WAFLAF 665 1963 BV2147 en

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dublicated or circulated electronically without prior written
approval of REINTJES GmbH.
© 2010 REINTJES GmbH

All Rights Reserved.
WAF/LAF 665 - 1963
Table of contents
Table of contents
1 Safety ............................................................................................................................................................ 5
1.1 Meaning of Warnings and Notes ............................................................................................................. 5
1.2 Basic measures of caution ....................................................................................................................... 6
1.3 Requirements for installation personnel ................................................................................................. 7
1.4 Safety information for installation ............................................................................................................ 8
1.5 Protective measures against fire and danger of explosion ................................................................. 9
2 Introduction to this Documentation .............................................................................................. 11

2.1 Maintaining the documentation ............................................................................................................. 12
2.2 Preconditions of warranty ....................................................................................................................... 12
2.3 Brief product description ......................................................................................................................... 13
2.4 Area of application and manner of intended use ................................................................................ 14
2.5 Use of the gearbox within the European Union .................................................................................. 14
3 Technical Data ........................................................................................................................................ 15
4 Transport, Storage and Preservation ........................................................................................... 19

4.1 Transport ................................................................................................................................................... 19
4.2 Storage ...................................................................................................................................................... 20
4.3 Preservation ............................................................................................................................................. 22
5 Description ............................................................................................................................................... 29
5.1 Gearbox standard execution .................................................................................................................. 29
5.2 Power Take Off PTO K21A .................................................................................................................... 35
5.3 Power Take Off PTO K31A .................................................................................................................... 36
5.4 Power Take Off PTO K41 ....................................................................................................................... 37
5.5 Power Take Off PTO K51 ....................................................................................................................... 38
5.6 Gearbox with shaft brake ....................................................................................................................... 40
5.7 Gearbox with trolling propulsion system (ADS) .................................................................................. 43
6 Installation and Alignment ................................................................................................................ 45

6.1 Requirements for installation personnel ............................................................................................... 45
6.2 Steps in preparation ................................................................................................................................ 45
6.3 Setting up the gearbox ............................................................................................................................ 46
6.4 Alignment .................................................................................................................................................. 47
6.5 Connection of gearbox components ..................................................................................................... 56
Index ............................................................................................................................................................ 59
Installation Instructions 3
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Table of contents
4 Installation Instructions
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Safety
1 Safety
1.1 Meaning of Warnings and Notes

Warnings and notes indicating various levels of danger or importance are used within this
documentation.
The signal word indicates the danger level in each case. Important notes to be observed for
problem-free, safe operation are indicated with an exclamation mark in front of them. These
are the individual danger levels:
1.1.1 Warnings
DANGER!
Imminent danger!
Death or serious injury will occur!
⇒ Human lives are acutely endangered
WARNING!
Possibly imminent danger
Death or serious injury may occur
⇒ Human lives are possibly endangered
CAUTION!
Light injury may occur
⇒ Danger of personal injury
1.1.2 Notes
CAUTION!
! Important information for safe and problem-free operation.
Possibly imminent danger of damage to the gearbox
Note without signal word:

! ... Here you will find notes on working effectively and safely.
Additional information and recommendations
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Safety
1.2 Basic measures of caution

Frequently, accidents occur as a result of not observing general safety regulations or
cautionary measures.
The individual chapters of this mounting instruction contain specific safety notes.
Accidents may often be avoided by recognizing potential hazard situations in advance.
Input side Output side
Dangerous places on the gearbox
Symbol Meaning Symbol Meaning

General Warning Sign Smoking and open fires prohibited!
1
This warnings must be observed!
Danger of being drawn or caught Wear tightly fitting protective

1
in by rotating components clothing e.g. coverall
Danger of electric shock! Wear ear protectors

Do not disconnect or service this
device until power supply has been
disconnected!
Caution, hot components Read instructions carefully!
1
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Safety
1.3 Requirements for installation personnel

Installation 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 mounting. 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” on page 19 and “Installation and
Alignment” on page 45.
In order ensure your safety and the safety of others during mounting, 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!
General protective measures and personal protection in the engine room
The gearbox may be operated and maintained only by qualified staff knowledgeable in its
operation and maintenance.
DANGER!
Rotating Parts!
Danger of accidents due to getting caught or drawn in!
⇒ Prior to trial run mount covers to all rotating parts to prevent being
caught or drawn in.
⇒ 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 mounting.
⇒ 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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Safety
1.4 Safety information for installation

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 installation 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.
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 installation.
⇒ Perform a daily sight check of the piping in order to recognize any leakage at
any early stage.
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Safety
1.5 Protective measures against fire and danger of explosion
General information
⇒ Immediately remove any oil residues completely.

⇒ Do not leave on the gearbox any rags or cloths used to wipe oil residues.
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.
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 fromfrom hoses.
⇒ Replace hoses no later than after 5 years.
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.
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Safety
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.
Foreign substances near to the gearbox
⇒ Ensure that no used parts, dirt or foreign substances are near the gearbox.
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Introduction to this Documentation
2 Introduction to this Documentation
This documentation comprises one set of installation and operating instructions

! for gearboxes belonging to the WAF and LAF model series.
This installation instructions contains information about:
• Safety
• Technical data
• Transport, storage and preservation
• Description of gearbox models
• Installation and alignment
The operating instructions contains information about:
• Putting the unit into operation

• Operation
• Maintenance
• Trouble-shooting
• Spare and replacement parts
• Drawings for installation, tubing and supervision
The procedures described in this documentation are of a general nature.
Actual characteristics may differ from this information depending on the particular
gearbox and equipment.
Please read the Installation instructions before installing the gearbox!

! Please be especially careful to observe the preceding safety information!
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.
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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
2.1 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.
2.2 Preconditions of warranty
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.
REINTJES strongly recommends that you have a torsional vibration calculation

performed for the entire system.
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.
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2.3 Brief product description

The gearboxes of the WAF and LAF model series are axially offset marine gearboxes with
built-in hydraulic disc clutches.
The gearboxes of the WAF model series are reverse-reduction gearboxes with two clutches.
The gear reduction ratios are the same in the Ahead and Astern directions.
The gearboxes of the LAF model series are reduction gearboxes with only one clutch.
Marine gearboxes can be supplied with identical and counter rotation of the input and output
shafts. The thrust bearings built into the gearbox absorb the propeller thrust.
The gearbox has been designed under the assumption that a highly flexible coupling will be
employed between the motor and the gearbox.
Control is effected by means of directional valves.
An auxiliary drive (PTO = power take off) may additionally be provided that can be used to drive
an additional pump or generator.
2.3.1 Illustration
WAF 665 (example)
Pressure build-up system
Control valve
Manometer
Oil pump
Input shaft
Oil
filter
Output shaft
Gearbox foot
Oil drain screw
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2.4 Area of application and manner of intended use

The gearboxes are intended for use in the propulsion systems of ships. They represent the
current state of the art.
Please refer to the type plate and/or the documentation for technical data and for information
on permissible conditions of operation (limits).
These details must be absolutely adhered to!
The coupling flange and flexible couplings must be suited to the gearbox. You must observe
the technical details of the gearbox. (see ”Technical Data” on page 15.)
The gearbox may only be used in a flawless technical condition, in a manner consistent with
its intended use and in awareness of safety issues and potential hazards!
Use in accordance with the intended purpose also comprises compliance with mounting and
operating instructions and with inspection and maintenance conditions.
Any use of the gearbox in a manner not described here will be deemed usage that
! is not in accordance with its intended purpose. REINTJES will not be liable for any
damage resulting from such use.
2.5 Use of the gearbox within the European Union

In cases when operation is subject to safety regulations of the European Union, the
manufacturer of the complete system must have it CE-approved and labelled accordingly.
Seagoing vessels are exempted from this requirement in accordance with the Machinery
Directive.
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Technical Data
3 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 665
• 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
You will find the spare and replacement parts lists in the operating instructions beginning on
page 85.
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Technical Data
The tables below present an overview of the performance data of the gearbox types described
in this documentation.
The data of your gearbox may differ from the information in these tables in individual
cases. The data on the type plate is authoritative in cases of doubt.
Table 1: Overview of characteristics for type WAF 665 - 1963

Type Gear ratio Input torque Nm Weight Kg
WAF 665 from 3,536 to 5,950 7553 1800
WAF 743 from 2,467 to 3,550 9550 1800
from 3,550 to 3,952 9260
WAF 763 from 4,625 to 5,750 9360 2300
WAF 773 from 6,153 to 7,455 9360 3100
WAF 843 from 2,091 to 3,500 13850 2030
from 3,500 to 3,905 13180
WAF 863 from 4,038 to 5,842 13180 3050
WAF 873 from 6,153 to 7,087 13180 4200
from 7,087 to 7,455 13080
WAF 1143 from 1,966 to 3,037 16230 2750
from 3,037 to 3,500 15280
from 3,500 to 3,909 14130
WAF 1163 from 4,500 to 4,958 15560 3600
from 4,958 to 5,500 14610
from 5,500 to 5,810 13850
WAF 1173 from 6,080 to 6,696 15560 3600
from 6,696 to 7,429 14320
WAF 1543 from 2,032 to 3,039 20050 3450
from 3,039 to 3,857 18140
WAF 1563 from 4,429 to 4,846 20050 4500
from 4,846 to 5,955 18140
WAF 1943 from 2,059 to 2,962 21960 4700
from 2,962 to 3,952 21010
WAF 1963 from 4,467 to 5,952 21010 5550
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Technical Data
Table 2: Overview of characteristics for type LAF 665 -1963

Type Gear ratio Input torque Nm Weight Kg
LAF 665 from 3,536 to 5,950 7553 1800
LAF 743 from 2,467 to 3,550 9550 1800
from 3,550 to 3,952 9260
LAF 763 from 4,625 to 5,750 9550 2300
LAF 773 from 6,153 to 7,455 9550 2300
LAF 843 from 2,091 to 3,500 13850 2300
from 3,500 to 3,905 13180
LAF 863 from 4,038 to 4,955 13850 3050
from 4,955 to 5,842 13180
LAF 873 from 6,153 to 7,087 13850 4200
from 7,087 to 7,455 13080
LAF 1143 from 1,966 to 3,037 16230 2450
from 3,037 to 3,500 15280
from 3,500 to 3,909 14130
LAF 1163 from 4,500 to 4,958 16230 3300
from 4,958 to 5,500 14610
from 5,500 to 5,810 13850
LAF 1173 from 6,080 to 6,696 15560 3600
from 6,696 to 7,429 14320
LAF 1543 from 2,032 to 3,039 20050 3000
from 3,039 to 3,857 18140
LAF 1563 from 4,429 to 4,846 20050 4000
from 4,846 to 5,955 18140
LAF 1943 from 2,059 to 2,962 21960 4060
from 2,962 to 3,952 21010
LAF 1963 4,467 23400 4940
from 4,467 to 5,952 21010
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Technical Data
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Transport, Storage and Preservation
4 Transport, Storage and Preservation
4.1 Transport
⇒ Upon receipt, immediately inspect the gearbox and accessories for any damage
incurred in transport.
⇒ Report any transport damage to the freight carrier immediately.
⇒ Inform the REINTJES service department
⇒ Do not put the gearbox into operation if there is any transport damage
WARNING!
The gearbox can fall over if improperly supported!
This may result in serious injury or death!
⇒ Under no circumstances should you put slings around shaft ends, pipes or
other externally mounted parts.
⇒ When suspending the unit, use only the lifting eyes intended for this purpose.
Traversing bridge
The gearbox weight (without oil but including
special accessories) is stamped on the type
plate.
Slings must be suitable for this load.

Secure slings to all of the eyebolts intended
Sling
for this purpose using shackles. max.45°
When lifting for transport, the gearbox must
be secured against tilting. To ensure this, use
all of the eyebolts intended for this purpose.
With the gearbox suspended from a sling, the

angle of the sling may not exceed 45° from Lifting eye
bolts
the perpendicular!
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WARNING!
Suspended load!
Danger of injury!
⇒ Use only transport aids and lifting equipment that are approved for the
anticipated load when used in the intended manner.
⇒ Transport aids and lifting equipment must be designed to be able to safely

hoist the load, hold it and set it down once again.
⇒ Observe the regulations and instructions for use provided by the manufacturer
of the transport aids and lifting equipment.
During transport, make sure:

! • Not to damage packaging, if further storage is intended afterward.
• Transport is carried out only by individuals competent in the use of transport
and lifting equipment.
• Appropriate and adequately dimensioned transport aids (e.g. traversing bridges)
are employed.
• Slings do not press against piping or externally mounted parts.
4.2 Storage
Please note that appropriate storage conditions are necessary in order to avoid any
! damage due to corrosion.
REINTJES will not be liable for any damage due to corrosion, nor any subsequent
damage arising from this, in cases when the guidelines and measures included in this
chapter are not observed.
⇒ Keep to a minimum the period of time between removal of the original packaging and putting
the gearbox into operation.
⇒ During this period, protect the gearbox from any harmful environmental effects and external
influences.
⇒ Until the gearbox is put into operation, leave all openings in the gearbox closed.
If, for inspection purposes, you cannot avoid opening the gearbox, you must close openings
immediately afterward. (see "Measures against corrosion during storage" on page 22.)
⇒ In cases of doubt, please contact the REINTJES service department.
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To avoid damage, the gearbox must be stored in an enclosed area.

! This reduces extreme variations in temperature and avoids any exposure to
moisture (e.g. through rain).
Outdoor storage is prohibited!
These factors have a positive effect on the permissible storage period:
• High-quality packaging including an adequate amount of drying agent

• Storage in climate-controlled rooms with low humidity
These factors have a negative effect on the permissible storage period:
• Damage to the packaging

• Storage under high humidity, with air containing salt or contaminated air
Additional steps are required if:
• Premature opening of the gearbox cannot be avoided

• The gearbox is stored for a longer period or under conditions other than those stipulated
(see "Measures against corrosion during storage" on page 22.)
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4.3 Preservation
4.3.1 General information

Initial preservation is done at REINTJES as specified in agreements by contract.
After a run on the test stand, the gearbox is preserved as specified in the order.
Spare parts or loose parts supplied with the shipment are treated using the preservation
procedures stipulated in the contract.
Preservation for dispatch is designed for a limited period of time and for certain storage
conditions.
The scope and effectiveness of these preservation procedures depend on:
• Conditions of storage
• Duration of storage
• Packaging
• Individual customer wishes
4.3.2 Initial preservation

During the factory bench test, the gearbox is run with a corrosion protection oil to preserve it.
In addition, following the bench test, the gearbox is filled with a VCI preservation oil (VCI = volatile
corrosion inhibitor).
Volatile corrosion inhibitors are agents that evaporate very slowly and deposit themselves on
the unpainted metal surfaces within the closed gearbox. Due to their polarity, they interrupt
electrochemical reactions resulting in corrosion.
In order to ensure that these volatile corrosion inhibitors retain their effectiveness for as long
as possible, all of the gearbox openings are closed. The shafts are sealed using an acid-free
grease.
Externally exposed, unpainted metal parts are protected using a wax-like preservation
substance. When stipulated in the order, the gearbox is additionally protected against
corrosion by means of moisture-proof packaging or special marine packaging.
4.3.3 Measures against corrosion during storage
General information
The following assumes that the storage conditions described in chapter 4.2 are followed.
Here we can merely describe general measures against corrosion.
If you are not certain whether protection is adequate for your particular case of application,
please consult with REINTJES about the necessary measures.
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As a result of damage to packaging, water and harmful environmental influences can have a
direct effect on the gearbox. Excessive moisture can penetrate the inner space of the gearbox
as a result of variations in temperature.
⇒ Immediately upon receipt of the gearbox, check the packaging for any transport damage.
⇒ Regularly check the outside packaging.
Table 3: Inspection intervals for corrosion protection of the gearbox
Inspection intervals:
European climate zone every 4 weeks
Tropical climate zone every 2 weeks
⇒ Inform REINTJES customer service immediately of any corrosion damage discovered

during inspection.
Immediately perform the following measures in the event of damage to packaging:
⇒ Dry off any pools of water collecting on the gearbox as a result of rain or condensation.
⇒ Check the drying agent provided with the shipment.
Replace the drying agent if its colour changes from white to blue.
⇒ Check preservation at shaft ends.

