BV2311 en

Installation Instructions
LAF 2346 4575
E BV2311 Version 1.1 / 06.02.2013
No part of this document may be reproduced in any form

(by printing, photocopying or other means) or processed,
duplicated or circulated electronically without prior written
approval of REINTJES GmbH.
2013 REINTJES GmbH

All Rights Reserved.
LAF 2346 4575

Table of contents
Table of contents
1
Safety .......................................................................................................................................................... 11
1.1 Meaning of Warnings and Notes ........................................................................................................... 11
1.2 Basic measures of caution ..................................................................................................................... 12
1.3 Requirements for installation personnel ............................................................................................... 13
1.4 Safety information for installation .......................................................................................................... 14
1.5 Protective measures against fire and danger of explosion ............................................................... 15
Introduction to this Documentation .............................................................................................. 17

2.1 Maintaining the documentation ............................................................................................................. 18
2.2 Preconditions of warranty ....................................................................................................................... 18
2.3 Brief product description ......................................................................................................................... 19
2.4 Area of application and manner of intended use ................................................................................ 20
2.5 Use of the gearbox within the European Union .................................................................................. 20
Technical Data ........................................................................................................................................ 21
Transport, Storage and Preservation ........................................................................................... 25

4.1 Transport ................................................................................................................................................... 25
4.2 Storage ...................................................................................................................................................... 26
4.3 Preservation ............................................................................................................................................. 28
Description ............................................................................................................................................... 35
5.1 Gearbox execution .................................................................................................................................. 35
5.2 Power Take Off PTO K41 ....................................................................................................................... 40
5.4 Gearbox with shaft brake ....................................................................................................................... 43
Installation and Alignment ................................................................................................................ 45

6.1 Responsibility ........................................................................................................................................... 45
6.2 Steps in preparation ................................................................................................................................ 45
6.3 Place of installation requirements ......................................................................................................... 46
6.4 Demands on the installation personnel ................................................................................................ 46
6.5 Setting up the gearbox ............................................................................................................................ 46
6.6 Alignment .................................................................................................................................................. 48
6.7 Connection to Propeller Shaft ................................................................................................................ 48
6.8 Fixing the gearbox to the foundation .................................................................................................... 50
6.9 Seat Chocks ............................................................................................................................................. 57
6.10 Screwed Connections ............................................................................................................................. 58
6.11 Connection to Engine .............................................................................................................................. 61
6.12 Connection to the gearbox PTO ............................................................................................................ 64
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Table of contents
6.13 Alignment Check ......................................................................................................................................65

6.14 Connection of Gearbox Components ...................................................................................................65
Index ............................................................................................................................................................69
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Safety
Safety
1.1
Meaning of Warnings and Notes

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

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

Frequently, accidents occur as a result of not observing general safety regulations or
cautionary measures.
The individual chapters of this installation instructions contain specific safety notes.
Accidents may often be avoided by recognizing potential hazard situations in advance.
Input side
Output side
Dangerous places on the gearbox
Symbol
Meaning
General Warning Sign
Symbol
Meaning
Smoking and open fires prohibited!
These warnings must be

observed!
Danger of being drawn or caught
in by rotating components
Wear tightly fitting protective

clothing e.g. coverall
Danger of electric shock!
Wear ear protectors
Do not disconnect or service this

device until power supply has been
disconnected!
1
Caution, hot components
Read instructions carefully!
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Safety
1.3
Requirements for installation personnel

Installation personnel must be trained in the use of transport aids and lifting equipment and
have a mastery of the tasks required in safely carrying out installation and alignment. This
includes skilled use of the tools required.
In order to maintain safety during operation, and to avoid any damage to the
gearbox, it is necessary for you to carefully read and to understand the chapters
Transport, Storage and Preservation from page 19 and Installation and Alignment from page 39.
In order to ensure your safety and the safety of others during installation, utilise only tools,
procedures, and methods of working in line with the most recent technology.
If the gearbox appears to require work not described in the documentation, please consult
the REINTJES service department or a REINTJES representative.
In addition to this documentation, please observe and follow applicable laws and
any other binding regulations governing accident prevention and environmental
protection!
General protective measures and personal protection in the engine room
The gearbox may be operated and maintained only by qualified staff knowledgeable in its
operation and maintenance.
DANGER!
Rotating Parts!
Danger of accidents due to getting caught or drawn in!
Prior to trial run mount covers to all rotating parts to prevent being
caught or drawn in.
Immediately repair any faults that pose a safety hazard!
Ensure that no foreign objects enter the inside of the gearbox during assembly.
Wear protective eyewear when cleaning with compressed air.
Danger of eye injuries due to dirt particles.
While the engine is running, wear ear protectors to prevent hearing
impairments.
Do not wear long hair loosely or any loose clothing or jewelry, including
rings, when near the gearbox while in operation.
Danger of injury due to getting caught or drawn in!
Do not touch the gearbox while it is warm from operation.
Danger of burns!
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Safety
1.4
Safety information for installation

The gearbox has been built in accordance with the most recent technology and with
recognized safety regulation standards. Yet, even when the gearbox is used appropriately,
due to its manner of functioning and depending on how it is installed, a danger of personal
injury or death to the user or other individuals may arise.
Observe the following procedures!
WARNING!
When working on the gearbox, prevent the engine from being switched on!
Danger of death due to rotating components!
Shut down the compressed air feed and bleed the air tubes.
Prior to any assembly work on the gearbox, place a sign reading "OUT OF
ORDER" or a similar warning sign on the start-up switch or starter button and on
the remote starter.
Make sure that the remote starter of the drive motor on the bridge is also disabled
and not functioning.
Safety prior to working on the gearbox
Before performing adjustments or repairs on the gearbox or on aggregates powered by the
gearbox, shut down the engine.
Secure the propeller and drive shafts against unchecked rotation.
Before loosening or dismantling any tubes or accessory parts in air, oil or water circulating
systems, first reduce the pressure.
WARNING!
Oil pipes on the gearbox are under pressure when in operation!
Any oil escaping as a result of cracks or other leakage can result in serious injury.
Avoid damaging piping during assembly.
Perform a daily sight check of the piping in order to recognize any leakage at any
early stage.
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Safety
1.5
Protective measures against fire and danger of explosion

General information
Immediately remove any oil residues completely.
Do not leave on the gearbox any rags or cloths used to wipe oil residues.
Pipes and tubes
Check all tubes and oil pipes daily for wear or damage.
Check to see that these have been laid, supported and fastened in accordance with
professional standards.
Tighten bolt joints only to the required torque.
Note that lubricants are flammable.
Never weld pipes or tubes carrying lubricants.
Do not straighten or bend any pipes or tubes under pressure during operation.
Immediately replace any bent or damaged pipes or tubes.
Do not replace steel pipes with copper ones.
Hoses
Do not damage hoses by subjecting them to mechanical force.
Check all hoses daily for any cracks forming or any mechanical damage.
Keep flames, acids and other corrosive or caustic liquids away from hoses.
Replace hoses no later than after 5 years.
Drained oil
Collect drained oil in a used oil collector.
Collect any rags soiled with oil in containers intended for this purpose.
Store all lubricants in appropriately labelled containers. Dispose of filter elements and
used oil either as recyclable substances or as hazardous wastes.
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Safety
Cables connected to the gearbox

Make sure that all cables are maintained in an undamaged condition.
Check to see that all cables are laid properly and cannot be damaged by abrasion.
Immediately after connecting any cables to the gearbox, remove any leftover pieces of cable
or refuse.
Use only wires and cables having the required diameter and type of insulation.
Protect cabling on the board side by means of fuses in front of them in circuits.
Foreign substances near to the gearbox
Ensure that no used parts, dirt or foreign substances are near the gearbox.
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Introduction to this Documentation
This documentation comprises one set of installation and operating instructions for
gearboxes belonging to the LAF model series.
This installation instructions contains information about:
Safety
Technical data
Transport, storage and preservation
Description of gearbox models
Installation and alignment
The operating instruction contains information about:
Putting the unit into operation

Operation
Maintenance
Trouble-shooting
Spare and replacement parts
Drawings for installation and supervision
The procedures described in this documentation are of a general nature.

Actual characteristics may differ from this information depending on the particular
gearbox and equipment.
Please read the Installation instructions before installing the gearbox!

Please be especially careful to observe the preceding safety information!
In order for the unit to operate without fault as well as for any warranty claims to be honoured,
it is necessary to observe this documentation in its entirety.
Anyone responsible for transport, installation, operation or maintenance of this equipment
must adhere to the contents of this documentation.
Your safety as well as the safety of others depends on correctly operating this gearbox.
The best protection against possible accidents is for the party operating the equipment to
exercise caution.
REINTJES will accept no liability for damage or faults during operation if this documentation
is not observed.
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Constant improvement and continued development may result in changes to your gearbox
that is not yet mentioned in these instructions.
All illustrations show basic principles only and may vary from the actual product. You cannot
derive any claims from the illustrations shown in this documentation.
Please address any questions about your gearbox or about this documentation to REINTJES
customer service:
service@reintjes-gears.de or on
working days: Phone +49 5151 104 0
In emergencies and on weekends: Phone +49 5151 104 237
2.1
Maintaining the documentation

This documentation belongs to the gearbox.
Please maintain the documentation for the entire service life of the gearbox.
Please pass on the complete documentation to any later owner or user.
2.2
Preconditions of warranty
REINTJES will only accept warranty claims when:
You install, operate, monitor and maintain the gearbox in accordance with our instructions.
Only the types of oil listed in the lubricant table are used.
You comply with the performance ratings and labelling stamped on the type plate.
No modifications may be made to the gearbox unless they have been approved by REINTJES.
REINTJES, as supplier of one of the components of the complete propulsion system, will not
assume responsibility for any problems with vibration resulting from the system as a whole.
REINTJES will not therefore assume any liability for complaints or damage resulting from this
type of vibration.
REINTJES strongly recommends that you have a torsional vibration calculation

performed for the entire system.
In any case, a whirling calculation must be done for any shaftlines connected to the
input or output shafts.
We additionally recommend having an axial vibration calculation done for propeller
shaftlines.
Torsional, axial and whirling can mutually excite each another. In order to preclude
this possibility, the results of the whirling calculation, axial vibration calculation and
torsional vibration calculation should be compared with each other in order to rule out
that any of the vibration types have the same natural frequencies.
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2.3
Brief product description

The gearboxes of the LAF series are axially offset marine reduction gearboxes with
a built-in hydraulic disc clutch.
Marine gearboxes can be supplied with identical and counter rotation of the input and
output shafts. The built-in thrust bearings absorb the propeller thrust.
The gearbox has been designed under the assumption that a highly flexible coupling
will be employed between the motor and the gearbox.
Control is effected by means of directional valves.
2.3.1
Illustration
LAF 2346 K41 (vertically offset)
Control valve
Pressure build-up system
Heat exchanger
Oil
filter
Input shaft
Oil
pump
Output shaft
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2.4
Area of application and manner of intended use

