OPERATING MANUAL

WAF 642
196.

LAF 642
196.
REINTJES GmbH
D-31784 Hameln
Federal Republic of Germany
Phone +49 51 51 1 04 - 0 BV2025.en 2004-04
Telefax +49 51 51 1 04 - 300 Subject to alterations
The operating manual present applies to all standard
gearboxes of type LAF / WAF 642-196.

The last figure in the gearbox designation is variable

(eg. WAF 1961, LAF 1962).

In this operating manual the last figure is marked

by a dot, if the data apply for all gearboxes with
identical figures for the first 2 or 3 digits

eg. WAF 643 → WAF 64.

LAF 1171 → LAF 117.

1
Table of Contents
1.0 General Information 5.0 Disassembly and Assembly
1.1 Introduction 3 5.1 General Information 30
1.2 Important Notes 3 5.1.1 Seals 30
1.3 Safety Information 3 5.1.2 Screws 30
1.4 Fire and Explosion Prevention 5 5.2 Screw Locking 30
1.5 Before-operation Checks 6 5.3 Glued Connection 31
5.4 Instructions for Hydraulic Assembly/
Disassembly with Taper 1:30 31
2.0 Installation and Alignment 5.5 Bearing Adjustments 33
5.6 Lubrication of Discs 35
2.1 Lifting Equipment 7 5.7 Recommended Maintenance
2.2 Alignment 7 Procedures for Heat Exchangers
2.3 Marine Gear Installation and Alignment 7 of BLOKSMA Make 36
2.4 Connection to Engine 7
2.5 Propeller Shaftline Check 8
2.6 Seat Chocks and Foundation Bolts 8 6.0 Spare Parts
2.7 Installation of Gearbox with
Longitudinal Mounting Arrangement 8 Ordering Notes 41
2.8 Alignment Check 9
WAF/LAF 64. – 196. 42
Piping and External Parts 43
Housing 45
3.0 Function and Operation Input Shaft 47
3.1 General Information 9 Intermediate Shaft 49
3.2 Name Plate Arrangement 9 Output Shaft 51
3.3 Hydraulic System 10 Power Take Off K21 53
3.4 Gearbox Actuation 12 Power Take Off K31 55
3.5 Pressure Limiting Valve 12 Power Take Off K41 57
3.6 Function of Series WAF/LAF 14 Power Take Off K51 59
3.7 Sectional Drawing WAF/LAF 15
3.8 Description of Power Take Off 16
3.9 Recommended Lubricants 17
3.10 Initial Operation 17 Service Repair Kits
3.11 Operating Instructions 17
A1 Heat Exchanger Typ P 130 60
3.12 Engagement Recommendations 18
A1 Heat Exchanger Typ OKTS/OKS 60
3.13 Trailing Operation, Engine STOP
A3 Duplex Filter Typ RFLD 61
and Propeller Rotating 18
A3 Duplex Filter Typ Pi 21.. 61
3.14 Emergency Operation 19
E 19 Oil Pump Typ KF 2/..,3/...,4/.. 62
H 1069/ H 1074 Operation Delay Pot with
V 232 Connection Plate 63
4.0 Maintenance H 768 Operation Delay Pot PTO clutch 63
V 247 Intermediate Plate 64
4.1 Maintenance Recommendations 19 K8 Emergency Operation Screw 64
4.2 Conversion Factors 20 V1 Control Valve (4/3 pneum.) 65
4.3 General Torque for Metric Fasteners 20 V1 Control Valve (4/3 electr.) 65
4.4 Maintenance Schedule 21 V1 Control Valve (4/2 pneum.) 66
4.5 Maintenance Task Descriptions 22 V1 Control Valve (4/2 electr.) 66
4.6 Completed Maintenance 27 V 114 Control Valve (4/2 pneum.) PTO clutch 67
4.7 Troubleshoothing 28 V 114 Control Valve (4/2 electr.) PTO clutch 67
4.8 Preservation of the Gearbox 29

2
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 marine
gear 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 marine gear which are not covered by
this manual.
If you have any questions regarding your marine
gear or this publication, please consult the
REINTJES Service Department.
1.2 Important Notes
The marine gears are subject to the REINTJES
warranty conditions as agreed upon in the
purchasing contract.
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 emcompassing. Should
you employ tools and equipment, procedures or
operating techniques not specifically recommended
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
damaged, 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.

Modifications of the gearbox are permissible only Supplementary to operating manual all generally
in consultation with REINTJES. valid legal and other binding regulations for accident
prevention and pollution control have to be observed
REINTJES will only consider warranty claims when and adhered to!
- 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.

3
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 develop-
ments 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!
Authorized and trained staff only are entitled to
operate, maintain and repair the gearbox.
The staff must not have long loose hair nor wear
loose clothing or jewellery incl. rings. 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 marine gear.
Ensure that the propulsion engine remote starting
system is deactivated.
Prior to commencing work on the engine or marine
gear, 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 marine gears,
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 pressureoperated system, ensure that it is
nolonger pressurized. 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.
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.
4
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 marine gear 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.
To avoid hearing damage, always wear ear
protectors when working on running machinery
in an enclosed area.
1.4 Fire and Explosion Prevention
Lubricating oil or fuel sprayed onto a hot surface
may catch fire causing personal injury and damage
to property. Check all lines and pipes for wear and
damage; ensure that they are correctly routed,
supported and secured. All connections must be
tightened to the specified torque.
Fluids must be drained into suitable containers and
all oil, fuel or coolant splashes must be cleaned up.
Accumulations of grease or oil constitute a fire
hazard.
Oil-soaked rags must be kept in the containers
provided. Do not leave rags or cleaning cloths on
the marine gear.
When replacing oil filter elements, ensure correct
installation and tightening. All lubricants must be
stored in clearly marked containers.
Filter elements and waste oil must be disposed
of as recyclable material or special waste.
Diesel fuel and all lubricants are highly flammable.
Do not weld fuel or lubricant carrying lines or pipes;
these must be thoroughly cleaned with a non-
flammable solution prior to welding.
Compliance with all “SMOKING PROHIBITED”
notices is mandatory.
Loose, damaged or otherwise leaking oil, fuel or
coolant lines and pipes may lead to overheating
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.
5
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 marine gear. 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 unneccessary 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.
Secure connections, specified wiring and correctly
treated cables all contribute to the prevention of
arcing or sparking which, in turn, could cause a fire.
A fire extinguisher should always be kept readily
available and its use must be practiced. Compliance
with the manufacturer’s inspection and maintenance
intervals, as shown on the instruction plates, or
labels, must be observed.
Lubricant draining should be carried out with
extreme care. Hot lubricants can cause personal
injury; allow the marine gear to cool completely
before commencing maintenance or repair work.
Remove plugs, lubrication fittings, pressure
connections, venting filters and drain plugs with
caution. To prevent spraying or splashing by
pressurized fluids, cover lubrication fittings and
plugs during removal.
1.5 Before-operation Checks
Ensure that all protective guards and covers are
correctly installed. To prevent accidents, always
exercise extreme care when working around rotating
components. Check the marine gear frequently for
potential hazards.

Do not, under any circumstances, start an engine or

operate the controls when a warning notice is
attached. Prior to starting the engine and operating
the marine gear, ensure that no work is in progress
within the immediate vicinity.

Model View and

Specifications

Input Shaft (6)

Intermediate Shaft (7)

WAF/LAF Reduction app. Weight

Ratios
WAF LAF
64. 2,483 : 1 to 4,409 : 1 1400 kg 1300 kg
66. 4,560 : 1 to 5,950 : 1 1800 kg 1650 kg
67. 6,417 : 1 to 7,476 : 1 2300 kg 2100 kg
74. 2,467 : 1 to 3,952 : 1 1800 kg 1700 kg
76. 4,625 : 1 to 5,750 : 1 2300 kg 2100 kg
77. 6,153 : 1 to 7,455 : 1 2900 kg 2650 kg
84. 2,091 : 1 to 3,905 : 1 2300 kg 2050 kg
86. 4,458 : 1 to 5,842 : 1 3100 kg 2850 kg
87. 6,153 : 1 to 7,455 : 1 4200 kg 3950 kg
114. 1,966 : 1 to 3,909 : 1 2800 kg 2600 kg
Control Valve (1) 116. 4,500 : 1 to 5,810 : 1 3600 kg 3300 kg
Oil Filter (2) 117. 6,087 : 1 to 6,810 : 1 4500 kg 4200 kg
Oil Cooler (3) 154. 2,032 : 1 to 3,857 : 1 3900 kg 3700 kg
Oil Pump (4) 156. 4,429 : 1 to 5,955 : 1 4500 kg 4400 kg
Output Shaft (5) 194. 2,059 : 1 to 3,952 : 1 4200 kg 4000 kg
196. 4,467 : 1 to 5,952 : 1 5650 kg 5300 kg