Repair the seal, if necessary, using acid-free grease.
⇒ Repair the damaged packaging.
-or better-
⇒ Replace the damaged film along with the drying agent.
Use only film of the same quality.
Remove the packaging when:
• The gearbox is brought on board the vessel to be installed

• The stipulated duration of storage is exceeded by more than 20%.
In this case, consult with REINTJES to decide on further protective measures.
Immediately after removing the original packaging, additional preservation measures

! will be necessary for ensuring that the gearbox is adequately protected against
corrosion.
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Measures after removing the packaging:
⇒ Protect the gearbox as well as possible against water and harmful environmental effects.
For instance, when covering the gearbox with tarpaulins, leave some space between them
and the gearbox. They should not act as a vapour seal!
⇒ Regularly inspect the gearbox for external corrosion damage.

During inspection, check to ensure that shaft ends are preserved and sealed.
Repair the seal using acid-free grease. (Refer to table 3 on page 23 for inspection intervals)
⇒ Regularly refill the gearbox with Branorol preservation oil.

After removing the packaging, initial refilling should be done after half of storage duration,
as stipulated in the contract, has passed.
Initial refilling should, however, be done no later than 12 weeks (European climate zone)
or 8 weeks (tropical climate zone) afterwards.
Table 4: Intervals for refilling VCI preservation oil

Intervals for refilling VCI preservation oil: Volume of preservation oil to be filled:
European climate zone every 12 weeks 1% of the operating oil volume, at least 1 litre
Tropical climate zone every 8 weeks 1% of the operating oil volume, at least 1 litre
You will find the operating oil volume on the type plate.
⇒ Please observe section "Opening the gearbox" on page 25 in this regard!
For unpacked gearboxes, apply the measures mentioned above even if the stipulated storage
duration has expired.
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Opening the gearbox

The agents of the VC preservation oil escape when the gearbox is opened.
Measures after opening the gearbox
⇒ Refill the gearbox with Branorol preservation oil. (Refer to table 4 on page 24 for volume)
⇒ IMPORTANT: Afterwards, close the gearbox air-tight.
A protective inhibitor atmosphere may not be able to form again after reclosing.
This depends on:
• The concentration of VCI agents

• The amount of moisture that has entered
• How well the gearbox is resealed afterwards
4.3.4 Measures against corrosion after putting the gearbox into operation
Long interruptions in operation

If the operation of the vessel or gearbox is to be interrupted for several weeks, measures are
required to protect the gearbox against corrosion.
Corrosion damage to the gearbox cannot be ruled if these measures are not followed. The type
and scope of measure that need to be performed depend on the options available at the
particular location. Variants A, B and C, described in the following, are equally as important.
Table 5:
Measures to protect against corrosion are required
after an interruption in operation of longer than
European climate zone: 4 weeks
Tropical climate zone: 2 weeks
Perform one of these protective measures once the period mentioned above has passed:
Variant A : Flush with operating oil
⇒ Flush the gearbox for 15 minutes using the mechanical gearbox oil pump by starting the
engine.
-or-
⇒ using the electrical stand-by pump, if available.
⇒ Replace the venting filter using the screw plug
⇒ Repeat flushing weekly
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Variant B : Flush with Valvoline 6 anticorrosive oil
⇒ Drain the operating oil
⇒ Fill with Valvoline 6 anticorrosive oil. Volume: approx. 0.8 x operating oil volume
⇒ Flush the gearbox for 15 minutes using the mechanical gearbox oil pump by starting the
engine.
-or-
⇒ using the electrical stand-by pump, if available.
⇒ Replace the venting filter using the screw plug.
⇒ Repeat flushing after no later than 12 weeks (Europe) or 8 weeks (tropics)
⇒ Seal the shafts using an acid-free grease.
Variant C : Fill the gearbox with Branorol VCI preservation oil
⇒ Drain the operating oil
⇒ Fill with Branorol VCI preservation oil. Volume and further service intervals: see table 4 on
page 24
⇒ Replace the venting filter using the screw plug.
⇒ Seal the shafts using an acid-free grease.
Note: Residual amounts of operating oil may remain in the gearbox after draining. This will not
reduce the effectiveness of the measures against corrosion. On the other hand, when putting
the gearbox back into operation, small residual quantities of anticorrosive oil may be mixed
with operating oil.
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Corrosion protection of the heat exchanger
Follow the safety instructions provided in this installation instruction.

! (refer to "Safety" beginning on page 5.)
In addition, observe any applicable safety precautions when mounting or dismantling
equipment.
Draining the water side of the heat exchanger during interruptions in operation
of longer than 2 weeks
Seawater circulating system:
⇒ Drain the seawater circulating system of the heat exchanger.
⇒ Flush the water side of the heat exchanger with freshwater.
⇒ Afterwards, fill the water side of the heat exchanger with freshwater mixed with an
anticorrosive additive.
The type of additive depends on the cooling system.
⇒ Observe the areas of application recommended by the additive manufacturer.
Freshwater circulating system:
⇒ Drain the freshwater circulating system of the heat exchanger.
⇒ Observe the areas of application recommended by the additive manufacturer
4.3.5 Product specifications for corrosion protection and preservation oils

VALVOLINE ROSTSCHUTZ 6, full-power anti-corrosion oil for gearboxes
BRANOROL 32/10, VCI preservation oil, mineral-oil-based
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Description
5 Description
5.1 Gearbox standard execution
5.1.1 Gearbox type

The gearboxes of the WAF and LAF series are axially offset marine gearboxes with built-in
hydraulic disc clutches.
The gearboxes of the WAF type series are reverse-reduction gearboxes with two clutches.
The gearboxes of the LAF type series are reduction gearboxes with only one clutch.
The gear reduction ratios are the same in the Ahead and Astern directions for all WAF-type
reverse-reduction gearboxes.
Marine gearboxes can be supplied with identical and counter rotation of the input and output
shafts. The built-in thrust bearings absorb the propeller thrust.
5.1.2 Path of drive

The engine power is transmitted to the input shaft by way of the flexible engine to gearbox
coupling.
Path of drive in counter rotation

Input shaft A - Clutch A (closed) - pinion shaft A -
Output shaft C.
Clutch housing B rotates without load.
The output shaft rotates in the opposite direction from
the input shaft.
Path of drive with identical rotation

Input shaft A - Clutch A (open) - Clutch B (closed) -
Intermediate shaft B - Output shaft C.
The output shaft rotates in the same direction as the
input shaft.
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Description
5.1.3 Aggregates and additionally mounted parts
Hydraulic system
This hydraulic system consists of:
• Oil pump
Control valve
Pressure delay
• Oil filter system
• Heat exchanger Valve block Oil filter
• Valve block with pressure
limiting valve Oil-
• Control valve pump
• Pressure oil system with
pressure delay pots
• Lubrication oil system
The operating oil pressure is
controlled by the pressure limiting
valve
Heat-
Output- exchanger
shaft
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Description
Hydraulic diagram (reverse gearbox)
Astern clutch Ahead clutch
Manometer pressure build-up system
Control valve
Pressure limiting
valve
Connections
for
pressure
measurement
Lubrication oil Heat exchanger
Duplex
filter
Oil pump
Dip stick
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Description
Oil pump
The oil pump, mechanically driven by the transmission,

is a gear pump that serves to supply the gearbox with
pressure oil and lubrication oil.
Oil filter
The oil filter serves to filter out solid particles from the
operating oil. This is a duplex filter with two filter elements
(during operation it is possible to switch from the soiled filter
element to a clean one).
A mechanical or electrical contamination indicator indicates
when a filter element is contaminated. On changing filters,
please refer to the maintenance chapter of the operating
manual, page 56
Heat exchanger
The heat exchanger is a tube-bundle heat exchanger.

Seawater or freshwater taken from a closed cooling water
circulating system is used as a coolant.
On maintenance of the oil cooler, please refer to the

maintenance chapter of the operating instructions,
beginning at page 62
Valve block with pressure limiting function
Operating pressure is regulated by a spring-loaded

pressure limiting valve.
Standard operating pressure is approx. 25 bar (2500 kPa

or 356 psi).
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Description
Control valve, electrical
The gears are engaged by means of axial slide valves which

are brought into the desired position of engagement by axially
shifting the control piston.
WAF gearbox - 4/3 directional valve with return spring.

LAF gearbox - 4/2 directional valve with lock (without return
spring)
Control with two control valves

For engaging the WAF gearbox, two electrically actuated 4/2
directional valves with lock (without spring return) have been
built in:
1. The first control valve V 1 shifts only in the positions

"clutch AHEAD or ASTERN",
2. the second control valve V 360 controls the clutch posi-
tions "ENGAGE / DISENGAGE".
In cases of failure of the electrical control (actuation), the two
control valves remain in the position to which they were
switched previously.
Control valve, pneumatical
The gears are engaged by means of axial slide valves, which

are brought into the desired position of engagement by axially
shifting the control piston.
The piston is displaced pneumatically.
Pressure build-up system
The pressure build-up system ensures smooth engagement of

the gearbox clutch.
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Description
Oil manometer and supervision
An oil pressure manometer is mounted on the gearbox for

monitoring oil pressure. This manometer indicates the operating
pressure.
Operating pressure is set differently depending on the gearbox
type.
Operating pressure is checked with the engine running at nominal
speed, the gearbox at operating temperature and the clutch
engaged.
With the engine running at nominal speed and the clutch
engaged, operating pressure must be within the range indicated
by the markers on the manometer.
The supervision system continuously measures current values

of operating characteristics such as temperature, pressure,
speed (optionnally) and oil level (optionnally). If any parameter
defined in the supervision plan is exceeded (e.g. temperature) or
not attained (e.g. pressure) an alarm is given in the form of
an electrical signal.
Electrical stand-by pump
The oil pump with electrical motor is designed to be used as a

stand-by pump in the event that the mechanical gear pump fails.
Danger of electric shock!

Do not disconnect or service this device until
power supply has been disconnected!
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Description
5.2 Power Take Off PTO K21A

The power take off may be used for auxiliary units (e.g. generator or an additional pump).
Size and design are built to order. This power take off may therefore only be used for the
application it is designed for.
Power take off Controllable Speed Rotating direction

K 21 A No = nengine Counter to engine
PTO K21 A: primary PTO - PTO shaft turns always even if the propeller standstill
Position: On the intermediate shaft, output sided
Operating conditions: Running engine
Path of drive: Running engine - clutch housing on input shaft - clutch housing on
intermediate shaft - PTO-shaft
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Description
5.3 Power Take Off PTO K31A

V.2
The power take off may be used for auxiliary units (e.g. generator V.1
or an additional pump).
Size and design are built to order. This power take off may
therefore only be used for the application it is designed for.

K 31A (V.1) No i x nengine Identical to engine
K 31A (V.2) No i x nengine Counter to engine
PTO K31 A: primary PTO - PTO shaft turns always even if the propeller
standstill
Position: Attached PTO gear on the intermediate shaft, output sided
Operating conditions: Running engine
Path of drive: Running engine - clutch housing on input shaft - clutch housing on
intermediate shaft - PTO shaft
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Description
5.4 Power Take Off PTO K41


K 41A No i x nengine Counter to engine
K 41B No i x nengine Counter to engine
K 41A: primary PTO - PTO shaft turns always even if the propeller standstill
K 41B: secondary PTO: PTO shaft turns only, if the propeller turns
K41A/B Position Above input shaft, on the output side

K41 A Operating conditions Running engine
primary PTO
Path of drive Running engine - input shaft with clutch housing - PTO pinion
primary PTO: - PTO shaft
K41 B Operating conditions Running engine, oil pressure sufficient, engaged main clutch
secondary PTO
Path of drive Running engine - input shaft with clutch housing - engaged
secondary PTO: main clutch - pinion shaft - PTO wheel - PTO pinion -PTO shaft
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Description
5.5 Power Take Off PTO K51


K 51A Yes i x nengine Counter to engine
K 51B Yes i x nengine Counter to engine
K 51A: primary PTO - PTO shaft turns always even if the propeller standstill
K 51B: secondary PTO: PTO shaft turns only, if the propeller turns
K 51 A/B Position above input shaft, output sided

K51 A Operating conditions Running engine, oil pressure sufficient, PTO clutch engaged
primary PTO
Path of drive Running engine - input shaft with clutch housing - PTO pinion -
primary PTO: engaged PTO clutch - PTO shaft
K51 B Operating conditions Running engine, oil pressure sufficient, main clutch and PTO clutch
secondary PTO engaged
Path of drive Running engine - input shaft with clutch housing - main clutch
secondary PTO: engaged - pinion shaft - PTO wheel - PTO pinion - PTO clutch
engaged - PTO shaft
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Description
5.5.1 Control of the PTO

The engaged speed range specified in the order acknowledgement has to be observed.
Only after this the main engine can be regulated to nominal speed. Any increase intended
afterwards must be approved by REINTJES.
WARNING!
Manual engaging of the PTO control valve
Danger of personnel by unintentional turning of the PTO shaft!
⇒ Don‘t engage the PTO clutch manually!
STOP-position of the PTO-control valve
In the Stop position the oil is lead to the lube oil lines and the sump. The annular piston is
pulled into his starting position by the return springs.
The disengaged disc clutch is permanetly supplied with lube oil. This results in an
! idling torque.
With disengaged clutch the PTO shaft may rotate provided the idling torque is higher
than the initial friction torque of the driven parts.
The idling torque depends on the present operating conditions.
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Description
5.6 Gearbox with shaft brake
5.6.1 Gearbox execution

The gearbox is the same as the standard execution (refer to 5.1) but with a mounted shaft
brake. This section therefore deals only with the components differing from the standard
model.
The hydraulic system
Pressure build-up
system brake
The hydraulic system additionally
Control valve
includes:
brake
• A control valve for the brake

• The pressure build-up system for
the brake
The pneumatic control for the brake
control valve is additionally mounted
on the gearbox so as to be ready for
operation.
Shaft
brake
Brake control valve
An additional control valve, for controlling the brake, is

mounted on the gearbox.
The control piston is actuated pneumatically.
Brake pressure build-up system
The pressure build-up system ensures smooth application

of the brake.
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Description
Hydraulic diagram (Reverse gearbox with brake)
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Description
Shaft brake
The shaft brake is applied automatically during a reversing

manoeuvre (change of direction of propeller rotation), between the
operating phases <disengaging the gearbox clutch ahead> and
<engaging the gearbox clutch astern>.
Engaging procedures
during reversing:
Disengage clutch Propeller shaft rotates without engine drive
Ahead
Apply brake Propeller shaft is braked to a speed of zero
revolutions
Engage clutch Astern Propeller shaft is accelerated in the opposite
and release the brake direction
The direction of propeller rotation is shifted from Astern to Ahead in
the same manner.
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Description
5.7 Gearbox with trolling propulsion system (ADS)
5.7.1 Gearbox execution

The gearbox is basically the same as the standard execution (refer to 5.1).
This section therefore deals only with the components differing from the basic gearbox.
The minimum output shaft speed with the clutch engaged is usually nengine (idle) x igearbox.
The electrical trolling propulsion system (ADS) additionally allows use of a low speed range for
a limited period of time.
(Please refer to operating manual chapter "ADS - trolling propulsion mode" on page 28).
The hydraulic system with ADS

pressure build-up valve proportional valve
The hydraulic system additio-

nally includes:
• A pressure build-up valve

• A proportional valve
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Description
Pressure build-up valve (ADS)

The pressure build-up valve is a directly Proportional valve
controlled pressure limiting valve that is Pressure build-up valve
actuated hydraulically. Pressure is limited
by means of a spring-loaded piston.
Pre-pressure and operating pressure during

trolling propulsion mode depend to a limited
extent on oil viscosity and on the flow volume
of the oil pump.
Proportional valve (ADS)

The proportional valve is mounted on the pressure build-up valve.
The current of the control oil in the proportional valve determines the amount of pressure and,
in turn, the amount of operating pressure in the engaged clutch during trolling propulsion mode.
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Installation and Alignment
6 Installation and Alignment
6.1 Requirements for installation personnel
• Installation and alignment are the responsibility of the yard.