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

In cases when operation is subject to safety regulations of the European Union, the
manufacturer of the complete system must have it CE-approved and labelled accordingly.
Seagoing vessels are exempted from this requirement in accordance with the Machinery
Directive.
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Technical Data
Technical Data
You will find the technical data for your gearbox on the type plate. The type plate of the gearbox
is mounted at the top part of the gearbox housing.
Copy the data for your gearbox to the type plate printed here:
Requesting spare parts

When making enquiries and ordering parts, please provide the following information:
GEARBOX NO. -
e.g.: K xxxxx
TYPE -
e.g.: LAF ...
INPUT CAPACITY -
e.g.: 2000 kW
GEAR REDUCTION RATIO - e.g.: 4.05 : 1
Please provide this additional information, listed in the spare parts lists, when ordering
spare parts:
Item number of the part

Designation
Required no. of pieces
You will find the spare and replacement parts lists in the operating instructions beginning on
page 75.
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Technical Data
The tables below present an overview of the performance data of the gearbox types described
in this documentation.
The data of your gearbox may differ from the information in these tables in individual
cases. The data on the type plate is authoritative in cases of doubt.
Table 1: Overview of characteristics for type LAF 2346 4575
Type
LAF 2346
LAF 2355
LAF 2365
LAF 2375
LAF 3445
LAF 3455
16
Gear ratio
Input torque Nm
Weight kg
Base gear
2,076
32470
5300
2,529
32470
3,033
32470
3,458
30950
4,041
28670
4,454
26700
3,923
32470
4,461
31160
4,916
29180
5,454
26750
5,762
25500
5,074
31270
5,560
28540
6,130
25890
6,455
24580
6,154
30350
6,440
29000
7,087
26350
7,455
25050
2,053
41540
2,515
41540
3,038
39620
3,462
37620
4,043
34560
4,524
32630
4,074
41540
4,480
37810
4,957
37810
5,524
35180
5,955
39920
6300
7200
9200
6400
7800
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Technical Data
Type
LAF 3465
LAF 3475
LAF 4545
LAF 4555
LAF 4566
LAF 4575
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Gear ratio
Input torque Nm
Weight kg
Base gear
5,077
39740
9700
5,583
36140
5,870
34380
6,524
30930
6,955
28070
6,160
38090
6,458
36330
7,136
32880
7,524
31190
1,923
52530
2,455
52530
2,931
52530
3,423
47090
3,952
42050
4,429
38360
3,960
49850
4,583
44290
5,091
40600
5,429
38460
5,773
36510
4,958
47910
5,500
43920
6,091
40250
6,429
38420
6,818
36510
6,120
45300
6,739
41560
7,091
39500
7,476
37460
10800
8000
9500
11100
13100
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Technical Data
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Transport, Storage and Preservation
4.1
Transport
Upon receipt, immediately inspect the gearbox and accessories for any damage
incurred in transport.
Report any transport damage to the freight carrier immediately.
Inform the REINTJES service department.
Do not put the gearbox into operation if there is any transport damage
WARNING!
The gearbox can fall over if improperly supported!
This may result in serious injury or death!
Under no circumstances should you put slings around shaft ends, pipes or other
externally mounted parts.
When suspending the unit, use only the lifting eyes intended for this purpose.
The gearbox weight (without oil but including special accessories) is stamped on the type plate.
Slings must be suitable for this load. Secure slings to all of the eyebolts intended for this
purpose using shackles.
When lifting for transport, the gearbox must be secured against tilting. To ensure this, use all
of the eyebolts intended for this purpose.
With the gearbox suspended from a sling, the angle of the sling may not exceed 45
from the perpendicular!
Traversing bridge
Lifting eye
bolts
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Sling
max.45
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WARNING!
Suspended load!
Danger of injury!
Use only transport aids and lifting equipment that are approved for the
anticipated load when used in the intended manner.
Transport aids and lifting equipment must be designed to be able to safely hoist
the load, hold it and set it down once again.
Observe the regulations and instructions for use provided by the manufacturer of
the transport aids and lifting equipment.
During transport, make sure:
Not to damage packaging, if further storage is intended afterward.

Transport is carried out only by individuals competent in the use of transport
4.2
and lifting equipment.

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

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

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

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

The gearbox is stored for a longer period or under conditions other than those stipulated
(see "Measures against corrosion during storage" on page 22.)
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4.3
Preservation
4.3.1
General information
Initial preservation is done at REINTJES as specified in agreements by contract.
After a run on the test stand, the gearbox is preserved as specified in the order.
Spare parts or loose parts supplied with the shipment are treated using the preservation
procedures stipulated in the contract.
Preservation for dispatch is designed for a limited period of time and for certain storage
conditions.
The scope and effectiveness of these preservation procedures depend on:
4.3.2
Conditions of storage
Duration of storage
Packaging
Individual customer wishes
Initial preservation
During the factory bench test, the gearbox is run with a corrosion protection oil to preserve it.
In addition, following the bench test, the gearbox is filled with a VCI preservation oil (VCI = volatile
corrosion inhibitor).
Volatile corrosion inhibitors are agents that evaporate very slowly and deposit themselves on
the unpainted metal surfaces within the closed gearbox. Due to their polarity, they interrupt
electrochemical reactions resulting in corrosion.
In order to ensure that these volatile corrosion inhibitors retain their effectiveness for as long
as possible, all of the gearbox openings are closed. The shafts are sealed using v-rings
and/or an acid-free grease.
Externally exposed, unpainted metal parts are protected using a wax-like preservation
substance. When stipulated in the order, the gearbox is additionally protected against
corrosion by means of moisture-proof packaging or special marine packaging.
4.3.3
Measures against corrosion during storage

General information
The following assumes that the storage conditions described in chapter 4.2 are followed.
Here we can merely describe general measures against corrosion.
If you are not certain whether protection is adequate for your particular case of application,
please consult with REINTJES about the necessary measures.
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As a result of damage to packaging, water and harmful environmental influences can have a
direct effect on the gearbox. Excessive moisture can penetrate the inner space of the gearbox
as a result of variations in temperature.
Immediately upon receipt of the gearbox, check the packaging for any transport damage.
Regularly check the outside packaging.
Table 2: Inspection intervals for corrosion protection of the gearbox
Inspection intervals:
European climate zone every 4 weeks
Tropical climate zone every 2 weeks
Inform REINTJES customer service immediately of any corrosion damage discovered

during inspection.
Immediately perform the following measures in the event of damage to packaging:
Dry off any pools of water collecting on the gearbox as a result of rain or condensation.
Check the drying agent provided with the shipment.
Replace the drying agent if its colour changes from white to blue.
Check preservation at shaft ends.
Repair the seal, if necessary, using acid-free grease.
Repair the damaged packaging.
-or better Replace the damaged film along with the drying agent.
Use only film of the same quality.
Remove the packaging when:
The gearbox is brought on board the vessel to be installed

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

will be necessary for ensuring that the gearbox is adequately protected against
corrosion.
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Measures after removing the packaging:

Protect the gearbox as well as possible against water and harmful environmental effects.
For instance, when covering the gearbox with tarpaulins, leave some space between them
and the gearbox. They should not act as a vapour seal!
Regularly inspect the gearbox for external corrosion damage.
During inspection, check to ensure that shaft ends are preserved and sealed.
Repair the seal using acid-free grease. (Refer to table 2 on page 23 for inspection intervals)
Regularly refill the gearbox with Branorol preservation oil.
After removing the packaging, initial refilling should be done after half of storage duration,
as stipulated in the contract, has passed.
Initial refilling should, however, be done no later than 12 weeks (European climate zone)
or 8 weeks (tropical climate zone) afterwards.
Table 3: Intervals for refilling VCI preservation oil
Intervals for refilling VCI preservation oil:
Volume of preservation oil to be filled:
European climate zone every 12 weeks
1% of the operating oil volume, at least 1 litre
Tropical climate zone every 8 weeks
1% of the operating oil volume, at least 1 litre
You will find the operating oil volume on the type plate.
Please observe section "Opening the gearbox" on page 25 in this regard!
For unpacked gearboxes, apply the measures mentioned above even if the stipulated storage
duration has expired.
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Opening the gearbox

The agents of the VCI preservation oil escape when the gearbox is opened.
Measures after opening the gearbox
Refill the gearbox with Branorol preservation oil. (Refer to table 3 on page 24 for volume)
IMPORTANT: Afterwards, close the gearbox air-tight.
A protective inhibitor atmosphere may not be able to form again after reclosing.
This depends on:
4.3.4
The concentration of VCI agents

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

Long interruptions in operation
If the operation of the vessel or gearbox is to be interrupted for several weeks, measures are
required to protect the gearbox against corrosion.
Corrosion damage to the gearbox cannot be ruled if these measures are not followed.
The type and scope of measure that need to be performed depend on the options available
at the particular location. Variants A, B and C, described in the following, are equally as
important.
Table 4:
Measures to protect against corrosion are required
after an interruption in operation of longer than
European climate zone: 4 weeks
Tropical climate zone: 2 weeks
Perform one of these protective measures once the period mentioned above has passed:
Variant A: Flush with operating oil
Flush the gearbox for 15 minutes using the mechanical gearbox oil pump by starting
the engine.
-or using the electrical stand-by pump, if available.
Replace the venting filter using the screw plug.
Repeat flushing weekly.
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Variant B: Flush with Valvoline 6 anticorrosive oil

Drain the operating oil.
Fill with Valvoline 6 anticorrosive oil. Volume: approx. 0.8 x operating oil volume.
Flush the gearbox for 15 minutes using the mechanical gearbox oil pump by starting
the engine.
-or using the electrical stand-by pump, if available.
Repeat flushing after no later than 12 weeks (Europe) or 8 weeks (tropics).
Seal the shafts using an acid-free grease.
Variant C: Fill the gearbox with Branorol VCI preservation oil
Drain the operating oil.
Fill with Branorol VCI preservation oil. Volume and further service intervals: see table 3 on
page 24.
Seal the shafts using an acid-free grease.
Note: Residual amounts of operating oil may remain in the gearbox after draining. This will not
reduce the effectiveness of the measures against corrosion. On the other hand, when putting
the gearbox back into operation, small residual quantities of anticorrosive oil may be mixed
with operating oil.
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Corrosion protection of the heat exchanger
Follow the safety instructions provided in this Installation Instructions.

