-MAIL service@reintjes-gears.de
© REINTJES GmbH 2010

2/2
BV1755.en
MARINE GEARBOXES 2001-05

General Information

Dismantling may be carried out by trained personnel only.


Please pay attention to the information contained in Section 1 of this operating manual.
All safety regulations must be complied with.
Please make sure that the engine cannot be started accidentally. All cooling water valves
must be closed. The oil must be drained off before the gearbox is disassembled.
All covers must be marked before being removed so that they can be replaced correctly.
The lubrication oil bore holes must also be considered, all parts must be marked before
being removed (e.g. pinion shaft carrier, lubrication of discs).

Seals
Some parts have been fitted with O-rings, e.g. the control valve.
Flat gaskets have been used for the inspection covers.
All other single parts are assembled with a liquid surface sealant (anaerobic sealant) having
almost no influence on the dimensions. These sealing areas must be cleaned and dried
before assembly. The sealing material must be applied on one part in the form of a
continuous band (2-3 mm - 0.1") along the centre line and inside past the drill holes.

Screws
All screws connecting parts with torque transmission, e.g.
input shaft - clutch housing or
output shaft - counter flange on propeller side,
must not be reused after disassembly. They are marked *8 in the spare parts lists.

BV1755.en_2001-05.doc 1/2
REINTJES BV1755.en 2001-05

Screw Locking
For assembly use screws withscrew-locking glue. The glue is applied either as a green
coating on the screws, or medium-strength screw glue must be used.
Prior to using the new screws the threaded holes have to be freed from glue remains by
using the corresponding tap.

Note:
Use always screw-locking, medium-strength metal glue for locking:
- shaft nuts, screws (without green coating), nuts mounted in the gearbox without securing
elements
- all external screws connecting the housing parts (near bearings)
- all screws which are transmitting force to other parts, e.g. bearing housing
- fixing screws for heat exchanger, filter, pump etc.
-

Example for application of glue

Pay attention to the following charts for tightening torques. Screws are only sufficiently
secured by using glue if they are tightened with the proper torque (assembly torque).
After dismantling and when re-assembling these screws, nuts and shaft nuts have to be free
from glue remains. The threaded holes have to be cleaned as well.

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BV1778.en
MARINE GEARBOXES 2001-05

Glued Connection
Input Shaft - Clutch Housing

The contacting surfaces of the connection input shaft - clutch housing have to be assembled
using a liquid sealant (anaerobic glue).
First the contact surfaces are cleaned with a solvent. Then an activator is sprayed onto both
sides. After the activator evaporated the contact surface of the input shaft is coated with the
anaerobic glue.
Then the parts are assembled and screwed up.

BV1778.en_2001-05.doc 1/1
BV1174.en
MARINE GEARBOXES 2001-05

Instructions for Hydraulic Assembly/ Disassembly with


Taper 1:30

1 Instructions for Hydraulic Assembly

Attention
Operations involving pressurized oil involve no danger provided strict compliance with
operating instructions is observed and correctly-fitting accessories in perfect condition are
used.
Please observe the following instructions:
- Prior to service, carefully check the pump,H.P. pipe and all other accessories. Do
not,under any circumstances, use pump components which show even the slightest
signs of damage or damaged accessories which are not designed for pressures of at
east 300 MPa (3000 bar).
- Make sure that the pump and the high- pressure pipe are completely filled with oil and
that all air has been expelled from the pump.
- The pipe must not be bent or otherwise subjected to violent treatment when pressurized.
Mishandling of the pipe can lead to accidents.
- The pressures required for expansion and force-on must permanently be checked with
pressure gauges.
- Ensure that adequate safety precautions are taken when working with high- pressure
hydraulic systems.
- Oil under extreme pressure can cause injuries.
- Always wear protective goggles.
- Oil under pressure must not be allowed to come into contact with the skin.

1.1 Inspection of Individual Components

Prior to assembly of the individual components (e.g. shaft and gear, shaft and flange) it is
necessary to carefully inspect the taper surfaces. Ensure that taper surface and oil
distribution groove transitions are free of burrs. Remove all burrs and rectify any other
damage found.
Instructions for Repair:
During repair operations, the nature and extent of the damage may require that shaft
concentricity, taper surface and bearing seating be checked.