! • Installation 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
installation and alignment. This includes skilled use of the tools required.
6.2 Steps in preparation

?
WARNING!
The gearbox can fall over if improperly secured!
This may result in serious injury or death!
⇒ Under no circumstances should you put slings around shaft ends, pipes or
other externally mounted parts.
⇒ When suspending the unit, use only the lifting eyes intended for this purpose.
When installing the gearbox, ensure that:

! • Transport is carried out only by individuals competent in the use of transport and
lifting equipment.
• Only suitable transport aids (e.g. traversing bridges) that are approved for the
weight of the gearbox are used.
• Slings do not press against piping or externally mounted parts. A risk of damage
exists!
Steps before installing the gearbox
⇒ Remove all protective coverings (Films, Transport Packaging).

⇒ Remove any dust or dirt.
⇒ Suspend the gearbox from a crane hook using suitable slings.
Please additionally observe the generally safety information as well as the information in
chapter "Transport" on page 19 and the information provided above!
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6.3 Setting up the gearbox
Before setting up the gearbox, make sure that you have current versions of these
! documents:
• Installation instruction (this manual)
• Drawing of installation
• Alignment calculation (Optional)
Make sure that you have read and understood the descriptions and information
concerning alignment contained in the mounting instruction.
The drawing of installation represents the basis for setting up the gearbox.
This drawing includes all dimensions and values relevant for setting up the gearbox.
You will find the valid drawing number for your gearbox on the order confirmation.
The drawing of installation may be obtained from REINTJES by providing the commission
number.
service@reintjes-gears.de
On weekdays: Phone (+49) 05151 104 0
⇒ Set the gearbox on the foundation in the intended position.

⇒ Secure the gearbox against shifting on the foundation until it has been aligned and
permanently fastened.
⇒ Protect the gearbox against corrosion, contamination and damage (refer to Preservation
beginning at page 22).
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6.4 Alignment
⇒ Determine the permissible GAP and SAG values for all shaft connections taking into
account the technical information (alignment calculation, thermal expansion and
manufacturrers‘ information) applying to the units to be connected.
⇒ In addition, take into account settlement effects for the cast-resin foundation.
Request the cast-resin manufacturer to send you detailed information on settlement.
⇒ For close-coupled gearboxes please note that the alignment and foundation of the engine
directly affects the output side of the gearbox.
⇒ Carry out the alignment work only after the vessel is afloat with absolutely no ground
contact with the sea bed.
⇒ The vessel should be equipped as far as possible. Missing heavy equipment, e.g. winches,
cranes, has to be duly considered.
⇒ Carry out the alignment work in the early morning. Direct sunlight can influence the
alignment result.
A prerequisite for the trouble-free operation of the gearbox is the careful alignment of
• the input shaft of the gearbox with the engine shaft

• the output shaft of the gearbox with the propeller shaft
• the PTO shafts with the connected auxiliary units
⇒ Take into account the thermal expansion of the engine, gearbox, aggregates and
foundations at operating temperature.
Also if torsionally flexible couplings or cardan shafts are used, precise alignment with the
engine will be required. Any misalignment will have negative effects on the service life of
the gearbox and the connected components.
Observe the manufacturers' instructions when aligning:
• the output shaft of the gearbox with the propeller shaft connection
• the engine with the input shaft of the gearbox
• the auxiliary units with the additional gearbox shafts (PTO)
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6.4.1 Connection to Propeller Shaft

A prerequisite for the connection of the propeller shaftline with the gearbox is that the
propeller shaft and/or the intermediate shaft be in the static operating position.
To be in the static operating position means:
• the propeller shaft and the intermediate shaft are in their bearings
• the propeller is mounted
• the intermediate shaft flanges are connected (if present)
• the flange facing the gearbox is in the alignment position (if necessary)
Steps in connecting to the propeller shaft

?
Alignment
screws
Hole
for screws
Surface for
collision chocks Surface for
lateral
collision chocks
Gearbox foot including fastening options
⇒ Screw the alignment screws into the gearbox foot.
⇒ Fix the adjusting screws on the foundation, with which you can align the gearbox
horizontally, in longitudinal and transverse directions.
⇒ With the adjusting screws, align the gearbox
vertically and horizontally in longitudinal and transverse directions with the propeller
flange, according to the specified data.
⇒ If an alignment calculation is available, you must observe the calculations and
procedures specified therein.
⇒ Take into consideration thermal expansion at operating temperature.
A thermal expansion diagram may be requested from REINTJES.
⇒ Additionally take into account settling effects when setting the gearbox up on a
cast-resin foundation.
Request detailed documentation on this from the manufacturer of the cast resin.
⇒ In the case of close-coupeled gearboxes, please note that the alignment and
foundation of the engine has a direct effect on the output side of the gearbox.
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⇒ With approved methods Example: Measuring of the GAP and SAG values:
(gauges, laser), measure the
horizontal and vertical GAP and gearbox output
SAG values between the gear- flange
box flange and the counter- propeller shaft SAG
flange on the propeller side.
GAP
Permissible tolerances:
Radial misalignment 0.05 mm
(centreline run-out 0.025 mm) - SAG
Angular misalignment 0.05 mm related to 300 mm flange diameter - GAP
⇒ Document your GAP and SAG values
⇒ Fix the gearbox to the foundation, as described in paragraph 6.4.2.
⇒ Check the gap and sag values.
⇒ Connect the propeller shaft to the gearbox output shaft after the gearbox is firmly
fixed to the foundation.
⇒ If you have a special, deviating installation situation, agree the necessary steps
with REINTJES prior to the installation.
6.4.2 Fixing the gearbox to the foundation
⇒ Ensure that the gearbox is installed distortion-free.

⇒ Observe the following requirements for seat chocks and screws.
⇒ Insert the seat chocks between the gearbox bases and the top plate.
⇒ Loosen the alignment screws before tightening the foundation screws.
⇒ After aligning the gearbox with the propeller shaft, screw the gearbox to the
foundation so that it is secured against shifting.
When cast resin is used, back off the alignment screws only after the thermosetting
! of the cast resin is finished!
Observe the regulations of the classification society as well as REINTJES’ operating

instructions for installation and alignment. You may also request from our factory REINTJES’
operating instructions for your gearbox and foundation type (steel seat chocks or cast resin)
by providing your commission number.
Any other foundation methods must be approved by REINTJES.

!
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Foundation with steel seat chocks
Various combinations may be used for fastening the gearbox:
• Seat chocks with fitting bolts and collision chocks

• Seat chocks with fitting bolts but without collision chocks (only for steel seat chocks)
• Seat chocks with through bolts and collision chocks
⇒ Observe the following requirements for seat chocks and screws in the table below.
Requirements for components used to fasten the gearbox

Seat chocks: Steel or cast steel is the preferred material for metal seat chocks.
Gray cast iron may also be used.
The height of the seat chock should be within the range of 20 to 80 mm.
The minimum height is 40 mm when using gray cast iron. The area of
the seat chock taken up by recesses should be less than 20% of the
total surface area of the seat chock.
Only rectangular seat chocks may be used.
The seat chock must be manufactured from one piece. Shims or lining
plates may not be used.
Metal seat chocks must be fitted by touching them up on both sides.
A contact marking area of at least 75% must be achieved.
The seat chocks may not be tack-welded.
Seat chocks must be adequately sized, closely fitted and designed in
accordance with the regulations of the classification society.
Fitting bolts: The strength of the fitting bolts that are used must comply with at least
ISO 898 property class 8.8.
The holes for the fitting bolts are pre-drilled.
Through bolts: The strength of the through bolts that are used must comply with at
least ISO 898 property class 8.8.
Through bolts must be tightened to the torque specified for the
particular thread size.
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Foundation with cast resin
The following combinations may be used for fastening the gearbox:
• Cast resin with fitting bolts and collision chocks

• Cast resin with through bolts and collision chocks
⇒ When a cast resin foundation is provided, commission a company authorized to pour

cast resin foundations to do planning and calculation and perform the work.
This company must also submit the required drawings, calculations and material data to
the classification society for approval.
The cast resin manufacturer will specify the type of foundation screws to use as well
as the tightening torque.
Responsibility for designing the collision chocks lies with the shipyard.
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6.4.3 Connection to the engine

(does not apply when the gearbox is close coupled to the engine by means of a bell housing)
Pre-conditions for connection to the engine:
• The gearbox is aligned with the propeller shaft.

• The gearbox has been provided with a foundation and fastened to it.
• The motor is aligned axially to the gearbox.
The space between gearbox and motor must correspond to the mounting length of the
flexible coupling. The axial reaction forces exerted by the flexible coupling on the engine
and gearbox should be kept to a minimum. Observe the specifications provided by the
engine and coupling manufacturers.
Steps for connection to the engine
⇒ Align the engine with the adjusting screws, horizontally in longitudinal and transverse
directions, and vertically in front of the input flange of the gearbox, according to the
specified data.
⇒ With approved methods (gauges, laser), measure the horizontal and vertical gap
and sag values.
Radial misalignment 0.05 mm (centreline run-out 0.025 mm) - SAG
⇒ Document your values for GAP and SAG.
⇒ Consider the thermal expansion of the engine, gearbox and foundation at operating
temperature.
⇒ Consider any possible shifting of the engine, the gearbox or any possible effects due
to the foundation.
⇒ Consider the maximum permissible reaction forces exerted by the flexible coupling
on the gearbox input shaft (refer to figure 2).
⇒ During all operations, observe the instructions of the engine and coupling manufacturers.
⇒ When the engine alignment and the alignment check are finished, the engine foundation
can be cast.
⇒ Connect gearbox and engine with the flexible coupling according to the manufacturer's
instructions.
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Fig. 1: Variables for determining the reaction forces of the flexible coupling
⇒ Determine the radial reaction force of the coupling FR:

FR = ∆r x Cr dyn
∆r - radial shaft misalignment;

Cr dyn - radial stiffness of the flexible coupling
⇒ Determine the corresponding bending moment MB:

MB=0.5 x Cax x D x X1 (refer to figure 1)
Cax - axial stiffness of the flexible coupling;

D - diameter of the connection between the flange and the flexible coupling
X1 - measured angular misalignment (GAP)
⇒ Check to make sure that FR and MB do not exceed the permissible load as shown in fig. 2.
⇒ Example for gearbox type WAF 863: FR = 2 kN; MB = 0.3 kNm (refer to reading
example in fig. 2)
Read off the maximum permissible reaction force.
FR perm = 2.70 (at MB=0) > FR
(intersection of "line 8xx" with horizontal line of fig. 2 (axis of radial force))
Determine the maximum permissible bending moment for FR = 2 kN
MB perm =0.4 > MB actual.
(intersection FR = 2.00 with "Linie 8xx" -> read off the corresponding MB value
from the vertical line (axis of bending moment) in fig. 2)
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Note: The maximum permissible loads indicated in fig. 2 are based on Lmax=350 mm,
i.e. a maximum distance of the point of application of the reaction force from the maximum
cone diameter of the gearbox shaft. (refer to figure 1)
⇒ Please contact REINTJES if resulting loads exceed the permissible loads.
665
bending moment [kNm] MB
0,4
MBperm
2,0
radial force [kN] FR FRperm = 2,7
Fig. 2: Allowable external forces on input shaft
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6.4.4 Connection to the gearbox PTO
Pre-conditions for connection to the PTO:
• The gearbox is aligned with the propeller shaft.

• The gearbox is aligned with the engine.
• The gearbox is firmly fixed on the foundation.
Operational steps for connection to PTO
⇒ Align the auxiliary unit driven by the PTO (e. g. generator) with the adjusting screws,
horizontally in longitudinal and transverse directions, and vertically in front of the PTO
shaft of the gearbox, according to the specified data.
⇒ With approved methods (gauges, laser), measure the horizontal and vertical gap
and sag values.
Radial misalignment 0.05 mm (centreline run-out 0.025 mm) - SAG
⇒ Document your GAP and SAG values.
⇒ Consider the thermal expansion of the gearbox, auxiliary unit and foundation at
operating temperature.
⇒ Consider that displacement of the auxiliary unit and gearbox can occur and that the
working forces can have an impact on the foundation.
⇒ Consider the maximum permissible reaction forces exerted by the flexible coupling
on the gearbox PTO shaft.
⇒ During all operations, observe the instructions of the auxiliary unit and coupling
manufacturers.
⇒ Fix the auxiliary unit on the foundation according to the supplier's instructions.
⇒ Determine the reaction forces of the flexible coupling as described in point 6.4.3.
⇒ Connect PTO and auxiliary unit with the flexible coupling.
The alignment will only be recognised as complete by REINTJES, if you completely

! documented the alignment of propeller shaft - gearbox, gearbox - engine and gearbox
PTO - auxiliary unit!
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6.4.5 Alignment check
Alignment check of the engine

(does not apply when the gearbox is close coupled to the engine by
means of a bell housing)
⇒ Check the gearbox foundation bolts for tightness.

⇒ Disconnect the flexible coupling on the engine.
⇒ Finally, check the GAPand SAG values and compare them with the data specified
by the coupling manufacturer. In case of deviations, please contact REINTJES.
Propeller-side alignment check

⇒ Remove the flange mounting screws on the propeller side.
⇒ Finally, check the GAPand SAG values and compare them with the specified data.
In case of deviations, please contact REINTJES.
PTO alignment check

⇒ Disconnect the flexible coupling.
⇒ Finally, check the GAPand SAG values and compare them with the data specified
by the coupling manufacturer. In case of deviations, please contact REINTJES.
DANGER!
Rotating Parts!
⇒ After alignment mount covers to all rotating parts to prevent being
caught or drawn in.
6.5 Connection of gearbox components
Connection of valve control and supervision
⇒ Lay the cables for the control and supervision system to the gearbox terminal box
and connect them in compliance with the supervision drawing.
On the gearbox itself, the cables for the control and supervision system are completely
connected.
⇒ Check the functioning of the valve control and the gearbox supervision system according
to the commissioning instructions. (refer to operating manual page 15)
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Connection of the shaft brake
⇒ Lay the compressed air line to the brake control valve.