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

VALVOLINE ROSTSCHUTZ 6, full-power anti-corrosion oil for gearboxes
BRANOROL 32/10, VCI preservation oil, mineral-oil-based
Attention!
Remove the v-rings marked with label before commissioning.
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Description
Description
5.1
Gearbox execution
5.1.1
Gearbox type
The gearboxes of the LAF series are axially offset marine reduction gearboxes with a built-in
hydraulic disc clutch.
Marine gearboxes can be supplied with identical and counter rotation of the input and output
shafts. The built-in thrust bearings absorb the propeller thrust.
5.1.2
Path of drive
The engine power is transmitted to the input shaft by way of the flexible engine to gearbox
coupling.
Path of drive in counter rotation

Input shaft A - Clutch A (closed) - Pinion shaft A Output shaft C.
The output shaft rotates in the opposite direction from
the input shaft.
Path of drive with identical rotation

Input shaft A - Clutch housing A - Clutch housing B Clutch B (closed) - Intermediate shaft B Output shaft C.
The output shaft rotates in the same direction as the
input shaft.
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Description
5.1.3
Aggregates and additionally mounted parts

Hydraulic system
The hydraulic system

consists of:
Control valve
Pressure delay
system
Oil pump
Oil filter
Oil
filter
Heat exchanger
Valve block with pressure
limiting valve
Control valve
Pressure oil system with
pressure delay pot
Lubrication oil system

The operating oil pressure is
controlled by the pressure
limiting valve.
Heat
exchanger
Output shaft
30
Oil
pump
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Description
Hydraulic diagram (LAF gearbox)
Main clutch
Heat exchanger
Oil filter
Gearbox
pump
Stand-by
pump
Dipstick
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Description
Oil pump
The oil pump, mechanically driven by the transmission,
is a gear pump that serves to supply the gearbox with
pressure oil and lubrication oil.
Oil filter
The oil filter serves to filter out solid particles from the
operating oil. This is a duplex filter with two filter elements
(during operation it is possible to switch from the soiled filter
element to a clean one).
A mechanical or electrical contamination indicator indicates
when a filter element is contaminated. On changing filters,
please refer to the maintenance chapter of the operating
manual, page 50.
Heat exchanger
The heat exchanger is a tube-bundle heat exchanger.
Seawater or freshwater taken from a closed cooling
water circulating system is used as a coolant.
On maintenance of the oil cooler, please refer to the
maintenance chapter of the operating instructions,
beginning at page 54.
Valve block with pressure limiting function

Operating pressure is regulated by a spring-loaded
pressure limiting valve.
Standard operating pressure is approx. 25 bar (2500 kPa
or 362 psi).
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Description
Control valve, electrical

The gears are engaged by means of axial slide valves which
are brought into the desired position of engagement by axially
shifting the control piston.
LAF gearbox - 4/2 directional valve with lock (without return
spring)
Pressure build-up system

The pressure build-up system ensures smooth
engagement of the gearbox clutch.
Oil manometer and supervision

An oil pressure manometer is mounted on the gearbox for
monitoring oil pressure. This manometer indicates the operating
pressure.
Operating pressure is set differently depending on the gearbox
type.
Operating pressure is checked with the engine running at nominal
speed, the gearbox at operating temperature and the clutch
engaged.
With the engine running at nominal speed and the clutch
engaged, operating pressure must be within the range indicated
by the markers on the manometer.
The supervision system continuously measures current values
of operating characteristics such as temperature, pressure,
speed (optionnally) and oil level (optionnally). If any parameter
defined in the supervision plan is exceeded (e.g. temperature) or not
attained (e.g. pressure) an alarm is given in the form of an electrical signal.
Electrical stand-by pump

The oil pump with electrical motor is designed to be used as a
stand-by pump in the event that the mechanical gear pump fails.

Do not disconnect or service this device until
power supply has been disconnected!
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Description
5.2
Power Take Off PTO K41

The power take off may be used for auxiliary units (e.g. generator or an additional pump).
Size and design are built to order. This power take off may therefore only be used for the
application it is designed for.
Power take off
Controllable
Speed
Rotating direction
K 41A
No
i x nengine
Counter to engine
K 41B
No
i x nengine
Counter to engine
K 41A: primary PTO - PTO shaft turns always even if the propeller standstill
K 41B: secondary PTO: PTO shaft turns only, if the propeller turns
K41A/B
K41 A
Position
Above input shaft, on the output side
Operating conditions
Running engine
primary PTO
K41 B
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Path of drive
primary PTO:
Running engine - input shaft with clutch housing - PTO pinion

- PTO shaft
secondary PTO
Running engine, oil pressure sufficient, engaged main clutch
Path of drive
secondary PTO:
Running engine - input shaft with clutch housing - engaged

main clutch - pinion shaft - PTO wheel - PTO pinion -PTO shaft
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Description
5.3

The power take off may be used for auxiliary units (e.g. generator or an additional pump).
Size and design are built to order. This power take off may therefore only be used for the
application it is designed for.
Power take off
Controllable
Speed
Rotating direction
K 51A
Yes
i x nengine
Counter to engine
K 51B
Yes
i x nengine
Counter to engine
K 51A: primary PTO - PTO shaft turns always even if the propeller standstill
K 51B: secondary PTO: PTO shaft turns only, if the propeller turns
K 51 A/B Position
above input shaft, output sided
K51 A
Running engine, oil pressure sufficient, PTO clutch engaged
primary PTO
K51 B
Path of drive
primary PTO:
Running engine - input shaft with clutch housing - PTO pinion engaged PTO clutch - PTO shaft
secondary PTO
Running engine, oil pressure sufficient, main clutch and PTO clutch
engaged
Path of drive
secondary PTO:
Running engine - input shaft with clutch housing main clutch engaged - pinion shaft - PTO wheel - PTO pinion PTO clutch engaged - PTO shaft
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Description
5.3.1
Control of the PTO

The engaged speed range specified in the order acknowledgement has to be observed. Only
after this the main engine can be regulated to nominal speed. Any increase intended afterwards must be approved by REINTJES.
WARNING!
Manual engaging of the PTO control valve
Danger of personnel by unintentional turning of the PTO shaft!
Dont engage the PTO clutch manually!
STOP-position of the PTO-control valve
In the Stop position the oil is lead to the lube oil lines and the sump. The annular piston is pulled
into his starting position by the return springs.
36
The disengaged disc clutch is permanetly supplied with lube oil. This results in an
idling torque.
With disengaged clutch the PTO shaft may rotate provided the idling torque is higher
than the initial friction torque of the driven parts.
The idling torque depends on the present operating conditions.
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Description
5.4
Gearbox with shaft brake
5.4.1
Gearbox execution
The gearbox is the same as the standard execution (refer to 5.1) but with a mounted shaft
brake. This section therefore deals only with the components differing from the standard
model.
5.4.2
Aggregates and additionally mounted parts

The hydraulic system
Pressure build-up
system brake
The hydraulic system additionally

includes:
A control valve for the brake

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

An additional control valve, for controlling the brake,
is mounted on the gearbox.
The control piston is actuated pneumatically.
Control valve brake
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Description
Brake pressure build-up system

The pressure build-up system ensures smooth application
of the brake.
Shaft brake
The shaft brake is applied automatically during disengaging
the clutch.
The brake is always engaged while the clutch is disengaged.
Hydraulic diagram (gearbox with brake)
Hydraulic block
Shaft brake
Main clutch
Heat exchanger
Oil filter
Control air
Gearbox pump
Dipstick
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Stand-by
pump
Lubrication oil
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Installation and Alignment
6.1
Responsibility
!
6.2
Installation and alignment are the responsibility of the yard.
Steps in preparation
WARNING!
The gearbox can fall over if improperly secured!
This may result in serious injury or death!
Under no circumstances should you put slings around shaft ends, pipes or
other externally mounted parts.
When suspending the unit, use only the lifting eyes intended for this purpose.
The lifting eye bolts are marked with the label "Sling here".
When installing the gearbox, ensure that:
Transport is carried out only by individuals competent in the use of transport

and lifting equipment.
Only suitable transport aids (e.g. traversing bridges) that are approved for the
weight of the gearbox are used.
Slings do not press against piping or externally mounted parts. A risk of
damage exists!
Steps before installing the gearbox

Remove all protective coverings (Films, Transport Packaging).
Remove any dust or dirt.
Suspend the gearbox from a crane hook using suitable slings.
Please additionally observe the generally safety information as well as the
information in chapter "Transport" on page 19 and the information provided above!
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6.3
Place of installation requirements

The necessary space for movement of the personnel in the working area must not be
restricted or may be hindered.
Free spaces to be considered especially are indicated in the drawing of installation.
The foundation must be designed to absorb the gearbox weight and working loads.
It has to be strictly considered that sufficient free space for dismantling of housing and shafts
is available for later maintenance.
6.4
Demands on the installation personnel

The installation must be carried out only by authorised staff of the supplier of the propulsion
system or the shipyard.
Required qualification of the installation personnel:
qualified mechanic for the mechanical installation

electrically skilled person for the electrical installation
The installation personnel must wear protective clothes according the regulations.
The protective clothes must be provided by the supplier of the propulsion system
or the shipyard.
6.5
Setting up the gearbox
Before setting up the gearbox, make sure that you have current versions
of these documents:
Installation Instructions (this manual)

Drawing of installation
Supervision Plan
Alignment calculation
Make sure that you have read and understood the descriptions and information
concerning alignment contained in this Installation Instructions.
The drawing of installation represents the basis for setting up the gearbox.
This drawing includes all dimensions and values relevant for setting up the gearbox.
The drawing number applying to your gearbox is indicated in the order acknowledgement.
The drawing of installation may also be obtained from REINTJES indicating the commission
number.
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service@reintjes-gears.de
On weekdays: Phone +49 5151 104 0
Aleays carry out the lifting of heavy components with several persons or use
lifting equipment.
Set the gearbox on the foundation in the intended position.
Secure the gearbox against shifting on the foundation until it has been aligned and
permanently fastened.
Protect the gearbox against corrosion, contamination and damage (refer to Preservation
beginning at page 22).
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6.6
Alignment
Determine the permissible GAP and SAG values for all shaft connections taking into
account the technical information (alignment calculation, thermal expansion and
manufacturrers information) applying to the units to be connected.
In addition, take into account settlement effects for the cast-resin foundation. Request the
cast-resin manufacturer to send you detailed information on settlement.
Carry out the alignment work only after the vessel is afloat with absolutely no ground
contact with the sea bed.
The vessel should be equipped as far as possible. Missing heavy equipment, e.g. winches,
cranes, has to be duly considered.
Carry out the alignment work in the early morning. Direct sunlight can influence the
alignment result.
A prerequisite for the trouble-free operation of the gearbox is the careful alignment of
the input shaft of the gearbox with the engine shaft

the output shaft of the gearbox with the propeller shaft
the PTO shafts with the connected auxiliary units
Take into account the thermal expansion of the engine, gearbox, aggregates and
foundations at operating temperature.
Also if torsionally flexible couplings or cardan shafts are used, precise alignment with the
engine will be required. Any misalignment will have negative effects on the service life
of the gearbox and the connected components.
Observe the manufacturers' instructions when aligning:
6.7
the output shaft of the gearbox with the propeller shaft connection
the engine with the input shaft of the gearbox
the auxiliary units with the additional gearbox shafts (PTO)
Connection to Propeller Shaft

A prerequisite for the connection of the propeller shaftline with the gearbox is that the
propeller shaft and/or the intermediate shaft be in the static operating position.
To be in the static operating position means:
42
the propeller shaft and the intermediate shaft are in their bearings
the propeller is mounted
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the intermediate shaft flanges are connected (if present)

the flange facing the gearbox is in the alignment position (if necessary)
Alignment
screws
Hole
for foundation bolts
Surface for
collision chocks
Surface for
lateral
collision chocks
Gearbox foot including fastening options
Steps in connecting to the propeller shaft

Screw the alignment screws into the gearbox foot.
Fix the adjusting screws on the foundation, with which you can align the gearbox
horizontally, in longitudinal and transverse directions.
With the adjusting screws, align the gearbox
vertically and horizontally in longitudinal and transverse directions with the propeller
flange, according to the specified data.
If an alignment calculation is available, you must observe the calculations and
procedures specified therein.
Take into consideration thermal expansion at operating temperature.
A thermal expansion diagram may be requested from REINTJES.
Additionally take into account settling effects when setting the gearbox up on a
cast-resin foundation.
Request detailed documentation on this from the manufacturer of the cast resin.
With approved methods
(gauges, laser), measure the
horizontal and vertical GAP and
SAG values between the gearbox flange and the counterflange on the propeller side.
Example: Measuring of the GAP and SAG values:

gearbox output
flange
propeller shaft
SAG
GAP
Permissible tolerances:
Radial misalignment 0.05 mm
(centreline run-out 0.025 mm) - SAG
Angular misalignment 0.05 mm related to 300 mm flange diameter - GAP
Document your GAP and SAG values
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Fix the gearbox to the foundation, as described in paragraph 6.8.