6
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, pipework or other
externally mounted equipment. The lifting equip-
ment 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
accesories. Only high flexible couplings must be
used.
On request, REINTJES will supply all data required
for alignment calculation (such as temperature
expansion curve, mass and stiffness distribution of
the gearbox output shaft and allowable bearing
loads).
If the customer or shipyard is in possession of an
alignment calculation for the complete propulsion
plant, then plant alignment must be completed in
accordance with such calculation. A copy of the
alignment calculation should, however, be submitted
to REINTJES for information.
Propulsion plant alignment diagrams are generated
by superimposing the fullload temperature
characteristics of the engine crankshaft, the gearbox
input and output shafts and the propeller shaftline.
These full-load temperature shaft-displacement
characteristic curves permit precision cold-state
alignment for optimized fullload operating conditions.
If alignment calculation for the complete propulsion
plant has not been made, it is mandatory to comply
with REINTJES instructions when aligning the marine
gear.
2.3 Marine Gear Installation and
Alignment
During gearbox installation it is essential to ensure
that sufficient free is space provided for disassembly
of housings, shafts, etc during later maintenance.
The gearbox has to be installed onto an adequate
strengthened foundation so that no housing
distortion can occur.
The installation, or foundation, drawing includes all
necessary marine gear mounting face dimensions.
Applicationspecific deviations must be confirmed in
consultation with the factory.
7
For propulsion plant alignment, it is mandatory
that the vessel be afloat with absolutely no
contact to 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
(PTO) shafts must be made in compliance with
manufacturer’s instructions.
Vertical alignment of gearbox to propeller or
intermediate shaft is effected by alignment screws
located in the gearbox seating.
For horizontal alignment we recommend fixing
alignment screws on the foundation.
2.4 Connection to Engine
Engine power transmission from the engine to the
marine gear 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 startup and
shutdown.
Alternatively care must be taken to ensure that, with-
in 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 manufac-
turer or the shipyard and is supplied assembled
with the marine gear, 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 accommo-
dating the the axial misalignment between the
engine and gearbox shafts at the specified operating
speeds.
Referenced to the gearbox, the flexibility of the
resilient engine mounts must be such as to allow
engine-to-gearbox alignment accuracy which
ensures that there is no possibility of appreciable
reactive forces at the bearings of the connected
gearbox shafts when operating temperatures prevail.
2.5 Propeller Shaftline Check
Radial and axial run-out
A prerequisite for correct propeller shaftline-to-
marine gear connection is that the propeller and/or
intermediate shaft does not “sag” and is in the
operational position.
Radial and axial run-out must not
exceed 0.05 mm.
Radial and Angular Misalignment
For these checks the coupling flange centering
recesses must be disengaged. Secure the dial gauge
carrier to the gear flange so that the stylus of one
gauge is in radial contact with the periphery of the
blocked propeller, or intermediate shaft flange and
that of the 2nd gauge is in axial contact with the
flange face.
With the plant at operating temperature and under
full-load operating conditions, the maximum
permissible deviations of both flanges towards
each other are as follows:
Radial misalignment 0.05 mm
(centerline run-out 0.025 mm)
Angular misalignment 0.05, referenced
to 300 mm flange diameter.
Order-specific instructions are applicable to universal
shaft alignment.
2.6 Seat Chocks and Foundation Bolts
Seat Chocks
Only rectangular seat chocks can be used.
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.
The foundation bolts must comply with requirements
of the particular application and be tightened to the
specified torque.
2.7 Installation of Gearbox with
Longitudinal Mounting Arrangement
On completion of alignment, the gear must be
attached to the foundation in such a manner that it is
secured against displacement and that the propeller
thrust is transmitted and led into the foundation.
Foundation with Steel Seat Chocks
There are various combination possibilities which
may be used for the attachment of marine gears with
side mounting faces (longitudinal foundation):
1. Seat chocks with fitting screws and
collision chocks.
2. Seat chocks with fitting screws,
without collision chocks.
3. Seat chocks with collision chocks and foundation
screws constructed as through screws.
8

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
authorized company which is also in a position to
submit the necessary drawings, calculations and
materials to the Classification Societies for approval.
2.8 Alignment Check
On completion of alignment and after the engine
and marine gear foundation bolts have been finally
tightened to specified torque, a check of the
mating accuracy of both marine gear flanges is
recommended whereby the flange securing
screws must be removed.
We accept no claims under warranty arising from
exceeding alignment tolerances of both gearbox
connecting flanges.
9
3.0 Function and Operation
3.1 General Information
The Series WAF and LAF gearboxes constitute a
shaft offset marine gear family. The Series WAF are
marine reverse-reduction gears whereas the LAF
units are marine reduction gears with one clutch
only.
The marine gear reduction ratios are identical for
Ahead and Astern propulsion, the transmission
torque is thus the same for both output directions
of rotation.
The marine gears are available with either identical
rotation or counter rotation input/output shafts.
Marine gear control can be effected from either the
engine room or the control room. Either an electrical
or a pneumatical control valve is mounted on the
gearbox.
The service life of the gearbox depends upon the
correct completion of the recommended operating
and maintenance services and the use of recom-
mended lubricants.
3.2 Name Plate Arrangement
The name plate is attached to the gear housing.
For parts ordering or other inquiries in respect of
your marine gear, the following information is
required from the name plate:
Gearbox No.
Type
Input power
Input speed
3.3 Hydraulic System
The hydraulic system comprised of a geartype
pump, an oil filter, heat exchanger, pressure limiting
valve, control valve, pressure oil system with clutch
engaging delay pot and lubrication oil system.
Oil supplied by the pump is filtered and then
conducted through the heat exchanger 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 oil pressure is regulated to operating pressure
by the pressure limiting 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, the pressure should
be within the green area on the gauge.
The normal operating pressure for
WAF/LAF 64. – WAF/LAF 196. is approx. 21-25 bar
(2100 – 2500 kPa or 304,5 – 362,5 psi).
Exception:
WAF/LAF 1141 – WAF/LAF 1961 is
approx. 16-20 bar
(1600 – 2000 kPa or 232 – 290 psi).
With the control valve in STOP position (neutral
position) the oil not needed to maintain pressure at
the pressure limiting valve is used for cooling the
clutch discs and lubrication of all bearing points and
tooth meshings.
10
If the control valve is actuated into position AHEAD
or ASTERN, the pressure oil is flowing from the
control valve to the appropriate clutch and the
pressurizing valve. The excess oil is used for
lubrication.
If the oil pressure exceeds the factory-set pressure
in the pressurizing valve, this valve opens and oil
is flowing into the operation delay pot. While filling
the delay pot, the pressure in the clutch pressure oil
system raises to the adjusted operating pressure
and the clutch is force locked.
When changing the control valve position to the
other side, the oil pressure in the engaged clutch will
be released. The clutch disengages and the oil
drains into the sump.
Engagement of the other clutch is achieved with the
same delay function.
The engaging delay system allows smooth clutch
engagment in consideration of the propeller inertia.
The pressurizing valve is set at the factory and
normally will not require adjustment.
Hydraulic Diagram

11
3.4 Gearbox Actuation 3.5 Pressure Limiting Valve
The complete shift unit for marine gear control, The operating pressure is regulated by a spring-
comprised of the pressure limiting valve and the loaded pressure limiting valve and set by
control valve, is mounted to the gearbox housing. adjustment screw V 13.
For readjustment purposes, the nut V 12 must be
Control Valve with Emergency Actuation slackened off. Pressure is increased by turning
The control valve is mounted onto the pressure adjusting screw V 13 clockwise and decreased by
limiting valve and can be easily replaced after turning it anticlockwise.
releasing screws and the control connections.
The valves used are axial slide valves whereby
the required control position is achieved by axial
displacement of a piston. Depending upon the
version installed the piston is displaced either
electrically or pneumatically.

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.
The pneumatic control valve emergency actuation
is done via the control lever, the engaged position
will rest.
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):
1. 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.
2. The mushroom-like button at the solenoid end
cap is pushed inwards by hand and locked in this
position by a bracket.
3. 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):
1. 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 electr. valve should not be cleaned with
degreasant and water afterwards. Use a dry
cloth for cleaning the control valve.

12
Intermediate Plate V247 The setting screw should only be screwed
in until the top is even with the lock nut.

Turning the setting screw in further will block the

valve. (At valves with hexagon screw, the screw
can be turned in so that the hexagon head is
against the lock nut).

Hot oil can cause personal injury. Do not allow hot

oil or hot parts to contact skin.

Before a re-setting of the pressure limiting valve

is intended due to changed pressure readings,
possible causes must be checked carefully.

The pressure gauge on the gearbox indicates the

operating pressure. With the engine 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 for

Warning
The adjustment screw is not secured against turning
out of the valve block and must not be removed by
screwing it out.
Oil will leak out if screw V 13 is removed while oil is
under pressure (engine STOP)!
WAF/LAF 64. – WAF/LAF 196. is approx. 21-25 bar
(2100 – 2500 kPa or 304,5 – 362,5 psi).
Exception:
WAF/LAF 1141 – WAF/LAF 1961 is
approx. 16 - 20 bar
(1600 – 2000 kPa or 232 – 290 psi).

13
3.6 Function of Series WAF/LAF IMPORTANT
Engine power is transmitted to the input shaft W 1 Engaging of the clutch at full speed of the engine
via the engine-to-marine gear coupling. When the is inadmissible.
input shaft is rotating, the oil pump E 19 provides the The engaging speed range specified in the order
pressurized oil for lubrication and clutch operation. acknowledgement has to be observed. Any
increase intended afterwards must be approved
The disengaged disc clutch will be supplied with by REINTJES.
lube oil. Shearing of cooling oil flowing to the outside
between the friction surfaces of the clutch results in In the case of propulsion with controllable pitch
an idling torque. propellers, clutch engaging is only permissible with
the propeller at zero pitch.
Note for LAF gearboxes:
At disengaged clutch the secondary parts may rotate
(output shaft, PTO), 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 W 1 - clutch housing K 15 - clutch
discs K 22 and K 23 - carrier K 30 - pinion R 1 -
gear R 2 - output shaft P 1.

Path of Drive at Identical Rotation

Input shaft W 1 - clutch housing K 15 -
clutch housing K 16 - intermediate shaft W 17 -
clutch discs K 22 and K 23 - carrier K 30 -
pinion R 119 - gear R 2 - output shaft P 1.

Stop Position
In the Stop position the oil is lead to the lube oil
lines and the sump. The annular piston K 17 is
held in position by the return springs K 6. Both
clutches are disengaged and the output shaft P 1
is stationary.

14
3.7 Sectional drawing
WAF/LAF 64. – 196.

15
3.8 Description of power take off
PTO-drive non-controllable (K31)
Attached to the gearbox is a PTO gear i.e.
to drive a hydraulic pump.
At running engine and turning input shaft the non-
controllable PTO shaft is turning independently of
disc clutch engaged er disengaged.
The sense of rotation of the power take-off is
identical to the input shaft.
Path of drive:
Input shaft W 1 – wheel R 113 – pinion shaft R 114
PTO non-controllable (K41)
Above the input shaft a non-controllable power
take off is built-in.
At running engine and turning input shaft the non-
controllable PTO shaft is turning independently of
disc clutch engaged or disengaged.
Sense of rotation:
Opposite the engine rotation.
Path of drive:
Input pinion shaft R 1 – wheel R 118 –
PTO shaft W 241
16
PTO controllable (K51)
Above the input shaft a controllable power take-off
is built-in.
The sense of rotation is opposite to the engine.
The PTO clutch is operated by oil pressure.
Stop Position
Annular piston N 14 is moved into its original
position by the return springs N 55. The PTO clutch
is disengaged.
The disengaged disc clutch will be continously
supplied with lube oil.
Shearing of cooling oil flowing to the outside
between the friction surfaces of the clutch plates
results in an idling torque.
At disengaged clutch the secondary parts of the
PTO may rotate, provided the idling torque is higher
than the initial friction torque of the driven parts.
The idling torque depends on the present operating
conditions.
Engaging
The running input shaft W 1 with the clutch housing
K 15 drives the wheel R 117 with the shaft N 198
and the carrier N 16 with the inner discs N 80.
The engaged control valve leeds the oil flow through
the pipes to the oil distributor E 483, which delivers
the pressure oil through the shaft N 1 behind the
piston N 14. The piston N 14 presses the inner discs
N 80 and outer discs N 79 together, the clutch is
force locked and the power is transmitted to the
PTO shaft N 1.
When the control valve is switched into STOP
position, the pressure oil is drained from the clutch.
IMPORTANT
The engaged speed range specified in the order
acknowledgement has to be observed.
Any increase intended afterwards must be
approved by REINTJES.
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.
Refill Capacities
(Approximate)
Installation Check
In the course of this last check prior to initial
operation, it is essential to ensure that all necessary
connections have been made as specified. All
necessary data must be recorded on the "Alignment
Certificate" which must be signed.
Having confirmed that the gearbox is in an
operationally safe condition and that the propulsion
plant is ready for service, initial operation may be
done.
On completion of the test-run the propulsion plant
alignment should be checked and the foundation
bolts must be checked for tight fit.