The connection is indicated in the installation drawing.
The initial pneumatic pressure must be 5 - 7 bar.
Connection of power take off
⇒ When connecting a pump or generator, mount an appropriately

sized flexible coupling. The shaft ends of the power take-offs are
cylindrical and have a fitted key.
Connection of the heat exchanger
Please note that the input cross-section of the heat exchanger on the water side may
! not be varied!
⇒ Install the pipes on the water side of the heat exchanger

with SAE counterflanges (see installation drawing). They must
be laid vibration-free. We recommend using rubber/steel-wire
compensators.
⇒ Seawater cooling
Install a filter in the seawater circuit.
Ensure that there is sufficient anodic protection in the water pipes.
⇒ Freshwater cooling
Inform REINTJES, if an anticorrosion additive is admixed to the freshwater circuit.
The additive can reduce the cooling capacity of the heat exchanger.
Connection of the stand-by pump
If the stand-by pump is mounted on the gearbox, the pump is

supplied complete with all required pipes.
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CAUTION!
If the pump direction is reversed, there is danger that excessive pressure
builds up in the pipes
Danger of injury from bursting pipes
⇒ When connecting the pump motor electric supply line, pay attention to
the indicated sense of rotation of the pump.
DANGER!
of electric shock!
Do not disconnect or service this device until power supply has been disconnected!
⇒ Lay the electric supply line to the standby oil pump.
⇒ Connect the motor according to the enclosed circuit diagram. You will find the
circuit diagram in the junction box of the pump motor.
⇒ During commissioning the pump must start running in the indicated sense of
rotation. Check the sense of rotation with an induction instrument and make the
proper terminal connections.
⇒ If the electric standby oil pump of your gearbox is supplied separately, you must also
lay and connect the suction and pressure pipes between the pump and the gearbox.
⇒ When connecting the pump pipes, pay attention to the indicated sense of rotation
of the pump.
⇒ Clean the pipes installed on board or changed during installation, e.g. by subjecting
them to acid treatment. The pipes must be free of dirt.
⇒ Observe the connection instructions (pipe cross section, length of pipe and number
of pipe bends).
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Index
Index
A Volume to be filled 24
Alignment check 56 Preservation oils 27
PTO K21 35
C PTO K31 36
Characteristics of the gearboxes 16 PTO K41 37
Check of the propeller shaft 48, 52 PTO K51 38
Corrosion protection 22
Interruptions in operation 25 R
Protective measures 25 Requirements for assembly personnel 7
Corrosion protection oils 27
S
D Safety 5
Description 29 Set-up 45, 46
Directional valves 33, 40 Shaft brake 42
Storage 20
E
Electrical lubrication oil pump 57 T
Technical Data 15
F Transport 19
Foundation 49 Transport and Storage 19
Foundation with cast resin 50 Transport damage 19
Types of Documentation 11
G
Gearbox execution 40, 43 V
Gearbox type 13, 29 valves
Directional 33, 40
H Pressure limiting 32, 44
Heat exchanger 32 VCI preservation oil 22
Hydraulic system 40, 43 Volatile corrosion inhibitors 22
I
Illustration of the gearbox 13
Initial preservation 22
Installation and Assembly 45
Introduction 11
L
Long interruptions in operation 25
O
Oil filter 32
Operation delay system 33, 40
P
Packaging inspection intervals 23
Path of drive 29
Preservation 22
Opening the gearbox 25
Preservation oil
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Index
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No part of this document may be reproduced in any form
(by printing, photocopying or other means) or processed,
dublicated or circulated electronically without prior written
approval of REINTJES GmbH.
© 2010 REINTJES GmbH

All Rights Reserved.
WAF/LAF 665 - 1963
Table of Contents
Table of Contents
1 Safety ............................................................................................................................................................ 5
1.1 Meaning of Warnings and Notes ............................................................................................................. 5
1.2 Basic measures of caution ....................................................................................................................... 6
1.3 Requirements for operating and maintenance personnel ................................................................... 7
1.4 Safety information for assembly .............................................................................................................. 8
1.5 Protective measures against fire and danger of explosion ................................................................. 9
2 Putting the unit into operation ........................................................................................................ 11

2.1 Note this safety information before putting the unit into operation the first time ........................... 11
2.2 Installation check ..................................................................................................................................... 12
2.3 Fill with operating oil (initial filling) ......................................................................................................... 12
2.4 Handling the checklists for putting the unit into operation ................................................................. 15
2.5 Checklist before initially putting the unit into operation ..................................................................... 16
2.6 Checklist before starting the engine ..................................................................................................... 19
2.7 Checklist for gearbox after engine start ............................................................................................... 20
2.8 Notes on the checklists for putting the unit into operation ................................................................ 21
3 Operation ................................................................................................................................................. 23
3.1 Engaging procedures for standard gearboxes .................................................................................... 23
3.2 Special operating modes ........................................................................................................................ 26
3.3 Emergency operation .............................................................................................................................. 30
3.4 Setting the pressure limiting valve ........................................................................................................ 35
4 Maintenance ............................................................................................................................................. 37
4.1 Maintenance plan .................................................................................................................................... 39
4.2 Maintenance job cards ............................................................................................................................ 41
4.3 Additional work for gearboxes equipped for trolling propulsion mode ............................................ 61
4.4 Check of tube bundle contamination in the heat exchanger ............................................................. 62
4.5 Replacement of the mechanical gearbox oil pump ............................................................................ 67
4.6 Conversion factors and screw tightening torque values .................................................................... 77
4.7 Screw Locking .......................................................................................................................................... 78
4.8 Maintenance performed .......................................................................................................................... 79
5 Trouble-shooting ................................................................................................................................... 81
6 Spare and replacement parts ........................................................................................................... 85

6.1 Heat exchanger A1, Type P... ............................................................................................................... 87
6.2 Duplex filter A3, Type RFLD .................................................................................................................. 89
6.3 Duplex filter A3, Type PI 210 ................................................................................................................. 91
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Table of Contents
6.4 Gearbox oil pump E19, Type KF 2/.., KF 3/.., KF 4/.. ........................................................................93
6.5 Operation Delay Pot H1069/H1074 / Connecting Plate V232 ..........................................................95
6.6 Control valve V1 (4/3-way-valve), electrical ........................................................................................97
6.7 Control valve V1 (4/2-way-valve), electrical ........................................................................................99
6.8 Control valve V1 (4/3-way-valve), pneumatical .................................................................................101
6.9 Control valve V1 (4/2 way-valve), pneumatical .................................................................................103
6.10 Control valve V360 (4/2-way-valve), electrical ..................................................................................105
6.11 Control block V247, type HB4A 0313 .................................................................................................107
6.12 Control valve V114 (4/2-way-valve), electrical, for PTO ..................................................................109
6.13 Control valve V114 (4/2 way-valve), pneumatical, for PTO ............................................................111
6.14 Operation Delay Pot H626 ....................................................................................................................113
6.15 Control valve V189 (4/2 way-valve), pneumatical, for shaft brake .................................................115
6.16 Operation Delay Pot H768, for shaft brake ........................................................................................117
6.17 Pressure build-up valve V316.00 (for ADS) .......................................................................................119
6.18 Proportional valve V304 (for ADS) ......................................................................................................121
6.19 Control block V247, type HB4A 0317 (for ADS 6xx) ........................................................................123
6.20 Control block V247, type HB4A 0320+DKF4O30 (for ADS 7xx-19xx) ..........................................125
Index ..........................................................................................................................................................127
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Safety
1 Safety
1.1 Meaning of Warnings and Notes

Warnings and notes indicating various levels of danger or importance are used within
this documentation.
The signal word indicates the danger level in each case. Important notes to be observed for
problem-free, safe operation are indicated with an exclamation mark in front of them. These
are the individual danger levels:
1.1.1 Warnings
DANGER!
Imminent danger!
Death or serious injury will occur!
⇒ Human lives are acutely endangered
WARNING!
Death or serious injury may occur
⇒ Human lives are possibly endangered
CAUTION!
Light injury may occur
⇒ Danger of personal injury
1.1.2 Notes
CAUTION!
! Important information for safe and problem-free operation.
Possibly imminent danger of damage to the gearbox
Note without signal word:

! ... Here you will find notes on working effectively and safely.
Additional information and recommendations
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Safety
1.2 Basic measures of caution

Frequently, accidents occur as a result of not observing general safety regulations or
cautionary measures.
The individual chapters of these operating instructions contain specific safety notes.
Accidents may often be avoided by recognizing potential hazard situations in advance.
Input side Output side
Dangerous places on the gearbox
Symbol Meaning Symbol Meaning

General Warning Sign Smoking and open fires prohibited!
1
This warnings must be observed!
Danger of being drawn or caught Wear tightly fitting protective

1
in by rotating components clothing e.g. coverall
Danger of electric shock! Wear ear protectors

Do not disconnect or service this
device until power supply has been
disconnected!
Caution, hot components Read instructions carefully!
1
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Safety
1.3 Requirements for operating and maintenance personnel

Maintenance personnel must be trained in the operation and maintenance of marine
gearboxes and have a mastery of the tasks required in safely carrying out maintenance.
This includes knowledge of procedures required in the event of failures or in cases of
emergency as well as professional skills required for using the tools.
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
“Putting the unit into operation” from page 11, “Operation” from page 23 and
“Maintenance” from page 37.
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!
General protective measures and personal protection in the engine room

The gearbox may be operated and maintained only by qualified staff knowledgeable in its
operation and maintenance.
DANGER!
Rotating Parts!
⇒ Prior to trial run mount covers to all rotating parts to prevent being caught or
drawn in.
⇒ 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 impair-
ments.
⇒ 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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Safety
1.4 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!
⇒ 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.
Safety prior to working on the gearbox
⇒ Before performing adjustments or repairs on the gearbox or on systems 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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Safety
1.5 Protective measures against fire and danger of explosion
General Information
⇒ Immediately remove any oil residues completely.
⇒ Do not leave on the gearbox any rags or cloths used to wipe oil residues.
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.
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.
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.
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Safety
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.
Foreign substances near to the gearbox

⇒ Ensure that no used parts, dirt or foreign substances are near the gearbox.
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Putting the unit into operation
2 Putting the unit into operation
2.1 Note this safety information before putting the unit into operation
the first time
DANGER!
If a warning sign has been mounted:
Danger of death due to open drive parts and gears!
⇒ Do not start the engine under any circumstances!
⇒ Do not operate the control unit!
⇒ Every time prior to putting the engine or gearbox into operation, carefully ensure
that no work is being done on these components or in the vicinity of them.
WARNING!
Rotating parts!
⇒ Prior to operation mount covers to all rotating parts to prevent being
caught or drawn in.
⇒ Do not wear long hair loosely or any loose clothing or jewellery,

including rings, when near the gearbox while in operation.
Please take note of the following before putting the unit into operation:
⇒ Before putting the gearbox into operation, remove all tools and any other loose objects
from it.
⇒ Make sure that all protective devices and covers have been mounted once again.
⇒ Inspect the gearbox for any possible hazards (i.e. sharp edges, loose cables, loose
screw connections)
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2.2 Installation check
2.2.1 Check of documents
Check to make sure you have most recent versions of these documents pertaining to
! the gearbox:
• Installation instructions (part of this documentation)
• Operating instructions (this document)
• Drawing of installation
• Supervision plan
• Alignment protocol
Check the alignment protocol to make sure all of the required details have been
entered and signed (responsibility of the shipyard).
The documents listed above include descriptions, illustrations and values
necessary for safely operating the unit.
2.2.2 Check of the gearbox
⇒ When performing a final check before putting the gearbox into operation, make sure that all
necessary cables, tubes and pipes (e.g. electricity, water and air) have been connected.
⇒ Check to make sure that all of the bolts holding the gearbox and the connected elements
are well seated.
2.3 Fill with operating oil (initial filling)
The gearbox is sealed air-tight when delivered.

! Before filling with oil, replace the screw plug on the gearbox with the venting filter
supplied.
The inside of the gearbox is preserved with preservation oil when delivered.
(refer to installation instructions, chapter “Preservation” on page 22)
Proceed as follows when filling with operating oil:
A fault can in many cases be attributed to using contaminated oil or the wrong
! type of operating oil.
Make sure to use the proper type of the operating oil and that the tools used to fill
with oil are clean!
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⇒ Loosen and remove the oil drain screw.

⇒ Drain the preservation oil.
Dispose of the preservation oil in accordance with legal
requirements for used oil disposal.
Oil drain screw
Any small amount of preservation oil remaining may be mixed
with the operating oil.
⇒ Clean the oil drain screw and screw it into the socket together
with a new sealing ring.
⇒ Before filling with oil, take a fresh oil sample.
⇒ Have the fresh oil sample analysed by a laboratory
authorised to perform oil analyses. Include the
analysis results among the gearbox documents.
Sampling set for oil sample

⇒ Loosen and remove the screw plug for filling the
gearbox with oil.
This screw is labelled with “OEL”.
⇒ Read off from the type plate the amount of oil required.
⇒ Pour in the operating oil specified in the REINTJES
lubricant table using a fine-mesh screen filter.
Venting filter
Screw plug
⇒ Standard-dip stick: Check the operating oil level
using the dip stick only when the propulsion
system is at a standstill.
MAX
The operating oil level must be between the “Min”
and “Max” markings shown on the dip stick.
(measurably approx. 10 min. after shut down of MIN
the system)
Dip stick
⇒ Dip stick with guiding tube: Check the
operating oil level using the dip stick. MAX
Check to ensure that the oil level is up to the
dip stick marking. MIN
Caution!
The dip stick has 3 markings!
⇒ The lower marking shows the operation oil level Operation
during the operation.
Dip stick
⇒ The two upper markings show the min. or max. oil
level of the shut down gearing. (measurably approx. 10 min. after shut down of the system)
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⇒ Replace the screw plug with the venting filter provided (refer to fig. on page 13 ).
⇒ Tighten the venting filter as much as possible by hand.
⇒ After filling with oil the first time, and before the sea trial, perform a short dock trial
without load of the gearbox. This fills the hydraulic system with oil.
⇒ Then check the oil level once more using the dip stick.
⇒ Add as much oil as is required for the level to reach the upper dip stick marking.
2.3.1 Amount of oil and type

The amount of operating oil required by your gearbox is specified on the gearbox type plate.
Conversion factors for amount of oil

multiplied by equals
litres 0,26 US gallons
litres 0,22 Imperial gallons
US gallons 3,79 litres
Imperial gallons 4,54 litres
US gallons 0,833 Imperial gallons
Refer to REINTJES lubricant table for approved types of operating oil.
The oil types listed in the lubricant table are specified under the responsibility of the
particular oil company.
REINTJES assumes no liability for damage that might arise from using unsuitable types
of operating oil.
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2.3.2 Filling the Oil filter

During the setup the Oil filter must be filled with oil.
A non-filled filter housing creates a pressure loss in the hydraulic system when
! changing on the other filter side.
This pressure loss can lead that the diesel engine is shut down by the pressure
switch "oil pressure to low, motor stop".
After switching on, with running gearbox:
⇒ Wait approx. 30 sec until the first filter side is fille with oil.
⇒ Switch to the second filter side with the lever. Leave this side also switched
on approx. 30 sec. until the complete filter is filled with oil.
These steps must be repeated after every filter change!!
The filter bell can also be manual filled with oil during the filter change.
2.4 Handling the checklists for putting the unit into operation
This description contains information about steps in preparing to put the unit into operation
and measures required beforehand and afterward.
The items which you must check and then initial for every gearbox are referred to here
with keywords.
Example:
Item to be checked OK? Notes

No other defects?
Gearbox without visible damage?
In certain cases you need to enter details or measured values.
⇒ Enter any additional comments or measures required for the item to be checked in
the “Notes” column at right.
⇒ Cross out any items not applicable to your gearbox.
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2.5 Checklist before initially putting the unit into operation

Person responsible for putting the unit into operation and for safety (name and position):
Ambient temperature °C (note)
2.5.1 Engine foundation
Type of foundation: (indicate applicable items)

Seat chocks and fitting bolts
Cast resin
Type
Flexible Manufacturer
Model
2.5.2 Gearbox foundation
Type of foundation: (indicate applicable items)

Cast resin
Foundation bolts, note Quantity: Dimensions:

Steel with
seat chocks and fitting bolts
Fitting bolts, note Quantity: Dimensions:
Front collision chocks
Lateral collision chocks
2.5.3 Lubrication oil system
Lubrication oil manufacturer:

Lubrication oil type
SAE:_________
Amount of oil filled:
_____________litres
Oil sample taken (100 ml), Take the sample using a clean sampling
label completed and attached glass, label it and send it to REINTJES.
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2.5.4 Cooling system
Cooling system: (indicate applicable items)

Seawater cooling Inlet temperature of
cooling water
Freshwater cooling (target)
______°C
2.5.5 Torsionally flexible coupling
Flexible coupling on engine side: Type

Manufacturer
Model
PTO coupling: Type
Manufacturer
Model
2.5.6 Gearbox alignment

Alignment protocol included as annex?
For engine - gearbox
For gearbox - propeller shaft
Alignment screws loosened?
2.5.7 Oil cooler

Plastic plug on cooling water inlet flange
removed?
Compensators for cooling water pipes
installed?
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2.5.8 Sight check

Gearbox without visible damage?
No changes may be recognised?

