Operating Manual

WAF 542 - 572

LAF 542 - 572
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REINTJES GmbH
8
0-31784 Hameln
Federal Republic of Germany
Phone +495151 104-0 BV2024.en 2008-02
Telefax +49 51 51 1 04-300 Subject to alterations
 Table of Contents

1.0 General Information 5.0 Disassembly and Assembly

1.1 Introduction 2 5.1 General Information 28
1.2 Important Notes 2 5.1.1 Seals 28
1.3 Safety Information 2 5.1.2 Screws 28
1.4 Fire and Explosion Prevention 4 5.2 Screw Locking 28
1.5 Pre-operation Checks 4 5.3 Glued Connection 29
5.4 Instructions for Hydraulic Assembly /
Disassembly with Taper 1:30 30
5.5 Lubrication of Discs 32
2.0 Installation and Alignment 5.6 Recommended Maintenance Procedures
for Heat Exchangers of BLOKSMA Make 33
2.1 Lifting Equipment 5
2.2 Alignment 5
2.3 Gearbox Installation and Alignment 5
2.4 Connection to Engine 5
6.0 Spare Parts
2.5 Connection to Propeller Shaftline 6 Ordering Notes 39
2.6 Propeller Shaftline Check 6
WAF 542 - 562
2.7 Seat Chocks and Foundation Bolts 6
Piping and External Parts 40/41
2.8 Installation of Gearbox with
Input Shaft 42/43
Longitudinal Mounting Arrangement 7
Intermediate Shaft 44/45
2.9 Alignment Check 7
Power Take Off K21 46/47
WAF 542
Output Shaft 48/49
3.0 Function and Operation WAF 562
Output Shaft 50/51
3.1 General Information 8
3.2 Name Plate Arrangement 8 WAF 572
3.3 Hydraulic System 9 Piping and External Parts 52/53
3.4 Gearbox Actuation 10 Input Shaft 54/55
3.5 Pressure Build-up Valve 12 Intermediate Shaft 56/57
3.6 Supervision Parameters 13 Power Take Off K21 58/59
3.7 Sectional Drawing WAF 542 - 572 14 Output Shaft 60/61
3.8 Function of Series WAF / LAF 15
3.9 Recommended Lubricants 15
3.10 Initial Operation 15
3.11 Operating Instructions 16
Service Repair Kits
3.12 Engagement Recommendations 16
3.13 Trailing Operation, Engine STOP A 1 Heat Exchanger Typ OK 62
and Propeller Rotating 17 A 1 Heat Exchanger Typ OKTS/OKS 62
3.14 Emergency Operation 17 A 1 Heat Exchanger Typ P130 63
A 3 Duplex Filter Typ Pi 63
E 19 Oil Pump Typ KF 1/.. 64
E 19 Oil Pump Typ KF 2/.. , 3/.. 64
V 1 Control Valve 4/3 pneum. 65
4.0 Maintenance V1 Control Valve 4/3 electr. 65
4.1 Maintenance Recommendations 18 V1 Control Valve 4/2 pneum. 66
4.2 Conversion Factors 19 V1 Control Valve 4/2 electr. 66
4.3 General Torque for Metric Fasteners 19 V 100 Pressure Build-up Valve 67
4.4 Maintenance Schedule 20 V1 Control Valve, Rotary piston 67
4.5 Maintenance Task Descriptions 21
4.6 Completed Maintenance 25
J 4.7 Troubleshooting 26
4.8 Preservation of the Gearbox 27

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 1.0 General Information
1.1 Introduction
This manual contains general information and safety
instructions, installation instructions, operating,
control and maintenance information.
Illustrations guide the operator through the gearbox
initial operation, operation and inspection
procedures.
Operational procedures described in this manual
are applicable to standard installations. Application-
specific procedures may differ slightly.
Your safety and the safety of others depends on
careful and correct operation of the equipment. A
good operator is the best possible accident-
prevention measure.
On-going improvements and advancements in
product design may have resulted in modifications to
your gearbox which are not covered by this manual.
If you have any questions regarding your gearbox or
this publication, please consult the REINTJES
Service Department.
1.2 Important Notes
The gearboxes are subject to the REINTJES
warranty conditions as agreed upon in the
purchasing contract.
Modifications of the gearbox are permissible only
in consultation with REINTJES.
REINTJES will only consider warranty claims when
- The gear has been installed, operated, supervised
and maintained in accordance with our
instructions.
- The oils employed are in accordance with our
Recommended Lubricants List.
- Power data and characteristics are in accordance
with those quoted on the name plate.
As supplier of only one component in the complete
propulsion plant, REINTJES is not responsible for
vibration problems resulting from the overall system.
REINTJES does not, therefore, accept any responsi-
bility for any complaints or damage caused by such
vibration.
We recommend that a vibration analysis be carried
out, taking into account the different load states of
the gearbox as well as the rotating, mounted and
add-on parts.
2
1.3 Safety Information
The majority of accidents which occur during
operation, maintenance and repair are caused by
failure to observe basic safety rules and accident-
prevention precautions. Accidents can often be
avoided by correct advance assessment of
potentially hazardous situations. The operating
personnel must, at all times, be alert to potential
hazards.
Furthermore, personnel must be fully trained, skilled
operators provided with the necessary tools and
equipment required to perform these functions
correctly.
Basic safety precautions are repeated in the
operating manual.
REINTJES cannot possible anticipate all situations
which may constitute a potential hazard. The
warnings contained in this manual and on the actual
product are therefore not, all encompassing.
Should you employ tools and equipment, procedures
or operating techniques not specifically recommend-
ed by REINTJES, it is mandatory to ensure that
these involve no risk to yourself or others. It is also
essential to ensure that the product cannot be dam-
aged or operational safety detrimentally
influenced by the lubricants, operating, maintenance
and repair techniques employed.
Prior to commencing any services, ensure that you
are in possession of the complete and most up-to-
date information available.
Supplementary to operating manual, all generally
valid legal and other binding regulations for accident
prevention and pollution control have to be observed
and adhered to!
WARNING
Incorrect operation, lubrication, maintenance or
repair of this product can be dangerous and may
even lead to injury.
Do not operate or perform any maintenance or
repair on this product, unless you have carefully
read and understood the operation, maintenance
and repair instructions.
 General
The gear has been built according to latest
developments in engineering and established safety
rules. Nevertheless, during operation dangers to life
and limb of operator or third party may occur.
Restrictions to gearbox and other materials may
also limit its use.
The gearbox must only be operated in perfect
technical condition as well as in accordance with
regulations.
The operator must be aware of rules for safety
and hazards and must follow the operating manual
including regulations concerning inspection and
maintenance. Faults which may impair safety must
be eliminated without delay!
Authorised and trained staff only are entitled to
operate, maintain and repair the gearbox.
Remove covers carefully. The last two, opposed,
cover or subassembly securing screws, or nuts,
must be loosened (not removed) slowly and evenly.
Release the cover to relieve any possible spring- or
other pressure before finally removing the last two
screws or nuts.
Before commencing any kind of service work, ensure
that all tools are in perfect condition and that you are
fully conversant with their use. Ensure that all tools,
electrical cables and other loose objects are
removed before returning the gearbox to service.
Make sure that no foreign substances can fall into
the gearbox.
Where necessary, always wear a helmet, face
protectors, protective clothing, safety shoes,
breathing equipment or take other, suitable safety
precautions. Wear goggles and protective clothing
when working with compressed air.

The staff must not have long loose hair nor wear To avoid hearing damage, always wear ear
loose clothing or jewellery inc!. rings. protectors when working on running machinery
in an enclosed area.
There is a danger of injury e.g. by getting stuck or
pulled in.
Unless otherwise specified, always shut down the
engine before carrying out repairs or adjustments to
the engine and driven machinery.
Attach a "DO NOT START, WORK IN PROGRESS"
or similar notice to the engine starting switch, or
button, before working on the gearbox.
Ensure that the propulsion engine remote starting
system is deactivated.
Prior to commencing work on the engine or gearbox,
disconnect and insulate the engine battery earth
cable to prevent accidental starting.
To avoid injury, provide all exposed drive shafts, belt
pulleys or similar rotating parts with safety guards.
When checking or working on open gearboxes,
secure the propeller and shaftline against
uncontrolled rotation.
Relieve pressure from all associated air, oil, fuel or
water systems prior to releasing, or removing, pipes,
subassemblies etc.
When removing components from a pressure-
operated system, ensure that it is no longer
pressurised. Do NOT check for pressure leaks
with your hand.
When checking for leaks, a piece of cardboard or
similar material should be used. Fluids escaping
under pressure, especially from a "pin-hole" leak,
can penetrate skin tissue and may lead to serious or
even fatal injury. If fluid penetrates the skin tissue,
consult a doctor familiar with such injuries as soon
, as possible and within a few hours at the latest.

3
 1.4 Fire and Explosion Prevention Secure connections, specified wiring and correctly
treated cables all contribute to the prevention of
Lubricating oil or fuel sprayed onto a hot surface arcing or sparking which, in turn, could cause a fire.
may catch fire causing personal injury and damage
to property. Check all lines and pipes for wear and A fire extinguisher should always be kept readily
damage; ensure that they are correctly routed, available and its use must be practised. Compliance
supported and secured. All connections must be with the manufacturer's inspection and maintenance
tightened to the specified torque. intervals, as shown on the instruction plates, or
labels, must be observed.
Fluids must be drained into suitable containers and
all oil, fuel or coolant splashes must be cleaned up. Lubricant draining should be carried out with
Accumulations of grease or oil constitute a fire extreme care. Hot lubricants can cause personal
hazard. injury; allow the gearbox to cool completely before
commencing maintenance or repair work.
Oil-soaked rags must be kept in the containers
provided. Do not leave rags or cleaning cloths on Remove plugs, lubrication fittings, pressure
the gearbox. connections, venting filters and drain plugs with
caution. To prevent spraying or splashing by
When replacing oil filter elements, ensure correct pressurised fluids, cover lubrication fittings and
installation and tightening. plugs during removal.
All lubricants must be stored in clearly marked
containers.
1.5 Pre-operation Checks
Filter elements and waste oil must be disposed of
as recyclable material or special waste. Ensure that all protective guards and covers are
correctly installed. To prevent accidents, always
Diesel fuel and all lubricants are highly flammable. exercise extreme care when working around rotating
Do not weld fuel or lubricant carrying lines or pipes; components. Check the gearbox frequently for
these must be thoroughly cleaned with a non- potential hazards.
flammable solution prior to welding.
Do not, under any circumstances, start an engine
Compliance with all "SMOKING PROHIBITED" or operate the controls when a warning notice is
notices is mandatory. attached. Prior to starting the engine and operating
Loose, damaged or otherwise leaking oil, fuel or the gearbox, ensure that no work is in progress
coolant lines and pipes may lead to overheating within the immediate vicinity.
and/or fire.
Do not bend or strike high-pressure lines. Do not
install distorted or damaged lines or pipes. Do not
replace steel pipes with copper tubing.
Flexible hoses must not be damaged by mechanical
influence, they have to be checked monthly for
cracks and damage. Open fire, acid or etching
liquids have to be kept away from flexible hoses.
Do not allow used components, dirt or foreign
materials to accumulate on, or around, the engine
and gearbox. Overheating or fire could result.
It is essential to ensure that wiring is maintained in
good condition, correctly routed and secured, at all
times. All cables must be checked at regular
intervals for wear and damage. Loose, disconnected
and unnecessary cables must be removed.
All cables must have the specified cross-section
and, if necessary, be protected by fuses. Use of
cables of smaller than specified cross-section and
bypass fuses is forbidden.

