OPERATING MANUAL WAF 642 196. LAF 642 196.

REINTJES GmbH D-31784 Hameln Federal Republic of Germany Phone +49 51 51 1 04 - 0 Telefax +49 51 51 1 04 - 300

BV2025.en 2004-04 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 LAF 1171

WAF LAF

64. 117.

Table of Contents
1.0 General Information
1.1 1.2 1.3 1.4 1.5 Introduction Important Notes Safety Information Fire and Explosion Prevention Before-operation Checks 3 3 3 5 6

5.0 Disassembly and Assembly

5.1 5.1.1 5.1.2 5.2 5.3 5.4 5.5 5.6 5.7 General Information Seals Screws Screw Locking Glued Connection Instructions for Hydraulic Assembly/ Disassembly with Taper 1:30 Bearing Adjustments Lubrication of Discs Recommended Maintenance Procedures for Heat Exchangers of BLOKSMA Make 30 30 30 30 31 31 33 35 36

2.0 Installation and Alignment

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Lifting Equipment Alignment Marine Gear Installation and Alignment Connection to Engine Propeller Shaftline Check Seat Chocks and Foundation Bolts Installation of Gearbox with Longitudinal Mounting Arrangement Alignment Check 7 7 7 7 8 8 8 9

6.0 Spare Parts

Ordering Notes WAF/LAF 64. 196. Piping and External Parts Housing Input Shaft Intermediate Shaft Output Shaft Power Take Off K21 Power Take Off K31 Power Take Off K41 Power Take Off K51 41 42 43 45 47 49 51 53 55 57 59

3.0 Function and Operation

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 General Information Name Plate Arrangement Hydraulic System Gearbox Actuation Pressure Limiting Valve Function of Series WAF/LAF Sectional Drawing WAF/LAF Description of Power Take Off Recommended Lubricants Initial Operation Operating Instructions Engagement Recommendations Trailing Operation, Engine STOP and Propeller Rotating 3.14 Emergency Operation 9 9 10 12 12 14 15 16 17 17 17 18 18 19

Service Repair Kits

A1 Heat Exchanger Typ P 130 A1 Heat Exchanger Typ OKTS/OKS A3 Duplex Filter Typ RFLD A3 Duplex Filter Typ Pi 21.. E 19 Oil Pump Typ KF 2/..,3/...,4/.. H 1069/ H 1074 Operation Delay Pot with V 232 Connection Plate H 768 Operation Delay Pot PTO clutch V 247 Intermediate Plate K8 Emergency Operation Screw V1 Control Valve (4/3 pneum.) V1 Control Valve (4/3 electr.) V1 Control Valve (4/2 pneum.) V1 Control Valve (4/2 electr.) V 114 Control Valve (4/2 pneum.) PTO clutch V 114 Control Valve (4/2 electr.) PTO clutch 60 60 61 61 62 63 63 64 64 65 65 66 66 67 67

4.0 Maintenance
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 Maintenance Recommendations Conversion Factors General Torque for Metric Fasteners Maintenance Schedule Maintenance Task Descriptions Completed Maintenance Troubleshoothing Preservation of the Gearbox 19 20 20 21 22 27 28 29

1.0 General Information

1.1 Introduction 1.3 Safety Information
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. Applicationspecific 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 accidentprevention 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. The majority of accidents which occur during operation, maintenance and repair are caused by failure to observe basic safety rules and accidentprevention 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-todate information available. Supplementary to operating manual all generally valid legal and other binding regulations for accident prevention and pollution control have to be observed and adhered to!

1.2

Important Notes

The marine gears are subject to the REINTJES warranty conditions as agreed upon in the purchasing contract. Modifications of the gearbox are permissible only in consultation with REINTJES. REINTJES will only consider warranty claims when - The gear has been installed, operated, supervised and maintained in accordance with our instructions. - The oils employed are in accordance with our Recommended Lubricants List. - Power data and characteristics are in accordance with those quoted on the name plate. As supplier of only one component in the complete propulsion plant, REINTJES is not responsible for vibration problems resulting from the overall system. REINTJES does not, therefore, accept any responsibility 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.

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.

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.

General
The gear has been built according to latest developments in engineering and established safety rules. Nevertheless, during operation dangers to life and limb of operator or third party may occur. Restrictions to gearbox and other materials may also limit its use. The gearbox must only be operated in perfect technical condition as well as in accordance with regulations. The operator must be aware of rules for safety and hazards and must follow the operating manual including regulations concerning inspection and maintenance. Faults which may impair safety must be eliminated without delay! 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.

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.

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 manufacturers 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.

1.4

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 nonflammable 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.

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 Ratios 2,483 4,560 6,417 2,467 4,625 6,153 2,091 4,458 6,153 1,966 4,500 6,087 2,032 4,429 2,059 4,467 : : : : : : : : : : : : : : : : 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 to to to to to to to to to to to to to to to to 4,409 5,950 7,476 3,952 5,750 7,455 3,905 5,842 7,455 3,909 5,810 6,810 3,857 5,955 3,952 5,952 : : : : : : : : : : : : : : : : 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

app. Weight WAF 1400 kg 1800 kg 2300 kg 1800 kg 2300 kg 2900 kg 2300 kg 3100 kg 4200 kg 2800 kg 3600 kg 4500 kg 3900 kg 4500 kg 4200 kg 5650 kg LAF 1300 kg 1650 kg 2100 kg 1700 kg 2100 kg 2650 kg 2050 kg 2850 kg 3950 kg 2600 kg 3300 kg 4200 kg 3700 kg 4400 kg 4000 kg 5300 kg

Control Valve (1) Oil Filter (2) Oil Cooler (3) Oil Pump (4) Output Shaft (5)

64. 66. 67. 74. 76. 77. 84. 86. 87. 114. 116. 117. 154. 156. 194. 196.

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 equipment must be secured against tilting. 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 manufacturers 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.

2.2

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.