BV1174.en_2001-05.doc 1/4
REINTJES BV1174.en 2001-05

1.2 Pressurizing Media and Assembly Preparations

Expansion of the component to be mounted (gear, flange, etc.) is to be effected


using SAE 10 oil (viscosity 32 cST at 40°C).
The oil used for expanding operations must be absolutely free of contaminants
and EP additives.
The components to be assembled should be at the same temperature, i.e. wherever possible
assembly should be carried out at ambient temperature.
All taper surfaces are to be thoroughly cleaned with a degreasing agent and thinly coated
with the SAE 10 hydraulic oil used for assembly (viscosity 32 cST at 40°C).

1.3 Force-on Dimension Check

Information for force-on dimension and expansion pressure will be given by REINTJES
service department on request.
The force-on dimension is stated in mm and comprised the nominal dimension and a
permissible tolerance, e.g. 13.3 + 1.2 mm.
To determine the force-on dimension push the component to be mounted (gear, flange, etc.)
onto the shaft.
The first checking dimension, required to establish the force-on dimension of the component
to be mounted, is calculated from that point at which the taper faces are in full contact with
each other without any pressure applied.
In order to be able to complete further force- on dimension checks it is now necessary to
select an additional reference point. A reference lip (shoulder) on the shaft is recommended
for this purpose.
Note the checking dimension thus obtained.
Position the assembly jig (hydraulic nut) handtight against the component to be mounted;
ensure that all threaded assembly jig elements are fully engaged with each other and that the
piston of the hydraulic nut is in its original position.
Connect hydraulic pumps as follows:
pump for expansion pressure to connection „B“
pump for force-on pressure to connection „A“

Pressure Connections
when starting the force-on process

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REINTJES BV1174.en 2001-05

1.4 Expansion and Force-on of Component to be Installed (Gear, Flange, etc.)

In order to be forced-on, the component to be installed must first be expanded.


In order to do this oil is forced between the taper faces until it emerges at the ends of the
connection.
The force-on action is achieved by repeatedly increasing and alternating the expansion and
force-on pressures until the component is forced-on into its final position acc. to the specified
force-on dimension.
During the force-on procedure the expansion pressure increase should not be allowed to
exceed 100 bar over a 3 minute period; this is necessary to avoid localized exceeding of the
max. permissible yield point value.
When the component is in its specified position the expansion pressure at connection "B"
must be relieved to allow the oil film between the taper surfaces to disperse. The force-on
pressure must be maintained at connection "A" for at least one hour.
Approximately 24 hours should be allowed to pass before the assembly is subjected to
maximum load. This time delay is necessary to ensure that all expansion fluid has been
expelled from the component mating faces.

NOTE
In this case of components with two connecting points for expansion pressure one of
these must be effectively plugged.

2 Instruction for Hydraulic Disassembly

Attention
Hydraulically assembled components are under extremely high pressure and can
cause injury when released. As the component to be removed can be suddenly
released at great force it is mandatory that this part be provided with a stop (hydraulic
nut) as a safety measure.

In order to remove the subject component (gear, flange, etc.) from the shaft, the installation /
removal jig (hydraulic nut) and hydraulic pumps must be assembled in the same positions
and manner as used for component assembly.
As a function of the max. force-on dimension, the annular piston must be forced out of the
hydraulic nut 3-4 mm (see sketch) and, with a force-on pressure of 100 bar applied at
connection "A", brought into contact with the component to be removed.
The force-on pressure in the hydraulic nut must then be released and the hydraulic pump
valve to the hydraulic nut connection "A" must be closed.
In order to be released, the component to be removed must first be expanded via
connection "B".
In order to achieve this, hydraulic oil is forced slowly between the component taper faces.
Expansion pressure increases should not exceed 100 bar over a period of 3 minutes.
Component release is indicated by a rise in pressure in the hydraulic nut which is indicated at
the pressure gauge of the hydraulic pump assigned to connection "A".

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REINTJES BV1174.en 2001-05

When the pressure rises in the hydraulic nut, the oil pump valve to connection "A" must be
opened and the pressure released. The expansion pressure must, however, be mantained
by continuous operation of the hydraulic pump assigned to connection "B" until the
component is completely released from its tapered seat.