Use of the Gearbox within the European Union

Refill Capacities In case the operation has to comply with the safety
WAF/LAF Liters U.S.Gal. Imperial regulations stipulated by the European Union, the
Model Gal. manufacturer of the complete plant will be
responsible for the CE-certification.
64. 50 13.0 10.8
66. 65 16.9 14.7
67. 90 23.4 19.5 3.11 Operating Instructions
74. 70 18.2 15.2
76. 75 19.5 16.2 Safety and maintenance are prerequisites for
77. 100 26.0 21.6 troublefree operation, maximum performance
84. 90 23.4 19.5 and a long service life.
86. 90 23.4 19.5
Safety is, initially, an abstract definition and can
87. 120 31.2 26.0
not, in all cases, be defined by regulations. The
114. 110 28.6 23.8
necessary safety measures can normally be
116. 125 32.5 27.7
determined by experience and intelligence.
117. 150 39.0 32.5
154. 150 39.0 32.5 Be alert at all times.
156. 150 39.0 32.5
194. 215 55.9 46.6 Observe possible danger sources.
196. 215 55.9 46.6
Take all necessary precautions.

Safety is EVERYBODY’S business.

3.10 Initial Operation
This Operating Manual includes descriptions of
Oil Filling maintenance services which have to be completed
Prior to shipment, the marine gear is preserved periodically. Familiarize yourself with the
internally. In the case units have been hermetically “Maintenance” chapter.
sealed, the sealing plug must be removed and the
venting filter (supplied loose) must be installed. The Periodic supervision and registration of measured
preservation oil must be drained, minor oil residues parameters provides a duty profile for the engine and
will mix with the service oil. marine gear. If certain conditions change then a
changed display may indicate a potential problem.
The amount of oil required is stamped into the name The necessary repairs can be performed before an
plate. Fill oil as specified into the marine gear until actual failure occurs with resultant non-scheduled
the upper mark on the dipstick is reached. The oil down time.
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.

17
3.12 Engagement Recommendations
The gearbox control is principially factory set at
idling speed.
The maximum engaging speed is stated in the order
acknowleddgement. The engagement procedures
described in the following are important for safe
control and economical operation of the complete
propulsion plant.
Engagement
If the control valve is set to NEUTRAL and the
propeller shaft stationary or turning only very slowly:
Set engine to engaging speed, engage the desired
propulsion mode and remain in this status for
approx. 3 seconds. Then increase engine revolutions
to the desired propulsion speed.
Propulsion Mode Reversal at Low Speed
Set engine to engaging speed and disengage
gearbox into STOP position, for reverse the
propulsion mode and remain at that status for
approx. 3 seconds, before increasing engine
revolutions to the desired propulsion speed.
Propulsion Mode Reversal at High Ship’s Speed
Reduce engine speed to engaging speed with
marine gear clutch engaged to utilize engine braking
effect at the propeller.
Only when the engine speed has dropped to 1.2 x
the engaging speed, swiftly reverse gearbox via
STOP position.
Remain at that status for approx. 3 seconds before
increasing engine revolutions to the desired
propulsion speed.
3.13 Trailing Operation, Engine STOP
Propeller Rotating
This condition covers all operating conditions in
which the propulsion plant is shut down and the
propeller, the shaftline and the gearbox shafts
are caused to rotate by entrained water.
Restricted Trailing Operation
With the standard marine gear without an additional
trailing oil pump, this is possible without any special
precautions.
Should this condition last longer than 12 hours all
marine gear lubrication points must be lubricated for
at least 5 minutes. This can be achieved by starting
the propulsion engine or by activating the electric
stand-by pump.
If the above mentioned shortterm lubrication is not
possible, the propeller shaft must be locked.
Unrestricted Trailing Operation
In this case the marine gear must be equipped with
a trailing oil pump.
The trailing oil pump is mounted at (or in) the marine
gear housing, depending on the operating conditions
and marine gear version. The trailing oil pump is
driven by the gearbox output shaft. Irrespective of
the direction of rotation, this pump always forces oil
into the system in the same direction and thus
ensures the marine gear lubrication oil supply.
Another possibility is the installation of an electric
pump to supply the gearbox lubrication oil system.

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.

At the same time, the marine gear and complete

propulsion plant are subjected to extremely heavy
loads.

Frequent crash-stop manoeuvres lead to an

increased wear of the propulsion plant.

18

3.14 Emergency Operation
In the event of pressure oil supply failure, emergency
operation is possible in that only one clutch is to be
tightened mechanically.
It is imperative to note that only the AHEAD
clutch is to be tightened mechanically.
First the engine must be stopped and secured
against unintentional starting.
Secure the propeller shaft and marine gear output
shaft against unintentional turning.
Determine which clutch is to be engaged:
for gearboxes with AHEAD as opposite sense of
rotation the clutch is located on the input shaft;
for gearboxes with AHEAD as identical sense of
rotation, the clutch is located on the intermediate
shaft.
Remove the associated cover.
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 maintenance personnel,
should work on the gearbox, and only correct tools,
original spare parts and lubricants in accordance
with our recommendation should be used.
Filter elements and waste oil must be disposed of
as recyclable material or special waste.
If required, our Service Department is available at all
times to provide advice and assistance.
4.1 Maintenance Recommendations
Has the “Function and Operation” chapter been read
and understood?

After removing the locking wire, tighten the screws
K 8 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.
Operator alertness provides the best protection
against possible dangers.
The operator must comply with safety instructions
and be familiar with all precautionary measures.

The propeller shaft will now turn immediately the Run a maintenance log book. Regular registration
engine is started, the propeller direction of rotation of recorded data can provide indication of internal
can not be reversed and in order to stop the changes. Rectify minor faults before they can
propeller, the engine must be shut down. develop into major repairs.

Note:
Extreme care must be exercised during emergency
operation; operation must be at the lowest possible
engine speed (below 70 % of rated speed). With the
emergency screws K 8 in service, transmission of
maximum torque is not permissible.
Keep the marine gear clean and dry at all times, this
facilitates early recognition of any possible leaks
thus preventing subsequent extensive damage.
As a matter of principle, never use chemical
detergents to clean rubber or synthetic components.
Wipe with a dry cloth only.

If emergency operation is no longer required, the

screws K 8 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
K 8 must be replaced. In the case of exceptionally
hard emergency service (complete loss of oil
pressure) the gearbox should be disassembled
and all bearings and gear components thoroughly
inspected.

19
4.2 Conversion Factors

Approximate Conversion Factors Metric ISO-Thread 2)

Multiply by To Get Thread Size Grade 8.8 Standard Torque

mm 0,03937 inch Metric Nm 1 ) lb ft
inch 25,4 mm M 5 5+ 1 4+ 1
kg 2,2 lb M 6 9+ 1 7+ 1
lb 0,454 kg M 8 21 + 2 16 + 2
kPa 0,145 psi M 10 41 + 4 30 + 3
psi 6,89 kPa M 12 71 + 7 52 + 5
psi 0,0689 bar M 14 113 + 12 84 + 8
bar 14,5 psi M 16 170 + 20 126 + 13
Nm 0,74 lb ft M 18 245 + 25 181 + 18
lb ft 1,36 Nm M 20 350 + 35 259 + 26
Nm 8,9 lb in M 22 470 + 47 348 + 35
lb in 0,113 Nm M 24 600 + 60 444 + 44
Liter 0,26 U.S. Gal. M 27 880 + 90 650 + 65
U.S. Gal. 3,79 Liter M 30 1190 + 120 880 + 90
U.S. Gal. 0,833 Imp. Gal. M 36 2100 + 210 1550 + 155
Temperature conversions M 39 2700 + 270 1990 + 199
°C=(°F-32) : 1,8 M 42 3300 + 330 2442 + 244
°F=(°Cx1,8) + 32 M 45 4100 + 410 3034 + 303
M 48 5000 + 500 3700 + 370

4.3 General Torque for Metric Fasteners Metric ISO-Thread 2)

Be very careful never to mix metric with customary Thread Size Grade 10.9 Standard Torque
(standard) fasteners. Metric Nm 1 ) lb ft
Mismatched or incorrect fasteners will cause marine M 5 7+ 1 5+ 1
gear damage or malfunction and may even result in M 6 13 + 1 10 + 1
personal injury. M 8 30 + 3 22 + 2
M 10 60 + 6 44 + 4
Original fasteners removed from the marine gear
should be saved for reassembly whenever possible. M 12 104 + 10 77 + 8
If new fasteners are needed, they must be of the M 14 165 + 16 122 + 12
same size and grade as the ones that are being M 16 250 + 25 185 + 19
replaced. M 18 350 + 35 259 + 26
M 20 490 + 50 363 + 36
The material strength identification is usually shown M 22 670 + 67 496 + 50
on the bolt head by numbers (8.8, 10.9 etc.). M 24 850 + 85 630 + 63

The following chart gives general torques for bolts M 27 1250 + 125 925 + 93
and nuts with Grade 8.8 and 10.9. M 30 1700 + 170 1260 + 126
M 36 3000 + 300 2210 + 221
M 39 3800 + 380 2800 + 280
M 42 4700 + 470 3478 + 348
M 45 5800 + 580 4292 + 429
M 48 7000 + 700 5180 + 518

1) Newton Meter (Nm) is approximately the same

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

20
4.4 Maintenance Schedule
The Maintenance Schedule summarizes the
maintenance services which are sub-divided into
Maintenance Stages.
Particularly arduous service conditions may require
modification of the Maintenance Schedule (reduced
intervals).
Maintenance Stage 6
After each operating period of ........... hours
or 10 years
or in conjunction with an engine major overhaul
Pay attention to the operating hours intervals
matching your marine gear size. Conjunction with
the engine maintenance intervals is permissible
provided that the operating hours specified are
not excessively exceeded.