2.4

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, within reasonably acceptable limits, the plant operating range be kept free of torsionally critical speeds. Selection of the flexible coupling is generally made by the engine manufacturer. The gearbox data required for torsional vibration calculation is supplied by REINTJES together with the associated order referenced torsional vibration diagram. If the coupling is specified by the engine manufacturer or the shipyard and is supplied assembled with the 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 accommodating the the axial misalignment between the engine and gearbox shafts at the specified operating speeds. Referenced to the gearbox, the flexibility of the resilient engine mounts must be such as to allow engine-to-gearbox alignment accuracy which ensures that there is no possibility of appreciable reactive forces at the bearings of the connected gearbox shafts when operating temperatures prevail.

2.3

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.

2.5

Propeller Shaftline Check

2.6

Seat Chocks and Foundation Bolts

Radial and axial run-out A prerequisite for correct propeller shaftline-tomarine 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.

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.

3.0 Function and Operation

Foundation with Cast Resin If cast-resin seat chocks are used, collision chocks will be necessary to transfer the propeller thrust to the ships 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.

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 recommended lubricants.

2.8

Alignment Check 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

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.

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.

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.

10

Hydraulic Diagram

11

3.4

Gearbox Actuation

3.5

Pressure Limiting Valve

The complete shift unit for marine gear control, comprised of the pressure limiting valve and the control valve, is mounted to the gearbox housing. Control Valve with Emergency Actuation The control valve is mounted onto the pressure limiting valve and can be easily replaced after 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.

The operating pressure is regulated by a springloaded pressure limiting valve and set by adjustment screw V 13. For readjustment purposes, the nut V 12 must be slackened off. Pressure is increased by turning adjusting screw V 13 clockwise and decreased by turning it anticlockwise.

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.

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)!

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).

13

3.6

Function of Series WAF/LAF

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

Engine power is transmitted to the input shaft W 1 via the engine-to-marine gear coupling. When the input shaft is rotating, the oil pump E 19 provides the pressurized oil for lubrication and clutch operation. The disengaged disc clutch will be supplied with lube oil. Shearing of cooling oil flowing to the outside between the friction surfaces of the clutch results in an idling torque. 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

WAF/LAF 64. 196.

Sectional drawing

15

3.8

Description of power take off

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.

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 noncontrollable 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

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.

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 noncontrollable 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

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.

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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.

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

Refill Capacities (Approximate)

WAF/LAF Model

Refill Capacities Liters U.S.Gal.

Imperial Gal.

64. 66. 67. 74. 76. 77. 84. 86. 87. 114. 116. 117. 154. 156. 194. 196.

50 65 90 70 75 100 90 90 120 110 125 150 150 150 215 215

13.0 16.9 23.4 18.2 19.5 26.0 23.4 23.4 31.2 28.6 32.5 39.0 39.0 39.0 55.9 55.9

10.8 14.7 19.5 15.2 16.2 21.6 19.5 19.5 26.0 23.8 27.7 32.5 32.5 32.5 46.6 46.6

3.11

Operating Instructions

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

3.10

Initial Operation

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

17

3.12

Engagement Recommendations

3.13

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 Ships 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. 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.

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.

18

4.0 Maintenance
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. 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. The propeller shaft will now turn immediately the engine is started, the propeller direction of rotation can not be reversed and in order to stop the propeller, the engine must be shut down. 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. 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. Operational safety, reliability and low maintenance costs can only be achieved by maintenance and care in compliance with our instructions. Furthermore, only trained maintenance personnel, should work on the gearbox, and only correct tools, original spare parts and lubricants in accordance with our recommendation should be used. Filter elements and waste oil must be disposed of as recyclable material or special waste. If required, our Service Department is available at all times to provide advice and assistance.

4.1

Maintenance Recommendations

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

19

4.2

Conversion Factors
Approximate Conversion Factors Multiply mm inch kg lb kPa psi psi bar Nm lb ft Nm lb in Liter U.S. Gal. U.S. Gal. by 0,03937 25,4 2,2 0,454 0,145 6,89 0,0689 14,5 0,74 1,36 8,9 0,113 0,26 3,79 0,833 Temperature conversions C=(F-32) : 1,8 F=(Cx1,8) + 32 To Get inch mm lb kg psi kPa bar psi lb ft Nm lb in Nm U.S. Gal. Liter Imp. Gal. Thread Size Metric M 5 M 6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 36 M 39 M 42 M 45 M 48 Metric ISO-Thread Nm 1 ) 5+ 1 9+ 1 21 + 2 41 + 4 71 + 7 113 + 12 170 + 20 245 + 25 350 + 35 470 + 47 600 + 60 880 + 90 1190 + 120 2100 + 210 2700 + 270 3300 + 330 4100 + 410 5000 + 500
2)

Grade 8.8 Standard Torque lb ft 4+ 1 7+ 1 16 + 2 30 + 3 52 + 5 84 + 8 126 + 13 181 + 18 259 + 26 348 + 35 444 + 44 650 + 65 880 + 90 1550 + 155 1990 + 199 2442 + 244 3034 + 303 3700 + 370

4.3

General Torque for Metric Fasteners

Thread Size Metric M 5 M 6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 36 M 39 M 42 M 45 M 48
1)

Metric ISO-Thread Nm 1 ) 7+ 1 13 + 1 30 + 3 60 + 6 104 + 10 165 + 16 250 + 25 350 + 35 490 + 50 670 + 67 850 + 85 1250 + 125 1700 + 170 3000 + 300 3800 + 380 4700 + 470 5800 + 580 7000 + 700

2)

Be very careful never to mix metric with customary (standard) fasteners. Mismatched or incorrect fasteners will cause marine gear damage or malfunction and may even result in personal injury. Original fasteners removed from the marine gear should be saved for reassembly whenever possible. If new fasteners are needed, they must be of the same size and grade as the ones that are being replaced. The material strength identification is usually shown on the bolt head by numbers (8.8, 10.9 etc.). The following chart gives general torques for bolts and nuts with Grade 8.8 and 10.9.

Grade 10.9 Standard Torque lb ft 5+ 1 10 + 1 22 + 2 44 + 4 77 + 8 122 + 12 185 + 19 259 + 26 363 + 36 496 + 50 630 + 63 925 + 93 1260 + 126 2210 + 221 2800 + 280 3478 + 348 4292 + 429 5180 + 518

Newton Meter (Nm) is approximately the same as 0,1 mkg. 2) ISO-Internationale Standard Organization.