Attention
The component being removed may be released suddenly when the pressure at
connection "A" is released to zero, for this reason it is mandatory that the hydraulic
nut (safety stop) be correctly installed.

If the max. expansion pressure is achieved and the component to be removed is


not released, proceed as follows:
- Increase expansion pressure at connection"B" by 10 %.
- Maintain this pressure for one hour.
- In addition, heat the component slowly and evenly.
(temperature max. 140°C or 284°F)
- Mount an additional puller.

Pressure Connections

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BV1758.en
MARINE GEARBOXES 2003-04

Recommended Maintenance Procedures for Heat


Exchangers of BLOKSMA Make

1 Introduction
In order to identify the heat exchanger please check the rating plate for the "BLOKSMA "
marking. The rating plate of the heat exchanger is located on one of the two cams of the oil
inlet and/or outlet.
We recommend having spare parts for maintenance work on board. Anodes and sealing
rings can be obtained from the REINTJES service department upon specifying the gearbox
number and type.

ATTENTION:
Checks of 2 Anodes and 3 Contamination Control shall be performed only with the
propulsion system shut down and the cooling water pump switched-off.
The gearbox and the heat exchanger shall have cooled down to lukewarm temperature.

2 Anodes
For protecting the water chamber and the tube bundle from corrosion the heat exchangers
are equipped with 3 anodes (A292): at water inlet, end cover and water outlet.
The anode consumption can differ. It is dependent on the installation and operating
conditions.
Based on the results of the first checks the precise intervals can be determined. Preventive
inspections have to be carried out regularly, as before.
The anodes have to be renewed when 60 % of their original volume have been consumed.

2.1 Intervals of Anode Checks

First inspection After 100 hours of operation


Inspections thereafter Every three months or on occasion of every cleaning

BV1758.en_2003-04.doc 1/5
REINTJES BV1758.en 2003-04

2.2 Visual Inspection

Cooling water circuit Shut inlet and outlet valves


Heat exchanger Drain cooling water
Anodes Screw out anodes and perform visual check
Result: OK Screw anode in hand-tight with new sealing ring
Result: Anode consumed Screw in hand-tight new anode with new sealing ring
Visual check finished • Open cooling water valves
• Switch on cooling water pump
• Vent heat exchanger
• Check anodes for waterproof installation

3 Contamination Control of Tube Bundle


3.1 Construction of Heat Exchanger

schematic drawing

1 Tube plate
2 O-rings
3 Fixing plate
4 Shell
5 Tube bundle

Both tube plates are identical:


• The outer O-rings seal the corresponding cover,
• the inner O-rings seal the shell,
• the central groove takes up the 4 fixing plates.
The fixing plates can be fitted at the open end cover or end cover alternatively.
Both covers can be mounted with rotated through 180° (accessibility of anodes).

Important
Never mount the covers to the wrong side.
The tube bundle has only one correct mounting position in the shell.
Never mount the tube bundle laterally inverted or twisted.

2/5
REINTJES BV1758.en 2003-04

3.2 Visual Inspection of Tube Bundle

The contamination of the tube bundle depends on the installation and operating conditions.
Based on the results of the first inspections further intervals can be determined.

Note
Always loosen and tighten the bolts of the cooling water connection flanges and the covers of
the heat exchanger crosswise.

For this simple visual inspection the hydraulic oil in the heat exchanger need not be drained.

Cooling water circuit Shut inlet and outlet valves


Heat exchanger Drain cooling water
Cooling water connections Screw off, sealing OK?, open end cover freely accessible
Covers Mark position of open end cover and end cover clearly with 1/1 und 2/2

Covers Loosen and screw off covers crosswise


Fixing plates Insert bolts from the other side,
screw fixing plates tight with nuts

In the middle of the open end cover a nylon


partition is inserted
Depending on the local installation conditions
Open end cover the tubes can be inspected and cleaned with a
End cover nylon tube brush
Inspection: OK Continue with 3.5 Assembly of Cover