Maintenance Stage 1 Gear Size Operating Hours

Daily before engine start
WAF/LAF 64.– 67. 30 000 hours
Check oil level WAF/LAF 74. – 77. 40 000 hours
WAF/LAF 84. – 87. 40 000 hours
WAF/LAF 114. – 117. 40 000 hours
Maintenance Stage 2 WAF/LAF 154. – 156. 60 000 hours
Daily with engine running WAF/LAF 194. – 196. 60 000 hours

Check operating pressure,
oil temperature,
heat exchanger cooling water temperature,
duplex filter contamination indicator,
visual checks and running noises
Observe the general notes as well as instructions for
hydraulic assembly/ disassembly of taper press
hubs with 1:30 taper. Some special tools are
required to perform the overhaul. Please contact
the REINTJES Service Department for information.

Check: shafts for run-out,

Maintenance Stage 3 bearing seats for damage,
After first 200 operating hours carriers,
gear and pinion teeth,
Change oil, annular piston,
replace filter element, carrier pins,
check threaded connections incl. foundation, oil distributor,
check connection to engine and propeller pressure gauge
and bolts of intermediate housing,
tighten swivel nuts and banjo bolts of threaded,
pipe connections in case of leakage, Replace: clutch discs,
check heat exchanger for leakage. rectangular rings,
screws and return springs for annular piston,
O-rings,
snap rings,
Maintenance Stage 4 all clutch housing screws *8,
After each operating period of 2000 hours anti-friction bearings,
or 6 months thrust bearing screws and springs,
Change oil, shaft seals and bushes,
replace filter element oil filter elements and seals,
oil pump,
inspection cover gaskets,
o-rings for control valve /
Maintenance Stage 5
pressure limiting valve,
After each operating period of 5000 hours
flexible hoses,
or 1 year
clean the complete gearbox
Check threaded connections incl. foundation,
connection to engine and propeller and
bolts of intermediate housing,
check heat exchanger for leakage and
replace seals, if necessary.

21
4.5 Maintenance Task Descriptions
Maintenance Stage 1
Daily before engine start
Oil Level Check
The oil level can only be checked at the dipstick,
with the propulsion plant shut down and the output
shaft stationary.
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, remove the venting filter marked
OEL (OIL).
22
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 engaged, gearbox at operating
temperature and engine at full-load speed, the
normal operating pressure is
WAF/LAF 64. – WAF/LAF 196. approx. 21-25 bar
Exception:
WAF/LAF 1141 – WAF/LAF 1961 approx. 16-20 bar
The operating pressure is regulated by a spring-
loaded pressure limiting valve and set
by adjusting screw V 13.
Note:
During propulsion with the electrically operated
trolling valve the operating conditions are so
different so the abovementioned pressures are
not applicable.
Pay attention to the supplementary descriptions
when the marine gear is engaged for trolling
propulsion mode.
Oil Temperature Check
The normal operating oil temperature after the heat
exchanger will be in the range of approx. 30 - 50 °C
and can be read off at the thermometer.
If the oil temperature is higher than the normal
operating temperature, determine the possible cause
and initiate the appropriate remedial measures.
Cooling Water 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.
Oil Filter Contamination Indicator Typ RFLD
Experience has shown that the contamination
indicator must be closely observed during the
first 100 operating hours.
The differential pressure increases when the filter
becomes more contaminated. Hereby a pin will be
pressed upwards and the indication changes from
green to red.
The differential pressure is higher where the viscosity
of the oil is higher and when the oil is cold in the
starting phase.
If the indication responds on cold starts only, it is not
necessary to change the element.
In the case of the (optional) electrical contamination
indication, the NC contact of the sensor opens. If the
electrical signal actuates an indication for a longer
period of time, 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”.
Oil Filter Contamination Indicator Typ Pi 21..
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
difference 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”.
23
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 malfunc-
tions 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 elements is
to be firstly carried out on all new or completely
overhauled marine gears. 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 G 3 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 the gearbox with a recommended oil into until
the oil level reaches the upper mark on the dipstick.
The oil capacity is indicated on the gearbox name
plate.
Replace the oil filter elements.
On completion of all maintenance tasks, start the
engine and run for 5 to 10 min. Shut down the
engine and recheck the oil level. The level must
remain at the upper mark on the dipstick. Do not
overfill the gearbox.
Compliance with the oil change intervals specified in
the Maintenance Schedule is mandatory, especially
the 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. If these tempera-
tures are exceeded, the oil change intervals are
reduced and must be determined in consultation
with REINTJES.
Independent of the oil change intervals we
recommend to check the flexible hoses monthly
for cracks and damage.
Maintenance Stage 4
After each operating period of 2000 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 Typ RFLD
24
Prior to carrying out the following maintenance
tasks, the filter element to be replaced must be
taken out of service. The change over lever (1) is
closest to the filter element which is in operation.
Direct the oil flow to the currently inoperative filter by
moving the lever (1) away from the filter element to
be replaced.
Slowly release the vent screw (2) and allow all
pressure to escape. Remove the vent screw
and O-ring.
Remove the drain plug (4) and O-ring from the filter
housing. Allow the oil and contaminant deposits to
drain from the filter housing.
Remove the cover securing screws. Turn the cover
(3) through 45° and carefully remove the cover and
O-ring.
Remove the filter element (5).
Remove the filter element (5) out of the housing by
turning it clockwise while pulling.
Clean the filter housing and drain plug.
Prior to filter system reassembly, check all O-rings
for damage; replace damaged O-rings.
Install the drain plug (4) and O-ring.
Install the new filter element with O-ring. Take care
not to damage the O-ring.
Install the filter cover (3) and O-ring. Ensure that the
O-ring is correctly seated.
Insert the vent screw (2) with O-ring loosely. With
the vent screw loose, move the diverter lever (1)
approx. 10° towards the centre; in this position the
filter housing will be filled with oil. Hold the lever (1)
in this position until bubble-free oil is discharged
at the vent screw (2). Tighten the vent screw to
specified torque and set the change over lever for
single-filter operation.
Filter Element Replacement Typ Pi 21..

When contamination has been established, the filter Important

has to be changed over to the other filter element.
Operate and hold pressure equalizing lever (9)
located in the changeover lever (2). At the same
time swivel changeover lever and engage the catch
on the other side. Now the lever is positioned at the
same side as the element to be replaced. Place
trough or drip pan underneath to collect leaking oil.
Loosen vent screw (3), maximum back out against
safety stop (filter support).
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 equalizing lever (9) long
enough until the oil emerge bubble-free from the
vent bore. Tighten vent screw (3). Check filter for
leaks by operating the pressure equalizing lever
once again.

Unscrew filter bowl (5) anticlockwise and clean with

a suitable medium.

Pull down filter element (6) by slight movements to

and fro, replace element.

Before assembling the element check O-rings for

damage. Replace, if necessary.

Push element (6) onto the seat (7) (with O-ring).

Firmly screw (5) in the bowl (with O-ring (8)).

25
Maintenance Stage 5 Part Checks
After each operating period of 5000 hours (and replacement as necessary):
or 1 year
Shafts for run-out,
bearing seats for damage,
Threaded Connections carriers,
The screw tightening torques should be checked carrier pins for annular piston,
with the gear cold. Particular attention must be paid gear and pinion teeth,
to the following connections: oil distributor,
pressure gauge
Engine - flexible coupling - marine gear.
Replace:
Marine gear output shaft flange - propeller shaft.
Clutch discs,
Marine gear mountings - foundation. rectangular rings,
Swivel nuts and banjo bolts of threaded pipe screws and return springs for annular piston,
connections. O-rings,
snap rings,
Check the rubber elements of the flexible coupling all clutch housing screws *8,
for porosity, cracking or other signs of damage. anti-friction bearings,
thrust bearing screws and springs,
Check the heat exchanger for leakage and replace shaft seals and bushes,
the seals, if necessary. oil filter elements and seals,
oil pump,
inspection cover gaskets,
Maintenance Stage 6 O-rings for control valve and pressure limiting valve,
After each operating period of ......... hours flexible hoses
or 10 years
or in conjunction with engine major overhaul Thoroughly clean the gear housing, vent filter and
all other parts which are to be reused.
Pay attention to the operating hours intervals
matching your marine gear size. Our Service Department is available at all times, to
answer any questions you may have.
Conjunction with the engine maintenance intervals
is permissible provided that the operating hours
specified are not excessively exceeded.

Gear Size Operating Hours

WAF/LAF 64. – 67. 30 000 hours
WAF/LAF 74. – 77. 40 000 hours
WAF/LAF 84. – 87. 40 000 hours
WAF/LAF 114. - 117. 40 000 hours
WAF/LAF 154. - 156. 60 000 hours
WAF/LAF 194. - 196. 60 000 hours

Observe the general notes as well as instructions for

hydraulic assembly/ disassembly of taper press hubs
with 1:30 taper. Some special tools are required to
perform the overhaul.
Please contact the REINTJES Service Department
for information.

26
4.6 Completed Maintenance

Gearbox No.

Type

Operating- Maintenance Stage Date Initials

hours

27
4.7 Troubleshooting

Disturbance

Probable Cause Remedial Action

1) Gear noise

Idle speed in critical range Raise idle speed

Anti-friction bearing damaged Check gear security and alignment,

(possibility of metallic residues in filter) inspect gear (replace bearings)

Hydraulic noise, pump sucks in air 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

Antifriction 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

Pump sucks in air see Item 2)

Pump drive or pump defective (wear) Repair or replace

Pressure limiting valve blocked Repair or replace

Non-return valve to electric pump Clean or replace

defective

Incorrect brand oil Check viscosity, change oil

28
Probable Cause Remedial Action

6) Operating pressure too high

Pressure limiting valve blocked Repair or replace

or defective

Oil cold Carry out gear warm-up procedure

Incorrect brand oil Check viscosity, change oil

7) Clutch slipping

Operating pressure too low see Item 5)

8) Clutch does not engage

Control valve not correctly Check engagement sequence and

positioned position

9) Clutch does not disengage

Control defective Check disengagement sequence,

disengage manually
(Check output shaft free movement)

Discs defective or seized Check emergency operation status,

separate if necessary
Check oil brand
Replace discs and inspect thoroughly

4.8 Preservation of the Gearbox

Preservation Measures
From outside the gearbox is protected from
corrosion by adequate packaging for transportation
and the storage period stated in the contract.
All openings of the gearbox are sealed.
For preservation of the inner parts the gearbox is
operated with preservation oil during the test run.
After the test run BRANOROL (VCI preservation oil)
is filled into the gearbox. This is indicated by the
plate on the gearbox:
Gearbox preserved with BRANOROL.
For initial operation drain off BRANOROL,
fill in oil and screw in venting filter.
The instructions on the plate must be strictly
observed!
Before putting the gearbox into operation, the
preservation oil must be drained (residual quantities
may remain in the gearbox). The gearbox must then
be filled with the indicated quantity of operating oil.
Never clean the interior of the gearbox with water or
other chemicals.
Packaging, Storage, Standstill Periods
The effectiveness of the preservation measures
depends on the packaging and the storage
conditions.
Defective packaging and unfavorable storage
conditions, e.g. high atmospheric humidity, saliferous
air or extremely changing temperatures etc., will
have a negative effect on the permissible storage
period.
On reception the gearbox packaging has to be
checked for transport damages immediately. In the
period after removal of the original packaging and
before initial operation adequate measures have to
be taken to ensure optimum protection of the
gearbox from environmental influences and external
damage.
All openings of the gearbox have to be kept sealed.
Additional anticorrosion measures according
to BV 1945 are necessary,
- if the packaging has been damaged or is taken off
more than 4 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.