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4.4

Maintenance Schedule

The Maintenance Schedule summarizes the maintenance services which are sub-divided into Maintenance Stages. Particularly arduous service conditions may require modification of the Maintenance Schedule (reduced intervals).

Maintenance Stage 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. Gear Size WAF/LAF WAF/LAF WAF/LAF WAF/LAF WAF/LAF WAF/LAF 64. 74. 84. 114. 154. 194. 67. 77. 87. 117. 156. 196. Operating Hours 30 40 40 40 60 60 000 000 000 000 000 000 hours hours hours hours hours hours

Maintenance Stage 1 Daily before engine start Check oil level

Maintenance Stage 2 Daily with engine running 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, bearing seats for damage, carriers, gear and pinion teeth, annular piston, carrier pins, oil distributor, pressure gauge Replace: clutch discs, rectangular rings, screws and return springs for annular piston, O-rings, snap rings, all clutch housing screws *8, anti-friction bearings, thrust bearing screws and springs, shaft seals and bushes, oil filter elements and seals, oil pump, inspection cover gaskets, o-rings for control valve / pressure limiting valve, flexible hoses, clean the complete gearbox

Maintenance Stage 3 After first 200 operating hours Change oil, replace filter element, check threaded connections incl. foundation, check connection to engine and propeller and bolts of intermediate housing, tighten swivel nuts and banjo bolts of threaded, pipe connections in case of leakage, check heat exchanger for leakage.

Maintenance Stage 4 After each operating period of 2000 hours or 6 months Change oil, replace filter element

Maintenance Stage 5 After each operating period of 5000 hours or 1 year Check threaded connections incl. foundation, connection to engine and propeller and bolts of intermediate housing, check heat exchanger for leakage and replace seals, if necessary.

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.

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 springloaded 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 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).

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 5C (5 to 9F). 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.

22

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.

Visual check and running noise Check the gear assembly for leaks and insecure parts. Ensure that only normal running noises are audible. Changes may indicate possible faults or malfunctions which can include, among others, misalignment between engine-gear-propeller shaft. Investigate all malfunctions. Where possible, rectify all faults immediately or after shutting down the engine. Be alert! Beware of danger! Maintenance Stage 3 After first 200 operating hours This oil change with changing filter 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.

23

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. 60C. If these temperatures are exceeded, the oil change intervals are reduced and must be determined in consultation with REINTJES. Independent of the oil change intervals we recommend to check the flexible hoses monthly for cracks and damage. 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

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.

24

Filter Element Replacement Typ Pi 21..

When contamination has been established, the filter 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). 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)).

Important Care must be taken to ensure that the filter bowl, after it has been tightened up, is slackened off by 1/8 up to 1/2 a turn. Operate only the pressure 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.

25

Maintenance Stage 5 After each operating period of 5000 hours or 1 year Threaded Connections The screw tightening torques should be checked with the gear cold. Particular attention must be paid to the following connections: Engine - flexible coupling - marine gear. Marine gear output shaft flange - propeller shaft. Marine gear mountings - foundation. Swivel nuts and banjo bolts of threaded pipe connections. Check the rubber elements of the flexible coupling for porosity, cracking or other signs of damage. Check the heat exchanger for leakage and replace the seals, if necessary. Maintenance Stage 6 After each operating period of ......... hours or 10 years or in conjunction with 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. Gear Size WAF/LAF 64. 67. WAF/LAF 74. 77. WAF/LAF 84. 87. WAF/LAF 114. - 117. WAF/LAF 154. - 156. WAF/LAF 194. - 196. Operating Hours 30 40 40 40 60 60 000 000 000 000 000 000 hours hours hours hours hours hours

Part Checks (and replacement as necessary): Shafts for run-out, bearing seats for damage, carriers, carrier pins for annular piston, gear and pinion teeth, oil distributor, pressure gauge Replace: Clutch discs, rectangular rings, screws and return springs for annular piston, O-rings, snap rings, all clutch housing screws *8, anti-friction bearings, thrust bearing screws and springs, shaft seals and bushes, oil filter elements and seals, oil pump, inspection cover gaskets, O-rings for control valve and pressure limiting valve, flexible hoses Thoroughly clean the gear housing, vent filter and all other parts which are to be reused. Our Service Department is available at all times, to answer any questions you may have.

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

Operatinghours

Maintenance Stage

Date

Initials

27

4.7

Troubleshooting

Disturbance Probable Cause 1) Gear noise Idle speed in critical range Anti-friction bearing damaged (possibility of metallic residues in filter) Hydraulic noise, pump sucks in air 2) Pump sucks in air Oil level in gearbox too low Suction line leaking 3) Oil loss Shaft seals (normal wear) Pipework Housing cover Plugs, oil drain plug Heat exchanger leaking 4) Gear temperature too high Oil level too high Cooling water flow rate too low Heat exchanger contaminated Antifriction bearing damaged (possibility of metallic residues in filter) Gear overload Clutch slipping, operating pressure too low 5) Operating pressure too low, fluctuating Pump sucks in air Pump drive or pump defective (wear) Pressure limiting valve blocked Non-return valve to electric pump defective Incorrect brand oil see Item 2) Repair or replace Repair or replace Clean or replace Check viscosity, change oil Rectify Adjust to correct rate Clean Inspect (replace bearings) Replace Rectify leak Clean mating faces, renew gaskets Tighten, replace sealing ring Replace sealings Determine and rectify cause of oil loss, top-up oil to max. mark Tighten threaded connection, or flange, replace seals or pipe Raise idle speed Check gear security and alignment, inspect gear (replace bearings) see Item 2) Remedial Action

Reduce input load see Item 5)

28

Probable Cause 6) Operating pressure too high Pressure limiting valve blocked or defective Oil cold Incorrect brand oil 7) Clutch slipping Operating pressure too low 8) Clutch does not engage Control valve not correctly positioned 9) Clutch does not disengage Control defective

Remedial Action

Repair or replace Carry out gear warm-up procedure Check viscosity, change oil

see Item 5)

Check engagement sequence and position

Check disengagement sequence, disengage manually (Check output shaft free movement) Check emergency operation status, separate if necessary Check oil brand Replace discs and inspect thoroughly

Discs defective or seized

4.8

Preservation of the Gearbox

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.