Check the gap and sag values.
Connect the propeller shaft to the gearbox output shaft after the gearbox is firmly
fixed to the foundation.
If you have a special, deviating installation situation, agree the necessary steps
with REINTJES prior to the installation.
service@reintjes-gears.de
On weekdays: Phone +49 5151 104 0
6.8
Fixing the gearbox to the foundation

Following the alignment with the propeller shaft, the gearbox can be fixed on the foundation,
as described in the following.
The design of the foundation bolts and their tightening torques lies exclusively with the
shipyard.
6.8.1
Gearboxes with Longitudinal Mounting Arrangement, Metal Seat Chocks,

Rigid Mounting
The following combinations are permissible for the gearbox fixation
1. Seat chocks with 4 fitting bolts, through bolts and collision chocks. for propeller
thrust AHEAD and ASTERN!
fitting bolt
through bolt
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2.Seat chocks with fitting bolts and through bolts without collision chocks,
(Number of fitting bolts depending on propeller thrust)
3. Seat chocks with collision chocks, with the foundation bolts designed as
through bolts.
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6.8.2
Gearboxes with Longitudinal Mounting Arrangement, Cast Resin Seat Chocks,

Rigid Mounting
The following combinations are permissible for the gearbox fixation:
1. Cast-resin seat chocks with 4 fitting bolts, collision chocks for propeller thrust
"AHEAD" and "ASTERN", and through bolts
fitting bolt
through bolt
2. Cast-resin seat chocks with collision chocks, with the foundation bolts designed as
through bolts.
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6.8.3
Gearboxes with Longitudinal Mounting Arrangement, Adjustable metal seat

chocks, Rigid Mounting
1. Vibracon SM elements or RotaChock elements with 4 fitting bolts, collision chocks
for propeller thrust "AHEAD" and "ASTERN", and through bolts
fitting bolt
through bolt
2. Vibracon SM elements or RotaChock elements with collision chocks, with the

foundation bolts designed as through bolts.
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6.8.4
Gearboxes with Transverse Mounting Arrangement, Rigid Mounting

1. Thrust bearing mounted on the engine side
Cast-resin seat chocks with through bolts and steel seat chocks with fitting bolts in the
area of the thrust bearing
with fitting bolts
2. Thrust bearing mounted on the engine side

Cast-resin seat chocks with through bolts, collision chocks for propeller thrust
"AHEAD", and fitting steel bushes with expansion bolts for propeller thrust "ASTERN"
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3.Thrust bearing mounted on propeller side

Cast-resin seat chocks with through bolts and steel seat chocks with fitting bolts in the
area of the thrust bearing
with fitting bolts

4.Thrust bearing mounted on propeller side
Cast-resin seat chocks with through bolts and fitting sleeves with expansion bolts for
propeller thrust "AHEAD" and "ASTERN"
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Basic principle of a simple collision chock

The collision chocks are designed to transfer the propeller thrust to the foundation.
Ensure that the gearbox is installed distortion-free.

The design of the collision chocks lies within the responsibility of the shipyard.
The collision chocks are to be structurally designed so that they can withstand the maximum
occurring propeller thrust without taking into account the foundation bolt preloading. Stopper
chocks are to be made from metallic materials. There must be metal-to-metal contact on
both sides and they must be secured against displacement.
Stopper chocks are to be manufactured to a wedge or double wedge design. Positioning of
the wedge-shaped chocks without clearance must be executed with the plant at its operating
thermal condition. The subsequent fixing of the chocks is to be ensured by screws or welding up the wedges over the entire wedge length. The design and correct installation of the
stopper chocks lies within the responsibility of the shipyard.
Observe the demands on seat chocks specified in paragraph 6.9.
Fit the seat chocks between the gearbox feet and the top plate.
Back off the alignment screws before tightening the foundation bolts.
Following the alignment with the propeller shaft, screw the gearbox to the foundation, so that
it is protected against displacement. In doing so, observe the demands and notes on the
bolts stated in paragraph 6.10.
Any other foundation methods must be approved by REINTJES.
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6.9
Seat Chocks
6.9.1
Metal Seat Chocks

The seat chocks have the task to keep the gearbox in the desired position and direct the reaction forces into the foundation as evenly as possible. The material to be preferred for metal seat
chocks shall be steel or cast steel. Cast iron may also be used.
The thickness of the seat chock shall amount to between 20 and 80 mm. When using cast
iron, the minimum thickness is 40 mm. The surface of recesses in the seat chock should be
less than 20% of the total surface of the seat chock.
Rectangular seat chocks must be used only.
The seat chock has to be manufactured from one part. Shims or lining plates are not
permissible.
Metal seat chocks have to be fit in through touching on both sides. The bearing share
achieved must be at least 75%.
Tack welding on seat chocks is not permissible.
Seat chocks must be sufficiently dimensioned and closely fitted. They have to be made in
accordance with the rules of the Classification Societies.
6.9.2
Cast-resin Seat Chocks

As a matter of principle, only approved material by authorised firms must be used in
compliance with the rules. Before casting resin under the gearbox, the calculations and the
tightening method for the foundation bolts have to be submitted to the Classification Society
for approval.
The foundation has to be designed such that the maximum stress values between the
gearbox and the cast-resin seat chock indicated by the manufacturer are not exceeded.
The height of the cast-resin seat chocks must be between 20 and 80 mm. In any case, the
height must always be less than the width and length of the part.
Observe the cast resin manufacturer's instructions.
The cast-resin seat chocks must be loaded only after thermosetting.
The alignment screws must be backed off before tightening the foundation bolts.
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6.9.3
Adjustable Metal Seat Chocks, type Vibracon SM or type RotaChock
As a matter of principle, only adjustable metal seat chocks, type Vibracon SM

(from Co. Machine Support, Netherlands) or type RotaChock, (Chock Design, Netherlands)
must be used in compliance with the instructions. Before installing the gearbox the
calculations and the tightening method for the foundation bolts have to be submitted to
the Classification Society for approval.
The foundation has to be designed such that the maximum stress values between the
gearbox and the Vibracon SM element or type RotaChock element indicated by the
manufacturer are not exceeded.
The alignment screws must be backed off out of contact with the foundation before
tightening the foundation bolts.
6.10
Screwed Connections
The gearbox foundation bolts comprise fitting bolts and/or through bolts.
The foundation bolts have to be calculated according to the state of the art. Under all operating
conditions, the preload of the bolts must be higher than the workload. The elongation of the
bolt has to be designed such, that the connection is not loosened in case of settlement
(recommendation: elongation of bolts must be greater than 0.17 mm).
Any lifting of the gearbox under dynamic stress must be excluded.
The working forces needed for calculating the bolts may be obtained from REINTJES. In
addition to the working forces, the forces added by mounted components must be included
in the calculation of the bolts.
As a matter of principle, the screwed connection must be secured against loosening.
The seats of bolt heads and nuts have to be plane-parallel. It must be ensured that the seat
under the bolt head and nut is sufficiently dimensioned in order not to exceed the permissible surface pressure.
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6.10.1
Fitting Bolts
The fitting bolts are designed to firmly fix the gearbox on the foundation.
When using metal seat chocks and a sufficient number of fitting bolts, the propeller thrust can
be transmitted through the foundation bolts exclusively. In this case the fitting bolts have to be
checked for bolt bearing pressure and shear. The fitting bolts have to be positioned in the direct
vicinity of the thrust bearing.
When using cast resin seat chocks the propeller thrust must not be transmitted through the
fitting bolts.
The geometry of the fitting bolts must be designed such that at least 50% of the height of the
gearbox foot and 50% of the height of the top plate are covered by the fitting shank.
The fitting bolts used must at least be of tensile strength 8.8 in accordance with
ISO 898. The fitting bolt bores are predrilled.
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6.10.2
Fitting bolts in combination with adjustable Metal Seat Chocks

The task of the fitting bolts is the exact fixing of the gearbox on the foundation.
A transmitting of the propeller thrust by the fitting bolts isn't permissible.
The geometry of the fitting bolt has to be so formed that at least 50% of the gearbox foot
height and 50% of the heights of the top plate are covered by the pass shaft.
The used fitting bolts must correspond to at least the strength class 8.8 to ISO 898.
The drillings for the fitting bolts are pre-drilled.
6.10.3
Fitting steel bushes with Expansion Bolts

The fitting steel bushes are designed to firmly fix the gearbox on the foundation and
transfer the propeller thrust. The fitting steel bushes have to be checked for bolt bearing
pressure and shear. The fitting steel bush bores are predrilled. The expansion bolts
used must at least be of tensile strength 8.8 in accordance with ISO 898. The fitting
steel bushes must have comparable material properties, however, they must at least
have a tensile strength of Rm = 800 N/mm and a yield point of Re = 640 N/mm.
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6.10.4
Through Bolts
The used through bolts must correspond to at least the strength class 8.8 according
to ISO 898.
The through bolts must comply with application-specific requirements and be tightened
to the specified torque.
6.11
Connection to Engine
Conditions for connection to engine:
The gearbox is aligned with the propeller shaft.

The gearbox is firmly fixed on the foundation.
The engine is aligned axially to the gearbox. The space between gearbox and engine
must correspond to the mounting length of the flexible coupling. The axial reaction
forces of the flexible coupling on engine and gearbox shall be as low as possible.
Observe the initial values of engine and flexible coupling manufacturer.
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Operational steps for connection to engine

Align the engine with the adjusting screws, horizontally in longitudinal and transverse
directions, and vertically in front of the input flange of the gearbox, according to the
specified data.
With approved methods (gauges, laser), measure the horizontal and vertical gap
and sag values.
Radial misalignment 0.05 mm (centreline run-out 0.025 mm) - sag
Angular misalignment 0.05 mm related to 300 mm flange diameter - gap
Document your gap and sag values.
Consider the thermal expansion of the engine, gearbox and foundation at operating
temperature.
Note that the resilient mounting elements of the engine will settle later.
Consider that displacement of the engine and gearbox can occur and that the working forces
can have an impact on the foundation.
Consider the maximum permissible reaction forces exerted by the flexible coupling on the
gearbox input shaft.
During all operations, observe the instructions of the engine and coupling manufacturers.
When the engine alignment and the alignment check are finished, the engine foundation can
be cast.
Connect gearbox and engine with the flexible coupling according to the manufacturer's
instructions.
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Variables for determining the reaction forces of the flexible coupling
Determine the radial reaction force of the coupling FR due to radial misalignment.
FR = r x Cr dyn
r - radial shaft misalignment;
Cr dyn - radial stiffness of the flexible coupling
Determine the corresponding bending moment MB due to angular misalignment.
MB=0.5 x Cax x D x X1
Cax - axial stiffness of the flexible coupling;
D - diameter of the connection between the flange and the flexible coupling/flywheel
X1 - measured angular misalignment (GAP)
Inform REINTJES of the reaction force FR, the bending moment MB and the
distance L for approval.
L = S + X = distance from point of application FR to big cone diameter of gearbox input shaft
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6.12
Connection to the gearbox PTO

Pre-conditions for connection to the PTO:
The gearbox is aligned with the propeller shaft.