29
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 consid-
ered, all parts must be marked before being
removed (e.g. pinion shaft carrier, lubrication of
discs).
5.1.1 Seals
Some parts have been fitted with O-rings, e.g.
the control valve.
Flat gaskets have been used for the inspection
covers.
All other single parts are assembled with a liquid
surface sealant (anaerobic sealant) having almost no
influence on the dimensions.
These sealing areas must be cleaned and dried
before assembly. The sealing material must be
applied on one part in the form of a continuous band
(2-3 mm - 0.1”) along the centre line and inside past
the drill holes.
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.
30
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
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. Then
the parts are assembled and screwed up.
5.4 Instructions for Hydraulic Assembly/
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 east 300 MPa (3000 bar).
- Make sure that the pump and the high-pressure
pipe are completely filled with oil and that all air
has been expelled from the pump.
- The pipe must not be bent or otherwise subjected
to violent treatment when pressurized. Mishandling
of the pipe can lead to accidents.
- The pressures required for expansion and force-on
must permanently be checked with pressure
gauges.
- Ensure that adequate safety precautions are
taken when working with high-pressure hydraulic
systems.
- Oil under extreme pressure can cause injuries.
- Always wear protective goggles.
- Oil under pressure must not be allowed to come
into contact with the skin.
31
Inspection of Individual Components
Prior to assembly of the individual components (e.g.
shaft and gear, shaft and flange) it is necessary to
carefully inspect the taper surfaces. Ensure that
taper surface and oil distribution groove transitions
are free of burrs. Remove all burrs and rectify any
other damage found.
Instructions for Repair:
During repair operations, the nature and extent of
the damage may require that shaft concentricity,
taper surface and bearing seating be checked.
Pressurizing Media and Assembly Preparations
Expansion of the component to be mounted (gear,
flange, etc.) is to be effected using SAE 10 oil
(viscosity 32 cST at 40°C).
The oil used for expanding operations must be
absolutely free of contaminants and EP additives.
The components to be assembled should be at the
same temperature, i.e. wherever possible assembly
should be carried out at ambient temperature.
All taper surfaces are to be thoroughly cleaned
with a degreasing agent and thinly coated with
the SAE 10 hydraulic oil used for assembly
(viscosity 32 cST at 40°C).
Force-on Dimension Check
Information for force-on dimension and expansion
pressure will be given by REINTJES service
department on request.
The force-on dimension is stated in mm and
comprised the nominal dimension and a
permissible tolerance, e.g. 13.3 + 1.2 mm.
To determine the force-on dimension push the
component to be mounted (gear, flange, etc.)
onto the shaft.
The first checking dimension, required to establish
the force-on dimension of the component to be
mounted, is calculated from that point at which
the taper faces are in full contact with each other
without any pressure applied.
In order to be able to complete further force-on
dimension checks it is now necessary to select an
additional reference point. A reference lip (shoulder)
on the shaft is recommended for this purpose.
Note the checking dimension thus obtained.
Position the assembly jig (hydraulic nut) 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
Expansion and Force-on of Component to be
Installed (Gear, Flange, etc.)
In order to be forced-on, the component to be
installed must first be expanded.
In order to do this oil is forced between the taper
faces until it emerges at the ends of the connection.
The force-on action is achieved by repeatedly
increasing and alternating the expansion and
force-on pressures until the component is forced-on
into its final position acc. to the specified force-on
dimension.
During the force-on procedure the expansion
pressure increase should not be allowed to exceed
100 bar over a 3 minute period; this is necessary to
avoid localized exceeding of the max. permissible
yield point value.
When the component is in its specified position the
expansion pressure at connection “B” must be
relieved to allow the oil film between the taper
surfaces to disperse. The force-on pressure must be
maintained at connection “A” for at least one hour.
Approximately 24 hours should be allowed to pass
before the assembly is subjected to maximum load.
This time delay is necessary to ensure that all
expansion fluid has been expelled from the
component mating faces.
32
NOTE
In this case of components with two connecting
points for expansion pressure one of these must
be effectively plugged.
Instruction for Hydraulic Disassembly
ATTENTION
Hydraulically assembled components are under
extremely high pressure and can cause injury
when released. As the component to be removed
can be suddenly released at great force it is
mandatory that this part be provided with a stop
(hydraulic nut) as a safety measure.
In order to remove the subject component (gear,
flange, etc.) from the shaft, the installation / removal
jig (hydraulic nut) and hydraulic pumps must be
assembled in the same positions and manner as
used for component assembly.
As a function of the max. force-on dimension, the
annular piston must be forced out of the hydraulic
nut 3-4 mm (see sketch) and, with a force-on pres-
sure of 100 bar applied at connection “A”, brought
into contact with the component to be removed.
The force-on pressure in the hydraulic nut must then
be released and the hydraulic pump valve to the
hydraulic nut connection “A” must be closed.
In order to be released, the component to be
removed must first be expanded via connection “B”.
In order to achieve this, hydraulic oil is forced slowly
between the component taper faces. Expansion
pressure increases should not exceed 100 bar
over a period of 3 minutes.
Component release is indicated by a rise in
pressure in the hydraulic nut which is indicated
at the pressure gauge of the hydraulic pump
assigned to connection “A”.
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 5.5 Bearing Adjustments
Output Shaft Thrust Bearing Axial Clearance
The component being removed may be released
suddenly when the pressure at connection “A” is NOTE: Bearing axial clearance must be checked and
released to zero, for this reason it is mandatory adjusted any time bearings are changed.
that the hydraulic nut (safety stop) be correctly
installed. Measure and Adjust
If the max. expansion pressure is achieved and the
component to be removed is not released, proceed
as follows:

- Increase expansion pressure at connection “B”

by 10 %.

- Maintain this pressure for one hour.

- In addition, heat the component slowly and

evenly. (temperature max. 140°C or 284°F)

- Mount an additional puller.

The thrust bearings consists of bearings (P 21)
Pressure Connections and (P 22). Zero clearance is specified without
preloading.

33
Measurement of bearings overall height
1. Stack inner bearings races on each other and
fasten the bearings together on a parallel plate.
Turn the bearings approx. 5 times in both
directions.
Adjust innern and outer rings coaxial and fix them
by a device (as shown in pict. 2) on the parallel
plate. The bearings should have no clearance but
make sure that it is still possible to rotate them.
Ensure the case does not touch anything.
NOTE: It is necessary that part 1+2 are
planeparallel.
Measure height (H) of the bearings at 6 points. Add
the measuements and divide the sum by 6 to find
the average height dimension (B).
(as shown in pict. 2)
34
2. Measure distance (C) from housing’s mating
surface to seat, of bearing outer ring (P 21).
3. Measure distance (D) from mating surface of
cover E 202 to bearing outer ring (P 22).
4. Subtract distance (D) from (C) to obtain
dimension (A). Dimensions (A) and (B) must
be equal.
(as shown in pict. 3)
ATTENTION
Bearing seat surfaces must remain parallel to
mating surfaces in all cases.
If dimension (A) is smaller than dimension (B),
machine the cover’s bearing seat surface (E).
If dimension (B) is smaller than dimension (A),
machine the housing’s mating surface (F) (as
shown in pict. 4).
5.6 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.

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.

The lubrication oil bores must radially overlap

to guarantee clutch disc lubrication.

35
5.7 Recommended Maintenance Procedures for Heat Exchangers of BLOKSMA Make

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

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

ATTENTION:

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

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

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

2.1 Intervals of Anode Checks

First inspection After 100 hours of operation

Inspections thereafter Every three months or on occasion of every cleaning

36
2.2 Visual Inspection

Cooling water circuit Shut inlet and outlet valves

Heat exchanger Drain cooling water

Anodes Screw out anodes and perform visual check

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

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

Visual check finished - Open cooling water valves

- Switch on cooling water pump

- Vent heat exchanger

- Check anodes for waterproof installation

3 Contamination Control of Tube Bundle

3.1 Construction of Heat Exchanger

schematic drawing

1 Tube plate

2 O-rings

3 Fixing plate

4 Shell

5 Tube bundle

Both tube plates are identical:

- The outer O-rings seal the corresponding cover,

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

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

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

Important

Never mount the covers to the wrong side.

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

37
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 partition 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

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)

38
A Take off both O-rings

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

(A) Pull out tube bundle carefully

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

Clean tube bundle according to the inspection result.

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

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

3.4 Re-assembly of Tube Bundle

Never use the old, dismounted O-rings.

Always fit new O-rings.

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

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

Shell Clean sealing surfaces carefully, check for damages

Apply thin layer of suitable lubricant to sealing surfaces

Tube plate Clean grooves carefully, check for damages

Apply suitable lubricant to grooves

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

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

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

39
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.

40
6.0 Spare Parts
Gearbox Identification Spare Parts
Data required for inquiries and/or ordering parts may In addition to the gear identification data your order
be taken from the name plate, in particular should specify
- item number,
- denomination of the part and
1. Gear No. - quantity.

2. Type The quantities indicated on the following pages

refer to gearboxes of the WAF series.
3. Input Capacity For LAF gearboxes this figures will differ depending
on the excecution counter or identical rotation.
4. Input Speed
Continuing improvement and advancement of
product design may cause changes to your gearbox
which may not be included in this manual.
The gear number is also stamped on the gearbox
Each printed manual will be reviewed and revised,
housing near the engine.
as required, to update and include these changes in
later editions.