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.

REINTJES Customer Service will provide further information upon request.

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5.0
5.1

Disassembly and Assembly

General Information 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

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

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.

30

5.3

Glued Connection Input Shaft - Clutch Housing

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 40C). 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 40C). 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.

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

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

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 pressure of 100 bar applied at connection A, brought into contact with the component to be removed. The force-on pressure in the hydraulic nut must then be released and the hydraulic pump valve to the hydraulic nut connection A must be closed. In order to be released, the component to be removed must first be expanded via connection B. In order to achieve this, hydraulic oil is forced slowly between the component taper faces. Expansion pressure increases should not exceed 100 bar over a period of 3 minutes. Component release is indicated by a rise in pressure in the hydraulic nut which is indicated at the pressure gauge of the hydraulic pump assigned to connection A. 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.

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

ATTENTION The component being removed may be released suddenly when the pressure at connection A is released to zero, for this reason it is mandatory that the hydraulic nut (safety stop) be correctly installed. If the max. expansion pressure is achieved and the component to be removed is not released, proceed as follows: Increase expansion pressure at connection B by 10 %. Maintain this pressure for one hour. In addition, heat the component slowly and evenly. (temperature max. 140C or 284F) Mount an additional puller.

5.5

Bearing Adjustments

Output Shaft Thrust Bearing Axial Clearance NOTE: Bearing axial clearance must be checked and adjusted any time bearings are changed. Measure and Adjust

Pressure Connections

The thrust bearings consists of bearings (P 21) 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)

2. Measure distance (C) from housings 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 covers bearing seat surface (E). If dimension (B) is smaller than dimension (A), machine the housings mating surface (F) (as shown in pict. 4).

34

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

36

2.2 Visual Inspection Cooling water circuit Heat exchanger Anodes Result: OK Result: Anode consumed Visual check finished Shut inlet and outlet valves Drain cooling water Screw out anodes and perform visual check Screw anode in hand-tight with new sealing ring Screw in hand-tight new anode with new sealing ring - 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 2 3 4 5

Tube plate O-rings Fixing plate Shell 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 Heat exchanger Cooling water connections Covers Covers Fixing plates Shut inlet and outlet valves Drain cooling water Screw off, sealing OK?, open end cover freely accessible Mark position of open end cover and end cover clearly with 1/1 and 2/2 Loosen and screw off covers crosswise 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 Inspection: OK Open end cover 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 Tube bundle Open end cover side Fixing plates A Drain oil, dependent on installation conditions Mark mounting position and check marking on open end cover side Take partition from tube bundle Screw off bolts and nuts, take off fixing plates - 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 B

Take off both O-rings 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 Tube plate Assemble tube bundle Positioned O-rings

Clean sealing surfaces carefully, check for damages Apply thin layer of suitable lubricant to sealing surfaces Clean grooves carefully, check for damages Apply suitable lubricant to grooves In reverse order of disassembly, pay attention to markings 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 Cooling water connections

As above (insert bolts from outside to inside) 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 anticorrosion 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
Spare Parts In addition to the gear identification data your order should specify - item number, - denomination of the part and - quantity. The quantities indicated on the following pages refer to gearboxes of the WAF series. For LAF gearboxes this figures will differ depending on the excecution counter or identical rotation. Continuing improvement and advancement of product design may cause changes to your gearbox which may not be included in this manual. Each printed manual will be reviewed and revised, 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.

Gearbox Identification Data required for inquiries and/or ordering parts may be taken from the name plate, in particular

1. Gear No. 2. Type 3. Input Capacity 4. Input Speed

The gear number is also stamped on the gearbox housing near the engine.

Please transfer the data indicated on the name plate of your gearbox to this form.

41

42

Piping and external parts

Item No. Designation Designation

Designation

Quantity per WAF-Gearbox 77. 87. 66. 76. 86. 116. 156. 196. 64. 74. 84. 114. 154. 194. Item No. Item No.

Quantity per WAF-Gearbox 77. 87. 66. 76. 86. 116. 156. 196. 64. 74. 84. 114. 154. 194.

Quantity per WAF-Gearbox 77. 87. 66. 76. 86. 116. 156. 196. 64. 74. 84. 114. 154. 194.

*S A B A B

A A A A A A A

1 2 3 4 5 6 7

*S

1 4 1 -

1 4 1 1 2 1

1 4 1 1 2 1

1 4 1 1 2 1

1 4 1 1 2 1

1 4 1 1 2 1

A B A B

43
A B A B 1 1 1 1 1 1 8 1 1 1 1 1 1 8 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 H H H 46 A 46 B 85 1 2 1 1 2 1 1 2 1 1 2 1 1 2 1

A 35 A 73 A 80 A 81 A 83 A 298 A 303 A 304 A B A B A B C

Heat exchanger Hexagon screw Duplex filter Threaded flange O-ring Threaded flange Allen screw with spring washer Pressure gauge Shutt-off valve Support for filter Hexagon screw Hexagon screw Oil distributor Allen screw O-ring 8 1 1 2 1 4 1 8 1 1 2 1 4 1 8 1 1 2 1 4 1

1 1 1 4 2 1 4 1

8 1 1 2 1 4 1

8 1 1 2 1 4 1

*S

H 90 H 91 H 128 H 179 H 179 H 182 H 183 H 184 H 195 H 197 H 197 H 1058 H 1058 H 1062 H 1063 H 1068 H 1068 H 1068 H 1069 H 1070 *S 4 H 1071

1 1 1 2 2 1 1 1 1 1 1 3 6 1 1 1 2 2 1

1 1 1 2 2 1 1 1 1 1 1 3 6 1 1 1 2 2 1 4

1 1 1 2 2 1 1 1 1 1 1 3 6 1 1 1 2 2 1 4

1 1 1 2 2 1 1 1 1 1 1 3 6 1 1 1 2 2 1 4

1 1 1 2 2 1 1 1 1 1 1 3 6 1 1 1 2 2 1 4

1 1 1 2 2 1 1 1 1 1 1 3 6 1 1 1 2 2 1 4

E E E E E E E E

19 23 29 107 234 235 236 238

Oil pump Dipstick Plug Venting filter Threaded flange Set of seals Threaded flange Allen screw with spring washer