4
 2.0 Installation and Alignment
2.1 Lifting Equipment
The gear dry weight (without oil but with special
accessories) is stamped onto the name plate.
The lifting rig must be attached to the lifting eyes
provided by means of shackles.
Under no circumstances must lifting equipment
be attached to shaft ends, pipe work or other
externally-mounted equipment. The lifting
equipment must be secured against tilting.
2.2 Alignment
A basic prerequisite for trouble free operation of a
propulsion plant is careful alignment of engine and
gearbox to the propeller shaft. Accurate alignment to
the engine is also necessary for flexible couplings,
since every alignment error has a disadvantageous
effect on the service life of the driving elements or
accessories. Only high flexible couplings must be
used.
On request, REINTJES will supply all data required
for alignment calculation (such as temperature
expansion curve, mass and stiffness distribution of
the gearbox output shaft and allowable bearing
loads).
If the customer or shipyard is in possession of an
alignment calculation for the complete propulsion
plant, then plant alignment must be completed in
accordance with such calculation. A copy of the
alignment calculation should, however, be submitted
to REINTJES for information.
2.3 Gearbox Installation and Alignment
During gearbox installation it is essential to ensure
that sufficient free space provided for disassembly of
housings, shafts, etc during later maintenance. The
installation, or foundation, drawing includes all nec-
essary gearbox mounting face dimensions.
The gearbox has to be installed onto an adequate
strengthened foundation so that no housing
distortion can occur. Under no circumstances must
the cylindrical pins, located in the bolted-on gearbox
mounting brackets, be removed when installing the
gearbox on the foundation. These cylindrical pins are
necessary for thrust-transmission and fixation.
If bolt-mounted foundation supports are not included
in the REINTJES scope of supply they must, in all
cases, fixed for thrust-transmission.
In the case of resilient mounting systems the natural
frequencies of the mounting elements must be
calculated. To ensure provision of the desired
insulation efficiency it is essential to ensure that the
mounting element natural frequency does not match
any of the propulsion plant excitation frequencies.
5
In cases where the propeller thrust is to be
accommodated by an integrated thrust bearing,
the mounting elements must also be capable of
absorbing propeller thrust.
Deviations specific to your application must be
confirmed in consultation with the factory.
For propulsion plant alignment, it is mandatory
that the vessel be afloat with absolutely
no-ground contact with the sea bed.
Alignment of the gear output shaft-to-propeller
shaftline connection, the engine to the gear input
shaft and the auxiliary units to the additional gearbox
(PTa) shafts must be made in compliance with
manufacturer's instructions.
Vertical alignment of gearbox to propeller or
intermediate shaft is effected by alignment screws
located in the gearbox seating. For horizontal
alignment we recommend to fix alignment screws
on the foundation.
2.4 Connection to Engine
Engine power transmission from the engine to the
gearbox must be via a torsionally flexible coupling.
Based on our experience we recommend that, when
selecting a torsionally flexible coupling for the
propulsion plant, the torsional flexible factor chosen
be such as to ensure that the resonance speed, of
the 1. grade vibrational form exited by the main
rotational harmonics of the engine, is so far below
the lowest specified operational speed that it is only
transgressed during engine start-up and shutdown.
Alternatively care must be taken to ensure that,
within reasonably acceptable limits, the plant
operating range be kept free of torsionally-critical
speeds.
Selection of the flexible coupling is generally made
by the engine manufacturer. The gearbox data
required for torsional vibration calculation is supplied
by REINTJES together with the associated
order- referenced torsional vibration diagram. If the
coupling is specified by the engine manufacturer or
the shipyard, and is supplied assembled with the
gearbox then REINTJES cannot accept responsibility
for the suitability or durability of the flexible coupling.
Compliance with the appropriate instructions is
mandatory for assembly/dismantling of the coupling
flange (hub).
The propulsion engine is normally resiliently
mounted; the gearbox may be rigidly or resiliently
mounted onto the foundation.
The torsionally flexible coupling used must also be
capable of accommodating the axial misalignment
between the engine and gearbox shafts at the
specified operating speeds.
Referenced to the gearbox, the flexibility of the
resilient engine mounts must be such as to allow
engine-to-gearbox alignment accuracy which
ensures that there is no possibility of appreciable
reactive forces at the bearings of the connected
gearbox shafts when operating temperatures prevail.
2.5 Connection to Propeller Shaftline
(only for WAF/LAF 542 - 562)
The gear output shaft can be connected to the
flange of the propeller shaft either by means of
through bolts (frictionally engaged) or by means of
fitting bolts (form-fit).
The torque of the through bolts are to be taken
from the assembly drawing. Here either commercial
hexagon nuts of the proper thickness, to be locked
with sealant, or hexagon nuts with a metallic clamp,
can be used.
The torque of the fitting bolts correspond to the
normal table values. Here hexagon nuts with a
metallic clamp can be used.
The foundation bolts must comply with
application- specific requirements and be
tightened to the specified torque.
2.6 Propeller Shaftline Check
Radial and axial run-out
A prerequisite for correct propeller shaftline-to-
gearbox connection is that the propeller and/or
intermediate shaft does not "sag" and is in the
operational position.
Radial and axial run-out must not
exceed 0.05 mm.
Radial and Angular Misalignment
For these checks the coupling flange centre-ring
recesses must be disengaged. Secure the dial gauge
carrier to the gear flange so that the stylus of one
gauge is in radial contact with the periphery of the
blocked propeller, or intermediate shaft flange and
that of the 2nd gauge is in axial contact with the
flange face.
With the plant at operating temperature and under
.J
full- load operating conditions, the maximum
permissible deviations of both flanges towards each
other are as follows:
Radial misalignment 0.05 mm
(centreline run-out 0.025 mm)
Angular misalignment 0.05 mm, referenced
to 300 mm flange diameter.
2.7 Seat Chocks and Foundation Bolts
Seat Chocks
Rectangular seat chocks must be used only.
Round discs or shim plates arranged one upon
the other are not permissible.
Seat chocks must be adequately dimensioned and
closely fitted. They are to be made in accordance
with the rules of the classification societies.
Fitting Bolts
The fitting bolts used must be of tensile strength 8.8
in accordance with ISO 898. The fitting bolt bores
are predrilled.
Through Bolts
Through bolts must be of the same tensile strength
as the fitting bolts.
1
 2.8 Installation of Gearbox with 2.9 Alignment Check
Longitudinal Mounting Arrangement On completion of alignment and after the engine and
On completion of alignment, the gear must be gearbox foundation bolts have been finally tightened
attached to the foundation in such a manner that it is to specified torque, a check of the mating accuracy
, 1 secured against displacement and that the propeller of both gearbox flanges is recommended whereby
thrust is transmitted and led into the foundation. the flange securing screws must be removed.
We accept no claims under warranty arising from
exceeding alignment tolerances of both gearbox
Foundation with Steel Seat Chocks
connecting flanges.
There are various combination possibilities which
may be used for the attachment of gearboxes with
side mounting faces (longitudinal foundation):
1. Seat chocks with fitting screws and collision
chocks.
2. Seat chocks with fitting screws, without collision
chocks.
3. Seat chocks with collision chocks and foundation
screws constructed as through screws.

Foundation with Cast Resin

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

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

7
3.0 Function and Operation

3.1 General Information In standard execution the gearbox is equipped with

The gearboxes of range WAF / LAF 542 to 572 are
vertically offset gearboxes with built-in, hydraulically
operated disc clutches.
The types WAF are reverse-reduction gears with
opposite or identical sense of rotation of input-
and output shaft.
The types LAF are reduction gears with one clutch
only on the input shaft (counter rotation) or
intermediate shaft (identical rotation).
The gearbox reduction ratios are identical for AHEAD
and ASTERN propulsion, the transmission torque is
thus the same for both output directions of rotation.
Gearbox control can be effected from either the
engine room or the control room.
a mechanically actuated control valve. Alternatively
we supply an electrically or pneumatically actuated
control valve.
The service life of the gearbox depends upon the
correct completion of the recommended operating
and maintenance services and the use of
recommended lubricants.
3.2 Name Plate Arrangement
The name plate is attached to the gear housing.
For parts ordering or other inquiries in respect of
your gearbox, the following information is required
from the name plate:
Gearbox No. _

Type
Input power _
Input speed _

control valve

pressure build-up valve

heat exchanger

input shaft

clutch for
opposite J
rotation

intermediate
shaft
oil filter

oil pump

wheel output shaft

8
3.3 Hydraulic System
The hydraulic system is comprised of a geartype
pump, an oil filter, heat exchanger, pressure build-up
valve, control valve, pressure oil system and
lubrication oil system.
Oil supplied by the pump is filtered and cooled in
order to keep the oil temperature from rising above
the normal operating temperature.
The heat exchanger consists of a tube bundle inside
a mantle. The oil flushes around the tube bundle, the
cooling water flows through the tube bundle. The
cooling water connections can be used for inlet,
outlet resp.
WAF gearboxes can be supplied without heat
exchanger for jacket water cooling (WAF-MKK).
The oil pressure is regulated to operation pressure
by the pressure build-up valve.
The pressure gauge on the gearbox indicates the
operating pressure. When the engine is running at
full speed, the clutch engaged and the gearbox at
normal operating temperature, this pressure should
be within the green area on the gauge.
The normal operating pressure is approx. 22 bar
(2200 kPa or 318 psi).
Please pay attention to the detailed description in
the section 3.5 Pressure Build-up Valve as well as
section 4.5 Maintenance stage 2
(Operating pressure check).

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9
3.4 Gearbox Actuation
The complete shift unit for gearbox control is
mounted onto the gearbox housing. The unit
consists of the pressure build-up valve and the
control valve with NG 10 hole pattern, so that as an
option a mechanically, electrically or pneumatically
operated control valve can be screwed on.
The control valve can be easily replaced after
releasing 4 screws and the actuating connections.
The bore in the lever is for an 8 mm angle joint.
There are four threaded M 6 x 12 bore holes (hole
pattern 54 x 40 mm) on the upper side of the valve
body for fastening the brace.
The switching angle from NEUTRAL to AHEAD or
ASTERN is 45 0 in each case with +/_5 0 tolerance. A
dead stop in the valve prevents switching through
beyond the switching position (45 0 + 50).

Control valve, mechanical + ...

The mechanically actuated control valve is designed
as a rotary piston valve. It is screwed in place
with 4 cylinder head screws M 6 x 55 with 5 + 1 Nm
tightening torque.
A higher tightening torque can lead to distortion
of the valve body.
The standard lever length is 65 mm. Lever lengths of
50 and 46.9 mm have been pre-punched and can be
drilled if required.
The lever can be placed either vertically or
horizontally on the control piston The lever is
secured on the control piston square with a washer
and an M 10 x 20 hexagonal screw.

In the STOP position (NEUTRAL), the operating pres-

Note:
The lever screw must not be tightened against the
dead stop (A) of the piston valve as this can lead to
damage in the valve.
When screwing tight, hold lever.
sure is approx. 1.5 bar, so that a contact for alarm
suppression can be tapped over the built-in limit
switch (cf. Section 3.5 as well).
Signs are placed at the end face of the valve body
(riveted in the factory). This marking of the control
position AHEAD/ASTERN corresponds to the lever's
assembly position.
For manual emergency operations the Bowden con-
trol cable joint must be unscrewed before the control
valve can be operated manually with the lever.
Please note the AHEAD marking at the valve.

10
 Control Valve, electrically or
pneumatically actuated
The electrically or pneumatically actuated valves
used are axial slide valves whereby the required
control position is achieved by axial displacement of
a piston.
In the event of pneumatic or electric control
(actuation) failure, the control valve can be actuated
manually.

Emergency Operation
In the event of pneumatic or electric control
(actuation) failure, the control valve can be displaced
manually by means of the manual emergency
control.
For electric control valves, there are different manual
actuation possible depending on function and
design.
A) Reverse reduction gearbox with clutch
engagement AHEAD - STOP - ASTERN,
4/3 way valve, STOP position spring returned
(without detent):
- The pin at the solenoid end cap is pushed
inwards by hand and locked in this position by
insertion of a locking pin into the transverse bore
in the end cap.
- The mushroom-like button at the solenoid end
cap is pushed inwards by hand and locked in this
position by a bracket.
- The end cap (location handle) is pushed inwards
by hand and turned radial for fixation.
To disengage release fixed position, the valve spring
will push the piston back into STOP (NEUTRAL)
position.
B) Reduction gearbox with clutch engagement ON /
OFF,
4/2 way valve, with detent (without return spring):
- The pin at the solenoid end cap is pushed
inwards by hand but is not locked in position,
the valve is going to secure itself.
Before a manual control is carried out please check
carefully the reason for this and ensure that faulty
operation is impossible.