3.3 Disassembly of Tube Bundle

The tube bundle can be pulled out to either side. In this description the indication of sides A
and B analogously applies to the corresponding side of open end cover and end cover.
Heat exchanger Drain oil, dependent on installation conditions
Tube bundle Mark mounting position and check marking on open end cover side
Open end cover side Take partition from tube bundle
Fixing plates Screw off bolts and nuts, take off fixing plates
A • Push in tube plate flush with shell
(or drive it in slightly using a piece of wood)
• Attention: Do not damage edges by hammer blows!)
B • Take off both O-rings
• Push in tube plate flush with shell
(or drive it in slightly using a piece of wood)
A Take off both O-rings

3/5
REINTJES BV1758.en 2003-04

B Push in tube bundle so far as to be able to seize the tube plate from
behind on side A
(A) Pull out tube bundle carefully
Note:
Lift and straighten tube bundle,
take care not to bend the baffles on the tube bundle

Clean tube bundle according to the inspection result.


If it has to be cleaned chemically, please ask for detailed information to be sent.
A tube bundle can only be replaced together with the shell.

3.4 Re-assembly of Tube Bundle

Never use the old, dismounted O-rings.


Always fit new O-rings.
For simple assembly and good sealing of the O-rings a special lubricant is required
(soap-free grease, e.g. Molikote, silicone paste or Parker O-lube).

Note
Never use Vaseline or other, unsuitable types of grease.
If unsuitable grease is used, any warranty claims will be refused.

Shell Clean sealing surfaces carefully, check for damages


Apply thin layer of suitable lubricant to sealing surfaces
Tube plate Clean grooves carefully, check for damages
Apply suitable lubricant to grooves
Assemble tube bundle In reverse order of disassembly, pay attention to markings
Positioned O-rings If necessary, apply lubricant to the outside
• Fit fixing plates, keep in position with bolts
• Fit partition on open end cover side

4/5
REINTJES BV1758.en 2003-04

3.5 Assembly of Covers

First screw on the side with the fixing plates (example with open end cover).
Open end cover • Clean sealing surfaces, check for damages
• Apply thin layer of suitable lubricant to sealing surfaces
• Fit cover without applying force
• Take out bolts, insert them from the other side,
screw on nuts (with spring washer) hand-tight
• Screw bolts tight crosswise
End cover As above (insert bolts from outside to inside)
Cooling water connections Fit, check for damaged sealings

After finishing the assembly fill and vent water circuit and hydraulic system and check for
tightness.

3.6 Temporary Shutdown

If the system has been out of operation for more than two weeks, the water circuit should
be drained and flushed. After that the heat exchanger should be filled with fresh water
containing an anti-corrosion additive.
NOTE:
- The type of additives depends on the cooling system.
In case of doubt please contact
BLOKSMA, Holland, Phone: +31 36 549 23 00, Fax: +31 36 549 23 90.

5/5
BV1756.en
MARINE GEARBOXES 2008-02

Technical Data

You will find the technical data for your gearbox on the type plate.
The type plate of the gearbox is mounted at the top part of the gearbox housing.
⇒ Copy the data for your gearbox to the type plate printed here:

Requesting spare parts


⇒ When making enquiries and ordering parts, please provide the following information:

• GEARBOX NO. - e.g.: K80xxx


• TYPE - e.g.: WAF 6xx
• INPUT CAPACITY - e.g.: 850 kW
• GEAR REDUCTION RATIO - e.g.: 4.05 : 1

⇒ Please provide this additional information, listed in the spare parts lists,
when ordering spare parts:

• Item number of the part


• Designation
• Required no. of pieces

BV1756.en_2008.02.doc 1/1
MARINE GEARBOXES PL 76643
Ersatzteilliste
Spare Parts List

Getriebe-Nr
Gearbox No. 76643
Getriebetyp
Gearbox Type VA 4851 V K41B
Untersetzung
4,500
Reduction
Drehsinn Antrieb
CLOCKWISE
Input Rotation
Drehsinn Abtrieb
ANTICLOCKWISE
Output Rotation
MotorHersteller
MAN
Engine Make
MotorTyp
7 L 32/40
Motor Type
Leistung
3500 kW
Engine Power
Motor Drehzahl
750 min-1
Engine Speed
Leistungsmoment Motor
4,667 kW/min-1
Power/Speed Ratio - Engine
zul. Leistungsmoment Getriebe
4,667 kW/min-1
allowable Power/Speed Ratio - Gearbox
MotorDrehmoment
44.563,4 Nm
Engine Torque
zul. Drehmoment Getriebe
44.566,6 Nm
Allowable Torque - Gearbox
Lieferdatum
03.Aug.2010
Delivery Date
Abnahme
GL/KUNDE
Marine Society
Einbauzeichnung
0-104-83450
Installation Drawing
Drehschwingungsschema
0-111-83464
Torsional Information