1 1 1 1 1 1 1

1 1 1 1 1 1 1

1 1 1 1 1 1 1

G G G

3 3 43

Plug screw Seal ring Plug

1 1 1

1 1 1

1 1 1

H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H H 1074 H 1101 H 1102 H 1102 H 1102 H 1103 H 1103 1 1 2 1 A B C A B *S * * * * 4 1 1 1 2 2 1 2 *S *S *S V 1 V 10 V 232 V 247 V 248 Control valve Allen screw Connection plate Intermediate plate Allen screw 1 4 1 1 4

2 3 4 4 5 6 7 8 9 10 11 12 13 13 14 14 16 17 17 18 18 20 21 29 30 31 32 33 42 44 45

1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Pipe Screwed union Pipe Plug screw Seal ring Screwed union Pipe Screwed union Screwed union Connection piece Plug screw Pipe clamp Allen screw Plug screw Plug screw Pipe clamp Allen screw Hexagon nut Operation delay pot Hexagon screw with washer Hexagon screw with washer Operation delay pot Support Pipe clamp Allen screw Hexagon nut Pipe clamp Allen screw

4 1 1 1 2 2 1 2 1 4 1 1 4

4 1 1 1 2 2 1 2 1 4 1 1 4

4 1 1 1 2 2 1 2 1 4 1 1 4

4 1 1 1 2 2 1 2 1 4 1 1 4

4 1 1 1 2 2 1 2 1 4 1 1 4

Screwed union Pipe Screwed union Reducing fitting Screwed union Pipe Screwed union Screwed union Pipe Screwed union Screwed union Pipe Screwed union Reducing fitting Reducing fitting Screwed union Pipe Screwed union Reducing fitting Reducing fitting Screwed union Pipe Screwed union Screwed union Pipe Screwed union Pipe Screwed union Screwed union Screwed union Connection piece for pressure gauge Support for pressure gauge Allen screw Screwed union

* *S

not standard Service repair kits

44

Housing
64. 1 10 1 1 10 1 1 66. 1 10 1 1 10 1 1 74. 1 10 1 1 10 1 1 77. 76. 1 10 1 1 10 1 1 156. 1 10 1 1 10 1 1 194. 1 10 1 1 10 1 1 196. 1 10 1 1 10 1 1 Quantity per WAF-Gearbox 87. 84. 86. 114. 116. 154. 1 1 1 1 1 10 10 10 10 10 1 1 1 1 1 1 1 1 1 1 10 10 10 10 10 1 1 1 1 1 1 1 1 1 1

Item No. E 2 E 4 E 57 E 107 E 563 E 715 E 716

Designation Cover Hexagon screw Cover Venting filter Hexagon screw Gasket Gasket

*1 *1

*1

45

G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G G

1 2 65 82 126 163 200 279 280 300 300 301 303 303 310 320 330 335 350 350 360 361 370 371 380 390 391 392 481 482 483

Housing bottom part Housing top part Shielding sheet Housing centre part Threaded pin Hexagon screw Hexagon screw Pipe Pipe Hexagon screw Hexagon nut Hexagon screw Hexagon screw Hexagon nut Hexagon screw Allen screw Cylindrical pin Cylindrical pin Hexagon screw Hexagon nut Allen screw Allen screw Allen screw Allen screw Cylindrical pin Allen screw Allen screw Allen screw Threaded pin Pipe Threaded pin

1 1 4 4 1 1 20 20 4 2 2 4 2 4 19 19 2 1 3 4 2 2 2 1 1 1

1 1 8 4 1 1 18 18 4 2 2 4 2 4 19 19 2 1 3 4 2 2 2 1 1 1

1 1 8 4 1 1 18 18 4 2 2 4 2 4 18 18 2 1 2 1 4 2 2 2 1 1 1

1 1 6 4 1 1 18 18 4 2 2 4 2 4 18 18 2 1 2 1 4 2 2 2 1 1 1

1 1 6 4 1 1 18 18 4 2 2 4 2 4 20 20 2 1 2 1 4 2 2 2 1 1 1

1 1 6 4 1 1 18 18 4 2 2 4 2 4 20 20 2 1 2 1 4 2 2 2 1 1 1

1 1 4 4 1 1 18 18 4 2 2 4 2 4 22 22 3 3 4 2 2 2 1 1 1

1 1 4 4 1 1 18 18 6 2 2 4 2 2 4 22 22 3 3 4 2 2 2 1 1 1

1 1 4 4 1 1 18 18 6 2 2 4 2 2 4 22 22 3 3 4 2 2 2 1 1 1

1 1 4 4 1 1 18 18 6 2 2 4 2 3 4 22 22 3 3 4 2 2 2 1 1 1

1 1 4 4 1 1 20 20 6 4 2 2 4 24 24 3 3 4 2 2 2 1 1 1

1 1 4 4 1 1 20 20 6 4 2 3 4 24 24 3 3 4 2 2 2 1 1 1

*1

can only be ordered completely

46

Input shaft
Item No. G 16 G 316 G 480 Designation Allen screw Retaining ring Retaining ring 66. 64. 2 1 1 Quantity per WAF-Gearbox 77. 87. 76. 86. 116. 156. 196. 74. 84. 114. 154. 194. 2 2 1 1 1 1 1 1 1 1 1 1

*S *8

47
R R R R R 1 32 33 43 105 Pinion shaft Shaft nut Threaded pin Retaining ring Retaining ring W 1 W 4 W 7 W 7 W 8 W 12 W 42 W 84 W 166 W 169 W 179 Input shaft Shaft nut Shaft nut Retaining ring Threaded pin Bush Fitted key Bush Hexagon screw Carrier pin Non-return valve