Note:
The electric valve should not be treated with
de-greasant and washed with water afterwards.
Use a dry cloth for cleaning the control valve.

11
3.5 Pressure Build-up Valve
The pressure build-up valve is designed as a
hydraulic block and bolt-mounted directly to the
gear housing. The top side of the valve incorporates
an NG 10 hole pattern for connection of the control
valve. Overflow oil from the pressure build-up valve
is lead into the gear case to lubricate and/or cool the
clutch discs, bearings and the gear meshing.
The pressure line and clutch control line connections
as well as the pressure measuring connections for
operating pressure and pressure in the control lines
are all located at the side of the pressure build-up
valve.
The pressure build-up valve is a directly controlled,
hydraulically actuated pressure limiting valve.
Pressure limitation is effected by means of a
spring-loaded piston.
The pressure build-up function is initiated via the
actuating piston. With the clutch engaged, the
actuating piston is supplied with control oil via
the integrated shuttle valve. A screwed-in nozzle
controls the time- referenced pressure-build-up
progression. In this procedure, the control oil passes
through a plug-in sinter filter.
After reaching the first pressure stage (approx. 7 bar)
the clutch pressure rises rapidly to operating
pressure. The oil viscosity and differing delivery
rates of the gear oil pump, due to varying engine
speeds, have only a minimal influence on the max.
operating pressure.
With the engine at full-load speed, gearbox at
normal operating temperature and the clutch
engaged, the max. operating pressure is
approx. 22 bar.
The operating pressure is pre-set at the factory and
cannot be adjusted.
With the clutch disengaged (control valve in the
NEUTRAL position) the pressure in the hydraulic sys-
tem is equal to the initial pressure pre-set at the
pressure build-up valve. This pressure can be
between 1.5 and 3.0 bar and is also only slightly
influenced by oil viscosity and gearbox oil pump
delivery rate.
The initial pressure is pre-set at the factory to
approx. 1.5 bar and determines the pressure
build-up time.
The sinter filter, located before the nozzle, must be
replaced at the specified maintenance intervals.
12
Automation and Supervision
With the clutch disengaged (control valve in the
NEUTRAL position) the operating pressure is
between 1.5 and 3.0 bar. If pressure alarms are
installed to supervise the operating pressure (22 bar
with clutch engaged) then such units must be
suppressed when the clutch is disengaged.
During propulsion with the electrically-operated
trolling valve the operating conditions are
different so the above- mentioned pressures
are not applicable.
Pay attention to the supplementary descriptions
when the gearbox is operated using the electrical
trolling valve.
Modification of Pressure Build-up Time
The requirements for smooth and rapid clutch
engagement are inherently contrary to each other.
Reduction of the engaging time automatically leads
to "hard" engagement and vice versa. For this
reason it is only possible - as a function of the
complete propulsion plant - to select the best
possible compromise between smooth and rapid
engagement.
During factory adjustment of the pressure build-up
period more emphasis is placed on smooth rather
than rapid engagement. As a result a smooth but rel-
atively rapid engagement of the disc clutch is
achieved for the majority of applications. This setting
is also suitable for the operation with the trolling
propulsion device.
Where the customer requires a short engaging time,
the necessary high initial pressure setting is not
suitable for trolling propulsion mode.
Please contact the REINTJES service department if
alterations to the engaging time / initial pressure
setting become necessary.
 3.6 Supervision Parameters

Version for 22 bar rated pressure

Supervision Operating oil pressure Operating oil temperature

Function

Normal operation
Specified 22 bar 1) up to 60° C normal
Clutch engaged

1,5 - 3 bar 2)
Clutch disengaged

Alarm 17 bar J, 3) 70° C i

Supervision
Standard Pressure gauge
0- 40 bar

Option Pressure switch 'I Thermometer

Temperatur switch

Remarks
1) at 30 - 60°C operating oil temperature
21 with control valve disengaged (NEUTRAL position)
3) 10 sec time delay to be provided
'I in NEUTRAL position deactivate alarm

Filter contamination
measuring point A43
alarm ~ p 5,0 bar i
supervision mechanical (visual alarm)

(Option and for trolling propulsion device

supervision electrical for audible alarm)

I 13
3.7 Sectional Drawing WAF 542 - 572

R 119 K 30

Pta K21 \

E 19

-----
P1 _ _ _

iii
1'1
:ll iii

I
I
14 j
I
 3.8 Function of Series WAF I LAF
Engine power is transmitted to the input shaft W1
via the engine-to-gearbox coupling. When the input
shaft is rotating, the oil pump provides the
pressurised oil for lubrication and clutch operation.
The disengaged disc clutch will be supplied with
lubrication oil. Shearing of cooling oil flowing to the
outside between the friction surfaces of the clutch
discs results in an idling torque.
Note for LAF gearboxes:
At disengaged clutch the secondary parts may rotate
(output shaft, PTa), provided the idling torque is
higher than the initial friction torque of the driven
parts.
The idling torque depends on the present operating
conditions.
Path of Drive at Counter Rotation
Input shaft W1 - clutch housing K15 - clutch
discs K23 and K22 - carrier K30 - pinion shaft R1
- wheel R2- output shaft P1 .
Path of Drive at Identical Rotation
Input shaft W1 - clutch housing K15 - clutch
housing K16 (at intermediate shaft W17) - clutch
discs K23 and K22 - carrier K30 - pinion shaft R119
- wheel R2 - output shaft P1.
When disengaging into the STOP position the clutch
will be pressure released and the oil is drained into
the sump. The annular piston K17 is held in position
by the return springs W164. The clutch is now
disengaged.
3.9 Recommended Lubricants
The oil companies are responsible for determination
of the oil types stated in the lubrication chart.
REINTJES is not liable for correctness of these data
nor for any amendments occuring.
REINTJES does not accept responsibility for any
damages due to use of unsuitable oils.
Important
For gearboxes with trolling propulsion system or
jacket water cooling (operating temperatures ~ 70°C
/ ~158°F) the use of lubricants certified in REINTJES
lubrication charts BV2060 is absolutely necessary.
3.10 Initial Operation
Oil Filling
Prior to shipment, the marine gear is preserved
internally. In the case units have been hermetically
sealed, the sealing plug must be removed and the
venting filter (supplied loose) must be installed. The
preservation oil must be drained, minor oil residues
will mix with the service oil.
The amount of oil required is stamped into the name
plate. Fill oil as specified into the marine gear until
the upper mark on the dipstick is reached. The oil
level can only be checked with the plant shut down
and using the dipstick.
After installation check and prior to sea trial a short
test run under limited load must be carried out. As
the hydraulic system will be filled with oil then, the
oil level must be re-checked on the dipstick and if
necessary oil must be filled up.

IMPORTANT
Engaging of the clutch at full speed of the engine
is inadmissible.
The engaging speed range specified in the order
acknowledgement has to be observed.
Any increase intended afterwards must be
approved by REINTJES.
In the case of propulsion with controllable pitch
propellers, clutch engaging is only permissible with
the propeller at zero pitch.

15
Installation Check 3.12 Engagement Recommendations
In the course of this last check prior to initial The gearbox control is principally factory set at idling
operation, it is essential to ensure that all necessary speed. The maximum engaging speed is stated in
connections have been made as specified. All nec- the order acknowledgement.
essary data must be recorded on the "Alignment
The engagement procedures described in the
Certificate" which must be signed.
following are important for safe control and
Having confirmed that the gearbox is in an economical operation of the complete propulsion
operationally safe condition and that the propulsion plant.
plant is ready for service, initial operation may be
done.
Engaging
On completion of the test-run the propulsion plant
alignment should be checked and the foundation If the control valve is set to NEUTRAL and the
bolts must be checked for tight fit. propeller shaft stationary or turning only very slowly:
Set engine to engaging speed, engage the desired
propulsion mode and remain in this status for
Use of the Gearbox within the European Union
approx. 3 seconds (pressure build-up in the clutch).
In case the operation has to comply with the safety
Then increase engine revolutions to the desired
regulations stipulated by the European Union, the
propulsion speed.
manufacturer of the complete plant will be
responsible for the CE-certification.
Propulsion Mode Reversal at Low Speed
3.11 Operating Instructions Set engine to engaging speed and disengage
gearbox into STOP position, and wait for
Safety and maintenance are prerequisites for
approx. 2 seconds, reverse the propulsion mode
trouble-free operation, maximum performance and
and remain at that status for approx. 3 seconds
a long service life.
(pressure build-up in the clutch), before increasing
Safety is, initially, an abstract definition and can engine revolutions to the desired propulsion speed.
not, in all cases, be defined by regulations. The nec-
essary safety measures can normally be
determined by experience and intelligence. Propulsion Mode Reversal at High Ship's Speed
Be alert at all times.
Reduce engine speed to engaging speed with
Observe possible danger sources.
gearbox clutch engaged to utilise engine braking
Take all necessary precautions.
effect at the propeller.
Safety is EVERYBODY'S business.
Only when the engine speed has dropped
This Operating Manual includes descriptions of
to 1.2 x the engaging speed, disengage the gearbox
maintenance services which have to be completed
into STOP position, and wait for 1 to 2 seconds.
periodically. Familiarise yourself with the
"Maintenance" chapter. Now reverse the propulsion mode and remain at that
status for approx. 3 seconds (pressure build-up in
Periodic supervision and registration of measured
the clutch) before increasing engine revolutions to
parameters provides a duty profile for the engine and
the desired propulsion speed.
gearbox. If certain conditions change then a
changed display may indicate a potential problem.
The necessary repairs can be laid down before an
actual failure occurs with resultant non-scheduled
down time.

16
 Emergency Manoeuvre (Crash-Stop)
It must be noted that propulsion mode reversal at
high engine speed does not increase safety.
A reduction of the STOP distance cannot be
achieved, or at best only to a minimal extent. On
the other hand the gearbox and complete propulsion
plant are subjected to extremely heavy loads.
Frequent crash-stop manoeuvres lead to an
increased wear of the propulsion plant.
j direction and thus ensures the gearbox lubrication
Note:
During propulsion with the electrically-operated
trolling valve the operating conditions are
different.
Pay attention to the supplementary descriptions
when the gearbox is engaged for trolling propulsion
mode.
3.13 Trailing Operation, Engine STOP
and Propeller Rotating
This condition covers all operating conditions in
which the propulsion plant is shut down and the
propeller, the shaftline and the gearbox shafts
are caused to rotate by entrained water.
Restricted Trailing Operation
With the standard gearbox without an additional
trailing oil pump, this is possible without any special
precautions.
Should this condition last longer than 12 hours all
gearbox lubrication points must be lubricated for at
least 5 minutes. This can be achieved by starting the
propulsion engine or by activating the electric
stand-by pump.
If the above-mentioned short-term lubrication is not
possible, the propeller shaft must be locked.
17
Unrestricted Trailing Operation
In this case the gearbox must be equipped with a
trailing oil pump.
The trailing oil pump is mounted at (or in) the
gearbox housing, depending on the operating
conditions and gearbox version. The trailing oil
pump is driven by the gearbox output shaft.
Irrespective of the direction of rotation, this pump
always forces oil into the system in the same
oil supply.
Another possibility is the installation of an electric
pump to supply the gearbox lubrication oil system.
3.14 Emergency Operation
In the event of pressure oil supply failure, emergency
operation is possible in that only one clutch can be
tightened mechanically.
It is imperative to note that only the AHEAD clutch
must be tightened mechanically.
Firstly the engine must be stopped and secured
against unintentional starting.
Secure the propeller shaft and gearbox output shaft
against unintentional turning.
Determine which clutch is to be engaged:
for gearboxes with AHEAD opposite sense of
rotation the clutch is located on the input shaft
and with AHEAD identical sense of rotation on the
intermediate shaft.
Remove the associated cover.
After removing the locking wire, tighten the screws
K8 evenly and diagonally. The disc pack is thus
compressed and the clutch is frictionally engaged.
Set the control valve to the NEUTRAL position and,
for safety reasons, do not move from that position.
The propeller shaft will now turn immediately the
engine is started, the propeller direction of rotation
cannot be reversed at the gearbox and in order to
stop the propeller the engine must be shut down.