19.07.2010 1/6
REINTJES PL 76643 de-en

Pos. für Teilenr. Benennung Menge


Pos. for Part No. Designation Quantity

A 1 *S A633470 WÄRMETAUSCHER heat exchanger 1


A 3 *S A631892 DOPPELSCHALTFILTER duplex filter 1
A 4 A633089 FLANSCH flange 1
A 6 A633089 FLANSCH flange 1
A 7 A9156 ZYLINDERSCHRAUBE allen screw 8
A 37 A 3 A338362 FILTERELEMENT filter element 2
A 80 A430536 HALTER support 1
A 81 A9130 ZYLINDERSCHRAUBE allen screw 2
A 83 A9130 ZYLINDERSCHRAUBE allen screw 2
A 282 A 1 A843059 O-RING o-ring 1
A 283 A506079 DICHTUNGSSATZ set of seals 1
A 289 A 1 A681245 WASSERKAMMER water channel 1
A 290 A 1 A301655 UMLENKKAMMER end cover 1
A 291 A 1 A681237 ROHRBÜNDEL tube bundle 1
A 292 A 1 A301671 ANODE anode 3
A 500 A987469 ABLASSSCHRAUBE, MAGNETISCH drain screw magnetic 2
D003.00 A42897 DECKEL cover 3
D003.01 A980369 DICHTUNG gasket 3
D003.02 A10812 SECHSKANTSCHRAUBE hexagon screw 21
D003.03 A210277 SCHEIBE washer 33
D003.04 A15547 STOPFEN plug 3
E 5 A993017 BUCHSE bush 1
E 7 A980904 DECKEL ZWEITEILIG cover two part 1
E 15 A61298 WÄLZLAGER anti-friction bearing 1
E 19 A989507 ÖLPUMPE oil pump 1
E 41 A598895 GEHÄUSE PUMPENTRIEB housing, pump drive 1
E 42 A101214 PUMPENRAD wheel 1
E 43 A623601 WELLENRAD wheel 1
E 44 A11738 GEWINDESTIFT threaded pin 1
E 97 A939285 DECKEL cover 1
E 104 A9857 SECHSKANTSCHRAUBE hexagon screw 8
E 107 A20508 ENTLÜFTUNGSFILTER venting filter 1
E 108 A10626 SECHSKANTSCHRAUBE hexagon screw 4
E 108 A210250 SCHEIBE washer 4
E 115 A10960 SECHSKANTSCHRAUBE hexagon screw 16
E 124 A7889 WÄLZLAGER anti-friction bearing 1
E 125 A8087 WÄLZLAGER anti-friction bearing 1
E 143 A10960 SECHSKANTSCHRAUBE hexagon screw 4
E 145 A996671 ÖLPUMPE oil pump 1
E 191 A706558 LAGERGEHÄUSE bearing housing 1
E 193 A331740 DECKEL ZWEITEILIG cover two part 1
E 202 A993460 DECKEL cover 1
E 244 A9865 SECHSKANTSCHRAUBE hexagon screw 12
E 296 A113298 DECKEL cover 1
E 297 A10979 SECHSKANTSCHRAUBE hexagon screw 6
E 325 A601934 ZYLINDERSCHRAUBE allen screw 6
E 372 A606570 BUCHSE bush 1