- Connected and separate parts
complete and not damaged?
Shaft seals in acceptable condition?
“Do not switch on” or similar warning

signs present on board for:
Control valve for gearbox clutch(es)
Control valve for shaft brake
No other defects?
2.5.9 Preservation

Was preservation performed during
storage?
Log recording preservation measures
completed regularly?
Protective layer completely removed
Paint layer undamaged?
Screw plug replaced with venting filter?
Internal inspection:
Sight check (through inspection
opening) performed?
Preservation oil completely drained?
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2.6 Checklist before starting the engine

Person responsible for putting the unit into operation and for safety (name and position):
Ambient temperature °C (note)
WARNING!
⇒ 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.
2.6.1 Check of the sensor connections in the terminal box in accordance with the
supervision plan

Gearbox terminal box correctly earthed?
Check to ensure that the sensors for the following are connected:
(if present)
Warning - oil pressure too low
Emergency stop main engine
Oil pressure present,
Gearbox clutch engaged,
“Oil filter contaminated” switch
Shaft brake engaged
Start stand-by pump
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2.7 Checklist for gearbox after engine start
2.7.1 Check gearbox
Item to be checked Measurements / Notes

Engine speed while idling
n=________min-1
Engine speed at nominal speed n=________min-1
Pressure with clutch engaged at nominal

speed __________bar
Oil temperature in steady state
__________ °C
Cooling water temperature in steady
state In __________ °C Out __________°C
Both sides of oilfilter filled with oil? Yes (see “Filling the Oil filter” on page 15.)

Clutch control valves can be actuated
mechanically?
Control valve can be actuated electrically
from all control cabins?
Gearbox noise level?
Gearbox without leakage?
Vibration level?
Sight check OK?
No other conspicuous items?
Oil level checked?

Oil filled to mark? (Note the amount)
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2.8 Notes on the checklists for putting the unit into operation
Check Comments / Notes / Values Name/Initials

chapter
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WAF/LAF 665 - 1963
Operation
3 Operation
3.1 Engaging procedures for standard gearboxes
During normal operation and at idling speed, you must adhere to these values:
! • 40-60°C oil temperature for types WAF/LAF 665 measured behind the oil cooler
• 30-50°C oil temperature for types WAF/LAF 7xx - 19xx measured behind the oil
cooler
• 21-25 bar operating pressure
A fault exists in the event that any of the values differ appreciably from those
cited above.
The engaging procedures described below are important in order to safely operate the
entire propulsion system and to avoid any unnecessary wear.
Electronic ship remote controls may be used to automate the procedures described.
This avoids the risk of faulty operation.
It is then possible to optimise the electronic program system during the sea trial.
You must adhere to these steps in engaging when using a manual remote control:
Engaging the gearbox
The engine is started, the gearbox control valve is in the NEUTRAL position and the
propeller shaft is stationary or rotating slowly. The engine is running at idling speed.
⇒ Set the engine to engaging speed.

⇒ Engage the gearbox for the desired direction of travel.
⇒ Wait until the pressure in the clutch has reached 18 bar (approx. 4 seconds)
⇒ Set the engine to the required operating speed.
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Operation
Reversing at slow speeds (type WAF only)
The ship is travelling at up to 50 % of its nominal speed.
⇒ Reduce the engine speed to engaging speed.

⇒ Shift the gearbox to the NEUTRAL position.
⇒ Wait approx. 1 second
⇒ Engage the gearbox for the other direction of travel.
Reversing at higher speeds
The ship is travelling within the range of 50-100% of its nominal speed.
⇒ Reduce the engine speed to engaging speed.

⇒ Wait until the speed of the ship has dropped to 50 %.
⇒ Shift the gearbox to the NEUTRAL position.
⇒ Wait approx. 1 second
⇒ Engage the gearbox for the other direction of travel.
Brake the gearbox/propeller shaft using the shaft brake

⇒ Shift the control to the NEUTRAL position. The brake will be automatically engaged
by the V189 valve.
⇒ Shift the control from the NEUTRAL position into the AHEAD or ASTERN position;
the shaft brake is automatically disengaged.
If the control lever is in the NEUTRAL position, the propeller shaft will be braked
until it comes to a halt.
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Operation
Stop manoeuvre with repeated engaging
The clutch has been designed and optimised to allow it to be engaged from AHEAD
to ASTERN several times during a stop manoeuvre. Experience reveals that this may
become necessary for stop manoeuvres from high speeds in order to prevent any damage
to the diesel engine.
During a stop manoeuvre the ship's control automatically interrupts engaging procedures
in order to prevent excessive strain on the engine.
⇒ For this case, you should provide, in the ship's control, for a period of delay for engaging
the clutch and reversing the direction. (Not supplied with the gearbox)
⇒ Please contact REINTJES for more detailed information.
Crash-stop
The object is to stop the ship from a high speed within the shortest possible distance.
CAUTION!
! During a crash-stop manoeuvre the propulsion system is subject to heavier
wear and greater strain due to heat build-up.
Perform a crash-stop manoeuvre in emergency cases only!
⇒ Proceed as described under “Reversing at higher speeds”
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Operation
3.2 Special operating modes
3.2.1 Trailing operation, engine at STOP with propeller free to turn
CAUTION!
! In the case of damage, lock the propeller shaft before putting it into trailing mode.
If this is not possible, carefully verify whether trailing mode with the shaft turning
freely might not result in further damage to the gearbox or the propulsion system.
Occasional trailing mode
Occasional trailing mode, i.e. in the case of a one-engine system, means:
• Due to damage, the ship can no longer be propelled on its own power
• The propulsion system is shut down
• The ship is tugged with external aid
• The propeller shaft turns freely with the water flowing against it
With a standard gearbox, this mode may be prolonged without limitation for up to 6 hours.
If the occasional trailing mode lasts longer than 6 hours:
⇒ Start the engine every 6 hours in order to run the gearbox oil pump.
-Or -
⇒ Lubricate the gearbox every 6 hours with the aid of the electrical stand-by pump.
⇒ In order to ensure that all lubrication points are supplied with oil, run the engine
or the stand-by pump for approx. 5 minutes.
⇒ Immobilise the propeller shaft if gearbox lubrication is not possible.
Regular trailing mode
Regular trailing mode, i.e. in the case of a two-engine system, means:
• One of the propulsion systems is shut down

• The ship continues to be driven by the other propulsion system
• The propeller shaft of the system that is shut down turns freely with the water
flowing against it
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Operation
Regular trailing mode without limitation is only possible:
• With the addition of a trailing pump

An additional pump mounted on the gearbox secures the lubrication to the gearbox
during trailing mode. This pump is driven directly by the propeller shaft.
• With an electrical stand-by pump
⇒ Switch on the electrical stand-by pump for the entire duration of trailing mode.
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Operation
3.2.2 ADS - trolling propulsion mode
The execution of the trolling propulsion control (ADS) is adapted to the parameters of ‚
your propulsion system. In the following it is therefore only possible to provide general
information and descriptions of trolling propulsion mode.
You will find a detailed description of the execution of your trolling propulsion system
under “Trolling propulsion mode (ADS)” in the appendix to the operating instructions.
Unsupervised operation of the trolling propulsion device is prohibited!

! If a cable breaks or the electronic control unit breaks down, the gearbox automatically
switches to normal operating mode, i.e. the prevailing torque and corresponding
engine speed are transmitted.
CAUTION!
! Risk of excessive strain to the clutch!
Trolling propulsion mode is not permissible in these cases:
• Travelling through ice

• Towing operation
• Fishing with trawling nets
Trolling propulsion mode with multi-engine systems
• With multi-engine systems, do not switch to trolling propulsion mode as long as

one or more gearboxes are running in normal operating mode.
• Do not switch any gearbox of a multi-engine system to normal mode as long as one
or more gearboxes are being run in trolling propulsion mode.
• No combination of operating modes is permissible, e.g. one gearbox in trolling

propulsion mode and one gearbox in normal mode.
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Operation
3.2.3 Switching trolling propulsion mode ON and OFF
Switch trolling propulsion mode on only when the engine speed is within the
! permissible range
CAUTION!
! Risk of irreparable clutch damage!
Under no circumstances should you run the system in trolling propulsion mode
with a soiled filter element by using “Bypass” to circumvent filtering.
⇒ Switch over filters immediately when the “contaminated filter” warning appears.
⇒ Replace the soiled filter element immediately.
Note in particular the following:

! For trolling propulsion mode, use only oil types listed in our BV2060/1 lubricant
table (oil types for trolling propulsion mode).
You must adhere to the oil change intervals specified in the maintenance plan.
The specified oil change intervals apply when trolling propulsion mode makes up
a maximum of 10 % of operating time. If this 10 % amounts to more than 200 hours,
a limit of 200 hours applies. You must consult the factory if the proportion of trolling
propulsion mode is higher.
In contrast to the information in the operating instructions, if the engine has been
operated in trolling propulsion mode, oil change intervals may not be extended
following an oil analysis.
Gearboxes with an electrical trolling propulsion device are equipped with a

20 µ / 25 µ filter. Ensure that you have replacement filter elements on board.
These fine filter elements cannot be cleaned.
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Operation
3.3 Emergency operation
3.3.1 Manual emergency operation
CAUTION!
! Perform emergency operation in cases of emergency only!
Prior to manual emergency operation, become familiar with control

of your gearbox:
WARNING!
The solenoids of the electrically control valve heat up to 150°C during
permanent operation!
Danger of burnings!
⇒ Wear protective gloves during manual emergency operation!
Emergency operation of the 4/3-way control valve for type WAF
In cases of failure of the electrical clutch control WAF
⇒ Note the signs on the valve indicating direction of travel. 1.
⇒ Press the mushroom head on the magnet to select the

2.
appropriate direction.
⇒ Lock the mushroom head in place with the bracket.
Emergency operation of the 4/2-way control valve for type LAF
In cases of failure of the electrical clutch control

LAF
⇒ Push in the bolt on the end cap of the magnet. The valve 2.
automatically locks in place.
1.
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Operation
Emergency operation using the hand control lever
LAF/WAF, in cases of failure of the pneumatic clutch

control
⇒ Put the hand lever in the required position (AHEAD,

STOP, ASTERN).
3.3.2 Emergency manual operation with gearboxes having two axial slide valves
(optional)
CAUTION!
! Perform emergency operation in cases of emergency only!
Prior to manual emergency operation, become familiar with control of

your gearbox:
CAUTION!
Never switch valve V1 from "Ahead" to "Astern"
when valve V360 is set to "ENGAGE"!
Risk of irreparable gearbox damage!
⇒ In all cases it is imperative to follow the sequence of operations!
V1
Sequence for emergency manual operation:
⇒ First, switch valve V360 to "DISENGAGE"
V360
⇒ To do this, push in the bolt on the

end cap of the magnet labelled "DISENGAGE"
on valve V360.
2.
The valve automatically locks in place.
1.
⇒ Shift valve V1 in the appropriate direction of travel,
"AHEAD" or "ASTERN".
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Operation
⇒ To do this, push in the bolt on the end cap of the magnet on valve V1 labelled
with the appropriate direction of travel.
⇒ Shift valve V360 to "ENGAGE"
⇒ To do this, push in the bolt on the

end cap of the magnet labelled "ENGAGE"
on valve V360.
When reversing the direction of travel, you must follow the sequence
described above!
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Operation
3.3.3 Emergency operation in cases of failure of the pressure oil supply
In cases of failure of the pressure oil supply, emergency operation may be continued
by mechanically immobilising one of the clutches.
WARNING!
Risk of unintentionally starting the engine.
Danger of death while working on the open gearbox!
⇒ Shut down the engine.
⇒ Shut down the compressed air feed for starting the engine and bleed the
air tubes.
⇒ Prior to any 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.
⇒ Secure the propeller and drive shafts against rotation.
CAUTION!
! When, after tightening the emergency screws, you start the engine, the shaft
system immediately rotates with the engine.
You can no longer reverse on the gearbox the direction in which the propeller rotates.
To bring the propeller to a halt, you must stop the engine.
In emergency operating mode, the engine is rigidly connected to the propeller shaft
! by way of the gearbox.
In emergency mode, proceed with extreme caution and with the lowest engine speed
possible (less than 70 % of the nominal speed).
Never apply the maximum imput torque when employing the K8 emergency screws.
After operation in emergency mode (failure of the pressure oil supply) you must have
the gearbox parts checked thoroughly for any damage.
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Operation
Thighten of the emergency screws
⇒ Determine which clutch must be immobilised for travelling AHEAD.
⇒ Remove the corresponding cover of the inspection

opening.
⇒ Remove the wire securing the emergency screws.

(Do not drop any pieces of wire into the gear-
box!)
⇒ NOTE! Tighten the emergency screws on only one

clutch.
⇒ Loosen the counter-nuts of all emergency screws.
⇒ Screw in the K8 emergency screws evenly using an Allen wrench

and as far as possible in opposing pairs.
⇒ Tighten the screws, pressing together the disc packet so that the clutch
is friction-locked. K8
⇒ Shift the control valve to the NEUTRAL position (by hand if necessary).
⇒ For safety reasons, do not engage the control valves any more
afterwards!
⇒ Close the inspection opening.
⇒ Start the engine.
The ship can then head to the nearest harbour for repairs.
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Operation
3.4 Setting the pressure limiting valve
CAUTION!
Hot oil!
Spraying or dripping oil can cause skin injuries.
⇒ To avoid skin injuries, wear protective clothing.
CAUTION!
! The B set-screw is not secured against loosening!
The operating oil is under pressure. Oil may spray or drip out when the
set-screw is removed.
The pressure limiting valve is set to optimal pressure during the bench test
! at the factory.
Before adjusting the setting, check for any possible causes or faults resulting
in pressure changes.
Please contact REINTJES (refer to page 37) before adjusting the setting!
To set the pressure limiting valve, proceed as follows:

⇒ Loosen counter nut A using Allen wrench.
⇒ Carefully turn set-screw B using Allen

wrench -
- turning clockwise means an increase in
pressure,
- turning counter-clockwise means a
decrease in pressure.
⇒ During adjustment, observe the manometer

mounted on the gearbox.
With the engine speed at full power and the

clutch engaged and gearbox in operating B A
temperature, the pressure must be within
the manometer markings.
⇒ Tighten counter nut A using Allen wrench.
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Operation
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Maintenance
4 Maintenance
You can ensure safe, dependable operation as well as low maintenance costs only by
having service and maintenance performed regularly according to specifications. The
jobs listed below may only be performed by staff trained in the maintenance of marine
gearboxes and only using tools, original spare parts and lubricants, specified in REINTJES
lubrication chart, that are suitable for the particular task.
Our customer service will be glad to aid and advise you in the event of any questions
concerning maintenance:
service@reintjes-gears.de or on
working days: Phone (+49) 05151 104 0
CAUTION!
No user serviceable parts inside!
⇒ Unauthorized opening of the gearbox voids manufacturer´s warranty.
WARNING!
Risk of unintentionally starting the engine during maintenance work!
Danger of death!
⇒ Shut down the compressed air feed for starting the engine and bleed the
air tubes.
⇒ Prior to any work on the gearbox, place a sign on it reading “OUT OF ORDER”
and a similar warning sign on the start-up switch, on the starter button and on
the remote starter.
Dispose of filter elements and used oil either as recyclable substances or as