Note:
Extreme care must be exercised during emergency
operation with the main clutch; operation must be at
the lowest possible engine speed (below 70% of
rated speed). With the emergency screws K8 in
service, transmission of maximum torque is not
permissible.
If emergency operation is no longer required, the
screws K8 must be returned to their original setting
and wire-locked.
On arrival in harbour the clutch discs must be
checked for damage and the screws K8 must
be replaced. In the case of exceptionally hard
emergency service (loss of oil pressure) the gearbox
should be disassembled and all bearings and gear
components thoroughly inspected.
18
4.0 Maintenance
Operational safety, reliability and low maintenance
costs can only be achieved by maintenance and
care in compliance with our instructions.
Furthermore only trained personnel, correct tools,
original spare parts and lubricants in accordance
with our recommendation should be employed.
Filter elements and waste oil must be disposed
of as recyclable material or special waste.
If required, our Service Department is available at all
times to provide advice and assistance.
4.1 Maintenance Recommendations
Has the "Function and Operation" chapter been read
and understood?
Operator alertness provides the best protection
against possible dangers.
The operator must comply with safety instructions
and be familiar with all precautionary measures.
Run a maintenance log book. Regular registration of
recorded data can provide indication of internal
changes. Rectify minor faults before they can
develop into major repairs.
Keep the gearbox clean and dry at all times, this
facilitates early recognition of any possible leaks
thus preventing subsequent extensive damage.
As a matter of principle, never use chemical deter-
gents to clean rubber or synthetic components.
Wipe with a dry cloth only.
1
J
 4.2 Conversion Factors

Approximate Conversion Factors Metric ISO-Thread ~

Multiply by To Get Thread Size Grade 8.8 Standard Torque

mm 0,03937 Inch Metric Nm') Ib ft
inch 25,4 mm M 5 5 + 1 4 + 1
kg 2,2 Ib M 6 9 + 1 7 + 1
lb 0,454 kg M 8 21 + 2 16 + 2
kPa 0,145 psi M10 41 + 4 30 + 3
psi 6,89 kPa M12 71 + 7 52 + 5
psi 0,0689 bar M14 113 + 12 84 + 8
bar 14,5 psi M16 170 + 20 126 + 13
Nm 0,74 Ib ft M18 245 + 25 181 + 18
Ib ft 1,36 Nm M20 350 + 35 259 + 26
Nm 8,9 Ib In M22 470 + 47 348 + 35
Ib in 0,113 Nm M24 600 + 60 444 + 44
Liter 0,26 U.S. Gal. M27 880 + 90 650 +-65
U.S. Gal. 3,79 LIter M30 1190 + 120 880 + 90
U.S. Gal. 0,833 Imp. Gal. M36 2100+210 1550 + 155
Temperature conversions M39 2700 + 270 1990 + 199
°C=(OF-32) : 1,8 M42 3300 + 330 2442 + 244
°F=(OCx1,8) + 32 M45 4100 + 410 3034 + 303
M48 5000 + 500 3700 + 370

4.3 General Torque for Metric Fasteners

Be very careful never to mix metric with other
Metric ISO-Thread 2
(standard) fasteners. Mismatched or incorrect
Thread Size Grade 10.9 Standard Torque
fasteners will cause gearbox damage or malfunction
Metric Nm') Ib ft
and may even result in personal injury.
M 5 7 + 1 5 + 1
Original fasteners removed from the gearbox should
M 6 13 + 1 10 + 1
be saved for re-assembly whenever possible. If new
M 8 30 + 3 22 + 2
fasteners are needed, they must be of the same size
M 10 60 + 6 44 + 4
and grade as the ones that are being replaced.
M12 104 + 10 77 + 8
The material strength identification is usually shown M14 165 + 16 122 + 12
on the bolt head by numbers (8.8, 10.9 etc.). The M 16 250 + 25 185 + 19
following chart. gives general torque for bolts and M18 350 + 35 259 + 26
nuts with Grade 8.8 and 10.9.
M20 490 + 50 363 + 36
M22 670 + 67 496 + 50
M24 850 + 85 630 + 63
M27 1250 + 125 925 + 93
M30 1700 + 170 1260 + 126
M36 3000 + 300 2210 + 221
M39 3800 + 380 2800 + 280
M42 4700 + 470 3478 + 348
M45 5800 + 580 4292 + 429
M48 7000 + 700 5180 + 518

1) Newton Meter (Nm) is approximately the same

as 0,1 mkg.
2) ISO-Internationale Standard Organization.

] 19
4.4 Maintenance Schedule
The Maintenance Schedule summarises the
maintenance services which are sub-divided into
Maintenance Stages.
Particularly arduous service conditions may require
modification of the Maintenance Schedule (reduced
intervals).
For gearboxes with jacket water cooling
(WAF--MKK) please pay attention to different
information in the maintenance schedule.
Maintenance Stage 5
After each operating period of 5000 hours
or 1 year
check threaded connections inc!. foundation,
check connection to engine and propeller and bolts
of intermediate housing,
check heat exchanger for leakage and replace seals,
if necessary,
check control valve actuation,
renew sinter filter in pressure build-up valve.

Maintenance Stage 6
Maintenance Stage 1 General overhaul every 30000 hours
Daily before engine start (WAF--MKK 15000 hours) or 10 years
check oil level check:
shafts for run-out,
bearing seats for damage,
Maintenance Stage 2
carriers,
Daily with engine running
wheel and pinion shaft teeth,
check annular piston,
carrier pins,
operating pressure,
oil distributor,
oil temperature,
pressure gauge,
heat exchanger cooling water temperature,
duplex filter contamination indicator,
visual checks and running noises
replace:
clutch discs
Maintenance Stage 3 rectangular rings, screws and return springs for
After first 200 operating hours annular piston,
O-rings,
change oil,
snap rings,
replace filter element
all clutch housing screws *8,
check threaded connections inc!. foundation,
anti-friction bearings,
check connection to engine and propeller and bolts
thrust bearing screws and springs,
of intermediate housing,
haft seals and bushes,
tighten swivel nuts and banjo bolts of threaded pipe
oil filter element and seals,
connections in case of leakage,
oil pump inspection,
check heat exchanger for leakage.
cover gaskets,
o-rings for control valve / pressure build-up valve,
flexible hoses,
Maintenance Stage 4
After each operating period of 2000 hours clean the complete gearbox.
(WAF--MKK 1200 hours) or 6 months
change oil,
replace filter element
1

20
4.5 Maintenance Task Descriptions
Maintenance Stage 1
Daily before engine start
Oil Level Check

The oil level can only be checked, with the
propulsion plant shut down, at the dipstick.
The oil level must be between the marks on the
dipstick.
If the oil level is low, fill up suitable oil until the level
reaches the upper mark on the dipstick.
Determine and rectify the cause of oil loss.
For filling in the oil screw out the venting filter
marked OEL (OIL).
Maintenance Stage 2
Daily with engine running
Operating Pressure Check
With the engine running and clutch engaged, the
maximum operating pressure is indicated on the
gearbox-mounted pressure gauge.
Oil viscosity, operating temperature and different
delivery rates of the oil pump, due to varying engine
speeds, have only a minor affect on the operating
pressure and the pressure build-up time.
With the clutch disengaged (control valve in
NEUTRAL position) the operating pressure is
approx. 1.5 to 3.0 bar.
With the clutch engaged, gearbox at operating
temperature and engine at full-load speed, the
normal operating pressure is approx. 22 bar.
For normal operating conditions (clutch engaged)
the operating pressure is pre-set and can not be
adjusted.

Note:
During propulsion with the electrically operated
trolling valve the operating conditions are so
different so the above mentioned pressures are
not applicable.
Pay attention to the supplementary descriptions
when the gearbox is engaged for trolling propulsion
mode.

21
 Oil Temperature Check
The normal operating oil temperature after the heat
exchanger will be in the range of approx. 30 - 60°C
(86°-140°F) and can be read off at the thermometer.
If the oil temperature is higher than the normal
operating temperature, determine the possible cause
and initiate the appropriate remedial measures.
In case of gearboxes with jacket water cooling
(WAF--MKK) the normal operating temperature can
reach 80°C (176°F) and rise to 90°C (194°F).
Cooling Water Temperature
Normally the cooling water temperature difference
across the oil heat exchanger should be 3° to 5°C
(5° to 9°F).
An increase of the cooling water temperature
difference indicates contamination of the water side
of the oil heat exchanger or an insufficient cooling
water flow rate.
The data for the oil cooler do not apply to gearboxes
with jacket water cooling (MKK).
Oil Filter Contamination Indicator
Experience has shown that the contamination
indicator must be closely observed during the first
100 operating hours.
With high viscosity or cold oil a high pressure differ-
ence may be effective during the warm-up phase.
This can lead to a temporary, false alarm indication.
Check the visual alarm indication by pressing down
the red pin. If the pin is again ejected immediately,
the filter element is contaminated.
If the NC contact of the transmitter opens and a
prolonged electrical audio alarm signal is initiated,
the filter element is contaminated.
In both cases the change over lever must be
operated to direct the oil flow through the alternative
filter bowl.
The filter element must be replaced as described
under "Maintenance Stage 4".
Permanent operation with a contaminated filter
element in "by-pass mode" is not permitted!
22
Visual check and running noise.
Check the gear assembly for leaks and insecure
parts. Ensure that only normal running noises are
audible.
Changes may indicate possible faults or
malfunctions which can include, among others,
misalignment between engine-gear-propeller shaft.
Investigate all malfunctions.
Where possible, rectify all faults immediately or
after shutting down the engine.
Be alert!
Beware of danger!
Maintenance Stage 3
After first 200 operating hours
This oil change with changing filter element is to
be firstly carried out on all new or completely
overhauled gearboxes.
All following oil changes are to be completed at the
intervals specified for Maintenance Stage 4.
Oil Change
Change the oil when engine is shut down and the oil
is warm (cooled down from operating temperature).
Warning
Hot oil or components can cause injury.
Avoid skin contact with hot oil and components.
Remove the oil drain plug and allow oil to drain
into a suitable container or pump the oil from the
gearbox into the container. Clean the drain plug and
reinstall it with a new sealing ring. Tighten plug to
specified torque.
Refill a recommended oil into the gearbox until the
oil level reaches the upper mark on the dipstick. The
oil capacity is indicated on the gearbox name plate.
The venting filter should be cleaned at every oil
change.
Replace the oil filter elements.
On completion of all maintenance tasks, start the
engine and run for 5 to 10 min. Shut down the
engine and recheck the oil level.
The level must remain at the upper mark on the -)
dipstick. Do not overfill the gearbox.
 Compliance with the oil change intervals specified in
the Maintenance Schedule is mandatory; especially
the first, (or initial) oil change. Prolongation of the oil
change intervals is only permissible when regular
and reliable analyses are carried out.
In addition to ageing checks the lubricating
capability must be checked.
The above mentioned intervals relies on a operating
temperature after the heat exchanger of approx.
60°C (140°F). If these temperatures are exceeded,
the oil change intervals are reduced and must be
determined in consultation with REINTJES.
In case of WAF gearboxes with jacket water cooling
(WAF--MKK) the normal operating temperature can
reach 80°C (176°F) and rise to 90°C (194°F).
Independent of the oil change intervals we
recommend to check the flexible hoses monthly
for cracks and damage.
1
23
Maintenance Stage 4
After each operating period of 2000 hours
(WAF--MKK 1200 hours) or 6 months
This maintenance stage determine the standard
intervals of oil change and oil filter element
replacement. Adhering to these intervals the oil
sludge must be checked for metallic residues.
Filter Element Replacement
When a signal is received, the filter has to be
changed over to the other filter element. Operate
and hold pressure equalising lever located in the
changeover lever. 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, maximum back out against pin
(safety stop).
Unscrew filter bowl anticlockwise and clean with a
suitable medium.
Pull down filter element by slight movements to and
fro, replace element.
Before assembling the element check a-rings for
damage. Replace, if necessary.
Push element onto the seat (with a-ring).
Firmly screw in the bowl (with a-ring).
Important
Care must be taken to ensure that the filter bowl,
after it has been tightened up, is slackened off by
1/8 up to 1/2 a turn.
Operate only the pressure equalising lever long
enough until the oil emerge bubble-free from the
vent bore. Tighten vent screw.
Check filter for leaks by operating the pressure
equalising lever once again.
Maintenance Stage 5
After each operating period of 5000 hours
or 1 year
Threaded Connections
The screw tightening torque should be checked with
the gear cold.
Particular attention must be paid to the following
connections:
Engine - flexible coupling - gearbox,
Gearbox output shaft flange - propeller shaft,
Gearbox mountings - foundation,
Swivel nuts and banjo bolts of threaded pipe
connections.
Check the rubber elements of the flexible coupling
for porosity, cracking or other signs of damage.
Check the heat exchanger for leakage and replace
the seals, if necessary.
The sinter filter in the pressure build-up valve
must be replaced.
Unscrew plug screw V 424 in the pressure build-up
valve V 100, remove sinter filter V351 with spring.
Check filter plate V 425 for contamination, if
necessary clean it and re-insert.
Insert a new sinter filter element with spring, and
tighten it using plug screw V 424 with new sealing
ring V 422C.
V424 V422C V351 V425 V100
24
Control valve actuation
The mechanical control valve engages AHEAD -
NEUTRAL - ASTERN in each case with
45° ±5° tolerance.
Checking of the remote control (cable control) is to
be carried out in accordance with manufacturer's
instructions.
We recommend using a well dimensioned,
mechanical ship wiring cable (Bowden cable),
running with a minimum of play.
Maintenance Stage 6
General Overhaul every 30000 hours
(WAF--MKK 15000 hours) or 10 years
The mentioned 15000 operating hours are valid only
for operating temperatures up to Boac (176°F).
Temperatures above BO° up to 90 aC (176° to 194°F)
will reduce the interval to 10000 operating hours.
Matching to the engine maintenance intervals is per-
missible provided that the operating hours specified
are not excessively exceeded.
Part Checks (and replacement as necessary):
shafts for run-out,
bearing seats for damage,
carriers,
carrier pins for annular piston,
gear and pinion teeth,
oil distributor,
pressure gauge.
Replace:
clutch discs,
rectangular rings, screws and return
springs for annular piston,
O-rings,
snap rings,
all clutch housing screws *8,
anti-friction bearings,
thrust bearing screws and springs,
shaft seals and bushes,
oil filter element and seals,
oil pump inspection,
cover gaskets,
O-rings for control valve and
pressure build-up valve,
flexible hoses.
Thoroughly clean the gear housing, vent filter
and all other parts which are to be reused.
Our Service Department is available at all times, to
answer any questions you may have.
4.6 Completed Maintenance