The gearbox is aligned with the engine.
The gearbox is firmly fixed on the foundation.
Operational steps for connection to PTO

Align the auxiliary unit driven by the PTO (e. g. generator) with the adjusting screws,
horizontally in longitudinal and transverse directions, and vertically in front of the PTO
shaft of the gearbox, according to the specified data.
With approved methods (gauges, laser), measure the horizontal and vertical gap
and sag values.
Radial misalignment 0.05 mm (centreline run-out 0.025 mm) - SAG
Angular misalignment 0.05 mm related to 300 mm flange diameter - GAP
Document your GAP and SAG values.
Consider the thermal expansion of the gearbox, auxiliary unit and foundation at
operating temperature.
Consider that displacement of the auxiliary unit and gearbox can occur and that the
working forces can have an impact on the foundation.
Consider the maximum permissible reaction forces exerted by the flexible coupling
on the gearbox PTO shaft.
During all operations, observe the instructions of the auxiliary unit and coupling
manufacturers. Fix the auxiliary unit on the foundation according to the supplier's
instructions.
Determine the reaction forces of the flexible coupling (as described in point 6.11).
Connect PTO and auxiliary unit with the flexible coupling, according to the manufacturer's
instructions.
58
The alignment will only be recognised as complete by REINTJES, if you completely

documented the alignment of propeller shaft - gearbox, gearbox - engine and gearbox
PTO - auxiliary unit!
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6.13
Alignment Check
6.13.1
Alignment Check on Engine Side

Check the gearbox foundation bolts for tightness.
Remove the flexible coupling on the engine.
Finally, check the gap and sag values and compare them with the data specified by the
coupling manufacturer. In case of deviations, please contact REINTJES.
6.13.2
Alignment Check on Propeller Side

Remove the flange mounting screws on the propeller side.
Finally, check the gap and sag values and compare them with the specified data.
In case of deviations, please contact REINTJES.
6.13.3
Alignment Check PTO

Remove the flexible coupling.
Finally, check the gap and sag values and compare them with the data specified by the
coupling manufacturer. In case of deviations, please contact REINTJES.
6.14
Connection of Gearbox Components
6.14.1
Connection of valve control and supervision system

Lay the cables for the control and supervision system to the gearbox junction box and
connect them in compliance with the supervision drawing.
On the gearbox itself, the cables for the control and supervision system are completely
connected.
Check the functioning of the valve control and the gearbox supervision system according to
the commissioning instructions.
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6.14.2
Connection of Shaft Brake

Lay the compressed air line to the brake control valve.
The connection is indicated in the installation drawing.
Install a dehumidifier in the compressed air system.
The initial pneumatic pressure must be 5 - 7 bar.
6.14.3
Connection of Heat Exchanger
Note that the cross section at the entry to the heat exchanger on the water
side must not be reduced!
Install the pipes on the water side of the heat exchanger
with SAE counterflanges (see installation drawing). They must
be laid vibration-free. We recommend using rubber/steel-wire
compensators.
Seawater cooling
The parts flown through by water of the heat exchanger consist of
seawater-proof materials. Nevertheless, for proper functioning the
following has to be observed:
Install a filter in the seawater circuit.
Ensure that there is sufficient anodic protection in the water pipes.
Freshwater cooling
Inform REINTJES, if an anticorrosion additive is admixed to the freshwater circuit.
The additive can reduce the cooling capacity of the heat exchanger.
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6.14.4
Connection of Electric Standby Oil Pump

If the stand-by pump is mounted on the gearbox, the pump
is supplied complete with all required pipes.
CAUTION!
If the pump direction is reversed, there is danger that excessive pressure
builds up in the pipes
Danger of injury from bursting pipes
When connecting the pump motor electric supply line, pay attention to the
indicated sense of rotation of the pump.
DANGER!
of electric shock!
Do not connect/disconnect or service this device until power supply has been
disconnected!
Lay the electric supply line to the standby oil pump.
Connect the motor according to the enclosed circuit diagram. You will find the circuit
diagram in the junction box of the pump motor.
During commissioning the pump must start running in the indicated sense of
rotation. Check the sense of rotation with an induction instrument and make the
proper terminal connections.
If the electric standby oil pump of your gearbox is supplied separately, you must also lay
and connect the suction and pressure pipes between the pump and the gearbox.
When connecting the pump pipes, pay attention to the indicated sense of rotation of the
pump.
Clean the pipes installed on board or changed during installation, e.g. by subjecting them
to acid treatment. The pipes must be free of dirt.
Observe the connection instructions (pipe cross section, length of pipe and number of
pipe bends).
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Index
Index
A
Operation delay system 39, 44
Alignment 48
Alignment Check 65
B
Brief product description 19
C
Characteristics of the gearboxes 22
Connection of Gearbox Components 65
Connection to Engine 61
Connection to Propeller Shaft 48
Connection to the gearbox PTO 64
Corrosion protection 28
Interruptions in operation 31
Protective measures 31
Corrosion protection oils 33
Packaging inspection intervals 29

Path of drive 35
Place of installation requirements 46
Preservation 28
Opening the gearbox 31
Preservation oil
Volume to be filled 30
Preservation oils 33
PTO K41 40
PTO K51 41
R
Requirements for assembly personnel 13
Responsibility 45
Demands on the installation personnel 46

Directional valves 39, 43
Safety 11
Screwed Connections 58
Seat Chocks 57
Setting up the gearbox 46
Set-up 45
Shaft brake 44
Storage 26
E
Electrical lubrication oil pump 67
Electrical stand-by pump 39
F
Fixing the gearbox to the foundation 50
Technical Data 21
Transport and Storage 25
Types of Documentation 17
Gearbox type 35
Gearbox with shaft brake 43
H
Heat exchanger 38
Hydraulic system 43
V
valves
Directional 39, 43
Pressure limiting 38
VCI preservation oil 28
I
Illustration of the gearbox 19
Initial preservation 28
Installation 45
Introduction 17
L
Long interruptions in operation 31
O
Oil filter 38
Oil pump 38
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Index
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No part of this document may be reproduced in any form

(by printing, photocopying or other means) or processed,
duplicated or circulated electronically without prior written
approval of REINTJES GmbH.
2013 REINTJES GmbH

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

2.1 Note this safety information before putting the unit into operation the first time ........................... 11
2.2 Installation check ..................................................................................................................................... 12
2.3 Fill with operating oil (initial filling) ......................................................................................................... 12
2.4 Handling the checklists for putting the unit into operation ................................................................. 15
2.5 Checklist before initially putting the unit into operation ..................................................................... 16
2.6 Checklist before starting the engine ..................................................................................................... 19
2.7 Checklist for gearbox after engine start ............................................................................................... 20
2.8 Notes on the checklists for putting the unit into operation ................................................................ 21
Operation ................................................................................................................................................. 23
3.1 Engaging procedures for standard gearboxes .................................................................................... 23
3.3 Shaft brake ............................................................................................................................................... 24
3.4 Special operating modes ........................................................................................................................ 25
3.5 Emergency operation .............................................................................................................................. 27
3.6 Setting the pressure limiting valve ........................................................................................................ 30
Maintenance ............................................................................................................................................. 31
4.1 Maintenance plan .................................................................................................................................... 33
4.2 Maintenance job cards ............................................................................................................................ 35
4.3 Check of tube bundle contamination in the heat exchanger ............................................................. 54
4.4 Replacement of the mechanical gearbox oil pump ............................................................................ 59
4.5 Conversion factors and screw tightening torque values .................................................................... 68
4.6 Screw Locking .......................................................................................................................................... 69
4.7 Maintenance performed .......................................................................................................................... 70
Trouble-shooting ................................................................................................................................... 71
Spare and replacement parts ........................................................................................................... 75

6.1 Gearbox oil pump A001.00, Type KF2/.., KF3/.., KF4/.. .................................................................... 77
6.2 Heat exchanger A002.00, Type P ... .................................................................................................... 79
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Table of Contents
6.3 Duplex filter A003.00, Type RFLD ........................................................................................................81

6.4 Control valve V1 (4/2-way-valve), electrical ........................................................................................83
6.5 Control valve V114 (4/2-way-valve), electrical, for PTO ....................................................................85
6.6 Control valve V189 (4/2 way-valve), pneumatical, for shaft brake ...................................................87
6.7 Operation Delay Pot H426.00 ................................................................................................................89
6.10 Control block V006.00, type HB4 D 0327 A ........................................................................................95
6.11 Control block V006.00, type HB 4 A 0328 B ........................................................................................97
6.12 Control block, type HB 4 B 0320A + DKF4O30 ..................................................................................99
Index ..........................................................................................................................................................101
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Safety
Safety
1.1
Meaning of Warnings and Notes

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

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

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

observed!
Danger of being drawn or caught
in by rotating components
Wear tightly fitting protective

clothing e.g. coverall
Wear ear protectors
Do not disconnect or service this

device until power supply has been
disconnected!
1
Caution, hot components
Read instructions carefully!
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Safety
1.3
Requirements for operating and maintenance personnel

Maintenance personnel must be trained in the operation and maintenance of marine
gearboxes and have a mastery of the tasks required in safely carrying out maintenance.
This includes knowledge of procedures required in the event of failures or in cases of
emergency as well as professional skills required for using the tools.
In order to maintain safety during operation, and to avoid any damage to the
gearbox, it is necessary for you to carefully read and to understand the chapters
Putting the unit into operation from page 11, Operation from page 23 and
Maintenance from page 31.
In order to ensure your safety and the safety of others during assembly, utilise only tools,
procedures, and methods of working in line with the most recent technology.
If the gearbox appears to require work not described in the documentation, please consult
the REINTJES service department or a REINTJES representative.
In addition to this documentation, please observe and follow applicable laws and
any other binding regulations governing accident prevention and environmental
protection!
General protective measures and personal protection in the engine room

The gearbox may be operated and maintained only by qualified staff knowledgeable in its
operation and maintenance.
DANGER!
Rotating Parts!
Prior to trial run mount covers to all rotating parts to prevent being caught
or drawn in.
Immediately repair any faults that pose a safety hazard!
Ensure that no foreign objects enter the inside of the gearbox during assembly.
Wear protective eyewear when cleaning with compressed air.
Danger of eye injuries due to dirt particles.
While the engine is running, wear ear protectors to prevent hearing
impairments.
Do not wear long hair loosely or any loose clothing or jewelry, including rings,
when near the gearbox while in operation.
Danger of injury due to getting caught or drawn in!
Do not touch the gearbox while it is warm from operation.
Danger of burns!
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Safety
1.4
Safety information for assembly