K K K K K K K K K K K K K K K K K K K 1 2 2 2 2 1 2 2 2 2 1 2 2 2 2

1 2 5 6 7 8 9 13 15 17 18 22 23 30 40 41 59 60 128

Clutch support Retaining ring Bolt Spring Rectangular ring Hexagon screw Hexagon nut Hexagon screw Clutch housing Annular piston Rectangular ring Inner disc Outer disc Carrier Carrier cover Allen screw Cover Allen screw O-ring

2 2 24 24 2 16 16 24 1 2 2 22 24 2 1 8 2 16 1

2 2 24 24 2 16 16 36 1 2 2 22 24 2 1 8 2 16 1

2 2 32 32 2 16 16 32 1 2 2 22 24 2 1 8 2 16 1

2 2 24 24 2 16 16 32 1 2 2 22 24 2 1 8 2 24 1 1 2 2 2 2

2 2 24 24 2 16 16 48 1 2 2 24 26 2 1 8 2 24 1 1 2 2 2 2

2 2 28 28 2 12 12 48 1 2 2 24 26 2 1 8 2 24 1 1 2 2 2 2

Item No. E 5 E 7 E 11 E 15 E 19 E 28 E 30 E 41 E 42 E 43 E 44 E 46 E 49 E 97 E 108 E 122 E 123 E 124 E 125 E 126 E 129 E 130 E 143 E 150 E 186 E 206 E 244 E 537 E 585 E 586 E 587 E 719 E 1102 E 1214 E 1215 E 1294 * * * *8 1 1 1 1 1 1 48 8 4 1 1 1 1 1 1 60 8 4 1 1 1 1 1 1 60 8 4 1 1 1 1 1 1 60 12 4 1 1 1 1 1 1 72 12 4

Designation Bearing housing Cover Shaft sealing ring Anti-friction bearing Oil pump *S Oil distributor * Hexagon screw Housing pump drive *9 * Pump wheel * Shaft wheel * Threaded pin * Hexagon screw * Tapered pin * Cover * Hexagon screw * Anti-friction bearing Anti-friction bearing Anti-friction bearing Anti-friction bearing Anti-friction bearing * Hexagon screw * Bearing housing pump drive *9 * Hexagon screw Hexagon screw * Hexagon screw Cover Hexagon screw Clamping sleeve Bush Washer Countersunk screw Allen screw * Clamping sleeve Bush Washer Countersunk screw

66. 64. 1 1 1 1 1 1 8 1 1 1 4 2 1 4 2 2 2 2 1 8 1 4 4 8 1 8 1 4 1 -

Quantity per WAF-Gearbox 77. 87. 76. 86. 116. 156. 196. 74. 84. 114. 154. 194. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 4 4 4 2 2 4 4 4 1 1 1 1 1 4 4 4 4 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 8 12 8 12 12 1 1 1 1 1 4 4 4 4 4 4 4 4 4 4 8 12 8 12 12 1 1 1 1 1 8 8 8 12 12 1 1 1 1 1 1 1 1 1 1 1 3 3 3 4 4 4 4 4 1 1 1 1 1 1 1 1 1 1 1 3 3 3 1 1 1 1 1 1 72 12 4

* *S *8 *9

not standard Service repair kits have to be renewed on dismantling (special screw) can only be ordered completely

48

Intermediate shaft

*S *8

Item No. K 8 K 9 K 13 K 16 K 17 K 18 K 22 K 23 K 30 K 59 K 60 K 119 K 120 K 125 Designation Hexagon screw Hexagon nut Hexagon screw Clutch housing Annular piston Rectangular ring Inner disc Outer disc Carrier Cover Allen screw Allen screw O-ring Carrier cover

66. 64. 16 16 24 1 2 2 22 24 2 2 16 8 1 1

Quantity per WAF-Gearbox 77. 87. 76. 86. 116. 156. 196. 74. 84. 114. 154. 194. 16 16 16 16 12 16 16 16 16 12 36 32 32 48 48 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 22 22 22 24 24 24 24 24 26 26 2 2 2 2 2 2 2 2 2 2 16 16 24 24 24 8 8 8 8 8 1 1 1 1 1 1 1 1 1 1

49
2 1 1 2 1 1 2 1 1 1 1 1 1 1 1 2 2 24 24 2 2 2 24 24 2 2 2 32 32 2 2 2 24 24 2 2 2 24 24 2 2 2 28 28 2 W W W W W W W 17 103 103 166 169 179 301 Intermediate shaft Shaft nut Retaining ring Hexagon screw Carrier pin Non-return valve Threaded pin

Item No. E 8 E 13 E 40 E 56 E 122 E 123 E 124 E 125 E 205 E 367 E 705 E 706 E 722 E 723 E 1030 E 1031 E 1032 R R R R R 32 33 43 105 119 Shaft nut Threaded pin Retaining ring Retaining ring Pinion shaft 2 2 2 2 1 2 2 2 2 1 2 2 2 2 1 2 2 2 2 1 2 2 2 2 1

Designation Cover Anti-friction bearing Cover Hexagon screw Anti-friction bearing Anti-friction bearing Anti-friction bearing Anti-friction bearing Hexagon screw Clamping sleeve Bearing housing Hexagon screw Oil distributor Hexagon screw Washer Countersunk screw Bush

66. 64. 1 1 1 8 2 2 2 2 8 1 1 8 -

Quantity per WAF-Gearbox 77. 87. 76. 86. 116. 156. 196. 74. 84. 114. 154. 194. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 12 8 12 12 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 8 8 8 12 12 1 1 1 1 1 1 1 8 12 1 1 1 1 4 4 4 4 1 1 1 3 3 3 1 1 1

G G G

16 281 484

Allen screw Retaining ring Retaining ring

2 2 2 2 1

K K K K K

1 2 5 6 7

Clutch support Retaining ring Bolt Spring Rectangular ring

*8

1 1 48 8 4 -

1 1 60 8 4 -

1 1 60 8 4 -

1 1 60 12 4 1

1 1 72 12 4 1

1 1 72 12 4 1

*S *8

Service repair kits have to be renewed on dismantling (special screw)