! hazardous wastes.
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Maintenance
Maintenance information
⇒ When doing any work, observe all currently applicable safety regulations as well
the information in the chapter on safety.
⇒ Keep a maintenance log.
Regular entries recording maintenance work and operating values can be helpful
in recognizing any detrimental changes.
⇒ Correct minor defects before they result in major repairs.
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Maintenance
4.1 Maintenance plan
Maintenance level 1 Daily:

⇒ With the engine at a standstill, check the oil level
(upper dip stick marking = operating oil level)
Maintenance level 2 Daily:
⇒ With the engine running, check
⇒ Operating pressure
⇒ Oil temperature
⇒ Contamination indicator for the duplex filter
⇒ Perform a sight check and check of running noise
Maintenance level 3 After the first 200 hours of operation:
⇒ Change the operating oil for the first time after initially putting the
unit into operation or perform an oil analysis, acc. to this result oil
cleaning or oil change.
⇒ Replace the filter elements.
⇒ Check the seat of all bolts
including those on the foundation, engine and propeller
connnections and on the bell housing.
⇒ Check the pipe fittings.
If there is any leakage, tighten the fittings.
⇒ Check the heat exchanger for leakage.
⇒ Check the anodes on the heat exchanger.
Maintenance level 4 After every 2000 hours of operation or after 6 months:
⇒ Change the operating oil after this interval.
⇒ Replace the filter elements.
Maintenance level 5 After every 5000 hours of operation or after 1 year:
⇒ Check the seat of all bolts
including those on the foundation, engine and propeller
connnections and on the bell housing.
⇒ Check the pipe fittings.
If there is any leakage, tighten the fittings.
Replace any leaky gaskets.
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Maintenance
Basic overhaul The following tasks must be performed by skilled REINTJES staff after:
Gearbox type Hours
665 30000 h
74x-117x 40000 h
154x - 1963 60000 h
hours of operation or after 10 years
The following checks are performed:
• Shafts, to ensure they are running true
• Roller bearings for any wear
• Carriers for any wear
• Gear and pinion teeth for any wear
• Guiding pins of annular pistons for any wear
• Oil distributor for any wear
• Manometer for functioning
Worn or damaged parts must be replaced.
The following need to be replaced:
- Clutch discs
- Square section rings, screws and return springs of the annular piston
- O-rings
- Circlips
- All clutch housing screws
- Roller bearings
- Screws and springs of the thrust bearing
- Shaft sealing rings and bushings
- Oil filter elements and gaskets
- Gearbox oil pump
- Inspection cover gaskets
- O-rings for the control valve and the pressure limiting valve
- Hoses (must be replaced every 5 years)
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Maintenance
4.2 Maintenance job cards
Maintenance job card
Gearbox types: WAF/LAF 665 - 1963
Maintenance job Maintenance level 1 To be performed if Duration of job in

no.:001 Daily, with engine at a possible at the same time minutes: 5
standstill as maintenance job no.:
002-004
Description of the
maintenance job: Check operating oil level (Standard dip stick with 2 markings).
Safety measures You can check the operating oil level with the dip stick only when the
unit is at a standstill.
Required tools None
Required parts None
Other materials Oil as specified in lubricant chart

Cloth, lint-free
Test equipment None
Working procedure Refer to next page
Location: Date: Page: 1 of 2
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Maintenance
Maintenance job Maintenance level: 1 To be performed if Duration of job in

no.:001 Daily, with engine at a possible at the same time minutes: 5
standstill as maintenance job no.:
002 - 004
Description of the maintenance job:
⇒ Check the operating oil level using the dip stick only when the
propulsion system is at a standstill.
The operating oil level must be between the “Min” and “Max” markings
shown on the dip stick.
(measurably approx. 10 min. after shut-down of the system) Dip stick
MAX
MIN
⇒ If the operating oil level is too low:
⇒ Unscrew the venting filter from the upper surface of the gearbox in
order to pour in operating oil.
⇒ Add oil and fill to the upper dip stick marking.

Use only the type of oil specified in lubricant chart.
You will find this list in the appendix to these operating instructions.
⇒ Screw on the venting filter as far as it will go.
Tighten the venting filter as much as possible by hand.
⇒ If you notice any oil loss, determine the cause. Venting filter
Seal any leaks immediately so as to avoid damage to the gearbox. in the opening for filling oil
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Maintenance
Maintenance job Maintenance level 1 To be performed if Duration of job in

no.:001 Daily possible at the same time minutes: 5
as maintenance job no.:
002-004
Description of the
maintenance job: Check operating oil level (Dip stick with guiding tube und 3 markings).
Safety measures You can check the operating oil level with the dip stick either when the
unit is at a standstill or during the operation.
Required tools None
Required parts None
Other materials Oil as specified in lubricant chart

Cloth, lint-free
Test equipment None
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Maintenance

no.:001 Daily possible at the same time minutes: 5
002 - 004
⇒ Check the operating oil level using the dip stick .

Caution!
The dip stick has 3 markings!
MAX
The lower marking shows the operation oil level during the operation.
⇒ The two upper markings show the min. or max. oil level of the shut
down gearing. (measurably approx. 10 min. after shut down of the MIN
system)
Operation Dip stick with

⇒ If the operating oil level is too low: guiding tube
:
⇒ Stop the engine first.

⇒ Unscrew the venting filter from the upper surface of the gearbox
in order to pour in operating oil.
⇒ Add oil and fill to the „MAX” dip stick marking.
Use only the type of oil specified in lubricant chart.
⇒ Screw on the venting filter as far as it will go.
Tighten the venting filter as much as possible by hand. Venting filter
⇒ If you notice any oil loss, determine the cause. in the opening for filling oil
Seal any leaks immediately so as to avoid damage to the gearbox.
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Maintenance

no.: 002 Daily, with engine running possible at the same time minutes: 5
001 - 004
Description of the
maintenance job: Check the operating pressure (with the gearbox warm from operation)
Safety measures Observe all current, generally applicable job safety regulations
Required tools None
Required parts None
Other materials --------
Test equipment None
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Maintenance

001 - 004
⇒ With the engine running, take a reading of the current operating pressure
from the gearbox manometer
(the pressure range in normal operating mode is between 21 and 25 bar).
If the value is outside of this range refer to “Trouble-shooting” on page 81.
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Maintenance

001 - 004
Description of the
maintenance job: Check the operating temperature (with the gearbox warm from operation)
Required tools None
Required parts None
Test equipment None
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Maintenance

001 - 004
⇒ Read off the oil temperature from the thermometer.

The operating temperature is
at type 665 between 40 and 60 °C
at types 7xx to 19xx between 30 and 50°C
when measured behind the oil cooler
The maximum operating oil temperature

at type 665 is 65°C.
at types 7xx to 19xx is 60°C
If the temperature exceeds this value refer to “Trouble-shooting” on page 81.

Thermometer
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Maintenance

001 - 003
Description of the
maintenance job: Check the contamination indicator for the oil filter
Safety measures Observe all current, generally applicable job safety regulations.
Required tools None
Required parts None
Test equipment None
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Maintenance

001 - 003

⇒ A contaminated filter element causes the electrical
Active filter side
contamination indicator (pressure sensor detecting
differential pressure) to continuously show contamination.
⇒ Do not replace the element as long as the indicator only

displays contamination during cold starts.
With high oil viscosity, or when the oil is cold during the
starting phase, differential pressure is higher and may
activate the contamination indicator.
⇒ If the contamination indicator does not go out when operating

temperature is reached, switch the filter to the clean side of
the filter using the switch lever.
The side of the filter where the handle of the lever is
Pressure sensor detecting
positioned, is the active filter side.
⇒ Replace the soiled filter element as soon as possible. differential pressure
Refer to maintenance level 4 for a description on how to exchange the filter element.
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Maintenance

001 - 004
Description of the
maintenance job: Sicht check and running noise check
Safety measures Observe all current, generally applicable job safety regulations.
Required tools None
Required parts None
Test equipment None
Working procedure ⇒ Check the gearbox for any leakage or any parts which might have loosened.
While doing this, listen for any abnormal running or operating noises.
⇒ If you notice any abnormal operating noises, contact REINTJES service.
Changes in running noises may be an indication of defects or of faulty alignment
between the engine, gearbox and propeller shaft.
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Maintenance
Maintenance job Maintenance level: 3 + 4 To be performed if Duration of job in

no.: 006 / 009 After the first 200 hours of possible at the same time minutes: 40
operation, then after every as maintenance job no.:
2000 hours or 6 months 010
Description of the
maintenance job: Change the operating oil
Safety measures Safeguard the engine against starting. (Note the safety information on page 37
of the operating instructions.)
Collect the used oil in appropriate used oil containers to avoid pollution of the
environment.
CAUTION!
Hot oil and hot components may lead to injury.
Avoid skin contact with hot oil or hot components!
Wear protective gloves!
Required tools Standard tool
Required parts New gasket for the oil drain screw
Other materials Oil as specified in the lubrication chart
Test equipment None
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Maintenance
Maintenance job Maintenance level: 3 + 4 To be performed if Duration of job in

no.: 006 / 009 After the first 200 hours of possible at the same time minutes: 40
operation, then after every as maintenance job no.:
2000 hours or 6 months 010
These intervals apply to operating temperatures of up to 60 °C as measured behind the oil cooler.
Higher operating temperatures require shorter exchange intervals.
Please consult with REINTJES service in this case.
After the first 200 hours of operation it is also admissible to carry out an oil analysis.
Depending on the results of the analysis REINTJES will decide if the oil must be changed or if it futher can
be used. Please contact REINTJES for detailed information about the oil analysis.
⇒ Perform the oil change with the gearbox at a standstill and while the operating oil is warm.
⇒ Loosen the oil drain screw and drain the operating oil.
⇒ Collect the used oil in appropriate used oil containers to avoid pollution of the environment.
⇒ Clean the oil drain screw and screw it into the socket together with a new sealing ring.
⇒ To fill the gearbox with oil, unscrew the venting filter from the upper surface of the gearbox .
The venting filter is labelled with the word “OEL”.
⇒ Fill the gearbox with oil, using a fine-mesh screen filter, up to the upper dip stick marking.
Use only the type of operating oil specified in REINTJES lubricant chart.
The amount of oil required is indicated on the type plate of your gearbox.
⇒ Screw the venting filter on to the gearbox as far as it will go.
Tighten the venting filter as much as possible by hand.
⇒ After filling with oil, start the engine.
⇒ Fill the hydraulic system by running the gearbox for 5 to 10 minutes.
-If an electrical stand-by pump has been installed (optional), you can also fill the hydraulic system
using this pump. -
⇒ Shut down the propulsion system once again.
⇒ After 10 minutes, check the oil level once again using the dip stick.
Add oil and fill to the upper dip stick marking.
⇒ CAUTION! Avoid overfilling the gearbox!
Adding more oil than specified can result in leakage in the vicinity of the output shaft.
⇒ After the oil change, perform a sight check of the fittings and oil pipes.
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Maintenance

no.: 008 After the first 200 hours of possible at the same time minutes: 20
operation as maintenance job no.: ---
Description of the
maintenance job: Check the oil cooler anodes
Safety measures DANGER! Hot water!

Danger of scalding
Shut down propulsion system and secure it for restarting!
Switch off cooling water pump!
Required tools Standard socket wrench set / open-end wrenches
Required parts 3x Anode A292

3x Copper sealing ring
Other materials Cloth, lint-free
Test equipment None
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Maintenance

no.: 008 After the first 200 hours of possible at the same time minutes: 20
operation as maintenance job no.: ---

The heat exchanger has been equipped with three anodes (A292) to protect the water manifold and tube
bundle from corrosion: water intake, reverse cover and water outlet.
The amount of wear to the anodes depends on operating conditions.

Low water quality and high water temperatures are the main causes of wear to the anodes.
Conditions of installation and operating periods also influence wear.
⇒Shut down the propulsion system and the water pump!

⇒Drain the water side of the heat exchanger. To do this, loosen the water flange.
(Caution, hot water!)
⇒Unscrew anodes A292 with the aid of open-end wrench SW 19.
⇒Exchange anodes A292 once they are worn down to 60 % of their original volume.
⇒ Screw in the new or still serviceable anodes together with a new copper or Anode with copper sealing ring
aluminium sealing ring .
⇒ Using an open-end wrench, tighten the anode as much as possible by hand.
⇒ In the maintenance log, record the date of the first anode exchange and each A292
one thereafter.
14
We recommend performing a monthly check during the first six months.

⇒ Based on the amount of wear to the anodes, determine future inspection and
exchange intervals.
Repeat this job at least every six months or every time the heat exchanger 83 mm
is cleaned.
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Maintenance

no.: 010 Every 2000 hours of possible at the same time minutes: 20
operation or 6 months as maintenance job no.:
009
Description of the
maintenance job: Filter element exchange (for filter type RFLD or PI)
Safety measures Caution! The filter is under pressure!

Bleed the contaminated filter side before exchanging the filter!
Observe all current, generally applicable job safety regulations

Allen wrenches
Required parts Filter element with o-ring

Gasket set
Other materials Flat oil pan
Test equipment None
Working procedure Refer to the next page for Filter RFLD

Refer to overnext page for Filter PI
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Maintenance

009
Filter Typ RFLD
1 Vent screw 3 1
2 Drain plug with sealing ring
3 Socket head cap screw for lid
4 Filter element
5 Change over lever
4
⇒ Prior to carrying out the following maintenance tasks, take the filter element to be
replaced out of service.
⇒ The change over lever (5) is closest to the filter element which is in operation.
⇒ Direct the oil flow to the currently inoperative filter by moving the lever (5) away from 5
the filter element to be replaced.
⇒ Slowly release the vent screw (1) and allow all pressure to escape. Remove the vent
screw and O-ring.
⇒ Remove the cover securing screws. Turn the cover through 45° and carefully remove
the cover and O-ring.
⇒ Remove the drain plug (2) and O-ring from the filter housing. Allow the oil and con-
taminant deposits to drain from the filter housing. 2
⇒ Remove the filter element (4) out of the housing by turning it clockwise while pulling.
⇒ Clean the filter housing and drain plug.
⇒ Prior to filter system reassembly, check all O-rings for damage; replace damaged O-rings.
⇒ Install the drain plug (2) and the O-ring
⇒ Install the new filter element with O-ring. Take care not to damage the O-ring.
⇒ Fill the filter housing with oil till the element is covered with oil. (see remark on bottom)
⇒ Install the filter cover and O-ring. Ensure that the O-ring is correctly seated.
⇒ Insert the vent screw (1) with O-ring loosely.
⇒ With the vent screw loose, move the diverter lever (5) approx. 10° towards the centre; In this position the remained
room fills with oil.
⇒ Hold the lever (5) in this position until bubble-free oil is discharged at the vent screw (1).
⇒ Tighten the vent screw to specified torque and set the change over lever for single-filter operation.
Air in the filter housing leads to a pressure loss in the hydraulic system!
This pressure loss can lead that the diesel engine is shut down by the pressure switch "oil pressure to low, motor
stop".
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Maintenance

009
Filter Type PI 2xx

1 Aeration screw
2 Changeover lever
1
3 Filter element
4 Filter bowl
5 Pressure equalizing lever 5
2 6
6 O-Ring Filter element
7 O-Ring Filter bowl
3
Description of the maintenance job: 7
⇒ Changed over to the other filter element, when contaminationsignal has been
established.
⇒ Operate and hold pressure equalizing lever (5) located in the changeover
4
lever (2). At the same time swivel changeover lever and engage the catch on
the other side.
Now the lever is positioned at the same side as the element to be replaced.
⇒ Place trough or drip pan underneath to collect leaking oil.
⇒ Loosen vent screw (1) maximum back out against safety stop (filter support).
⇒ Unscrew filter bowl (4) anticlockwise and empty it into an appropriate used oil container.
⇒ Clean the filterbowl (4) inside and outside.
⇒ Pull down filter element (3) by slight movements to and fro, replace element.
⇒ Before assembling the element check O-rings (6+7) for damage.
Replace, if necessary.
⇒ Push a new element (3) onto the seat.
⇒ Firmly screw in the bowl (4) with O-ring (7).
⇒ Care must be taken to ensure that the filter bowl (4), after it has been
tightened up, is slackened off by 1/8 turn.
⇒ Operate only the pressure equalizing lever (5) long enough until the oil
emerge bubble-free from the vent bore.
⇒ Tighten vent screw (1).
⇒ Check filter for leaks by operating the pressure equalizing lever (5) once again.
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Maintenance

no.: 011 Every 5000 hours of possible at the same time minutes: 360 = 6h
operation or 12 months as maintenance job no.: ---
Description of the
maintenance job: Screwed joints
WARNING!
Prior working on the gearbox, stop the propulsion plant and
prevent the engine from being switched on!
Danger of injuries caused by hot oil and water!