19.07.2010 2/6
REINTJES PL 76643 de-en

Pos. für Teilenr. Benennung Menge


Pos. for Part No. Designation Quantity
E 374 A599689 BUCHSE bush 1
E 423 A932663 SPALTDICHTUNG sealing ring 1
E 423 A932671 ZUGFEDER spring 1
E 425 A211753 SPRITZRING splash ring 1
E 425 A932671 ZUGFEDER spring 1
E 451 A211753 SPRITZRING splash ring 1
E 451 A719404 ZUGFEDER spring 1
E 452 A719390 SPALTDICHTUNG sealing ring 1
E 452 A719404 ZUGFEDER spring 1
E 497 A11100 SECHSKANTSCHRAUBE hexagon screw 2
E 497 A12599 SECHSKANTMUTTER hexagon nut 2
E 498 A994257 ZYLINDERSTIFT cylindrical pin 2
E 498 A12556 SECHSKANTMUTTER hexagon nut 2
E 687 *4 A507679 WÄLZLAGER anti-friction bearing 2
E 688 A8427 WÄLZLAGER anti-friction bearing 1
E 719 A10820 SECHSKANTSCHRAUBE hexagon screw 12
E 738 *4 A818844 BUCHSE (1 SATZ) bush (one set) 1
E 795 A437778 DICHTUNG gasket 1
E 956 A557650 DECKEL ZWEITEILIG cover two part 1
E 957 A9881 SECHSKANTSCHRAUBE hexagon screw 8
E 991 A62855 FEDER spring 12
E 992 A62855 FEDER spring 12
E 996 A994116 LAGERGEHÄUSE bearing housing 1
E 998 A13714 SPANNSTIFT clamping sleeve 1
E 1000 A557528 LAGERGEHÄUSE bearing housing 1
E 1004 A944742 SPALTDICHTUNG sealing ring 1
E 1004 A377953 ZUGFEDER spring 1
E 1005 A211753 SPRITZRING splash ring 1
E 1005 A377953 ZUGFEDER spring 1
E 1017 A745936 LAGERGEHÄUSE bearing housing 1
E 1019 A11347 VERSCHLUSSSCHRAUBE plug screw 1
E 1049 A698067 ZWISCHENGEHÄUSE bell housing 1
E 1050 A9423 ZYLINDERSCHRAUBE allen screw 12
E 1058 A10197 SECHSKANTSCHRAUBE hexagon screw 12
E 1174 A975818 DECKEL cover 1
E 1175 A9172 ZYLINDERSCHRAUBE allen screw 16
E 1176 A14249 FEDER spring 12
E 1465 A278211 SICHERUNGSRING retaining ring 1
E 1595 A657840 V-RING v-ring 1
E 1595 A74594 V-RING v-ring 1
E 1596 A961620 V-RING v-ring 1
E010.01 A23086 VERSCHRAUBUNG screwed union 1
E010.02 A16330 STAHLROHR,PRÄZ. pipe,accuracy 1
E010.03 A486914 BUCHSE bush 1
E010.04 A506850 ROHRSCHELLE pipe clamp 2
E010.05 A528684 ZYLINDERSCHRAUBE allen screw 2
G 65 A738956 RADKASTEN gear shielding 1
G 163 A705268 SCHEIBE washer 4
G 163 A17264 ZYLINDERSCHRAUBE allen screw 4

19.07.2010 3/6
REINTJES PL 76643 de-en

Pos. für Teilenr. Benennung Menge


Pos. for Part No. Designation Quantity
G 292 A111716 SPANNSTIFT clamping sleeve 2
G 600 A992645 GEHÄUSE housing 1
P 1 A100514 ABTRIEBSWELLE output shaft 1
P 20 A550485 WÄLZLAGER anti-friction bearing 1
P 21 A36714 WÄLZLAGER anti-friction bearing 1
P 22 A111023 WÄLZLAGER anti-friction bearing 1
P 33 A559695 BUCHSE bush 1
P 41 A535095 BUCHSE bush 1
P 42 A559709 BUCHSE bush 1
P 74 A150533 WÄLZLAGER anti-friction bearing 1
P 130 A53490 WELLENMUTTER shaft nut 1
P 136 A11819 GEWINDESTIFT threaded pin 2
P 141 A17230 SICHERUNGSRING retaining ring 1
P 171 A628760 BUCHSE bush 1
P 219 A753262 BUCHSE bush 1
R 1 A100514 RITZELWELLE pinion shaft 1
R 2 A100514 STIRNRAD wheel 1
R 32 A41211 WELLENMUTTER shaft nut 1
R 33 A11827 GEWINDESTIFT threaded pin 2
R 36 A108561 BUCHSE bush 1
R 118 A984244 STIRNRAD wheel 1
V 8 A989190 DRUCKBEGRENZUNGSVENTIL pressure limiting valve 1
V 301 A201669 RÜCKSCHLAGVENTIL non-return valve 1
V 302 A201669 RÜCKSCHLAGVENTIL non-return valve 1
V 420 A573183 ANSCHLUSSTÜCK connection piece 1
V 421 A9121 ZYLINDERSCHRAUBE allen screw 4
V 508 A996069 RÜCKSCHLAGVENTIL non-return valve 1
W 202 A11711 GEWINDESTIFT threaded pin 1
W 241 A699454 WELLE PTO pto shaft 1
W 243 A557870 BUCHSE bush 1
W 244 A21547 WELLENMUTTER shaft nut 1
W 245 A13684 SPANNSTIFT clamping sleeve 1
W 245 A690767 PASSFEDER fitted key 1
W 246 A12971 SICHERUNGSRING retaining ring 1
W 420 A735124 SCHEIBE washer 1
W 421 A10715 SECHSKANTSCHRAUBE hexagon screw 4