Whenever a question arises regarding your

REINTJES gearbox or this manual, please
consult the REINTJES service department.

Please transfer the data indicated on the name plate

of your gearbox to this form.

41
42
 Piping and external parts
Quantity per WAF-Gearbox Quantity per WAF-Gearbox Quantity per WAF-Gearbox
77. 87. 77. 87. 77. 87.
Item 66. 76. 86. 116. 156. 196. Item 66. 76. 86. 116. 156. 196. Item 66. 76. 86. 116. 156. 196.
No. Designation 64. 74. 84. 114. 154. 194. No. Designation 64. 74. 84. 114. 154. 194. No. Designation 64. 74. 84. 114. 154. 194.

A 1 Heat exchanger *S 1 1 1 1 1 1 H 2 Screwed union 1 1 1 - - - H 90 Pipe 1 1 1 1 1 1

A 2 Hexagon screw 4 4 4 4 4 4 H 3 Pipe 1 1 1 1 1 1 H 91 Screwed union 1 1 1 1 1 1
A 3 Duplex filter *S 1 1 1 1 1 1 H 4 A Screwed union 1 1 1 - - - H 128 Pipe 1 1 1 1 1 1
A 4 Threaded flange - 1 1 1 1 1 H 4 B Reducing fitting 1 1 1 - - - H 179 A Plug screw 2 2 2 2 2 2
A 5 O-ring - 2 2 2 2 2 H 5 Screwed union 1 1 1 1 1 1 H 179 B Seal ring 2 2 2 2 2 2
A 6 Threaded flange - 1 1 1 1 1 H 6 Pipe 1 1 1 1 1 1 H 182 Screwed union 1 1 1 1 1 1
A 7 Allen screw with H 7 Screwed union 1 1 1 1 1 1 H 183 Pipe 1 1 1 1 1 1
spring washer - 8 8 8 8 8 H 8 Screwed union 1 1 1 1 1 1 H 184 Screwed union 1 1 1 1 1 1
A 35 Pressure gauge 1 1 1 1 1 1 H 9 Pipe 1 1 1 1 1 1 H 195 Screwed union 1 1 1 1 1 1
A 73 Shutt-off valve 1 1 1 1 1 1 H 10 Screwed union 2 1 1 1 1 1 H 197 A Connection piece 1 1 1 1 1 1
A 80 Support for filter 1 - - - - - H 11 Screwed union 2 1 1 1 1 2 H 197 B Plug screw 1 1 1 1 1 1
A 81 Hexagon screw 4 2 2 2 2 2 H 12 Pipe 1 1 1 1 1 1 H 1058 A Pipe clamp 3 3 3 3 3 3
A 83 Hexagon screw 2 - - - - - H 13 A Screwed union 1 1 1 1 1 1 H 1058 B Allen screw 6 6 6 6 6 6
A 298 Oil distributor 1 1 1 1 1 1 H 13 B Reducing fitting 1 1 1 - - - H 1062 Plug screw 1 1 1 1 1 1

43
A 303 Allen screw 4 4 4 4 4 4 H 14 A Reducing fitting 1 1 1 1 1 1 H 1063 Plug screw 1 1 1 1 1 1
A 304 O-ring 1 1 1 1 1 1 H 14 B Screwed union 1 1 1 1 1 1 H 1068 A Pipe clamp 1 1 1 1 1 1
H 16 Pipe 1 1 1 1 1 1 H 1068 B Allen screw 2 2 2 2 2 2
E 19 Oil pump *S 1 1 1 1 1 1 H 17 A Screwed union 1 1 1 1 1 1 H 1068 C Hexagon nut 2 2 2 2 2 2
E 23 Dipstick 1 1 1 1 1 1 H 17 B Reducing fitting 1 1 1 1 1 1 H 1069 Operation delay pot *S 1 1 1 1 1 1
E 29 Plug 1 1 1 1 1 1 H 18 A Reducing fitting 1 1 1 1 1 1 H 1070 Hexagon screw
E 107 Venting filter 1 1 1 1 1 1 H 18 B Screwed union 1 1 1 1 1 1 with washer 4 4 4 4 4 4
E 234 Threaded flange 1 1 1 - - - H 20 Pipe 1 1 1 1 1 1 H 1071 Hexagon screw
E 235 Set of seals 1 1 1 1 1 1 H 21 Screwed union 1 1 1 1 1 1 with washer 4 4 4 4 4 4
E 236 Threaded flange 1 1 1 1 1 1 H 29 Screwed union 1 1 1 1 1 1 H 1074 Operation delay pot *S 1 1 1 1 1 1
E 238 Allen screw with H 30 Pipe 1 1 1 1 1 1 H 1101 Support * 1 1 1 1 1 1
spring washer 8 8 8 8 8 8 H 31 Screwed union 1 1 1 1 1 1 H 1102 A Pipe clamp * 1 1 1 1 1 1
H 32 Pipe 1 1 1 1 1 1 H 1102 B Allen screw * 2 2 2 2 2 2
G 3 Plug screw 1 1 1 1 1 1 H 33 Screwed union 1 1 1 1 1 1 H 1102 C Hexagon nut * 2 2 2 2 2 2
G 3 Seal ring 1 1 1 1 1 1 H 42 Screwed union 1 1 1 1 1 1 H 1103 A Pipe clamp 1 1 1 1 1 1
G 43 Plug 1 1 1 - - - H 44 Screwed union 1 1 1 1 1 1 H 1103 B Allen screw 2 2 2 2 2 2
H 45 Connection piece for
pressure gauge 1 1 1 1 1 1 V 1 Control valve *S 1 1 1 1 1 1
H 46 A Support for V 10 Allen screw 4 4 4 4 4 4
pressure gauge 1 1 1 1 1 1 V 232 Connection plate *S 1 1 1 1 1 1
H 46 B Allen screw 2 2 2 2 2 2 V 247 Intermediate plate *S 1 1 1 1 1 1
H 85 Screwed union 1 1 1 1 1 1 V 248 Allen screw 4 4 4 4 4 4
* not standard
*S Service repair kits
44
 Housing
Quantity per WAF-Gearbox
Item 77. 87.
No. Designation 64. 66. 74. 76. 84. 86. 114. 116. 154. 156. 194. 196.
E 2 Cover 1 1 1 1 1 1 1 1 1 1 1 1
E 4 Hexagon screw 10 10 10 10 10 10 10 10 10 10 10 10
E 57 Cover 1 1 1 1 1 1 1 1 1 1 1 1
E 107 Venting filter 1 1 1 1 1 1 1 1 1 1 1 1
E 563 Hexagon screw 10 10 10 10 10 10 10 10 10 10 10 10
E 715 Gasket 1 1 1 1 1 1 1 1 1 1 1 1
E 716 Gasket 1 1 1 1 1 1 1 1 1 1 1 1

G 1 Housing bottom part *1 - - - - - - - - - - - -

G 2 Housing top part *1 - - - - - - - - - - - -
G 65 Shielding sheet 1 1 1 1 1 1 1 1 1 1 1 1
G 82 Housing centre part *1 - - - - - - - - - - - -
G 126 Threaded pin 1 1 1 1 1 1 1 1 1 1 1 1
G 163 Hexagon screw 4 8 8 6 6 6 4 4 4 4 4 4
G 200 Hexagon screw 4 4 4 4 4 4 4 4 4 4 4 4
G 279 Pipe 1 1 1 1 1 1 1 1 1 1 1 1
G 280 Pipe 1 1 1 1 1 1 1 1 1 1 1 1
G 300 Hexagon screw 20 18 18 18 18 18 18 18 18 18 20 20

45
G 300 Hexagon nut 20 18 18 18 18 18 18 18 18 18 20 20
G 301 Hexagon screw 4 4 4 4 4 4 4 6 6 6 6 6
G 303 Hexagon screw 2 2 2 2 2 2 2 2 2 2 - -
G 303 Hexagon nut 2 2 2 2 2 2 2 2 2 2 - -
G 310 Hexagon screw 4 4 4 4 4 4 4 4 4 4 4 4
G 320 Allen screw 2 2 2 2 2 2 2 2 2 2 2 2
G 330 Cylindrical pin 4 4 4 4 4 4 4 2 2 3 2 3
G 335 Cylindrical pin - - - - - - - 4 4 4 4 4
G 350 Hexagon screw 19 19 18 18 20 20 22 22 22 22 24 24
G 350 Hexagon nut 19 19 18 18 20 20 22 22 22 22 24 24
G 360 Allen screw 2 2 2 2 2 2 3 3 3 3 3 3
G 361 Allen screw 1 1 1 1 1 1 - - - - - -
G 370 Allen screw 3 3 2 2 2 2 3 3 3 3 3 3
G 371 Allen screw - - 1 1 1 1 - - - - - -
G 380 Cylindrical pin 4 4 4 4 4 4 4 4 4 4 4 4
G 390 Allen screw 2 2 2 2 2 2 2 2 2 2 2 2
G 391 Allen screw 2 2 2 2 2 2 2 2 2 2 2 2
G 392 Allen screw 2 2 2 2 2 2 2 2 2 2 2 2
G 481 Threaded pin 1 1 1 1 1 1 1 1 1 1 1 1
G 482 Pipe 1 1 1 1 1 1 1 1 1 1 1 1
G 483 Threaded pin 1 1 1 1 1 1 1 1 1 1 1 1

*1 can only be ordered completely

46
 Input shaft
Quantity per WAF-Gearbox Quantity per WAF-Gearbox
77. 87. 77. 87.
Item 66. 76. 86. 116. 156. 196. Item 66. 76. 86. 116. 156. 196.
No. Designation 64. 74. 84. 114. 154. 194. No. Designation 64. 74. 84. 114. 154. 194.
E 5 Bearing housing 1 1 1 - - - G 16 Allen screw 2 2 2 - - -
E 7 Cover 1 1 1 1 1 1 G 316 Retaining ring 1 1 1 1 1 1
E 11 Shaft sealing ring 1 1 1 1 1 1 G 480 Retaining ring 1 1 1 1 1 1
E 15 Anti-friction bearing 1 1 1 1 1 1
E 19 Oil pump *S 1 1 1 1 1 1 K 1 Clutch support 2 2 2 2 2 2
E 28 Oil distributor * 1 1 1 1 1 1 K 2 Retaining ring 2 2 2 2 2 2
E 30 Hexagon screw 8 8 12 - - - K 5 Bolt 24 24 32 24 24 28
E 41 Housing pump drive *9 * - - - - - - K 6 Spring 24 24 32 24 24 28
E 42 Pump wheel * 1 1 1 1 1 1 K 7 Rectangular ring 2 2 2 2 2 2
E 43 Shaft wheel * 1 1 1 1 1 1 K 8 Hexagon screw *S 16 16 16 16 16 12
E 44 Threaded pin * 1 1 1 1 1 1 K 9 Hexagon nut 16 16 16 16 16 12
E 46 Hexagon screw * 4 4 4 4 4 4 K 13 Hexagon screw *8 24 36 32 32 48 48
E 49 Tapered pin * 2 2 2 4 4 4 K 15 Clutch housing 1 1 1 1 1 1
E 97 Cover * 1 1 1 1 1 1 K 17 Annular piston 2 2 2 2 2 2
E 108 Hexagon screw * 4 4 4 4 4 4 K 18 Rectangular ring 2 2 2 2 2 2
E 122 Anti-friction bearing 2 2 2 2 2 2 K 22 Inner disc 22 22 22 22 24 24
E 123 Anti-friction bearing 2 2 2 2 2 2 K 23 Outer disc 24 24 24 24 26 26