Allen wrench, torque wrench
Required parts None
Test equipment Torque wrench
Working procedure Refer to the next page
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Maintenance
Gearbox type: WAF/LAF 665 - 1963

no.: 011 Every 5000 hours of possible at the same time minutes: 360 = 6h
operation or 12 months as maintenance job no.: ---
⇒ Before performing these jobs, block the propulsion system!

⇒ Check the tightening torque of bolts while the gearbox is cold.
⇒ In particular, check these connections:
Engine - flexible coupling - gearbox

Gearbox output flange - propeller shaft
Gearbox supports - foundation
Union nuts and banjo bolts of the pipe fittings
Check the rubber parts of the flexible coupling for brittleness, cracks or other damage.
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Maintenance
4.3 Additional work for gearboxes equipped for trolling propulsion mode
Additional maintenance for gearboxes equipped for trolling propulsion mode

Oil change
⇒ Make sure to adhere precisely to the intervals for changing operating oil specified
in the maintenance plan for trolling propulsion mode.
The specified oil change intervals apply when trolling propulsion mode makes up a
maximum of 10 % of operating time.
If this 10 % amounts to more than 200 hours, a limit of 200 hours applies.
If you operate the unit in trolling propulsion mode more of the time, consult with
REINTJES to determine the necessary measures.
It is not permissible to extend oil change intervals even if an oil analysis reveals
positive results.
⇒ Immediately replace any contaminated filter elements.
Gearboxes with electrical trolling propulsion devices are equipped with a finer filter.
Ensure that you have replacement fine filter elements on board.
These fine filter elements cannot be cleaned.
⇒ If you notice an increase in engagement time,
check the sinter filter element in the pressure
Sinter filter
build-up valve.
Exchange the sinter filter once it has become
clogged.
Our customer service will be glad to assist on any other questions:

! Email service@reintjes-gears.de Tel. +0049 5151 104-0
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Maintenance
4.4 Check of tube bundle contamination in the heat exchanger
WARNING!
Prior working on the gearbox, stop the propulsion plant and prevent the
engine from being switched on!
⇒ Danger of injuries caused of hot oil and water!
CAUTION!
The operating oil is under pressure!
Danger of injury!
⇒ First bleed the pressure.
⇒ Be careful when loosening the cover!
4.4.1 Structure of tube plates
1. Tube plate
2. O-rings
3. Fixing plates
4. Jacket
5. Tube bundle
Both of the tube plates are the same

1 2 3 4 5
• The outer o-rings seal the cover in each case.
• The inner o-rings seal the jacket.
• The four fixing plates are inserted in the groove at centre.
The fixing plates may be inserted either from the intake cover or the reverse cover end.
Both covers may be mounted rotated by 180 degrees (improved access to anodes).
In any case, avoid reversing the back and front when mounting the covers.
! There is only one correct position for installing the tube bundle in the jacket.
Make sure not to install the tube bundle with the ends reversed or turned.
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Maintenance
4.4.2 Sight check of the tube bundle

The amount of dirt deposited on the tube bundle depends on conditions of installation
and operation.
⇒ Perform the first sight check 3 months after putting the gearbox into operation.
You can determine future intervals based on the results of the first inspections.
The bolts holding the cooling water coupling flange and the covers of the heat
! exchanger must always be loosened and tightened in opposite pairs.
Sight check by removing the covers
The hydraulic oil in the heat exchanger does not need to be drained when performing this
simple sight check.
⇒ Close the valves for the water intake and water outlet
⇒ Drain the cooling water.
⇒ Unscrew the cooling water connectors.
⇒ Check whether the connector gaskets are still in good order.
⇒ Mark the position of intake
cover A with 1/1 and the posi-
tion of reverse cover B with 2/2.
⇒ Loosen the bolts of the covers
in opposite pairs and remove
the bolts.
Intake cover A Reverse cover B

⇒ Remove covers A and B.
A nylon separator is inserted at the centre of intake
cover A.
Take care not to damage this separator.
⇒ Secure the tube bundle in place with the fixing plates.
To do this, insert the cover bolts through the holes from the
back and bolt the fixing plates in place using the nuts.
⇒ Check to see how heavily the covers and tubes are soiled.
Separator Fixing plates
Clean the tube bundle using a nylon tube brush.
Wipe off the covers with a lint-free cloth.
Tube cleaning brush
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Maintenance
4.4.3 Dismantling the tube bundle
If there is enough room on board, you can leave the heat exchanger mounted and remove
the tube bundle at the gearbox.
The tube bundle can be pulled out from either side. In this description, sides A and B should
be taken to be the intake cover side as A and the reverse cover side as B (see pictures above).
⇒ Loosen and remove the oil drain screw (SW19).

⇒ Drain the oil into a pan.
⇒ Mark the position in which the tube bundle is built in.
The tube bundle must afterwards be mounted in exactly the
same position.
⇒ Remove the separator on intake cover side A.
⇒ Remove the bolts and nuts from the flange holes.
⇒ Remove the 4 fixing plates.
Separator Fixing plates
During the next step, be careful not to damage the edges by pounding them
! with a hammer.
⇒ On the A side, push in the tube plate so that it is flush with the jacket.
Using a piece of wood and a rubber mallet, carefully drive in the tube plate.
⇒ On side B, remove both o-rings.
⇒ On the B side, push in the tube plate so that it is flush with the jacket.
⇒ On side A, remove both o-rings.
⇒ Push the tube bundle in on side B far enough so that you
are able to reach in behind the tube plate on side A.
⇒ Taking hold of the tube bundle, pull it out straight toward
side A.
Be careful not to bend the baffles on the tube bundle!
Pulling out the tube bundle
If you wish to clean the tube bundle using chemical agents, request from REINTJES
! detailed information on cleaners and procedures.
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Maintenance
4.4.4 Mounting the tube bundle
The tube bundle and jacket have matching dimensions. The entire heat exchanger
! therefore needs to be replaced in order to replace the tube bundle!
⇒ Never employ used or salvaged o-rings.

Always insert the tube bundle together with new o-rings.
⇒ Carefully clean the sealing surfaces.

At the same time check the sealing surfaces for damage.
⇒ Apply a soap-free lubricant (e.g. Molikote, silicone paste or
Parker O-lube) to the sealing surfaces.
Do not use vaseline or other lubricants containing soap.

!
⇒ Clean the grooves in the tube plate.
At the same time check the tube plate for damage.
⇒ Pay attention to the marking when inserting the tube bundle.
⇒ Lubricate the grooves of the tube plate on side A using a soap-free lubricant.
⇒ Insert new o-rings in the grooves.
Lubricate the o-rings from the outside.
⇒ Carefully push the tube bundle back into the jacket so that the
tube plate is visible on side B.
⇒ Lubricate the grooves of the tube plate using a soap-free
lubricant.
⇒ Insert new o-rings in the grooves.
Lubricate the o-rings from the outside.
⇒ Push the tube bundle into the jacket so that the tube plate is flush with the flange on side B.
⇒ Insert the fixing plates and secure them in place by means
of the cover bolts on side A.
⇒ Place the separator on the intake cover side (A)
Refer to fig. at right
⇒ Clean the sealing surfaces of the intake cover.
Check the cover for damage.
⇒ Lubricate the sealing surfaces using a soap-free lubricant.
⇒ Place the cover on the tube plate. Separator Fixing plates
⇒ Take out the bolts and insert them from the other side.
⇒ Tighten the nuts with spring washers as much as possible by hand.
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Maintenance
⇒ Tighten the bolts in opposite pairs.

⇒ Mount the reverse cover in the same way.
⇒ Mount the cooling water connectors. When doing this, replace any damaged gaskets.
⇒ Connect the oil pipes to the heat exchanger.
⇒ After completing assembly, fill the water circulating system and the hydraulic system
⇒ Vent the heat exchanger by loosening an anode.
At the same time check all connections to make sure they are water-tight.
4.4.5 Corrosion protection of the heat exchanger
Follow the safety instructions provided in this operation instruction.

! (see ”Safety” from page 5.)
In addition, observe any applicable safety precautions when mounting or
dismantling equipment.
Draining the water side of the heat exchanger during interruptions in operation
of longer than 2 weeks:
Seawater circulating system:
⇒ Drain the seawater circulating system of the heat exchanger.

⇒ Flush the water side of the heat exchanger with freshwater.
⇒ Observe the areas of application recommended by the additive manufacturer.
Freshwater circulating system:
⇒ Drain the freshwater circulating system of the heat exchanger.

⇒ Observe the areas of application recommended by the additive manufacturer
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Maintenance
4.5 Replacement of the mechanical gearbox oil pump
4.5.1 Oil pump mounted directly on the drive shaft

Steps in dismantling and reassembling the oil pump
Overview of positions for the following steps

(drawing may vary from the mounted parts - subject to technical changes)
Dismantling the pipes

⇒ Loosen the fittings of the suction and pressure
pipes using open-ended spanners.
⇒ Using open-ended spanners, also loosen the

fittings fastening the control pipe to the pump and
filter.
⇒ Remove the pipes and store them for reassembly
later on.
⇒ Loosen the 4 fastening bolts and

remove them
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Maintenance
⇒ Pull out the pump.

⇒ If the pump is stuck in place, carefully pry it out using
a lever to apply pressure evenly.
Do not use a rubber or plastic hammer!
⇒ Clean the flange surface and tapped holes of any

residual adhesive.
⇒ Place the defective pump on a working surface.

⇒ Loosen and remove the fittings on the control, suction
and pressure sides. These are needed for the new
pump.
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Maintenance
⇒ Take the new pump out of the package.

⇒ Remove the plastic plugs from the connectors.
Prior to mounting the pump, make sure that the

connectors are mounted properly. Note the rotating
direction!
⇒ Screw the fittings into the connector threads on the
new pump applying liquid sealant.
⇒ Apply liquid surface sealant to the pump

flange as shown.
⇒ Make sure that the contact surface of the flange

and the holes are clean.
⇒ Lightly lubricate the pump shaft and the drive shaft
hole.
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Maintenance
⇒ Apply some thread-locking fluid to the bolts.

⇒ Insert the pump as far as possible into the
pump flange.
⇒ Make sure that the fitting key fits into the groove on
the drive shaft.
⇒ Tighten the pump against the flange
evenly by means of the bolts.
⇒ Mount the suction, pressure and control pipes on the

pump using open-ended spanners.
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Maintenance
4.5.2 Oil pump mounted on the pump drive

Steps in dismantling the oil pump with pump drive
Overview of positions for the following steps

(drawing may vary from the mounted parts - subject to technical changes)
Dismantling the pressure and control pipes

⇒ Using an open-ended spanner, loosen the fittings
fastening the pressure pipe to the pump and filter.
⇒ Loosen the fittings of the control pipe using an

open-ended spanner.
⇒ Remove the pipes and store them for reassembly
later on.
Loosening the suction pipe

⇒ Using an open-ended spanner, completely loosen
only the fittings fastening the suction pipe to the
pump.
⇒ Using an open-ended spanner, only loosen slightly
the lower fittings of the suction pipe in order to
swing it away from the pump. This prevents
residual oil from leaking into the bilge.
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Maintenance
Labelling the pump flange

⇒ Mark the position at which the pump drive housing
and the bearing housing are installed with two
punch marks.
⇒ Mark the punch marks additionally with a felt
marker to be able to find them more easily.
Withdrawing the tapered pins E49

⇒ Fit the thread with a suitable sleeve or with two M10
nuts and screw on an M8 nut.
⇒ Using a ring spanner, pull the pin out of
pump drive case E41.
Dismantling the pump drive case

⇒ Loosen the Allen screws, labelled E719, of the
pump housing.
⇒ Carefully remove the pump drive housing and
place it on a workbench with the pump downward.
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Maintenance
⇒ Using a ring spanner, loosen bolt E1745 of the pump

drive gear.
⇒ Place the bolt and washer
aside for reassembly.
⇒ Loosen the 4 bolts, labelled E143, of the pump

flange (do not unscrew them completely!).
The pump should only be loose so as to be able to more
easily remove the pump drive gear.
⇒ Carefully tighten the pump in a vice with soft jaws.

⇒ Put a three-armed extractor over the
pump drive gear and pull it off.
⇒ Now screw out the 4 bolts, labelled E143, of the

pump flange.
⇒ Remove the defective pump.
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Maintenance
Mounting the mechanical oil pump
⇒ Apply oil to the pump shaft.
⇒ Place the fitted key into the groove.
⇒ Place cover E41 of the pump drive onto a

working surface.
⇒ Coat the contact surface of the pump
flange with liquid surface sealant.
⇒ Mount oil pump E19 on the cover using the E143

bolts.
⇒ Ensure that the pump is positioned properly
(i.e. by the markings) when setting it on the cover.
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Maintenance
⇒Heat pump drive gear

R104.00 to approx. 80°C/
176°F.
Caution! Hot parts! Danger of

injury!
Wear protective gloves!
⇒ Place the pump drive gear on the pump shaft.
⇒ Put a drop of bolt-locking fluid on bolt E1745.

⇒ Lock pump drive gear E42 in place using the bolt.
⇒ Seal the sealing surface of cover E41

using liquid surface sealant.
⇒ Place the cover onto the bearing housing.

⇒ Fix the cover in place with the E49 tapered pins.
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Maintenance
⇒ Fasten cover E41 using Allen screws E719.
⇒ Fasten the suction pipe.
⇒ Fasten the pressure pipe.

⇒ Fasten the control pipe.
⇒ Check the fittings to ensure they are well seated.
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Maintenance
4.6 Conversion factors and screw tightening torque values
Approximate values for conversion Be careful never to mix metric screws and nuts with imperial
factors screws and bolts. The use of improper or improperly fitting
screws and nuts results in damage or faulty operation of the
Multiply by equals
gearbox or even personal injury.
mm 0.03937 inch Any replacement screws and nuts required must be of the
inch 25.4 mm same size and of the same property class as the originals.
kg 2.2 lb The head of the screw usually has a label identifying the
lb 0.454 kg property class. This is identified with the digits 8.8, 10.9 etc.
kPa 0.145 psi
The following tables list tightening torque values for screws
psi 6.89 kPa
and nuts of the property classes 8.8 and 10.9.
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
litres 0.26 US
US gallons 3.79 litres
US gallons 0.833 Imperial
Temperature conversion °C = (°F - 32) : 1,8 / °F = (°C x 1,8) + 32
Metric ISO thread 1) Metric ISO thread 1)

Thread Tightening torque for Thread Tightening torque for
size property class 8.8 size property class 10.9
Metric Nm lb ft Metric Nm 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) ISO= International Organisation for standardisation
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Maintenance
4.7 Screw Locking
⇒ For assembly use screws with screw-locking glue only.
The glue is applied either as a coating by the screw manufacturer,

or you must use a usual medium-strength screw glue.
After dismantling and before re-assembling these screws, free nuts

and shaft nuts from glue remains. The threaded holes have to be
cleaned as well.
Free threaded holes from glue remains by using a corresponding tap
Pay attention to the charts for tightening torques.