50

Output shaft

Item No. E 104 E 115 E 193 E 202 E 203 E 219 66. 12 8 1 1 6 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 196. 12 12 1 1 12 1 1 1 1 1 1 1 2 1 1

Designation Hexagon screw Hexagon screw Cover Cover Spring Shaft sealing ring

64. 12 8 1 1 8 1

Quantity per WAF-Gearbox 84. 114. 77. 87. 154. 194. 74. 76. 86. 116. 156. 12 8 8 12 12 8 8 8 12 12 1 1 1 1 1 1 1 1 1 1 6 6 12 12 8 1 1 1 1 1

P P P P P P P P

1 2 20 21 22 32 43 44

Output shaft Bush Anti-friction bearing Anti-friction bearing Anti-friction bearing Bush Threaded pin Shaft nut

51

Wheel

*2

*2

pay attention to assembly and dismantling instruction for taper press hubs with 1:30 taper

52

Power take off (K21)

Item No. E 26 E 27 E 34 E 181 E 182 E 412 E 1103 E 1204 E 1205 E 1296

Designation Shaft sealing ring Cover Anti-friction bearing Bearing housing Hexagon screw Hexagon screw Clamping sleeve Bush Washer Countersunk screw

66. 64. 1 1 1 1 8 6 1 -

Quantity per WAF-Gearbox 77. 87. 76. 86. 116. 156. 196. 74. 84. 114. 154. 194. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 12 8 12 12 6 6 6 8 6 1 1 1 1 1 1 1 1 1 1 1 3 3 3

53

W 19 W 20 W 21 W 171 W 265 W 342

Fitted key PTO-shaft Bush Retaining ring Bush Retaining ring

1 1 1 1 1 1

1 1 1 1 1 -

1 1 1 1 1 -

1 1 1 1 1 -

1 1 1 1 1 1

1 1 1 1 1 -

54

Power take off (K31)

Item No.

Designation

66. 64.

Quantity per WAF-Gearbox 77. 87. 76. 86. 116. 156. 196. 74. 84. 114. 154. 194.

55
1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

E E E E E E E E E E E E E E E E E E

34 604 605 606 607 608 637 638 855 856 857 859 860 861 863 883 884 885

Anti-friction bearing Housing Hexagon screw Housing cover Allen screw Tapered pin Anti-friction bearing Anti-friction bearing Oil chamber plate Countersunk screw Retaining ring Cover Hexagon screw Anti-friction bearing Plug screw Cover Hexagon screw Shaft sealing ring

1 1 12 1 18 4 1 1 2 6 1 1 6 1 1 1 6 1

1 1 12 1 18 4 1 1 2 6 1 1 6 1 1 1 6 1

1 1 12 1 18 4 1 1 2 6 1 1 6 1 1 1 6 1

1 1 12 1 18 4 1 1 2 6 1 1 6 1 1 1 6 1

1 1 12 1 18 4 1 1 2 6 1 1 6 1 1 1 6 1

1 1 12 1 18 4 1 1 2 6 1 1 6 1 1 1 6 1

R R

107 108

Wheel Pinion shaft / Wheel

*2 *2

W W W W W W W W

20 171 220 223 265 271 272 299

Intermediate shaft PTO Retaining ring Shaft Fitted key Bush Bush Shaft nut Shaft nut

*2

pay attention to assembly and dismantling instruction for taper press hubs with 1:30 taper

56

Power take off (K41)

Item No. 1 8 1 1 1 1 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 1 1 1 1 8 1 1 1 8 1 1 1 1 8 1 1 1 8 1 1 1 1 8 1 1 1 8 1 1 1 1 8 1 1 1 8 1 1 1 1 8 1 1

Designation

66. 64.

Quantity per WAF-Gearbox 77. 87. 76. 86. 116. 156. 196. 74. 84. 114. 154. 194.

E E E E E E E E E

296 297 631 687 688 956 957 958 965

Cover Hexagon screw Anti-friction bearing Anti-friction bearing Anti-friction bearing Cover Hexagon screw Shaft sealing ring Bush

G G G G

283 498 500 501

Pipe Threaded pin Orifice Orifice

57

118

Pinion shaft / Wheel

*2

W W W W

241 243 244 245

PTO shaft Bush Retaining ring Fitted key

*2

pay attention to assembly and dismantling instruction for taper press hubs with 1:30 taper

58

Power take off (K51)

Item No.

Designation

66. 64.

Quantity per WAF-Gearbox 77. 87. 76. 86. 116. 156. 196. 74. 84. 114. 154. 194.

*8

59
1 1 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 1 1 1 2 4 1 1 1 1 2 4 1 1 1 1 2 4 1 1 1 1 2 4 R 117 Pinion shaft

E E E E E E E E E E E E E E E E E E E E *8

76 107 112 113 164 184 187 457 483 486 580 581 640 657 802 862 897 948 948 948

Hexagon screw Venting filter Bearing housing Hexagon screw Cover Cover Shaft sealing ring Bush Oil distributor Hexagon screw Cover Hexagon screw Cover Hexagon screw Gasket Gasket Hexagon screw Adjustment shims Adjustment shims Adjustment shims

8 1 1 8 1 1 1 1 1 4 1 8 1 8 1 1 8 2 2 2

8 1 1 8 1 1 1 1 1 4 1 8 1 8 1 1 8 2 2 2

8 1 1 8 1 1 1 1 1 4 1 8 1 8 1 1 8 2 2 2

8 1 1 8 1 1 1 1 1 4 1 8 1 8 1 1 8 2 2 2

8 1 1 8 1 1 1 1 1 4 1 8 1 8 1 1 8 2 2 2

8 1 1 8 1 1 1 1 1 4 1 8 1 8 1 1 8 2 2 2

G G G G G G

439 456 457 491 492 493

Pipe Orifice Orifice Threaded pin Locking plate Hexagon screw

N N N N

1 11 12 14

PTO shaft Clutch support Clutch housing Annular piston

Item No. N 15 N 16 N 21 N 36 N 39 N 47 N 50 N 52 N 55 N 57 N 58 N 59 N 59 N 60 N 67 N 68 N 73 N 76 N 78 N 79 N 80 N 195 N 196 N 197 N 199 N 200 N 201 N 202 N 203 N 305 Designation Rectangular ring Carrier Anti-friction bearing Hexagon screw Anti-friction bearing Bush Fitted key Carrier pin Spring Bolt Hexagon screw Wire socket Locking wire Non-return valve Cover Rectangular ring Hexagon screw Retaining ring Allen screw Outer disc Inner disc Retaining ring Retaining ring Anti-friction bearing Retaining ring Fitted disc Retaining ring Anti-friction bearing Anti-friction bearing Star spring 1 1 1 1