The gearbox has been built in accordance with the most recent technology and with
recognized safety regulation standards. Yet, even when the gearbox is used appropriately,
due to its manner of functioning and depending on how it is installed, a danger of personal
injury or death to the user or other individuals may arise.
Observe the following procedures!
WARNING!
the remote starter.
Safety prior to working on the gearbox
Before performing adjustments or repairs on the gearbox or on systems powered by the
gearbox, shut down the engine.
Secure the propeller and drive shafts against unchecked rotation.
Before loosening or dismantling any tubes or accessory parts in air, oil or water circulating
systems, first reduce the pressure.
WARNING!
Oil pipes on the gearbox are under pressure when in operation!
Any oil escaping as a result of cracks or other leakage can result in serious injury.
Avoid damaging piping during assembly.
Perform a daily sight check of the piping in order to recognize any leakage at any
early stage.
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Safety
1.5
Protective measures against fire and danger of explosion

General information
Immediately remove any oil residues completely.
Do not leave on the gearbox any rags or cloths used to wipe oil residues.
Pipes and tubes
Check all tubes and oil pipes daily for wear or damage.
Check to see that these have been laid, supported and fastened in accordance with
professional standards.
Tighten bolt joints only to the required torque.
Note that lubricants are flammable.
Never weld pipes or tubes carrying lubricants.
Do not straighten or bend any pipes or tubes under pressure during operation.
Immediately replace any bent or damaged pipes or tubes.
Do not replace steel pipes with copper ones.
Hoses
Do not damage hoses by subjecting them to mechanical force.
Check all hoses daily for any cracks forming or any mechanical damage.
Keep flames, acids and other corrosive or caustic liquids away from hoses.
Replace hoses no later than after 5 years.
Drained oil
Collect drained oil in a used oil collector.
Collect any rags soiled with oil in containers intended for this purpose.
Store all lubricants in appropriately labelled containers. Dispose of filter elements and
used oil either as recyclable substances or as hazardous wastes.
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Safety
Cables connected to the gearbox

Make sure that all cables are maintained in an undamaged condition.
Check to see that all cables are laid properly and cannot be damaged by abrasion.
Immediately after connecting any cables to the gearbox, remove any leftover pieces of cable
or refuse.
Use only wires and cables having the required diameter and type of insulation.
Protect cabling on the board side by means of fuses in front of them in circuits.
Foreign substances near to the gearbox
Ensure that no used parts, dirt or foreign substances are near the gearbox.
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2.1
Note this safety information before putting the unit into operation
the first time
DANGER!
If a warning sign has been mounted:
Danger of death due to open drive parts and gears!
Do not start the engine under any circumstances!
Do not operate the control unit!
Every time prior to putting the engine or gearbox into operation, carefully ensure
that no work is being done on these components or in the vicinity of them.
WARNING!
Rotating parts!
Prior to operation mount covers to all rotating parts to prevent being caught or
drawn in.
Do not wear long hair loosely or any loose clothing or jewellery, including rings,
when near the gearbox while in operation.
Please take note of the following before putting the unit into operation:
Before putting the gearbox into operation, remove all tools and any other loose objects
from it.
Make sure that all protective devices and covers have been mounted once again.
Inspect the gearbox for any possible hazards (i.e. sharp edges, loose cables, loose
screw connections)
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2.2
Installation check
2.2.1
Check of documents
Check to make sure you have most recent versions of these documents
pertaining to the gearbox:
Installation instructions (part of this documentation)

Operating instructions (this document)
Drawing of installation
Supervision plan
Alignment protocol
Check the alignment protocol to make sure all of the required details have been
entered and signed (responsibility of the shipyard).
The documents listed above include descriptions, illustrations and values
necessary for safely operating the unit.
2.2.2
Check of the gearbox

When performing a final check before putting the gearbox into operation, make sure that all
necessary cables, tubes and pipes (e.g. electricity, water and air) have been connected.
Check to make sure that all of the bolts holding the gearbox and the connected elements
are well seated.
2.3
Fill with operating oil (initial filling)

The inside of the gearbox is preserved with preservation oil when delivered. (refer to
installation instructions, chapter Preservation on page 22)
12
Attention!
Remove the v-rings marked with label before commissioning.
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A fault can in many cases be attributed to using contaminated oil or the wrong type of
operating oil.
Make sure to use the proper type of the operating oil and that the tools used to fill with
oil are clean!
Before filling with oil, take a fresh oil sample.
Have the fresh oil sample analysed by a laboratory
authorised to perform oil analyses. Include the
analysis results among the gearbox documents.
Sampling set for oil sample
Loosen and remove the oil drain screw.

Drain the preservation oil.
Dispose of the preservation oil in accordance with legal
requirements for used oil disposal.
Any small amount of preservation oil remaining may be mixed
with the operating oil.
Clean the oil drain screw and screw it into the socket together
with a new sealing ring.
oil drain screw
Loosen and remove the screw plug for filling the gearbox
with oil.
The screw plug is labelled with OEL (Oil).
Read off from the type plate the amount of oil required.
Pour in the operating oil specified in the REINTJES lubricant
table using a fine-mesh screen filter.
Screw plug
Standard-dipstick: Check the operating oil level

using the dipstick only when the propulsion
system is at a standstill.
The operating oil level must be between the Min
and Max markings shown on the dipstick.
(measurably approx. 10 min. after shut down of
the system)
MAX
MIN
Dipstick
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Dipstick with guiding tube: Check the

operating oil level using the dipstick.
Check to ensure that the oil level is up to the
dipstick marking.
Caution!
The dipstick has 3 markings!
MAX
MIN
The lower marking shows the operation oil level

during the operation.
Operation
Dipstick
The two upper markings show the min. or max. oil

level of the shut down gearing. (measurably approx. 10 min. after shut down of the system)
Screw on according to your type of gearbox (see drawing of installation) either the screw
plug or the venting filter as far as it will go.
Tighten the screw plug or the venting filter as much as possible by hand.
After filling with oil the first time, and before the sea trial, perform a short dock trial
without load of the gearbox. This fills the hydraulic system with oil.
Then check the oil level once more using the dipstick.
Add as much oil as is required for the level to reach the upper dipstick marking.
!
2.3.1
Screw on according to your type of gearbox (see drawing of installation) the venting
filter supplied and tighten it as much as possible by hand.
Amount of oil and type

The amount of operating oil required by your gearbox is specified on the gearbox type plate.
Conversion factors for amount of oil
multiplied
by
equals
litres
litres
US gallons
Imperial gallons
US gallons
0,26
0,22
3,79
4,54
0,833
US gallons
Imperial gallons
litres
litres
Imperial gallons
Refer to REINTJES lubricant table for approved types of operating oil.

The oil types listed in the lubricant table are specified under the responsibility of the
particular oil company.
REINTJES assumes no liability for damage that might arise from using unsuitable types
of operating oil.
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2.3.2
Filling the Oil filter

During the setup the Oil filter must be filled with oil.
A non-filled filter housing creates a pressure loss in the hydraulic system when
changing on the other filter side.
This pressure loss can lead that the diesel engine is shut down by the pressure switch
"oil pressure to low, motor stop".
After switching on, with running gearbox:

Wait approx. 30 sec until the first filter side is filled with oil.
Switch to the second filter side with the lever. Leave this side also switched on
approx. 30 sec. until the complete filter is filled with oil.
These steps must be repeated after every filter change!!
The filter bell can also be manual filled with oil during the filter change.
2.4
Handling the checklists for putting the unit into operation

This description contains information about steps in preparing to put the unit into operation
and measures required beforehand and afterward.
The items which you must check and then initial for every gearbox are referred to here with
keywords.
Example:
Item to be checked
OK?
Notes
No other defects?
Gearbox without visible damage?
In certain cases you need to enter details or measured values.

Enter any additional comments or measures required for the item to be checked in the
Notes column at right.
Cross out any items not applicable to your gearbox.
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2.5
Checklist before initially putting the unit into operation

Person responsible for putting the unit into operation and for safety (name and position):
Ambient temperature
2.5.1
C (note)
Engine foundation
Type of foundation: (indicate applicable items)
Seat chocks and fitting bolts
Cast resin
Type
Manufacturer
Model
Flexible
2.5.2
Gearbox foundation
Type of foundation: (indicate applicable items)
Cast resin
Foundation bolts, note
Quantity:
Dimensions:
Quantity:
Dimensions:
Steel with
seat chocks and fitting bolts
Fitting bolts, note
Front collision chocks
Lateral collision chocks
2.5.3
Lubrication oil system

Lubrication oil manufacturer:
Lubrication oil type
SAE:_________
Amount of oil filled:
_____________litres
Oil sample taken (100 ml),
label completed and attached
16
Take the sample using a clean sampling

glass, label it and send it to REINTJES.
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2.5.4
Cooling system
Cooling system: (indicate applicable items)
Seawater cooling
Inlet temperature of
cooling water
(target)
Freshwater cooling
______C
2.5.5
2.5.6
Torsionally flexible coupling

Flexible coupling on engine side:
Type
Manufacturer
Model
PTO coupling:
Type
Manufacturer
Model
Gearbox alignment
Item to be checked
OK?
Notes
OK?
Notes
Alignment protocol included as annex?

For engine - gearbox
For gearbox - propeller shaft
For gearbox PTO - auxiliary unit
Alignment screws loosened?
2.5.7
Oil cooler
Item to be checked
Plastic plug on cooling water inlet flange
removed?
Compensators for cooling water pipes
installed?
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2.5.8
Sight check
Item to be checked
OK?
Notes
OK?
Notes
Gearbox without visible damage?

No changes may be recognised?
- Connected and separate parts
complete and not damaged?
Shaft seals in acceptable condition?
Do not switch on or similar warning
signs present on board for:
Control valve for gearbox clutch
Control valve for shaft brake
No other defects?
2.5.9
Preservation
Item to be checked
Was preservation performed during
storage?
Log recording preservation measures
completed regularly?
Protective layer completely removed
Paint layer undamaged?
Screw plug replaced with venting filter?
External v-rings removed at the
input shaft?
output shaft?
PTO shaft?
Internal inspection:
Sight check (through inspection
opening) performed?
Preservation oil completely drained?
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2.6
Checklist before starting the engine

Person responsible for putting the unit into operation and for safety (name and position):
Ambient temperature
C (note)
WARNING!
the remote starter.
2.6.1
Check of the sensor connections in the terminal box in accordance with the
supervision plan
Item to be checked
OK?
Notes
Gearbox terminal box correctly earthed?