Gearbox No.
Type

Operating Maintenance Stage Date Initials

hours

25
4.7 Troubleshooting

Disturbance
Probable Cause Remedial Action

1) Gear noise
Idle speed in critical range
Anti-friction bearing damaged
(possibility of metallic residues in filter)
Hydraulic noise, pump sucks in air
Raise idle speed
Check gear security and alignment,
inspect gear (replace bearings)
see Item 2)

2) Pump sucks in air

Oil level in gearbox too low Determine and rectify cause of oil
loss, top-up oil to max. mark
Suction line leaking Tighten threaded connection, or
flange, replace seals or pipe

3) Oil loss
Shaft seals (normal wear) Replace
Pipework Rectify leak
Housing cover Clean mating faces, renew gaskets
Plugs, oil drain plug Tighten, replace sealing ring
Heat exchanger leaking Replace sealings

4) Gear temperature too high

Oil level too high Rectify
Cooling water flow rate too low Adjust to correct rate
Heat exchanger contaminated Clean
Anti-friction bearing damaged Inspect (replace bearings)
(possibility of metallic residues in filter)
Gear overload Reduce input load
Clutch slipping, operating see Item 5)
pressure too low

5) Operating pressure too low, fluctuating 1

Pump sucks in air see Item 2)
Pump drive or pump defective (wear) Repair or replace
Pressure build-up valve blocked Replace
Non-return valve to electric pump defective Clean or replace
Incorrect brand oil Check viscosity, change oil

I
.,
26
 Probable Cause
6) Operating pressure too high
Pressure build-up valve blocked or defective
Oil cold
Incorrect brand oil
7) Clutch slipping
Operating pressure too low
8) Clutch does not engage
Control valve not correctly positioned
9) Clutch does not disengage
Control defective
Discs defective or seized
4.8 Preservation of the Gearbox
Preservation Measures
From outside the gearbox is protected from corro-
sion by adequate packaging for transportation and
the storage period stated in the contract.
All openings of the gearbox are sealed.
For preservation of the inner parts the gearbox is
operated with preservation oil during the test run.
After the test run BRANOROL (VCI preservation oil)
is filled into the gearbox. This is indicated by the
plate on the gearbox:
Gearbox preserved with BRANOROL.
For initial operation drain off BRANOROL,
fill in oil and screw in venting filter.
The instructions on the plate must be strictly
observed!
Before putting the gearbox into operation, the
preservation oil must be drained (residual quantities
may remain in the gearbox). The gearbox must then
be filled with the indicated quantity of operating oil.
Never clean the interior of the gearbox with water or
other chemicals.
27
1
Remedial Action
Replace
Carry out gear warm-up procedure
Check viscosity, change oil
see Item 5)
Check engagement sequence and position
Check disengagement sequence,
disengage manually
(Check output shaft free movement)
Check emergency operation status,
separate if necessary, Check oil brand
Replace discs and inspect thoroughly
Packaging, Storage, Standstill Periods
The effectiveness of the preservation measures
depends on the packaging and the storage condi-
tions.
Defective packaging and unfavorable storage condi-
tions, e.g. high atmospheric humidity, saliferous air
or extremely changing temperatures etc., will have a
negative effect on the permissible storage period.
On reception the gearbox packaging has to be
checked for transport damages immediately. In the
period after removal of the original packaging and
before initial operation adequate measures have to
be taken to ensure optimum protection of the gear-
box from environmental influences and external
damage.
All openings of the gearbox have to be kept sealed.
Additional anticorrosion measures according to
BV1945 are necessary,
- if the packaging has been damaged or is taken off
several weeks before initial operation,
- if the gearbox is to be stored longer or under less
favorable conditions than stated in the contract or
- if installed gearboxes are to be taken out of
service for a longer period.
REINTJES Customer Service will provide further
information upon request.
5.0 Disassembly and Assembly
5.1 General Information
Dismantling may be carried out by trained
personnel only.
Please pay attention to the information contained in
Section 1 of this operating manual.
All safety regulations must be complied with.
Please make sure that the engine cannot be started
accidentally. All cooling water valves must be closed.
The oil must be drained off before the gearbox is
disassembled.
All covers must be marked before being removed so
that they can be replaced correctly. The lubrication
oil bore holes must also be considered, all parts
must be marked before being removed (e.g. pinion
shaft carrier, Section 5.5 lubrication of discs).
5.1.1 Seals
Some parts have been fitted with a-rings, e.g.
the control valve.
Flat gaskets have been used for the inspection
covers.
All other single parts are assembled with a liquid
surface sealant (anaerobic sealant) having almost no
influence on the dimensions.
These sealing areas must be cleaned and dried
before assembly. The sealing material must be
applied on one part in the form of a continuous band
(2-3 mm - 0.1") along the centre line and inside past
the drill holes. On the other part the activator must
be applied. The parts must be tightened within five
minutes with the correct tightening torque.
5.1.2 Screws
All screws connecting parts with torque
transmission,
e.g. input shaft - clutch housing or
output shaft - counter flange on propeller side,
must not be reused after disassembly. They are
marked '8 in the spare parts lists.
28
5.2 Screw Locking
For assembly use screws with screw-locking glue.
The glue is applied either as a green coating on the
screws, or medium-strength screw glue must be
used.
Prior to using the new screws the threaded holes
have to be freed from glue remains by using the
corresponding tap.
Note:
Use always screw-locking, medium-strength metal
glue for locking:
shaft nuts, screws (without green coating), nuts
mounted in the gearbox without securing
elements
all external screws connecting the housing parts
(near bearings)
all screws which are transmitting force to other
parts, e.g.bearing housing
fixing screws for heat exchanger, filter, pump etc.
Example for application of glue
2 threads without glu~
3 threads with glue
Pay attention to the following charts for tightening
torques.
Screws are only sufficiently secured by using glue if
they are tightened with the proper torque (assembly
torque).
After dismantling and when re-assembling these
screws, nuts and shaft nuts have to be free from
glue remains. The threaded holes have to be cleaned
as well.
 5.3 Glued Connection
Input Shaft - Clutch Housing

The contacting surfaces of the connection input shaft -

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

glue

_ . L - _ . _ . _ ._ _ • _ _

'1

I
:I
29
 5.4 Instructions for Hydraulic Assemblyl
Disassembly with Taper 1:30
Instructions for Hydraulic Assembly
Attention
Operations involving pressurized oil involve no
danger provided strict compliance with operating
instructions is observed and correctly-fitting
accessories in perfect condition are used.
Please observe the following instructions:
Prior to service, carefully check the pump, H.P.
pipe and all other accessories. Do not, under any
circumstances, use pump components which
show even the slightest signs of damage or
damaged accessories which are not designed
for pressures of at least 300 MPa (3000 bar).
Make sure that the pump and the high-pressure
pipe are completely filled with oil and that all air
has been expelled from the pump.
- The pipe must not be bent or otherwise
subjected to violent treatment when pressurized.
Mishandling of the pipe can lead to accidents.
- The pressures required for expansion and
force-on must permanently be checked with
pressure gauges.
Ensure that adequate safety precautions are
taken when working with high-pressure hydraulic
systems.
- Oil under extreme pressure can cause injuries.
- Always wear protective goggles.
Oil under pressure must not be allowed to come
into contact with the skin.
Inspection of Individual Components
Prior to assembly of the individual components (e.g.
shaft and gear, shaft and flange) it is necessary to
carefully inspect the taper surfaces. Ensure that
taper surface and oil distribution groove transitions
are free of burrs. Remove all burrs and rectify any
other damage found.
Instructions for epair:
During repair operations, the nature and extent of
the damage may require that shaft concentricity,
taper surface and bearing seating be checked.
Pressurizing Medi and Assembly Preparations
Expansion of the component to be mounted
(gear, flange, etc.) is to be effected using SAE 10
oil (viscosity 32 cST at 40°C).
The oil used for expanding operations must be
absolutely free of contaminants and EP additives.
30
The components to be assembled should be at the
same temperature, Le. wherever possible assembly
should be carried out at ambient temperature.
All taper surfaces are to be thoroughly cleaned with
a degreasing agent and thinly coated with the SAE
10 hydraulic oil used for assembly (viscosity 32 cST
at 40°C).
Force-on Dimension Check
Information for force-on dimension and expansion
pressure will be given by REINTJES service
department on request.
The force-on dimension is stated in mm and
comprised the nominal dimension and a permissible
tolerance, e.g. 13.3 + 1.2 mm.
To determine the force-on dimension push the
component to be mounted (gear, flange, etc.) onto
the shaft.
The first checking dimension, required to establish
the force-on dimension of the component to be
mounted, is calculated from that point at which the
taper faces are in full contact with each other with-
out any pressure applied.
In order to be able to complete further force-on
dimension checks it is now necessary to select an
additional reference point. A reference lip (shoulder)
on the shaft is recommended for this purpose.
Note the checking dimension thus obtained.
Position the assembly jig (hydraulic nut) hand-tight
against the component to be mounted; ensure that
all threaded assembly jig elements are fully engaged
with each other and that the piston of the hydraulic
nut is in its original position.
Connect hydraulic pumps as follows:
pump for expansion pressure to connection "B",
pump for force-on pressure to connection "A",
Pressure Connections
when starting the force-on process
AnnUJ3, plSllln SllIr1lng poSitlDn
For n"....slluh. e
hyll... "tl<: ""I dnUl pl4to
A
...-
Assembly
,
 Expansion and Force-on of Component to be
Installed (Gear, Flange, etc.)
In order to be forced-on, the component to be
installed must first be expanded.
In order to do this oil is forced between the taper
faces until it emerges at the ends of the connection.
The force-on action is achieved by repeatedly
increasing and alternating the expansion and
force-on pressures until the component is forced-on
into its final position ace. to the specified force-on
dimension.
During the force-on procedure the expansion
pressure increase should not be allowed to exceed
100 bar over a 3 minute period; this is necessary to
avoid localized exceeding of the max. permissible
yield point value.
When the component is in its specified position
the expansion pressure at connection "B" must be
relieved to allow the oil film between the taper
surfaces to disperse. The force-on pressure must be
maintained at connection "A" for at least one hour.
Approximately 24 hours should be allowed to pass
before the assembly is subjected to maximum load.
This time delay is necessary to ensure that all
expansion fluid has been expelled from the
component mating faces.
In order to be released, the component to be
removed must first be expanded via connection "B".
In order to achieve this, hydraulic oil is forced slowly
between the component taper faces. Expansion
pressure increases should not exceed 100 bar over
a period of 3 minutes.
Component release is indicated by a rise in pressure
in the hydraulic nut which is indicated at the
pressure gauge of the hydraulic pump assigned
to connection "A".
When the pressure rises in the hydraulic nut, the oil
pump valve to connection "A" must be opened and
the pressure released. The expansion pressure must,
however, be mantained by continuous operation of
the hydraulic pump assigned to connection "B" until
the component is completely released from its
tapered seat.
Attention
The component being removed may be released
suddenly when the pressure at connection "A" is
released to zero, for this reason it is mandatory
that the hydraulic nut (safety stop) be correctly
installed.
If the max. expansion pressure is achieved and the
component to be removed is not released, proceed
as follows:

NOTE Increase expansion pressure at connection "B"

by 10 %.
In this case of components with two connecting
points for expansion pressure one of these must Maintain this pressure for one hour.
be effectively plugged.
In addition, heat the component slowly and
Instruction for Hydraulic Disassembly evenly. (temperature max. 140°C or 284 oF)
Attention Mount an additional puller.
Hydraulically assembled components are under
extremely high pressure and can cause injury
when released. As the component to be removed
can be suddenly released at great force it is
Annul ,,,I.lon d;';pl.ced
mandatory that this part be provided with a stop For max. slroke, see
(hydraulic nut) as a safety measure. hydraulic nut dala plate

B A
In order to remove the subject component (gear,
flange, etc.) from the shaft, the installation / removal
jig (hydraulic nut) and hydraulic pumps must be
assembled in the same positions and manner as
----..
Dis.assembly
used for component assembly.

As a function of the max. force-on dimension, the

annular piston must be forced out of the hydraulic
nut 3-4 mm (see sketch) and, with a force-on
pressure of 100 bar applied at connection "A",
brought into contact with the component to be
removed.

The force-on pressure in the hydraulic nut must then

be released and the hydraulic pump valve to the
hydraulic nut connection "A" must be closed.

31
 5.5 Lubrication of Discs
The discs are lubricated and cooled when clutch is disengaged.
Lubrication and cooling of the discs is effected from inside to
outside through radial bores in pinion and detachable carrier.

The oil flows between the sinusoidal inner discs and outer
discs lined with sintered metal to the outside and is discharged
through clutch housing bores into the gear housing.

Exemplary Arrangement WAF 443 - 47.

Clutch housing

Discs

Carrier

Pinion shaft

Assembly of carrier

The carrier is provided with threaded holes at one side only.

The carrier has to be pushed onto the pinion splined shaft such
that the threaded holes are visible, at front end.

By no means must the lubrication oil bores of carrier and

pinion be misaligned.

1
The lubrication oil bores must radially overlap to guarantee clutch disc lubrication.

32
 5.6 Recommended Maintenance Procedures for Heat Exchangers of BLOKSMA Make

1 Introduction
In order to identify the heat exchanger please check the rating plate for the "BLOKSMA " marking. The rating
plate of the heat exchanger is located on one of the two cams of the oil inlet and/or outlet.

We recommend having spare parts for maintenance work on board. Anodes and sealing rings can be obtained
from the REINTJES service department upon specifying the gearbox number and type.

/.
A_2_92_+H-IH-it-H_++t---+-. _ . -tl-.- .4.292

'/

ATTENTION:

Checks of 2 Anodes and 3 Contamination Control shall be performed only with the propulsion system
shut down and the cooling water pump switched-off.

The gearbox and the heat exchanger shall have cooled down to lukewarm temperature.

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

2.1 Intervals of Anode Checks

1 First inspection After 100 hours of operation
Inspections thereafter Every three months or on occasion of every cleaning

33
 2.2 Visual Inspection

Cooling water circuit Shut inlet and outlet valves

Heat exchanger Drain cooling water

Anodes Screw out anodes and perform visual check

Result: OK Screw anode in hand-tight with new sealing ring

Result: Anode consumed Screw in hand-tight new anode with new sealing ring

Visual check finished - Open cooling water valves

- Switch on cooling water pump

- Vent heat exchanger

- Check anodes for waterproof installation

3 Contamination Control of Tube Bundle

3.1 Construction of Heat Exchanger

schematic drawing
]

1 Tube plate

2 O-rings

3 Fixing plate

4 Shell

5 Tube bundle

Both tube plates are identical:

The outer O-rings seal the corresponding cover,

the inner O-rings seal the shell,
the central groove takes up the 4 fixing plates.

The fixing plates can be fitted at the open end cover or end cover alternatively.

Both covers can be mounted with rotated through 180 (accessibility of anodes).
0

Important

Never mount the covers to the wrong side.

The tube bundle has only one correct mounting position in the shell.
Never mount the tube bundle laterally inverted or twisted.

34
 3.2 Visual Inspection of Tube Bundle

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

Note

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

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

Cooling water circuit Shut inlet and outlet valves

Heat exchanger Drain cooling water

Cooling water connections Screw off, sealing OK?, open end cover freely accessible

Covers Mark position of open end cover and end cover clearly with 1/1 and 2/2

Covers Loosen and screw off covers crosswise

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

In the middle of the open end cover a nylon par-

tition is inserted

Depending on the local installation conditions the

tubes can be inspected and cleaned with a nylon
tube brush

End cover Open end cover

Inspection: OK Continue with 3.5 Assembly of Cover

3.3 Disassembly of Tube Bundle

The tube bundle can be pulled out to either side. In this description the indication of sides A and B analogously
applies to the corresponding side of open end cover and end cover.

Heat exchanger Drain oil, dependent on installation conditions

Tube bundle Mark mounting position and check marking on open end cover side

Open end cover side Take partition from tube bundle

Fixing plates Screw off bolts and nuts, take off fixing plates

1 A - Push in tube plate flush with shell

(or drive it in slightly using a piece of wood)

- Attention: Do not damage edges by hammer blows!)

B - Take off both O-rings

- Push in tube plate flush with shell

(or drive it in slightly using a piece of wood)

35
 A Take off both a-rings

B Push in tube bundle so far as to be able to seize the tube plate from
behind on side A

(A) Pullout tube bundle carefully

Note:
Lift and straighten tube bundle,
take care not to bend the baffles on the tube bundle .'

Clean tube bundle according to the inspection result.

If it has to be cleaned chemically, please ask for detailed information to be sent.

A tube bundle can only be replaced together with the shell.

3.4 Re-assembly of Tube Bundle

Never use the old, dismounted a-rings.

Always fit new O-rings.

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

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

Shell Clean sealing surfaces carefully, check for damages

Apply thin layer of suitable lubricant to sealing surfaces

Tube plate Clean grooves carefully, check for damages

Apply suitable lubricant to grooves

Assemble tube bundle In reverse order of disassembly, pay attention to markings

Positioned a-rings If necessary, apply lubricant to the outside

Fit fixing plates, keep in position with bolts
• Fit partition on open end cover side

36
 3.5 Assembly of Covers

First screw on the side with the fixing plates (example with open end cover).

Open end cover - Clean sealing surfaces, check for damages

- Apply thin layer of suitable lubricant to sealing surfaces

- Fit cover without applying force

- Take out bolts, insert them from the other side,

screw on nuts (with spring washer) hand-tight

- Screw bolts tight crosswise

End cover As above (insert bolts from outside to inside)

Cooling water connections Fit, check for damaged sealings

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

3.6 Temporary Shutdown

If the system has been out of operation for more than two weeks, the water circuit should be drained
and flushed. After that the heat exchanger should be filled with fresh water containing an anti-
corrosion additive.

NOTE:
The type of additives depends on the cooling system.
In case of doubt please contact
BLOKSMA, Holland, Phone: +31 36 549 23 00, Fax: +31 36 549 23 90.

37
Notes and remarks:

38
 6.0 Spare Parts
Technical Data Requesting spare parts

You will find the technical data for your gearbox on When making enquiries and ordering parts, please
the type plate. provide the following information:
The type plate of the gearbox is mounted at the top
part of the gearbox housing.
GEARBOX NO. - e.g.: K80xxx
Copy the data for your gearbox to the type plate
printed here: TYPE - e.g.: WAF 6xx
DRIVE POWER - 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

o 0

SERIAL NO. N~
TYPE YEAR BUILT I I
CHARACTERISTICS I
DIRECTION OF ROTATIO~N;--I-N-PUT-S-ID-E---;==========::::::::I
LOOKING FROM .
PROPELLER TO OUTPUT SIDE I
ENGINE .
REDUCTION I OUTPUT SPEED 11/min
===~
INPUT CAPACITY IkW INPUT SPEED 11fmin
ADMISSIBLE ====~ INm
WEIGHT kg
INPUT TORQUE ====~
OIL QUANTITY IL SAEI ISO VG

o Made in Germany o

~J

I
I
I
39
 H 12
H9 H 10 A1 H 13 v1 H 20 H 16

H 24

A 80

A3
+;:.
o
H7

H 17

E 19

\~ H5

~ 1 (
H 104 H 103 A 298 H 29 H 33 H2 H 85 H 30

0-102-65331
- o....-...i
"\
'-'-'

Piping and External Parts WAF 542 - 562 0-102-65331

Quantity per WAF-Gearbox Quantity per WAF-Gearbox
Item. Item.
No. Designation 542 562 No. Designation 542 562
A 1 Heat exchanger 'S 1 1 H 18 A Reducing fitting 1 1
A 3 Duplex filter 'S 1 1 H 18 B Screwed union 1 1
A 35 Pressure gauge 1 1 H 20 Pipe 1 1
A 54 Thermometer 1 1 H 21 A Screwed union 1 1
A 73 Shut-off valve 1 1 H 21 B Extention 1 1
A 80 Support 1 1 H 22 A Screwed union 1 1
A 298 Oil distributor 1 1 H 22 B ReduCing fitting 1 1
A 301 Connection piece 1 1 H 23 P'Ipe I 1 1
H 24 Screwed union 1 1
E 19 Oil pump ·S 1 1 H 29 Screwed union 1 1
E 23 Dip stick 1 1 H 30 Pipe 1 1
E 107 Venting filter 1 1 H 31 Screwed union 1 1
H 2 Screwed union 1 1 H 32 Pipe 1 1
+:>. H 33 Screwed union
...... H 3 Pipe 1 1 1 1
H 4 A Screwed union 1 1 H 42 Screwed union 1 1
H 4 B Reducing fitting 1 1 H 43 Pipe 1 1
H 5 Screwed union 1 H 44 Screwed union 1 1
1
H 6 Pipe 1 1 H 45 Intermediate piece pressure gauge 1 1
H 7 Screwed union 1 1 H 46 A Support pressure gauge 1 1
H 8 Screwed union 1 1 H 46 B Allen screw 2 2
H 9 Pipe 1 1 H 85 Screwed union 1 1
H 10 Screwed union 1 1 H 90 Pipe 1 1
H 11 Screwed union 1 1 H 103 Pipe 1 1
H 12 Pipe 1 1 H 104 Screwed union 1 1
H 13 Screwed union 1 1 H 128 Pipe 1 1
H 14 A Reducing fitting 1 1
H 14 B Screwed union 1 1 V 1 Control valve ·S 1 1
H 16 Pipe 1 1 V 100 Pressure build-up valve ·S 1 1
H 17 Screwed union 1 1 V 339 Intermediate plate 1 1