47
E 124 Anti-friction bearing 2 2 2 2 2 2 K 30 Carrier 2 2 2 2 2 2
E 125 Anti-friction bearing 2 2 2 2 2 2 K 40 Carrier cover 1 1 1 1 1 1
E 126 Anti-friction bearing * 1 1 1 1 1 1 K 41 Allen screw 8 8 8 8 8 8
E 129 Hexagon screw * 8 8 12 8 12 12 K 59 Cover 2 2 2 2 2 2
E 130 Bearing housing pump drive *9 * 1 1 1 1 1 1 K 60 Allen screw 16 16 16 24 24 24
E 143 Hexagon screw 4 4 4 4 4 4 K 128 O-ring 1 1 1 1 1 1
E 150 Hexagon screw * 4 4 4 4 4 4
E 186 Hexagon screw 8 8 12 8 12 12 R 1 Pinion shaft 1 1 1 1 1 1
E 206 Cover 1 1 1 1 1 1 R 32 Shaft nut 2 2 2 2 2 2
E 244 Hexagon screw 8 8 8 8 12 12 R 33 Threaded pin 2 2 2 2 2 2
E 537 Clamping sleeve 1 1 1 1 1 1 R 43 Retaining ring 2 2 2 2 2 2
E 585 Bush - - - 1 1 1 R 105 Retaining ring 2 2 2 2 2 2
E 586 Washer - - - 1 1 1
E 587 Countersunk screw - - - 3 3 3 W 1 Input shaft 1 1 1 1 1 1
E 719 Allen screw * 4 4 4 4 4 4 W 4 Shaft nut * 1 1 1 1 1 1
E 1102 Clamping sleeve 1 1 1 1 1 1 W 7 Shaft nut - - - 1 1 1
E 1214 Bush - - - 1 1 1 W 7 Retaining ring 1 1 1 - - -
E 1215 Washer - - - 1 1 1 W 8 Threaded pin - - - 1 1 1
E 1294 Countersunk screw - - - 3 3 3 W 12 Bush 1 1 1 1 1 1
W 42 Fitted key * 1 1 1 1 1 1
W 84 Bush * 1 1 1 - - -
* not standard W 166 Hexagon screw *8 48 60 60 60 72 72
*S Service repair kits W 169 Carrier pin 8 8 8 12 12 12
*8 have to be renewed on dismantling (special screw)
*9 can only be ordered completely W 179 Non-return valve 4 4 4 4 4 4
48
 Intermediate shaft
Quantity per WAF-Gearbox Quantity per WAF-Gearbox
77. 87. 77. 87.
Item 66. 76. 86. 116. 156. 196. Item 66. 76. 86. 116. 156. 196.
No. Designation 64. 74. 84. 114. 154. 194. No. Designation 64. 74. 84. 114. 154. 194.
E 8 Cover 1 1 1 1 1 1 K 8 Hexagon screw *S 16 16 16 16 16 12
E 13 Anti-friction bearing 1 1 1 1 1 1 K 9 Hexagon nut 16 16 16 16 16 12
E 40 Cover 1 1 1 1 1 1 K 13 Hexagon screw *8 24 36 32 32 48 48
E 56 Hexagon screw 8 8 12 8 12 12 K 16 Clutch housing 1 1 1 1 1 1
E 122 Anti-friction bearing 2 2 2 2 2 2 K 17 Annular piston 2 2 2 2 2 2
E 123 Anti-friction bearing 2 2 2 2 2 2 K 18 Rectangular ring 2 2 2 2 2 2
E 124 Anti-friction bearing 2 2 2 2 2 2 K 22 Inner disc 22 22 22 22 24 24
E 125 Anti-friction bearing 2 2 2 2 2 2 K 23 Outer disc 24 24 24 24 26 26
E 205 Hexagon screw 8 8 8 8 12 12 K 30 Carrier 2 2 2 2 2 2
E 367 Clamping sleeve 1 1 1 1 1 1 K 59 Cover 2 2 2 2 2 2
E 705 Bearing housing 1 1 1 - - - K 60 Allen screw 16 16 16 24 24 24
E 706 Hexagon screw 8 8 12 - - - K 119 Allen screw 8 8 8 8 8 8
E 722 Oil distributor - 1 - 1 1 1 K 120 O-ring 1 1 1 1 1 1
E 723 Hexagon screw - 4 - 4 4 4 K 125 Carrier cover 1 1 1 1 1 1
E 1030 Washer - - - 1 1 1
E 1031 Countersunk screw - - - 3 3 3 R 32 Shaft nut 2 2 2 2 2 2
R 33 Threaded pin 2 2 2 2 2 2

49
E 1032 Bush - - - 1 1 1
R 43 Retaining ring 2 2 2 2 2 2
G 16 Allen screw 2 2 2 - - - R 105 Retaining ring 2 2 2 2 2 2
G 281 Retaining ring 1 1 1 1 1 1 R 119 Pinion shaft 1 1 1 1 1 1
G 484 Retaining ring 1 1 1 1 1 1
W 17 Intermediate shaft 1 1 1 1 1 1
K 1 Clutch support 2 2 2 2 2 2 W 103 Shaft nut - - - 1 1 1
K 2 Retaining ring 2 2 2 2 2 2 W 103 Retaining ring 1 1 1 - - -
K 5 Bolt 24 24 32 24 24 28 W 166 Hexagon screw *8 48 60 60 60 72 72
K 6 Spring 24 24 32 24 24 28 W 169 Carrier pin 8 8 8 12 12 12
K 7 Rectangular ring 2 2 2 2 2 2 W 179 Non-return valve 4 4 4 4 4 4
W 301 Threaded pin - - - 1 1 1

*S Service repair kits

*8 have to be renewed on dismantling (special screw)
50
 Output shaft
Quantity per WAF-Gearbox
84. 114.
Item 77. 87. 154. 194.
No. Designation 64. 66. 74. 76. 86. 116. 156. 196.
E 104 Hexagon screw 12 12 12 8 8 12 12 12
E 115 Hexagon screw 8 8 8 8 8 12 12 12
E 193 Cover 1 1 1 1 1 1 1 1
E 202 Cover 1 1 1 1 1 1 1 1
E 203 Spring 8 6 6 6 12 12 8 12
E 219 Shaft sealing ring 1 1 1 1 1 1 1 1

P 1 Output shaft 1 1 1 1 1 1 1 1
P 2 Bush 1 1 - - - - - -
P 20 Anti-friction bearing 1 1 1 1 1 1 1 1
P 21 Anti-friction bearing 1 1 1 1 1 1 1 1
P 22 Anti-friction bearing 1 1 1 1 1 1 1 1
P 32 Bush 1 1 1 1 1 1 1 1
P 43 Threaded pin 2 2 2 2 2 2 2 2
P 44 Shaft nut 1 1 1 1 1 1 1 1

51
R 2 Wheel *2 1 1 1 1 1 1 1 1

*2 pay attention to assembly and dismantling instruction for taper press hubs with 1:30 taper
52
 Power take off (K21)
Quantity per WAF-Gearbox
77. 87.
Item 66. 76. 86. 116. 156. 196.
No. Designation 64. 74. 84. 114. 154. 194.
E 26 Shaft sealing ring 1 1 1 1 1 1
E 27 Cover 1 1 1 1 1 1
E 34 Anti-friction bearing 1 1 1 1 1 1
E 181 Bearing housing 1 1 1 1 1 1
E 182 Hexagon screw 8 8 12 8 12 12
E 412 Hexagon screw 6 6 6 6 8 6
E 1103 Clamping sleeve 1 1 1 1 1 1
E 1204 Bush - - - 1 1 1
E 1205 Washer - - - 1 1 1
E 1296 Countersunk screw - - - 3 3 3

W 19 Fitted key 1 1 1 1 1 1
W 20 PTO-shaft 1 1 1 1 1 1
W 21 Bush 1 1 1 1 1 1
W 171 Retaining ring 1 1 1 1 1 1
W 265 Bush 1 1 1 1 1 1

53
W 342 Retaining ring 1 - - - 1 -
54
 Power take off (K31)
Quantity per WAF-Gearbox
77. 87.
Item 66. 76. 86. 116. 156. 196.
No. Designation 64. 74. 84. 114. 154. 194.
E 34 Anti-friction bearing 1 1 1 1 1 1
E 604 Housing 1 1 1 1 1 1
E 605 Hexagon screw 12 12 12 12 12 12
E 606 Housing cover 1 1 1 1 1 1
E 607 Allen screw 18 18 18 18 18 18
E 608 Tapered pin 4 4 4 4 4 4
E 637 Anti-friction bearing 1 1 1 1 1 1
E 638 Anti-friction bearing 1 1 1 1 1 1
E 855 Oil chamber plate 2 2 2 2 2 2
E 856 Countersunk screw 6 6 6 6 6 6
E 857 Retaining ring 1 1 1 1 1 1
E 859 Cover 1 1 1 1 1 1
E 860 Hexagon screw 6 6 6 6 6 6
E 861 Anti-friction bearing 1 1 1 1 1 1
E 863 Plug screw 1 1 1 1 1 1

55
E 883 Cover 1 1 1 1 1 1
E 884 Hexagon screw 6 6 6 6 6 6
E 885 Shaft sealing ring 1 1 1 1 1 1

R 107 Wheel *2 1 1 1 1 1 1
R 108 Pinion shaft / Wheel *2 1 1 1 1 1 1

W 20 Intermediate shaft PTO 1 1 1 1 1 1

W 171 Retaining ring 2 2 2 2 2 2
W 220 Shaft 1 1 1 1 1 1
W 223 Fitted key 1 1 1 1 1 1
W 265 Bush 1 1 1 1 1 1
W 271 Bush 1 1 1 1 1 1
W 272 Shaft nut 1 1 1 1 1 1
W 299 Shaft nut 1 1 1 1 1 1