Check to ensure that the sensors for the following are connected:
(if present)
Warning - oil pressure too low
Start stand-by pump
Emergency stop main engine
Oil pressure present
Gearbox clutch engaged
PTO clutch engaged
Oil filter contaminated switch
Shaft brake engaged
Oil level too low
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2.7
Checklist for gearbox after engine start
2.7.1
Check gearbox
Item to be checked
Measurements / Notes
Engine speed while idling

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

speed
__________bar
Oil temperature in steady state

__________ C
Cooling water temperature in steady
state
In __________ C
Both sides of oilfilter filled with oil?
Yes
(see Filling the Oil filter on page 15.)
Item to be checked
OK?
Notes
Out __________C
Clutch control valves can be actuated

mechanically?
Control valves can be actuated
electrically from all control cabins?
Gearbox noise level?
Gearbox without leakage?
Vibration level?
Sight check OK?
No other conspicuous items?
Oil level checked?
Oil filled to mark? (Note the amount)
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2.8
Notes on the checklists for putting the unit into operation

Check
chapter
Comments / Notes / Values
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Operation
Operation
3.1
Engaging procedures for standard gearboxes
During normal operation and at idling speed, you must adhere to these values:
30-50C oil temperature measured behind the oil cooler

21-25 bar operating pressure
A fault exists in the event that any of the values differ appreciably from those
cited above.
The engaging procedures described below are important in order to safely operate the
entire propulsion system and to avoid any unnecessary wear.
Electronic ship remote controls may be used to automate the procedures described.
This avoids the risk of faulty operation.
It is then possible to optimise the electronic program system during the sea trial.
You must adhere to these steps in engaging when using a manual remote control:
Engaging the gearbox

The engine is started, the gearbox control valve is in the NEUTRAL position and the
propeller shaft is stationary or rotating slowly. The engine is running at idling speed.
Set the engine to engaging speed.
Engage the gearbox for the desired direction of travel.
Wait until the pressure in the clutch has reached 18 bar (approx. 10 seconds)
Set the engine to the required operating speed.
3.2

The engaged speed range specified in the technical description of the order
acknowledgement has to be observed.
WARNING!
Manual engaging of the PTO control valve
Danger of personal injury by unintentional turning of the PTO shaft!
Do not engage the PTO clutch manually (except in an emergency case)!
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Operation
3.3
Shaft brake
The gearbox is equipped with a built-in multiple disc shaft brake. The maximal admissible
braking torque at the gearbox output shaft is stated in the "Technical Description".
Clutch and brake are interlocked hydraulically. An engagement of clutch and brake at the same
time is not possible.
When engaging the clutch, pressurised oil flows to the hydraulic/pneumatic control valve V188
which blocks the control air flow to the brake control valve V189. The return spring pushes the
valve piston into OFF-position. The brake is released.
When the clutch control valve V1 is set to OFF-position the oil pressure in the control pipe
drops rapidly. Valve V188 returns to OFF-position and opens the control air pipe to shaft brake
control valve V189. Valve 189 shifts to ON-position and engages the shaft brake.
NOTICE!
The shaft brake must not be engaged at maximum speed of the vessel!
During operation of the propulsion system with constant engine speed mode the control
valve V196 must be switched on. The shaft brake is switched off.
The control valve V196 must be automatically switched on (shaft brake function
switched off) if the engine shuts down automatically and the gearbox clutch will be
disengaged automatically too.
It is the shipyards responsibility to provide a corresponding interlocking system.
Clutch shaft brake
Control air
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Operation
3.4
Special operating modes
3.4.1
Trailing operation
NOTICE!
For gearboxes with shaft brake: trailing mode with the shaft turning freely is
prohibited!
Danger of damage to the gearbox!
NOTICE!
In the case of damage, lock the propeller shaft before putting it into trailing mode.
If this is not possible, carefully verify whether trailing mode with the shaft turning
freely might not result in further damage to the gearbox or the propulsion system.
Occasional and regular trailing mode

Occasional trailing mode, i.e. in the case of a two-engine system, means:
One of the propulsion systems is shut down

The ship continues to be driven by the other propulsion system
The propeller shaft of the system that is shut down turns freely with the water flowing
against it
This mode may be prolonged without limitation for up to 6 hours.
If the occasional trailing mode lasts longer than 6 hours:
Start the engine every 6 hours in order to run the gearbox oil pump.
-Or Lubricate the gearbox every 6 hours with the aid of the electrical stand-by pump.
In order to ensure that all lubrication points are supplied with oil, run the engine or the
stand-by pump for approx. 5 minutes.
Immobilise the propeller shaft if gearbox lubrication is not possible.
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Operation
Regular trailing mode without limitation is only possible:
With the addition of a trailing pump (optional)

An additional pump mounted on the gearbox secures the lubrication to the gearbox
during trailing mode. This pump is driven directly by the propeller shaft.
With an electrical stand-by pump (optional)

Switch on the electrical stand-by pump for the entire duration of trailing mode.
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Operation
3.5
Emergency operation
3.5.1
Manual emergency operation
NOTICE!
Perform emergency operation in cases of emergency only!
Prior to manual emergency operation, become familiar with control of your gearbox:
WARNING!
The solenoids of the electrically control valve heat up to 150C during
permanent operation!
Danger of burnings!
Wear protective gloves during manual emergency operation!
Emergency operation of the 4/2-way control valve

In cases of failure of the electrical clutch control
Push in the bolt on the end cap of the magnet.
The valve automatically locks in place.
2.
1.
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Operation
3.5.2
Emergency operation in cases of failure of the pressure oil supply

In cases of failure of the pressure oil supply, emergency operation may be continued by
mechanically immobilising the clutch.
DANGER!
Risk of unintentionally starting the engine.
Danger of death while working on the open gearbox!
Shut down the engine.
Shut down the compressed air feed for starting the engine and bleed the
air tubes.
Prior to any work on the gearbox, place a sign reading "OUT OF ORDER"
or a similar warning sign on the start-up switch or starter button and on the
remote starter.
Make sure that the remote starter of the engine on the bridge is also disabled and
not functioning.
Secure the propeller and drive shafts against rotation.
NOTICE!
When, after tightening the emergency screws, you start the engine, the shaft
system immediately rotates with the engine.
To bring the propeller to a halt, you must stop the engine.
In emergency operating mode, the engine is rigidly connected to the propeller shaft
by way of the gearbox.
In emergency mode, proceed with extreme caution and with the lowest engine speed
possible (less than 70 % of the nominal speed).
Never apply the maximum input torque when employing the K107.02 emergency
screws.
After operation in emergency mode (failure of the pressure oil supply) you must have
the gearbox parts checked thoroughly for any damage.
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Operation
Tighten of the emergency screws

Remove the corresponding cover of the
inspection opening.
Remove the wire securing the
emergency screws.
(Do not drop any pieces of wire into
the gearbox!)
Loosen the counter-nuts of all
emergency srews.
Screw in the K107.02 emergency screws
evenly using an Allen wrench and as far as possible in
opposing pairs.
Tighten the screws, pressing together the disc packet so
that the clutch is friction-locked.
Shift the control valve to the NEUTRAL position (by hand if
necessary).
K107.02
For safety reasons, do not engage the control valve any

more afterwards!
Close the inspection opening.
Start the engine.
The ship can then head to the nearest harbour for repairs.
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Operation
3.6
Setting the pressure limiting valve

CAUTION!
Hot oil!
Spraying or dripping oil can cause skin injuries.
To avoid skin injuries, wear protective clothing.
NOTICE!
The set-screw B is not secured against loosening!
The operating oil is under pressure. Oil may spray or drip out when the
set-screw is removed.
The pressure limiting valve is set to optimal pressure during the bench test
at the factory.
Before adjusting the setting, check for any possible causes or faults resulting in
pressure changes.
Please contact REINTJES (refer to page 31) before adjusting the setting!
To set the pressure limiting valve, proceed as follows:

Loosen counter nut A using an Allen wrench.
Carefully turn set-screw B using an Allen wrench
turning clockwise means pressure increase,
turning counter-clockwise means pressure
decrease.
During adjustment, observe the manometer
mounted on the gearbox.
With the engine speed at full power and the
clutch engaged and gearbox in operating
temperature, the pressure must be within the
manometer markings.
Tighten counter nut A using an Allen wrench.
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Maintenance
Maintenance
You can ensure safe, dependable operation as well as low maintenance costs only by having
service and maintenance performed regularly according to specifications. The jobs listed
below may only be performed by staff trained in the maintenance of marine gearboxes and only
using tools, original spare parts and lubricants, specified in REINTJES lubrication chart, that
are suitable for the particular task.
Our customer service will be glad to aid and advise you in the event of any questions
concerning maintenance:
service@reintjes-gears.de or on
working days: Phone +49 5151 104 0
CAUTION!
No user serviceable parts inside!
Unauthorized opening of the gearbox voids manufacturers warranty.
WARNING!
Risk of unintentionally starting the engine during maintenance work!
Danger of death!
Shut down the compressed air feed for starting the engine and bleed the
air tubes.
Prior to any work on the gearbox, place a sign on it reading OUT OF ORDER
and a similar warning sign on the start-up switch, on the starter button and on the
remote starter.
Dispose of filter elements and used oil either as recyclable substances or as

hazardous wastes.
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Maintenance
Maintenance information
When doing any work, observe all currently applicable safety regulations as well the
information in the chapter on safety.
Keep a maintenance log.
Regular entries recording maintenance work and operating values can be helpful in
recognizing any detrimental changes.
Correct minor defects before they result in major repairs.
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Maintenance
4.1
Maintenance plan
Maintenance level 1
Daily:
With the engine at a standstill (if possible), check the oil level
(upper dipstick marking = operation oil level), or with the engine
running (lower dipstick marking = operation oil level)
If a daily check of the oil level is not possible it must be done before
starting a voyage and after finishing the voyage. In any case the oil
level must be checked at least every 4 weeks.
Maintenance level 2
Daily:
With the engine running, check
Operating pressure
Oil temperature
Contamination indicator for the duplex filter
Perform a sight check and check of running noise
Maintenance level 3
After the first 300 hours of operation:

Change the operating oil for the first time after initially putting the unit into
operation or perform an oil analysis, acc. to this result oil cleaning or oil
change.
Replace the filter elements.
Check the seat of all bolts including those on the foundation,
engine and propeller connections and on the bell housing.
Check the pipe fittings. If there is any leakage, tighten the fittings.
Check the heat exchanger for leakage.
Check the anodes on the heat exchanger.
Maintenance level 4
After every 3000 hours of operation or after 6 months:

Change the operating oil after this interval.
Replace the filter elements.
Maintenance level 5
After every 6000 hours of operation or after 1 year:

Check the seat of all bolts including those on the foundation,
engine and propeller connections and on the bell housing.
Check the pipe fittings.
If there is any leakage, tighten the fittings.
Replace any leaky gaskets.
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Maintenance
Basic overhaul
The following tasks must be performed by skilled REINTJES staff after:

60000 hours of operation or after 10 years:
Shafts, to ensure they are running true

Roller bearings for any wear
Carriers for any wear
Gear and pinion teeth for any wear
Guiding pins of annular pistons for any wear
Oil distributor for any wear
Worn or damaged parts must be replaced.