0-211-83684
A103 A861880 DRUCKSCHALTER pressure switch 1
A105 A861880 DRUCKSCHALTER pressure switch 1
A113 A879096 DRUCKPRÜFVENTIL pressure test valve 1
A113 A980813 ANSCHLUSSPLATTE connection plate 1
A119 A186830 KABELEINFÜHRUNG cable entrance 9
A119 A572730 DICHTRING sealing ring 9
A120 A186856 KABELEINFÜHRUNG cable entrance 3
A120 A632643 DICHTRING sealing ring 3
A121 A112399 KUGELHAHN shut-off valve 1
A125 A861880 DRUCKSCHALTER pressure switch 1
A159 A74357 ROHRSCHELLE pipe clamp 2

19.07.2010 4/6
REINTJES PL 76643 de-en

Pos. für Teilenr. Benennung Menge


Pos. for Part No. Designation Quantity
A159 A572500 ZYLINDERSCHRAUBE allen screw 2
A168 A45128 DRAHTSEIL locking wire 1
A168 A45110 SEILKLEMME wire-rope grip 1
A21 A993769 KLEMMGEHÄUSE terminal box 1
A24 A8761 ZYLINDERSCHRAUBE allen screw 4
A35 A62510 MANOMETER pressure gauge 1
A35 A861871 MANOMETERADAPTER joining piece 1
A35 A861901 VERSCHRAUBUNG screwed union 1
A43.1 A985048 SCHMUTZANZEIGE contamination indicator 1
A43.2 A985048 SCHMUTZANZEIGE contamination indicator 1
A461 A861880 DRUCKSCHALTER pressure switch 1
A480 A945021 TEMPERATURFÜHLER temperature sensor 1
A480 A945030 SCHUTZROHR protection tube 1
A490 A945021 TEMPERATURFÜHLER temperature sensor 1
A490 A945030 SCHUTZROHR protection tube 1
A55 A25232 THERMOMETER, GERADE thermometer 1
A57 A69183 NIVEAUSCHALTER oil level switch 1
H200 A23019 VERSCHRAUBUNG screwed union 1
H201 A44679 STAHLROHR 8X1,0 pipe 8 1
H202 A23019 VERSCHRAUBUNG screwed union 1
H630 A991961 VERSCHRAUBUNG screwed union 1
H631 A95389 STAHLROHR 12X1,0 pipe 12 1
H632 A23035 VERSCHRAUBUNG screwed union 1
H633 A95389 STAHLROHR 12X1,0 pipe 12 1
H675 A506834 ROHRSCHELLE pipe clamp 1
R1 A988832 WIDERSTAND resistance 1
R2 A988832 WIDERSTAND resistance 1
W480 A842052 ANSCHLUSSKABEL supply cable 1
W490 A842052 ANSCHLUSSKABEL supply cable 1

19.07.2010 5/6
REINTJES PL 76643 de-en

EDV-Ersatzteilliste, Fußnoten EDP-List of Spare Parts, Notes

*10 besteht aus G1/G2 kann nur komplett bestellt werden consisting of G1/G2 can only be ordered completely

*11 besteht aus G1/G82/G2 kann nur komplett bestellt consisting of G1/G82/G2 can only be ordered completely
werden