*2 pay attention to assembly and dismantling instruction for taper press hubs with 1:30 taper
56
 Power take off (K41)
Quantity per WAF-Gearbox
77. 87.
Item 66. 76. 86. 116. 156. 196.
No. Designation 64. 74. 84. 114. 154. 194.
E 296 Cover 1 1 1 1 1 1
E 297 Hexagon screw 8 8 8 8 8 8
E 631 Anti-friction bearing 1 1 1 1 1 1
E 687 Anti-friction bearing 1 1 1 1 1 1
E 688 Anti-friction bearing 1 1 1 1 1 1
E 956 Cover 1 1 1 1 1 1
E 957 Hexagon screw 8 8 8 8 8 8
E 958 Shaft sealing ring 1 1 1 1 1 1
E 965 Bush 1 1 1 1 1 1

G 283 Pipe 1 1 1 1 1 1
G 498 Threaded pin 1 1 1 1 1 1
G 500 Orifice 1 1 1 1 1 1
G 501 Orifice 1 1 1 1 1 1

R 118 Pinion shaft / Wheel *2 1 1 1 1 1 1

57
W 241 PTO shaft 1 1 1 1 1 1
W 243 Bush 1 1 1 1 1 1
W 244 Retaining ring 1 1 1 1 1 1
W 245 Fitted key 1 1 1 1 1 1

*2 pay attention to assembly and dismantling instruction for taper press hubs with 1:30 taper
58
 Power take off (K51)
Quantity per WAF-Gearbox Quantity per WAF-Gearbox
77. 87. 77. 87.
Item 66. 76. 86. 116. 156. 196. Item 66. 76. 86. 116. 156. 196.
No. Designation 64. 74. 84. 114. 154. 194. No. Designation 64. 74. 84. 114. 154. 194.
E 76 Hexagon screw 8 8 8 8 8 8 N 15 Rectangular ring 1 1 1 1 1 1
E 107 Venting filter 1 1 1 1 1 1 N 16 Carrier 1 1 1 1 1 1
E 112 Bearing housing 1 1 1 1 1 1 N 21 Anti-friction bearing 1 1 1 1 1 1
E 113 Hexagon screw 8 8 8 8 8 8 N 36 Hexagon screw *8 22 22 22 22 22 22
E 164 Cover 1 1 1 1 1 1 N 39 Anti-friction bearing 1 1 1 1 1 1
E 184 Cover 1 1 1 1 1 1 N 47 Bush 1 1 1 1 1 1
E 187 Shaft sealing ring 1 1 1 1 1 1 N 50 Fitted key 1 1 1 1 1 1
E 457 Bush 1 1 1 1 1 1 N 52 Carrier pin 4 4 4 4 4 4
E 483 Oil distributor 1 1 1 1 1 1 N 55 Spring 12 12 12 12 12 12
E 486 Hexagon screw 4 4 4 4 4 4 N 57 Bolt 12 12 12 12 12 12
E 580 Cover 1 1 1 1 1 1 N 58 Hexagon screw 8 8 8 8 8 8
E 581 Hexagon screw 8 8 8 8 8 8 N 59 Wire socket 2 2 2 2 2 2
E 640 Cover 1 1 1 1 1 1 N 59 Locking wire 1 1 1 1 1 1
E 657 Hexagon screw 8 8 8 8 8 8 N 60 Non-return valve 2 2 2 2 2 2
E 802 Gasket 1 1 1 1 1 1 N 67 Cover 1 1 1 1 1 1

59
E 862 Gasket 1 1 1 1 1 1 N 68 Rectangular ring 1 1 1 1 1 1
E 897 Hexagon screw 8 8 8 8 8 8 N 73 Hexagon screw *8 12 12 12 12 12 12
E 948 Adjustment shims 2 2 2 2 2 2 N 76 Retaining ring 1 1 1 1 1 1
E 948 Adjustment shims 2 2 2 2 2 2 N 78 Allen screw 8 8 8 8 8 8
E 948 Adjustment shims 2 2 2 2 2 2 N 79 Outer disc 12 12 12 12 12 12
N 80 Inner disc 11 11 11 11 11 11
G 439 Pipe 1 1 1 1 1 1 N 195 Retaining ring 1 1 1 1 1 1
G 456 Orifice 1 1 1 1 1 1 N 196 Retaining ring 1 1 1 1 1 1
G 457 Orifice 1 1 1 1 1 1 N 197 Anti-friction bearing 1 1 1 1 1 1
G 491 Threaded pin 1 1 1 1 1 1 N 199 Retaining ring 2 2 2 2 2 2
G 492 Locking plate 2 2 2 2 2 2 N 200 Fitted disc 1 1 1 1 1 1
G 493 Hexagon screw 4 4 4 4 4 4 N 201 Retaining ring 1 1 1 1 1 1
N 202 Anti-friction bearing 1 1 1 1 1 1
N 1 PTO shaft 1 1 1 1 1 1 N 203 Anti-friction bearing 1 1 1 1 1 1
N 11 Clutch support 1 1 1 1 1 1 N 305 Star spring 1 1 1 1 1 1
N 12 Clutch housing 1 1 1 1 1 1
N 14 Annular piston 1 1 1 1 1 1 R 117 Pinion shaft 1 1 1 1 1 1

*8 have to be renewed on dismantling (special screw)

 A 1 Heat Exchanger Typ P 130 A 1 Heat Exchanger Typ OKTS/OKS

60
A 282 Set of seals consisting of 1 A 282 Set of seals consisting of 1
O-ring (4) A Gasket (1)
A 289 Open end cover 1 B Gasket (1)
A 290 End cover 1 C Gasket (1)
A 291 Tube bundle 1 D Disc (6)
A 292 Anode 1 E O-ring (1)
F Gasket (2)
G Gasket (2)
A 287 Support, complete 2
A 288 Housing 1
A 289 Open end cover 1
A 290 End cover 1
A 291 Tube bundle 1
A 292 Anode 2
OKTS: gasket B and C must suit the
cover shape, modify if necessary
OKS: select matching gasket B
61
A 3 Duplex Filter Typ RFLD A 3 Duplex Filter Typ Pi 210

A 37 Filter element with O-ring 2 A 37 Filter element 2

A 43 Contamination indicator A 43 Contamination indicator 1
see additional order Visual standard
A 283 Set of seals consisting of 1 A 283 Set of seals consisting of 1
A O-ring (2) A O-ring (2)
B O-ring (2) B O-ring (2)
A 323 Switch lever, complete 1 C O-ring (1)
D O-ring (1)
Additional order: A 323 Switch lever, complete 1
A 43 Contamination indicator, 2
visual Additional order:
alternativly A 43 Contamination indicator, 1
A 43 Contamination indicator, 2 electrical
electrical
 E 19 Oil Pump Type KF 2/.., KF 3/.., KF 4/..

62
E 714 Set of seals consisting of 1
A Shaft sealing ring (1)
B O-ring (1)
C O-ring (1)
D Gasket (1)
E 725 Bearing 1

Note: mark position of cover before dismantling.

When assembling pay attention to correct mating
of cover and gasket D.
63
H 1069 H 1074 Operation Delay Pot H 768 Operation Delay Pot

H 1072 H 1073 Set of seals consisting of 1 V 198 Non-return valve (aeration valve, 1
A O-ring (1) execution depends on pot size)
B O-ring (1) V 187 Sealing ring 1
V 233 V 234 Non-return valve 1
(Aeration valve)

V 232 Connection Plate

V 235 O-ring 2
V 237 Plug screw 2
V 237 Threaded pin 2
V 237 O-ring 2
V 238 Ball 4
V 239 Spring 2
V 240 Seal lock nut 2
V 241 Adjusting screw 2
V 305 O-ring 2
 K 8 Hexagon Screw
V 247 Intermediate Plate (Emergency Operation Screw)

64
V 12 Hexagon nut (lock nut) 1 K 61 Kit locking wire consisting of 1
V 13 Threaded pin (set screw) 1 Locking wire (1)
V 20 Valve slide 1 Wire socket (4)
V 21 Spring 1
V 250 Set of seals consisting of 1
A O-ring (1)
B O-ring (2)
C O-ring (1)
D O-ring (1)
V 251 Housing (for set screw) 1
V 252 Piston 1
65
V 1 Control Valve (4/3 WL 5-10, pneumatical) V 1 Control Valve (4/3 NG 10, electrical)

V 223 Set of seals consisting of 1 V 223 Set of seals consisting of 1

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

D and F consisting of 2 parts

one fitting into the other
 V 1 Control Valve (4/2 WL 5-10, pneumatical) V 1 Control Valve (4/2 NG 10, electrical)

66
V 223 Set of seals consisting of 1 V 223 Set of seals consisting of 1
A O-ring (5) A O-ring (5)
B O-ring (2) B O-ring (2)
C O-ring (2) C O-ring (2)
D Turcon-step-seal (2) D O-ring (2)
O-ring (2) V 259 Solenoid 2
E Quadring (1) V 260 Plug-in connector 1
F Turcon-glyd-ring (1) V 261 Plug-in connector 1
O-ring (1) V 262 Manual emergency control 2
V 263 Pneuko piston, complete 1 4/2 NG 10 without spring return
V 264 Seal ring for piston 1

D and F consisting of 2 parts

one fitting into the other
Detail X disc installed as STOP
67
V 114 Control Valve (4/2 WL 5-10, pneumatical) V 114 Control Valve (4/2 NG 10, electrical)

V 102 Setof seals consisting of 1 V 102 Set of seals consisting of 1

A O-ring (5) A O-ring (5)
B O-ring (2) B O-ring (2)
C O-ring (2) C O-ring (2)
D Turcon-step-seal (2) D O-ring (2)
O-ring (2) V 368 Solenoid 2
E Quadring (1) V 369 Plug-in connector 1
F Turcon-glyd-ring (1) V 370 Plug-in connector 1
O-ring (1) V 393 Manual emergency control for 2
V 375 Pneuko piston, complete 1 4/2 NG 10 without spring return
V 376 Seal ring for piston 1

D and F consisting of 2 parts

one fitting into the other
Detail X disc installed as STOP
Notes and remarks:

68
REINTJES GMBH
D-31784 Hameln
Phone + 49 51 51 - 104 - 0
Fax + 49 51 51 - 104 - 300