! Screws are only sufficiently secured by using glue if they are tightened with the
proper torque (assembly torque). (See ”Conversion factors and screw tightening
torque values” on page 77.)
2 threads without glue
3 treads with glue
Use always screw-locking, medium-strength metal glue for locking:
• fixing screws for heat exchanger, filter, pump etc.
CAUTION!
Possible destruction risk!
Valid for screws and bolts with mechanical stress.
⇒ All screws and bolts connecting parts with torque transmission
must not be re-used after disassembly.
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Maintenance
4.8 Maintenance performed

Gearbox type: ____________________
Gearbox no. ____________________
Hours of operation Maintenance level/job Date Initials
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Maintenance
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Trouble-shooting
5 Trouble-shooting
Fault Cause Repair

Oil temperature too Cooling water flow rate too low ⇒ Increase the water flow rate using the water
high valve.
Heat exchanger soiled ⇒ Clean the heat exchanger
Oil flow rate too low ⇒ Check the gearbox oil pump and the pipes for
any leaks.
⇒ Check to see if the oil pump is intaking air.
⇒ Carefully tighten the pipe fittings.
Clutch slips; operating pressure too ⇒ Check the items listed under “Operating
low pressure too low, variable”.
Oil temperature too Water flow rate through heat ⇒ Decrease the water flow rate using the water
low exchanger too high valve.
Operating pressure Gearbox oil pump intakes air ⇒ Check the items listed under “Gearbox oil pump
too low, variable intakes air”.
Pressure limiting valve blocked ⇒ Replace the pressure limiting valve.
Check valve of electrical stand-by ⇒ Check whether oil flowing back through the
pump is defective electrical stand-by pump causes it to rotate.
This is a sign that the check valve is not closing.
⇒ Clean the check valve to remove any dirt and
rinse if necessary.
Wrong type of operating oil ⇒ Compare the type of operating oil used with
lubrication chart found in the appendix to
these operating instructions.
⇒ Use only oil types listed in this chart.
⇒ Change the oil if the gearbox was filled with an
inappropriate oil type
(see ”Change the operating oil” on page 52.).
Operating pressure Filter bell of the oil filter not complete ⇒ Filling filter housing completely with oil.
falls strongly after filled with oil (see ”Filling the Oil filter” on page 15.)
switching over the
filter element
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Trouble-shooting
Fault Cause Repair

Operating pressure Defective pressure limiting valve ⇒ Replace the pressure limiting valve.
too high
Cold operating oil ⇒ Let the gearbox idle until it reaches operating
temperature.
Idle periods in cold waters result in a higher oil
viscosity.
Wrong type of operating oil ⇒ Compare the type of oil used with lubrication
chart found in the appendix to these operating
instructions.
⇒ Use only oil types listed in the lubrication chart.
⇒ Change the operating oil if the gearbox was filled
with an inappropriate oil type (see ”Change the
operating oil” on page 52.).
Oil loss Shaft sealing rings (normal wear) ⇒ In this case, consult
REINTJES customer service.
In the pipe system ⇒ Carefully tighten the fittings.
⇒ Immediately replace any leaking or cracked
pipes.
Screw plug, oil drain screw ⇒ Tighten the screw.
⇒ Replace the screw gasket
⇒ Replace the screw
Heat exchanger leaking ⇒ Replace the heat exchanger gaskets. Use gasket
set A282 in this case (see ”Heat exchanger A1,
Type P...” on page 87.)
Gearbox noise Idling speed is in critical range ⇒ Increase the idling speed.
Torsional vibration resonance of the ⇒ Change the speed in order to avoid critical speed
engine is transmitted to the gearbox ranges.
⇒ Check the flexible coupling on the input side.
Hydraulic noises, gearbox oil pump ⇒ Check the items listed under “Gearbox oil pump
intakes air intakes air”.
Gearbox oilpump Gearbox oil level too low ⇒ Check the gearbox for leakage.
intakes air ⇒ Repair the cause of oil loss. (E.g. replace sealing
rings, tighten screws or fittings on pipes.)
⇒ Add oil and fill to the upper dip stick marking.
Suction pipe leaks ⇒ Carefully tighten the suction pipe fittings.

⇒ Replace the gaskets on the flange fittings.
Tighten the flange screws.
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Trouble-shooting
Fault Cause Repair

Clutch slips Operating oil pressure too low ⇒ Check the items listed under “Operating
pressure too low, variable”.
Clutch slips at high Operating oil pressure too low ⇒ Check the items listed under “Operating
engines speeds pressure too low, variable”.
⇒ Reduce engine speed until the clutch no longer
slips.
⇒ Avoid switching directions of rotation.
-or-
⇒ Change the direction of rotation only with the
propeller at a standstill and the engine at idling
speed.
Clutch does not Control valve not properly engaged ⇒ From the control cabin, shift from “Neutral” to the
engage desired direction of travel several times.
⇒ Shift the gearbox by hand in order to check valve
functioning.
-or-
⇒ For electrical shifting valves, check the shifting
position using the pressure switch signal:
WAF:(optional) AHEAD and ASTERN A74/A75
LAF: Clutch engaged A74
Clutch does not Control defective ⇒ From the control cabin, shift into the “Neutral”
disengage position several times.
⇒ Disengage the gearbox by hand in order to check
valve functioning.
Discs are defective or seized ⇒ Check whether the emergency screws are tight.
⇒ If the clutch still does not disengage even though
the screws are loose, you need to have the discs
replaced. In this case, consult REINTJES
customer service.
Oil pressure too low ⇒ Check the items listed under “Operating
pressure too low, variable”.
Operation Manual 83
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Trouble-shooting
84 Operation Manual
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Spare and replacement parts
6 Spare and replacement parts
The installation and use of non-original parts may pose a safety hazard or impair
! functioning of the gearbox. REINTJES assumes no liability whatsoever for damage
arising from the use of such parts.
We require this information when ordering spare parts:

!
1. Gearbox type e.g. WAF 665
2. Commission number e.g. K 80 000
3. Input power
4. Input speed
Providing these details avoids having to request further information and speeds
up delivery.
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6.1 Heat exchanger A1, Type P...
Pos.- No. Qty. Designation

A 282 1 Set of seals consisting of
4 O-rings
A289 1 Open end cover
A290 1 Endcover
A291 1 Tube bundle
A292 3 Anode
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88 Operation Manual
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6.2 Duplex filter A3, Type RFLD
A37
A283
A323
A43
A500

A 37 2 Filter element with o-ring
A 43 2 Contamination indicator electrical, standard
A 283 1 Set of seals consisting of:
A O-ring (2)
B O-ring (2)
A 323 1 Switch lever, complete
A 500 1 Drain screw, magnetic
Additional order:
A 43 2 Contamination indicator, mechanical
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6.3 Duplex filter A3, Type PI 210

A 37 2 Filter element
A 43 1 Contamination indicator electrical, standard
A 283 1 Set of seal consisting of
A O-ring (2)
B O-ring (2)
C O-ring (1)
D O-ring (1)
A 323 1 Switch lever, complete
Additional order:
A 43 1 Contamination indicator, visual
Operation Manual 91
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6.4 Gearbox oil pump E19, Type KF 2/.., KF 3/.., KF 4/..

E 714 1 Set of seals consisting of:
A Shaft sealing ring (1)
B O-ring (1)
C O-ring (1)
D Gasket (1)
E 725 1 Bearing
Note: Mark the position of the cover before dismantling.When
assembling pay attention to correct mating of cover and gasket D.
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6.5 Operation Delay Pot H1069/H1074 / Connecting Plate V232
Pos.- No. Pos.- No. Qty. Designation

H 1072 H 1073 1 Set of seals consisting of:
A O-Ring (1)
B O-Ring (1)
V 233 V 234 1 Non-return valve (Aeration valve)

V 235 2 O-Ring
V 237 2 Plug screw
V 237 2 Threaded pin
V 237 2 O-Ring
V 238 4 Ball
V 239 2 Spring
V 240 2 Seal lock nut
V 241 2 Adjusting srew
V 305 2 O-Ring
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6.6 Control valve V1 (4/3-way-valve), electrical
Pos-No. Qty. Name

V 223 1 Set of seals consisting of
A O-ring (5)
B O-ring (2)
C O-ring (2)
D O-ring (2)
V 259 2 Solenoid
V 260 1 Plug-in connector
V 262 2 Manual emergency control for 4/3 NG 10 with spring-return
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A O-ring (5)
B O-ring (2)
C O-ring (2)
D O-ring (2)
V 259 2 Solenoid
V 262 2 Manual emergency control for 4/2 NG 10 without spring-return
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100 Operation Manual

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6.8 Control valve V1 (4/3-way-valve), pneumatical
Pos- No. Qty. Designation

A O-ring (5)
B O-ring (2)
C O-ring (2)
D Turcon-Step seal (2)
O-Ring (2)
E Quadring (1)
F Turcon-glyd ring (1)
O-Ring (1)
V 263 1 Pneuko piston, complete
V 264 1 Seal ring for piston
D and F consisting of 2 parts one fitting into the other
Operation Manual 101

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6.9 Control valve V1 (4/2 way-valve), pneumatical

A O-ring (5)
B O-ring (2)
C O-ring (2)
O-ring (2)
E Quadring (1)
F Turco-Glyd ring (1)
O-Ring (1)
Detail X disc installed as STOP.

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A O-ring (5)
B O-ring (2)
C O-ring (2)
D O-ring (2)
V 365 2 Solenoid

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6.11 Control block V247, type HB4A 0313

V 247 1 Control block, ordering only completely
Repair set for type HB4A 0313 , consist of:
20 1 End cover screw

30 1 Spring disc
40 1 Control spoo
50 1 Pressure spring
70 1 Sealing ring CU
140 1 Hexagon screw M10
150 1 Hexagon nut M10

Set of sealing parts for type HB4A 0313, ordering only completely:
80 1 O-Ring
90 1 O-Ring

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6.12 Control valve V114 (4/2-way-valve), electrical, for PTO

A O-ring (5)
B O-ring (2)
C O-ring (2)
D O-ring (2)
V 368 2 Solenoid

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6.13 Control valve V114 (4/2 way-valve), pneumatical, for PTO

A O-ring (5)
B O-ring (2)
C O-ring (2)
O-ring (2)
E Quadring (1)
O-Ring (1)

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6.14 Operation Delay Pot H626

H 195 1 Non-return valve (Aeration valve) ; depending on Potsize
V 192 1 Sealing ring

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6.15 Control valve V189 (4/2 way-valve), pneumatical, for shaft brake

A O-ring (5)
B O-ring (2)
C O-ring (2)
O-ring (2)
E Quadring (1)
O-Ring (1)

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6.16 Operation Delay Pot H768, for shaft brake

V 198 1 Non-return valve (Aeration valve) ; depending on Potsize
V 187 1 Sealing ring

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6.17 Pressure build-up valve V316.00 (for ADS)

V 316.50 1 Sinter filter-element
V 316.51 1 Set of seals consisting of:
A O-Ring (1)
B O-Ring (1)
C O-Ring (2)
D O-Ring (2)
E O-Ring (1)
F O-Ring (1)
V 316.52 1 Sealing nut

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6.18 Proportional valve V304 (for ADS)
V 304

V 304 1 Proportional valve complete
with two o-rings and connecting plug

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6.19 Control block V247, type HB4A 0317 (for ADS 6xx)

V 247 1 Control block, ordering only completely
Repair set for type HB4A 0317 , consist of:
20 1 End cover screw

30 1 Spring disc
40 1 Plug screw
140 1 Hexagon screw M10

Set of sealing parts for type HB4A 0317, ordering only completely:
60 1 O-Ring
80 3 O-Ring
90 1 O-Ring

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6.20 Control block V247, type HB4A 0320+DKF4O30 (for ADS 7xx-19xx)

Control block type HB4A 0320, ordering only completely:
10 1 DKF4O30-Mounting group
100 2 O-Ring

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Index
Index
A Operating oil fill 12
ADS - trolling propulsion mode 28 Operation Delay 95
Operation modes 23
B
Behaviour in cases of fault 30 P
Pressure limiting valve 35
C set 35
Checklist
Preservation 18 R
Sensor connections 19 Requirements for assembly personnel 7
Checklists for putting into operation 15 Reversing 24
Connection to the engine 30, 77
Conversion factors 77 S
Crash-stop 25 Safety 5
Screw plug 14
D Service repair sets 93
Dip stick marking 14 Shaft brake, engage 24
E T
Emergency operation 30, 33 Tightening torque 77
Emergency screws 33 Trailing operation 26
Engaging the gearbox 23 Trolling propulsion mode 28
Maintenance 41, 43
F
Failure of pressure oil supply 33 V
Fresh oil sample 13 Venting filter 14
H
Heat exchanger
Maintenance 41, 43
I
Installation check 12
L
Lubricant amount 14
Lubricant recommended 14
M
Maintenance 37
Maintenance job card 41, 43
Maintenance level 39
Maintenance plan 39
Manual emergency operation 30
O
Oil
fill 12
Oil drain screw 13

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Index

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WAFLAF 665 1963 BV2147 en

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© 2010 REINTJES GmbH

2 Introduction to this Documentation .............................................................................................. 11

3 Technical Data ........................................................................................................................................ 15

4 Transport, Storage and Preservation ........................................................................................... 19

6 Installation and Alignment ................................................................................................................ 45

1.1 Meaning of Warnings and Notes

Note without signal word:

Additional information and recommendations

1.2 Basic measures of caution

Accidents may often be avoided by recognizing potential hazard situations in advance.

Input side Output side

Dangerous places on the gearbox

Symbol Meaning Symbol Meaning

This warnings must be observed!

Danger of being drawn or caught Wear tightly fitting protective

in by rotating components clothing e.g. coverall

Danger of electric shock! Wear ear protectors

1.3 Requirements for installation personnel

General protective measures and personal protection in the engine room

1.4 Safety information for installation

Observe the following procedures!

Safety prior to working on the gearbox

⇒ Before performing adjustments or repairs on the gearbox or on aggregates powered

1.5 Protective measures against fire and danger of explosion

⇒ Immediately remove any oil residues completely.

Pipes and tubes

⇒ Do not damage hoses by subjecting them to mechanical force.

⇒ Collect drained oil in a used oil collector.

Store all lubricants in appropriately labelled containers. Dispose of filter elements

Cables connected to the gearbox

⇒ Make sure that all cables are maintained in an undamaged condition.

Foreign substances near to the gearbox

2 Introduction to this Documentation

This documentation comprises one set of installation and operating instructions

This installation instructions contains information about:

The operating instructions contains information about:

• Putting the unit into operation

Please read the Installation instructions before installing the gearbox!

Anyone responsible for transport, installation, operation or maintenance of this equipment

2.1 Maintaining the documentation

2.2 Preconditions of warranty

REINTJES will only accept warranty claims when:

REINTJES strongly recommends that you have a torsional vibration calculation

2.3 Brief product description

Control is effected by means of directional valves.

2.4 Area of application and manner of intended use

These details must be absolutely adhered to!

2.5 Use of the gearbox within the European Union

Requesting spare parts

• GEARBOX NO. - e.g.: K80xxx

• Item number of the part

Table 1: Overview of characteristics for type WAF 665 - 1963

Table 2: Overview of characteristics for type LAF 665 -1963

4 Transport, Storage and Preservation

⇒ Report any transport damage to the freight carrier immediately.

⇒ Inform the REINTJES service department

Slings must be suitable for this load.

With the gearbox suspended from a sling, the

⇒ Transport aids and lifting equipment must be designed to be able to safely

During transport, make sure:

⇒ In cases of doubt, please contact the REINTJES service department.