*12 besteht aus G1/G82/G2/G433 kann nur komplett bestellt consisting of G1/G82/G2/G433 can only be ordered
werden completely

*13 besteht aus G1/G144/G34 kann nur komplett bestellt consisting of G1/G144/G34 can only be ordered
werden completely

*14 besteht aus G1/G2/G98 kann nur komplett bestellt consisting of G1/G2/G98 can only be ordered completely
werden

*15 besteht aus G020.00/G030.00/G040.00 kann nur consisting of G020.00/G030.00/G040.00 can only be
komplett bestellt werden ordered completely

*16 besteht aus G1/G2/G433 kann nur komplett bestellt consisting of G1/G2/G433 can only be ordered
werden completely

*17 besteht aus G020.00/G040.00 kann nur komplett bestellt consisting of G020.00/G040.00 can only be ordered
werden completely

*18 besteht aus G020.00/G030.00/G040.00/G050.00 kann consisting of G020.00/G030.00/ G040.00/ G050.00 can
nur komplett bestellt werden only be ordered completely

*19 besteht aus G1/G82/G2/G107 kann nur komplett bestellt consisting of G1/G82/G2/G107 can only be ordered
werden completely

*2 Beachte Montage- und Demontageanleitung für Pay attention to assembly and dismantling instructions
Kegelpreßverbände mit Kegel 1:30 (siehe Anhang). for taper press hubs 1:30 (stated in the appendix)

*20 besteht aus E927/E932 kann nur komplett bestellt consisting of E927/E932 can only be ordered completely
werden

*21 besteht aus E620/E627 kann nur komplett bestellt consisting of E620/E627 can only be ordered completely
werden

*3 muß warm aufgesetzt werden must be mounted in hot condition

*4 muß als Lagerkombination bestellt werden must be ordered as bearing combination

*5 Nur in Einzelteilen lieferbar. Muß am Getriebe angepaßt Supplied in single Parts only. Have to be matched and
und fertiggestellt werden. finished on the Gearbox.

*8 müssen nach Demontage erneuert werden have to be renewed on dismantling (special screws)
(Spezialschrauben)

*9 Gehäuse Pumpentrieb und Lagergehäuse Pumpentrieb Housing Pump Drive and Bearing Housing Pump Drive
können nur zusammen bestellt werden. can only be ordered together.

*S Service Reparatur Satz Service Repair Kit

19.07.2010 6/6
A1
MARINE GEARBOXES 2004-08

SERVICE REPAIR SET


Heat Exchanger Type P ...

A1 Heat Exchanger Type P ...


A 282 Set of seals consisting of 1
O-ring (4)
A 289 Open end cover 1
A 290 Endcover 1
A 291 Tube bundle 1
A 292 Anode 3

P130_A.DOC 22.08.08 1/1


A3
MARINE GEARBOXES 2005-01

SERVICE REPAIR SET


Duplex Filter Type RFLD

A3 Duplex Filter Type RFLD


A 37 Filter element with O-ring 2
A 43 Contamination indicator
electrical
A 283 Set of seals consisting of 1
A O-ring (2)
B O-ring (2)
A 323 Switch lever, complete 1
A 500 Drain screw, magnetic 1

Additional order:
A 43 Contamination indicator 2
visual
alternatively
A 43 Contamination indicator 2
electrical

RFLD_A.DOC 31.01.05 1/1


E19
MARINE GEARBOXES 2004-08

SERVICE REPAIR SET


Oil Pump Type KF 2/.., KF 3/.., KF 4/..

E 19 Oil Pump Type KF 2/.. KF 3/.. KF 4/..


E 714 Set of seals consisting of 1
A Shaft sealing ring (1)
B O-ring (1)
C O-ring (1)
D Gasket (1)
E 725 Bearing 1

Note: Mark position of cover before


dismantling.
When assembling pay attention to
correct mating of cover and gasket D.

KF2_A.DOC 15.02.05 1/1


V8
MARINE GEARBOXES 2004-08

SERVICE REPAIR SET


Pressure Limiting Valve

V8 Pressure limiting valve


V 12 Locknut 1
V 13 Set screw 1
V 20 Valve slide 1
V 21 Spring 1

V8_OB_A.DOC 04.10.04 1/1