66. 64. 1 1 1 22 1 1 1 4 12 12 8 2 1 2 1 1 12 1 8 12 11 1 1 1 2 1 1 1 1 1

Quantity per WAF-Gearbox 77. 87. 76. 86. 116. 156. 196. 74. 84. 114. 154. 194. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 22 22 22 22 22 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 4 4 4 12 12 12 12 12 12 12 12 12 12 8 8 8 8 8 2 2 2 2 2 1 1 1 1 1 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 12 12 12 12 12 1 1 1 1 1 8 8 8 8 8 12 12 12 12 12 11 11 11 11 11 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

*8

have to be renewed on dismantling (special screw)

A 1 1 1 1 1 A A A A A A 287 288 289 290 291 292 A 282

Heat Exchanger

Typ P 130

Heat Exchanger

Typ OKTS/OKS 1

60

282

A A A A

289 290 291 292

Set of seals consisting of O-ring (4) Open end cover End cover Tube bundle Anode

Set of seals consisting of A Gasket (1) B Gasket (1) C Gasket (1) D Disc (6) E O-ring (1) F Gasket (2) G Gasket (2) Support, complete Housing Open end cover End cover Tube bundle Anode OKTS: gasket B and C must suit the cover shape, modify if necessary OKS: select matching gasket B

2 1 1 1 1 2

61 Typ RFLD 2 1 1 A 2 A 2 43 1 Additional order: Contamination indicator, electrical 323 A A A 37 43 283 A 3 Duplex Filter Typ Pi 210 2 1 1 Filter element Contamination indicator Visual standard Set of seals consisting of A O-ring (2) B O-ring (2) C O-ring (1) D O-ring (1) Switch lever, complete 1

Duplex Filter

A A

37 43

283

323

Filter element with O-ring Contamination indicator see additional order Set of seals consisting of A O-ring (2) B O-ring (2) Switch lever, complete

43

43

Additional order: Contamination indicator, visual alternativly Contamination indicator, electrical

E 1 (1) (1) (1) (1) 1

19

Oil Pump

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

62

714

725

Set of seals consisting of A Shaft sealing ring B O-ring C O-ring D Gasket Bearing

Note: mark position of cover before dismantling. When assembling pay attention to correct mating of cover and gasket D.

63 H 768 1 V 1 187 V 198 Operation Delay Pot Non-return valve (aeration valve, execution depends on pot size) Sealing ring 1 1 2 2 2 2 4 2 2 2 2

H 1069

H 1074

Operation Delay Pot

H 1072

H 1073

233

234

Set of seals consisting of A O-ring (1) B O-ring (1) Non-return valve (Aeration valve)

232

Connection Plate

V V V V V V V V V

235 237 237 237 238 239 240 241 305

O-ring Plug screw Threaded pin O-ring Ball Spring Seal lock nut Adjusting screw O-ring

K K 61

247

Intermediate Plate

Hexagon Screw (Emergency Operation Screw) Kit locking wire consisting of Locking wire (1) Wire socket (4) 1

64 (1) (2) (1) (1) 1 1 1 1 1 O-ring O-ring O-ring O-ring 1 1

V V V V V

12 13 20 21 250

V V

251 252

Hexagon nut (lock nut) Threaded pin (set screw) Valve slide Spring Set of seals consisting of A B C D Housing (for set screw) Piston

65 V V 223 1 Control Valve (4/3 NG 10, electrical) 1 1 V V V V 1 1 259 260 261 262 Set of seals consisting of A O-ring (5) B O-ring (2) C O-ring (2) D O-ring (2) Solenoid Plug-in connector Plug-in connector Manual emergency control for 4/3 NG 10 with spring return 2 1 1 2

Control Valve (4/3 WL 5-10, pneumatical)

223

V V

263 264

Set of seals consisting of A O-ring (5) B O-ring (2) C O-ring (2) D Turcon-step seal (2) O-ring (2) E Quadring (1) F Turcon-glyd ring (1) O-ring (1) Pneuko piston, complete Seal ring for piston

D and F consisting of 2 parts one fitting into the other

V 1 V 223

Control Valve (4/2 WL 5-10, pneumatical)

Control Valve (4/2 NG 10, electrical) 1

66 V V V V 1 1 259 260 261 262

223

V V

263 264

Set of seals consisting of A O-ring (5) B O-ring (2) C O-ring (2) D Turcon-step-seal (2) O-ring (2) E Quadring (1) F Turcon-glyd-ring (1) O-ring (1) Pneuko piston, complete Seal ring for piston

Set of seals consisting of A O-ring (5) B O-ring (2) C O-ring (2) D O-ring (2) Solenoid Plug-in connector Plug-in connector Manual emergency control 4/2 NG 10 without spring return

2 1 1 2

D and F consisting of 2 parts one fitting into the other Detail X disc installed as STOP

67 V V 102 114 Control Valve (4/2 NG 10, electrical) 1 1 V V V V 1 1 368 369 370 393 Set of seals consisting of A O-ring (5) B O-ring (2) C O-ring (2) D O-ring (2) Solenoid Plug-in connector Plug-in connector Manual emergency control for 4/2 NG 10 without spring return 2 1 1 2

114

Control Valve (4/2 WL 5-10, pneumatical)

102

Set A B C D

V V

375 376

of seals consisting of O-ring (5) O-ring (2) O-ring (2) Turcon-step-seal (2) O-ring (2) E Quadring (1) F Turcon-glyd-ring (1) O-ring (1) Pneuko piston, complete Seal ring for piston

D and F consisting of 2 parts one fitting into the other Detail X disc installed as STOP

Notes and remarks:

68

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