'S Service repair kit

 R 33 [j 480 G 16 R 43 E5
E 123 E 244

+:>.
N

\
\
I
I
l R 132 I K1
K 22
K 15
K 59 VI 7
v/1
E 186 E 1017 K 23 KS K 18 VI 179

0-102-64978

- - ---! --:.J ", ~

 -
Input shaft WAF 542 - 562 0-102-64978
Quantity per WAF-Gearbox Quantity per WAF-Gearbox
Item Item
No. Designation 542 562 No. Designation 542 562
E 5 Bearing housing 1 1 K 8 Hexagon screw 8 8
E 7 Cover 1 1 K 8 Locking wire 1 1
E 11 Shaft sealing ring 1 1 K 8 Wire socket 2 2
E 15 Anti-friction bearing 1 1 K 13 Hexagon screw *8 12 12
E 19 Oil pump *S 1 1 K 15 Clutch housing 1 1
E 30 Hexagon screw 12 12 K 17 Annular piston 1 1
E 122 Anti-friction bearing 1 1 K 18 Rectangular ring 1 1
E 123 Anti-friction bearing 1 1 K 22 Innen disc 11 11
E 124 Anti-friction bearing 1 1 K 23 Outer disc 12 12
E 125 Anti-friction bearing 1 1 K 30 Carrier 1 1
E 143 Hexagon screw 4 4 K 59 Cover 1 1
E 186 Allen screw 8 8 K 60 Allen screw 8 8
E 206 Cover 1 1
~ E 244 Hexagon screw 8 8 R 1 Pinion shaft 1 1
w R 3 Fitted disc
E 389 Allen screw 20 20 2 2
E 537 Clamping sleeve 1 1 R 32 Shaft nut 1 1
E 1017 Bearing housing 1 1 R 33 Threaded pin 1 1
R 43 Retaining ring 1 1
G 16 Locking plate 1 1 R 44 Retaining ring 1 1
G 17 Hexagon screw 2 2 R 105 Retaining ring 1 1
G 128 Lubrication pipe 1 1 R 167 Star spring 1 1
G 480 Retaining ring 2 2
W 1 Input shaft 1 1
K 1 Clutch support 1 1 W 7 Retaining ring 1 1
K 2 Retaining ring 1 1 W 12 Bush 1 1
K 5 Bolt 12 12 W 166 Hexagon screw *8 24 24
K 6 Spring 12 12 W 169 Carrier pin 4 4
K 7 Rectangular ring 1 1 W 179 Non-return valve 1 1

's Service repair set

'8 Have to be renewed on dismantling (special screws)
 R 33 E 125 G 502 G 484 R 105 K2 G 16
E 367 I E 124 I R 119 I E 123 I

~
~

K 16 W 166 I E 389 W 103 I

, E8
I
K1 K22 K59 K5 K 18 W 179 E 706 E 205 W17
K23
0-102-64979

--
 :...-...J

Intermediate shaft WAF 542 - 562 0-102-64979

Quantity per WAF-Gearbox Quantity per WAF-Gearbox
Item Item
No. Designation 542 562 No. Designation 542 562

E 8 Oil distributor 1 1 K 8 Hexagon screw 8 8

E 13 Anti-friction bearing 1 1 K 8 Locking wire 1 1
E 40 Cover 1 1 K 8 Wire socket 2 2
E 56 Allen screw 8 8 K 13 Hexagon screw *8 12 12
E 122 Anti-friction bearing 1 1 K 16 Clutch housing 1 1
E 123 Anti-friction bearing 1 1 K 17 Annular piston 1 1
E 124 Anti-friction bearing 1 1 K 18 Rectangular ring 1 1
E 125 Anti-friction bearing 1 1 K 22 Inner disc 11 11
E 205 Hexagon screw 8 8 K 23 Outer disc 12 12
E 367 Clamping sleeve 1 1 K 30 Carrier 1 1
E 389 Allen screw 20 20 K 59 Cover 1 1
E 705 Bearing housing 1 1 K 60 Allen screw 8 8
E 706 Hexagon screw 12 12
1 R 3 Fitted disc 2 2
~ E 1015 Bearing housing 1
01 R 32 Shaft nut 1 1
G 16 Locking plate 1 1 R 33 Threaded pin 1 1
G 17 Hexagon screw 2 2 R 43 Retaining ring 1 1
G 484 Retaining ring 2 2 R 44 Retaining ring 1 1
G 502 Lubrication pipe 1 1 R 105 Retaining ring 1 1
R 119 Pinion shaft 1 1
K 1 Clutch support 1 1 R 167 Star spring 1 1
K 2 Retaining ring 1 1
K 5 Bolt 12 12 W 17 Intermediate shaft 1 1
K 6 Spring 12 12 W 103 Retaining ring 1 1
K 7 Rectangular ring 1 1 W 166 Hexagon screw *8 24 24
W 169 Carrier pin 4 4
W 179 Non-return valve 2 2

'8 Have to be renewed on dismantling (special screws)

 W 19 E 125 G 502 R 43 K 60 R3 E 13
E 1103 I E 124 K13 I K 30 I R 167 I

~
0)

R 32
I K 22
K 16 I
,oJ 171 E 182 E 1015 K 23 K 59 K5 K 18 EB

0-102-64980

-... -_.-
 Power take off K 21 WAF 542 - 562 0-102-64980
Quantity per WAF-Gearbox Quantity per WAF-Gearbox
Item Item
No. Designation 542 562 No. Designation 542 562
E 8 Oil distributor 1 1 K 8 Hexagon screw 8 8
E 13 Anti-friction bearing 1 1 K 8 Locking wire 1 1
E 26 Shaft sealing ring 1 1 K 8 Wire socket 2 2
E 27 Cover 1 1 K 13 Hexagon screw "8 12 12
E 34 Anti-friction bearing 1 1 K 16 Clutch housing 1 1
E 122 Anti-friction bearing 1 1 K 17 Annular piston 1 1
E 123 Anti-friction bearing 1 1 K 18 Rectangular ring 1 1
E 124 Anti-friction bearing 1 1 K 22 Inner disc 11 11
E 125 Anti-friction bearing 1 1 K 23 Outer disc 12 12
E 181 Bearing housing 1 1 K 30 Carrier 1 1
E 182 Hexagon screw 8 8 K 59 Cover 1 1
E 205 Hexagon screw 8 8 K 60 Allen screw 8 8
E 389 Allen screw 20 20
~ E 412 Hexagon screw 6 6 R 3 Fitted disc 2 2
"-J
E 705 Bearing housing 1 1 R 32 Shaft nut 1 1
E 706 Hexagon screw 12 12 R 33 Threaded pin 1 1
E 1015 Bearing housing 1 1 R 43 Retaining ring 1 1
E 1103 Clamping sleeve 1 1 R 44 Retaining ring 1 1
R 105 Retaining ring 1 1
G 16 Locking plate 1 1 R 119 Pinion shaft 1 1
G 17 Hexagon screw 2 2 R 167 Star spring 1 1
G 484 Retaining ring 2 2
G 502 Lubrication pipe 1 1 W 19 Fitted key 1 1
W 20 Intermediate shaft PTa 1 1
K 1 Clutch support 1 1 W 21 Bush 1 1
K 2 Retaining ring 1 1 W 103 Retaining ring 1 1
K 5 Bolt 12 12 W 166 Hexagon screw "8 24 24
K 6 Spring 12 12 W 169 Carrier pin 4 4
K 7 Rectangular ring 1 1 W 171 Retaining ring 2 2
W 179 Non-return valve 1 1
W 265 Bush 1 1

'8 Have to be renewed on dismantling (special screws)

C>
m
....
CO
Q ' Q)

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I
o

N
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48
-· - -, ---""
, _."
..........

Output shaft WAF 542 0-102-64981

Quantity per WAF-Gearbox
Item.
No. Designation 542

E 104 Hexagon screw 8

E 115 Hexagon screw 8
E 193 Cover 1
E 202 Cover 1
E 203 Spring 6
E 219 Shaft sealing ring 1
G 65 Gear shielding 1
G 163 Hexagon screw 4
p 1 Output shaft 1
p 20 Anti-friction bearing 1
p 21 Anti-friction bearing 1
p 22 Anti-friction bearing 1
~
co P 29 Hexagon screw 6
p 30 Adjustment disc 1
R 2 Wheel *2

'2 Pay attention to assembly and dismantling instructions for taper press hubs with 1:30 taper
 co
co
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coI
r~
a.
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0- 1

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.. -.- .....

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/
/

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t.::J l:J

50
- - ,
- ,
- .
--...I
.,

Output shaft WAF 562 0-102-64986

Quantity per WAF-Gearbox
Item
No. Designation 562

E 104 Hexagon screw 12

E 115 Hexagon screw 8
E 193 Cover 1
E 202 Cover 1
E 203 Spring 8
E 219 Shaft sealing ring 1
G 65 Gear shielding 1
G 163 Hexagon screw 4
p 1 Output shaft 1
p 20 Anti-friction bearing 1
p 21 Anti-friction bearing 1
p 22 Anti-friction bearing 1
0'1
...... P 32 Bush 1
P 43 Threaded pin 1
p 44 Shaft nut 1
R 2 Wheel *2

'2 Pay attention to assembly and dismantling instructions for taper press hubs with 1:30 taper
 A 301 H9 H8 H 12 H 30 H 24 H 20 E 107 H 184 H 43 A 73 H 42 H 16
I
H7 A 80

01
I\.)

H SA
H SB

E 19

I
A1 E 23 H 44 H3 H2 H 23

0-102-65332
 -'

Piping and External Parts WAF 572 0-102-65332

Quantity per WAF-Gearbox Quantity per WAF-Gearbox
Item Item
No. Designation 572 No. Designation 572
A 1 Heat exchanger ·S 1 H 18 A Reducing fitting 1
A 3 Duplex filter ·S 1 H 18 B Screwed union 1
A 35 Pressure gauge 1 H 20 Pipe 1
A 54 Thermometer 1 H 21 A Screwed union 1
A 73 Shut-off valve 1 H 21 B Extention 1
A 80 Support 1 H 22 A Reducing fitting 1
A 301 Connection piece 1 H 22 B Screwed union 1
H 23 Pipe 1
E 19 Oil pump *S 1 H 24 Screwed union 1
E 23 Dip stick 1 H 30 Pipe 1
E 107 Venting filter 1 H 31 A Screwed union 1
H 2 Screwed union 1 H 31 B Reducing fitting 1
H 3 Pipe 1 H 32 Pipe 1
(J'l
w H 4 A Screwed union 1 H 33 A Screwed union 1
H 4 B Reducing fitting 1 h 33 B Reducing fitting 1
H 5 A Reducing fitting 1 H 42 Screwed union 1
H 5 B Screwed union 1 H 43 Pipe 1
H 6 Pipe 1 H 44 Screwed union 1
H 7 Screwed union 1 H 45 Intermediate piece pressure gauge 1
H 8 Screwed union 1 H 46 A Support pressure gauge 1
H 9 Pipe 1 H 46 B Allen screw 2
H 10 A Screwed union 1 H 90 Pipe 1
H 10 B Reducing fitting 1 H 103 Pipe 1
H 11 Screwed union 1 H 104 Screwed union 1
H 12 Pipe 1 H 128 Pipe 1
H 13 Screwed union 1 H 195 A Reducing fitting 1
H 14 A Reducing fitting 1 H 195 B Screwed union 1
H 14 B Screwed union 1 V 1 Control valve *S 1
H 16 Pipe 1 V 100 Pressure build-up valve *S 1
H 17 Screwed union 1 I V 339 Intermediate plate 1

·S Service repair kit

 E 143 R 33 E 125 f 1017 G 480 R 105 K2 G 532
E 19 E 206 I E 537 I E 124 I R1 G 480 I E 122 I K 113

01
~
_-lL. _

\
\1 1
K1 K5 K15 E30 E 11 \oJ 7

0-102-64987

,---
 ----'

Input shaft WAF 572 0-102-64987

Quantity per WAF-Gearbox Quantity per WAF-Gearbox
Item Item
No. Designation 572 No. Designation 572

E 5 Bearing housing 1 K 8 Hexagon screw 8

E 7 Cover 1 K 8 Locking wire 1
E 11 Shaft sealing ring 1 K 8 Wire socket 2
E 15 Anti-friction bearing 1 K 13 Hexagon screw *8 12
E 19 Oil pump *S 1 K 15 Clutch housing 1
E 30 Hexagon screw 12 K 17 Annular piston 1
E 122 Anti-friction bearing 1 K 18 Rectangular ring 1
E 123 Anti-friction bearing 1 K 22 Inner disc 11
E 124 Anti-friction bearing 1 K 23 Outer disc 12
E 125 Anti-friction bearing 1 K 30 Carrier 1
E 143 Hexagon screw 4 K 59 Cover 1
E 186 Allen srew 8 K 60 Allen screw 8
E 206 Cover 1
8 R 1 Pinion shaft 1
01 E 244 Hexagon screw

f'
01 R 3 Fitted disc 2
E 537 Clamping sleeve 1
1 R 32 1
E 1017 Bearing housing Shaft
R 33 Threa ed pin 1
G 480 Retaining ring 2 R 43 Retai ing ring 1
G 532 Retaining ring 1 R 44 Retaining ring 1
R 105 Retaining ring 1
K 1 Clutch support 1 R 167 Star spring 1
K 2 Retaining ring 1
K 5 Bolt 12 W 1 Input shaft 1
K 6 Spring 12 W 7 Retaining ring 1
K 7 Rectangular ring 1 W 12 Bush 1
W 166 Hexagon screw *8 24
W 169 Carrier pin 4
W 179 Non-return valve 1

·s Service repair kit

·S Have to be renewed on dismantling (special screws)
 G533 R 43 K 60 R3
E 122 I K 13 I K 30 I R 167
\

(.Jl
0')

K 17 W166 E 705
K1 K 59 K5 K 18 W 179 E 706 W17

0-102-64988

- -
 - - "'

Intermediate shaft WAF 572 0-102-64988

Quantity per WAF-Gearbox Quantity per WAF-Gearbox
Item Item
No. Designation 572 No. Designation 572

E 8 Oil distributor 1 K 8 Hexagon screw 8

E 13 Anti-friction bearing 1 K 8 Locking wire 1
E 40 Cover 1 K 8 Wire socket 2
E 56 Allen screw 8 K 13 Hexagon screw *8 12
E 122 Anti-friction bearing 1 K 16 Clutch housing 1
E 123 Anti-friction bearing 1 K 17 Annular piston 1
E 124 Anti-friction bearing 1 K 18 Rectangular ring 1
E 125 Anti-friction bearing 1 K 22 Inner disc 11
E 205 Hexagon screw 8 K 23 Outer disc 12
E 367 Clamping sleeve 1 K 30 Carrier 1
E 705 Bearing housing 1 K 59 Cover 1
E 706 Hexagon screw 12 K 60 Allen screw 8
E 1015 Bearing housing 1
(]1 R 3 Fitted disc 2
--....I G 484 Retaining ring 2 R 32 Shaft nut 1
G 533 Retaining ring 1 R 33 Threaded pin 1
R 43 Rectangular ring 1
K 1 Clutch support 1 R 44 Rectangular ring 1
K 2 Retaining ring 1 R 105 Rectangular ring 1
K 5 Bolt 12 R 119 Pinion shaft 1
K 6 Spring 12 R 167 Star spring 1
K 7 Rectangular ring 1
W 17 Intermediate shaft 1
W 103 Rectangular ring 1
W 166 Hexagon screw *8 24
W 169 Carrier pin 4
W 179 Non-return valve 2

'8 Have to be renewed on dismantling (special screws)

 \oJ 19 E125 E 1015 R 43
E 1103 I E 124 I K 13 K 30
I
E13
J

(J'l
co

I
\oJ' 21 I E 181
I
VI 166 I E 705 I
IN 171 E34 IN 265 K1 K5 K 18 IN 179 E 706 \~ 20

0-102-64989

- - '---
1
-
Power take off K 21 WAF 572 0-102-64989
Quantity per WAF-Gearbox Quantity per WAF-Gearbox
Item Item
No. Designation 572 No. Designation 572
E 8 Oil distributor 1 K 8 Hexagon screw 8
E 13 Anti-friction bearing 1 K 8 Locking wire 1
E 26 Shaft sealing ring 1 K 8 Wire socket 2
E 27 Cover 1 K 13 Hexagon screw '8 12
E 34 Anti-friction bearing 1 K 16 Clutch housing 1
E 122 Anti-friction bearing 1 K 17 Annular piston 1
E 123 Anti-friction bearing 1 K 18 Rectangular ring 1
E 124 Anti-friction bearing 1 K 22 Inner disc 11
E 125 Anti-friction bearing 1 K 23 Outer disc 12
E 181 Bearing housing 1 K 30 Carrier 1
E 182 Hexagon screw 8 K 59 Cover 1
E 205 Hexagon screw 8 K 60 Allen screw 8
E 412 Hexagon screw 6
01 E 705 Bearing housing 1 R 3 Fitted disc 2
CO
E 706 Hexagon screw 12 R 32 Shaft nut 1
E 1015 Bearing housing 1 R 33 Threaded pin 1
E 1103 Bearing housing 1 R 43 Retaining ring 1
R 44 Retai'ling ring 1
G 484 Retaining ring 2 R 105 Retaining ring 1
G 533 Retaining ring 1 R 119 Pinion shaft 1
R 167 Star spring 1
K 1 Clutch support 1
K 2 Retaining ring 1 W 19 Fitted key 1
K 5 Bolt 12 W 20 Intermediate shaft PTa 1
K 6 Spring 12 W 21 Bush 1
K 7 Rectangular ring 1 W 103 Retaining ring 1
W 166 Hexagon screw *8 24
W 169 Carrier pin 4
W 171 Retairling ring 2
W 179 Non-r~turn valve 1
W 265 Bush 1

'8 Have to be renewed on dismantling (special screws)

 o0)
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60
--- - - - - ., -.-

Output shaft WAF 572 0-102-64990

Quantity per WAF-Gearbox
Item
No. Designation 572

E 104 Hexagon screw 8

E 115 Hexagon screw 8
E 193 Cover 1
E 202 Cover 1
E 203 Spring 6
E 219 Shaft sealing ring 1
G 65 Gear shielding 1
G 163 Washer 4
G 163 Hexagon screw 4
p 1 Output shaft 1
p 2 Bush 1
P 20 Anti-friction bearing 1
en P 21 Anti-friction bearing 1
-'"
P 22 Anti-friction bearing 1
p 32 Bush 1
p 43 Threaded pin 2
p 44 Shaft nut 1
R 2 Wheel '2 1

"2 Pay attention to assembly and dismantling instructions for taper press hubs with 1:30 taper
 A 289

A289

A 1 Heat Exchanger Type OKTS/OKS

(j)
I\.) I A 1 Heat Exchanger Type OK A 282 Set of seals consisting of 1
A Gasket (1 )
A 282 Set of seals B Gasket (1 )
consisting of 1 C Gasket (1 )
A O-ring (2) D Disc (6)
B Rubber profil (1 ) EO-ring (1)
CO-ring (1 ) F Gasket (2)
A 287 Support, complete 2 G Gasket (2)
A 288 Housing 1
A 289 Open end cover 1 A 287 Support, complete 2
A 290 End cover 1 A 288 Housing 1
A 291 Tube bundle 1 A 289 Open end cover 1
A 290 End cover 1
A 291 Tube bundle 1
A 292 Anode 2

OKTS: Gasket Band C must suit

the cover shape, modify if necessary
OKS: Select matching gasket B

- - - ~
 ----

A3

A 323

CJ')
w

I A 1 Heat Exchanger Type P 130 A 3 Duplex Filter Type Pi 210

A 282 Set of seals consisting of 1 A 37 Filter element 2

O-ring (4) A 43 Contamination indicator
A 289 Open end cover 1 visual standard 1
A 290 Endcover 1 A 283 Set of seals
A 291 Tube bundle 1 consisting of 1
A 292 Anode 3 A O-ring (2)
B O-ring (2)
CO-ring (1)
DO-ring (1)
A 323 Switch lever, complete 1

Additional order:
A 43 Contamination indicator,
electrical 1
 E 19

~
E714

E19

E725

~..J

0)
.j:::".
E 19 Oil Pump Type KF 1/.. E 19 Oil Pump Type KF 2/.. KF 3/.. KF 4/..

E 714 Set of seals E 714 Set of seals

consisting of consisting of 1
A Shaft sealing ring (1 ) A Shaft sealing ring (1 )
B a-ring (1) B a-ring (1 )
E 725 Bearing 1 c a-ring (1 )
o Gasket (1)
E 725 Bearing 1

Note: Mark position of cover before

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

- -- ~
 V1
V'261~~. ,
V1
V259~ ~~

(j)
01

I v ., Control Valve (4/3 WL 5-10, pneumatical) V 1 Control Valve (4/3 NG 10, electrical)

V 223 Set of seals V 223 Set of seals

consisting of 1 consisting of 1
A a-ring (5) A a-ring (5)
B a-ring (2) B a-ring (2)
c a-ring (2) c a-ring (2)
o Turcon-step seal (2) o a-ring (2)
a-ring (2) V 259 Solenoid 2
E Quadring (1 ) V 260 Plug-in connector
F Turcon-glyd ring (1) V 261 Plug-in connector
a-ring (1 ) see additional order
V 263 Pneuko piston, complete 1 V 262 Manual emergency control
V 264 Seal ring for piston 1 for 4/3 NG 10 with spring return 2

o and F consisting of 2 parts one Additional order:

fitting into the other V 260 Plug-in connector 1
V 261 Plug-in connector 1
 V1
-I VZ6 0(
V259~
V1
.... ~

V260~_ !.
,,~

.l .~

1
V259

0'>
0'> I
V 1 Control Valve (4/2 WL 5-10, pneumatical) V 1 Control Valve (4/2 NG 10, electrical)

V 223 Set of seals V 223 Set of seals

consisting of 1 consisting of 1
A O-ring (5) A O-ring (5)
B O-ring (2) B O-ring (2)
CO-ring (2) CO-ring (2)
D Turcon-step seal (2) DO-ring (2)
O-ring (2) V 259 Solenoid 2
E Quadring (1 ) V 260 Plug-in connector
F Turcon-glyd ring (1) V 261 Plug-in connector
O-ring (1 ) see additional order
V 263 Pneuko piston, complete 1 V 262 Manual emergency control
V 264 Seal ring for piston 1 for 4/2 NG 10 without spring return 2

D and F consisting of 2 parts one fitting Additional order:

into the other Detail X disc installed as STOP V 260 Plug-in connector 1
V 261 Plug-in connector 1

-
 - -
V100

V4l3
+-~--:+
I

~a F-C-B-D-E-A-C

V223 B A

V3S1
m
-....I

V 100 Pressure Build-up Valve Type C V 1 Control Valve (Rotary piston, mechanical)

V 351 Sinter filter-element 1 V 223 Set of seals

V 422 Set of seals consisting of 1
consisting of 1 A a-ring (3)
A a-ring (1 ) B a-ring (1 )
B a-ring (1 )
c a-ring (2) Sketch seen from underneath,
D a-ring (2) additional service information
E Quadring (1 ) on request.
Fa-ring (1 )
V 423 Sealnut
 J

1
]
]
]
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