The following need to be replaced:
- Clutch discs
- Brake discs
- Square section rings, screws and return springs of the annular piston
- O-rings
- Circlips
- All clutch housing screws
- Roller bearings
- Control valves
- Pressure limiting valve
- Temperature sensors,
- Pressure gauge,
- Screws and springs of the thrust bearing
- Shaft sealing rings and bushings
- Oil filter elements and gaskets
- Gearbox oil pump
- Inspection cover gaskets
- O-rings for the control valve and the pressure limiting valve
- Hoses (must be replaced every 5 years)
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Maintenance
4.2
Maintenance job cards
Maintenance job card
Gearbox types:
LAF
Maintenance job
no.: 001
Maintenance level 1
Description of the
maintenance job:
Daily, with engine at a

standstill
To be performed if
possible at the same
time as maintenance
job no.: 002 - 005
Duration of job
in minutes: 5
Check operating oil level (Dipstick with 2 markings).
Safety measures
You can check the operating oil level with the dipstick only when the
unit is at a standstill.
Required tools
None
Required parts
None
Other materials
Oil as specified in lubricant chart

Cloth, lint-free
Test equipment
None
Working procedure
Refer to next page
Location:
Date:
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Maintenance
Gearbox types:
LAF
Maintenance job
no.: 001
Maintenance level: 1
Daily, with engine at a
standstill
To be performed if
time as maintenance
job no.: 002 - 005
Duration of job
in minutes: 5
Description of the maintenance job:

Check the operating oil level using the dipstick only when the
propulsion system is at a standstill.
The operating oil level must be between the Min and Max
markings shown on the dipstick.
(measurably approx. 10 min. after shut-down of the system)
Dipstick
MAX
MIN
If the operating oil level is too low:
Unscrew the screw plug or the venting filter from the upper surface of the
gearbox in order to pour in operating oil.
Add oil and fill to the upper dipstick marking.
Use only the type of oil specified in lubricant chart.
Screw on the screw plug or the venting filter as far as it will go.
If you notice any oil loss, determine the cause.
Seal any leaks immediately so as to avoid damage to the gearbox.
Screw plug
Venting filter
Location:
36
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 001
Maintenance level 1
Description of the
maintenance job:
Daily
To be performed if
time as maintenance
job no.: 002 - 005
Duration of job
in minutes: 5
Check operating oil level (Dipstick with guiding tube und 3 markings).
Safety measures
You can check the operating oil level with the dipstick either when the
unit is at a standstill or during the operation.
Required tools
None
Required parts
None
Other materials
Oil as specified in lubricant chart

Cloth, lint-free
Test equipment
None
Working procedure
Refer to next page
Location:
Date:
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 001
Daily
To be performed if
time as maintenance
job no.: 002 - 005
Duration of job
in minutes: 5

Check the operating oil level using the dipstick.
Caution!
The dipstick has 3 markings!
The lower marking shows the operation oil level during the operation.
The two upper markings show the min. or max. oil level of the shut
down gearing. (measurably approx. 10 min. after shut down of the
system)
MAX
MIN
Operation
If the operating oil level is too low:
Unscrew the screw plug or the venting filter from the upper surface of the
gearbox in order to pour in operating oil.
Add oil and fill to the MAX dipstick marking.
Use only the type of oil specified in lubricant chart.
If you notice any oil loss, determine the cause.
Seal any leaks immediately so as to avoid damage to the gearbox.
Dipstick with
guiding tube
Screw plug
Venting filter
Location:
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 002
Daily, with engine running
To be performed if
time as maintenance
job no.: 001 - 005
Duration of job
in minutes: 5
Description of the
maintenance job:
Check the operating pressure (with the gearbox warm from operation)
Safety measures
Observe all current, generally applicable job safety regulations
Required tools
None
Required parts
None
Other materials
--------
Test equipment
None
Working procedure
Refer to next page
Location:
Date:
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 002
To be performed if
time as maintenance
job no.: 001 - 005
Duration of job
in minutes: 5

With the engine running and clutch engaged take a reading of the current
operating pressure from the gearbox manometer
(the pressure range in normal operating mode is between 21 and 25 bar).
If the value is outside of this range refer to Trouble-shooting on page 71.
Location:
40
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 003
To be performed if
time as maintenance
job no.: 001 - 005
Duration of job
in minutes: 5
Description of the
maintenance job:
Check the operating temperature (with the gearbox warm from operation)
Safety measures
Required tools
None
Required parts
None
Other materials
--------
Test equipment
None
Working procedure
Refer to next page
Location:
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 003
To be performed if
time as maintenance
job no.: 001 - 005
Duration of job
in minutes: 5

Read off the oil temperature from the thermometer.
The operating temperature is between 30 and 50C
when measured behind the oil cooler
The maximum operating oil temperature is 65C / 149F.
If the temperature exceeds this value refer to Trouble-shooting on page 71.
Thermometer
Location:
42
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 004
To be performed if
time as maintenance
job no.: 001 - 005
Duration of job
in minutes: 5
Description of the
maintenance job:
Check the contamination indicator for the oil filter
Safety measures
Observe all current, generally applicable job safety regulations.
Required tools
None
Required parts
None
Other materials
--------
Test equipment
None
Working procedure
Refer to next page
Location:
Date:
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 004
To be performed if
time as maintenance
job no.: 001 - 005
Duration of job
in minutes: 5

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

displays contamination during cold starts.
With high oil viscosity, or when the oil is cold during the starting
phase, differential pressure is higher and may activate the
contamination indicator.
If the contamination indicator does not go out when operating
temperature is reached, switch the filter to the clean side of
the filter using the switch lever.
The side of the filter where the handle of the lever is
positioned, is the active filter side.
Replace the soiled filter element as soon as possible.
Refer to maintenance level 4 for a description on how
to exchange the filter element.
Location:
44
Date:
Pressure sensor detecting

differential pressure
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 005
To be performed if
time as maintenance
job no.: 001 - 004
Duration of job
in minutes: 10
Description of the
maintenance job:
Sight check and running noise check
Safety measures
Observe all current, generally applicable job safety regulations.
Required tools
None
Required parts
None
Other materials
--------
Test equipment
None
Working procedure
Check the gearbox for any leakage or any parts which might have loosened.
While doing this, listen for any abnormal running or operating noises.
If you notice any abnormal operating noises, contact REINTJES service.
Changes in running noises may be an indication of defects or of faulty alignment
between the engine, gearbox and propeller shaft.
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 006 / 009
Maintenance level: 3/4
Description of the
maintenance job:
Safety measures
After the first 300 hours of

operation, then after every
3000 hours or 6 months
To be performed if
time as maintenance
job no.: 010
Duration of job
in minutes: 60
Change the operating oil
Safeguard the engine against starting. (Note the safety information on page 31
of the operating instructions.)
Collect the used oil in appropriate used oil containers to avoid pollution of the
environment.
CAUTION!
Hot oil and hot components may lead to injury.
Avoid skin contact with hot oil or hot components!
Wear protective gloves!
Required tools
Standard tool
Required parts
New gasket for the oil drain screw
Other materials
Oil as specified in the lubrication chart
Test equipment
None
Working procedure
Refer to next page
Location:
Date:
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 006 / 009
Maintenance level: 3/4

After the first 300 hours of
operation, then after every
3000 hours or 6 months
To be performed if
time as maintenance
job no.: 010
Duration of job
in minutes: 60
These intervals apply to operating temperatures of up to 60 C as measured behind the oil cooler.
Higher operating temperatures require shorter exchange intervals.
Please consult with REINTJES service in this case.
After the first 300 hours of operation it is also admissible to carry out an oil analysis.
Depending on the results of the analysis REINTJES will decide if the oil must be changed
or if it further can be used. Please contact REINTJES for detailed information about the oil analysis.
Perform the oil change with the gearbox at a standstill and while the operating oil is warm.
Loosen the oil drain screw and drain the operating oil.
Collect the used oil in appropriate used oil containers to avoid pollution of the environment.
Clean the oil drain screw and screw it into the socket together with a new sealing ring.
Unscrew the screw plug or the venting filter from the upper surface of the gearbox in order to
pour in operating oil.
The screw plug or the venting filter is labelled with "OEL".
Fill the gearbox with oil, using a fine-mesh screen filter, up to the upper dipstick marking.
Use only the type of operating oil specified in REINTJES lubricant chart.
The amount of oil required is indicated on the type plate of your gearbox.
After filling with oil, start the engine.
Fill the hydraulic system by running the gearbox for 5 to 10 minutes.
-If an electrical stand-by pump has been installed (optional), you can also fill the hydraulic system
using this pump. Shut down the propulsion system once again.
After 10 minutes, check the oil level once again using the dipstick.
CAUTION! Avoid overfilling the gearbox!
Adding more oil than specified can result in leakage in the vicinity of the output shaft.
After the oil change, perform a sight check of the fittings and oil pipes.
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 008
Description of the
maintenance job:
After the first 300 hours

of operation
To be performed if
time as maintenance
job no.: ---
Duration of job
in minutes: 20
Check the oil cooler anodes
Safety measures
DANGER!
Shut down propulsion system and secure it for restarting!
Switch off cooling water pump!
Hot water!
Danger of scalding!
Required tools
Standard socket wrench set / open-end wrenches
Required parts
3x Anode A002.56
3x Copper sealing ring
Other materials
Cloth, lint-free
Test equipment
None
Working procedure
Refer to next page
Location:
Date:
48
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 008
After the first 300 hours
of operation
To be performed if
time as maintenance
job no.: ---
Duration of job
in minutes: 20

The heat exchanger has been equipped with three anodes (A002.56) to protect the water manifold
and tube bundle from corrosion: water intake, reverse cover and water outlet.
The amount of wear to the anodes depends on operating conditions.
Low water quality and high water temperatures are the main causes of wear to the anodes.
Conditions of installation and operating periods also influence wear.
14
Shut down the propulsion system and the water pump!

Drain the water side of the heat exchanger. To do this, loosen the water flange.
(Caution, hot water!)
Unscrew anodes A002.56 with the aid of open-end wrench SW 19.
Exchange anodes A002.56 once they are worn down to 60 % of their original volume.
Screw in the new or still serviceable anodes together with a new copper or Anode with copper sealing ring
aluminium sealing ring .
Using an open-end wrench, tighten the anode as much as possible by hand.
In the maintenance log, record the date of the first anode exchange and each
A002.56
one thereafter.
We recommend performing a monthly check during the first six months.
Based on the amount of wear to the anodes, determine future inspection and
exchange intervals.
83 mm
Repeat this job at least every six months or every time the heat exchanger
is cleaned.
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 010
Description of the
maintenance job:
Every 3000 hours of

operation or 6 months
To be performed if
time as maintenance
job no.: 006/009
Duration of job
in minutes: 20
Filter element exchange
Safety measures
Caution! The filter is under pressure!

Bleed the contaminated filter side before exchanging the filter!
Required tools

Allen wrenches
Required parts
Filter element with o-ring

Gasket set
Other materials
Flat oil pan
Test equipment
None
Working procedure
Refer to the next page
Location:
Date:
50
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Maintenance

Gearbox types:
LAF
Maintenance job
no.: 010
Every 3000 hours of
To be performed if
time as maintenance
job no.: 006/009
Duration of job
in minutes: 20
Filter Typ RFLD

1
Vent screw
Drain plug with sealing ring
Socket head cap screw for cover
Filter element
Change over lever

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

Gearbox types:
LAF
Maintenance job
no.: 011
Every 6000 hours of
To be performed if
time as maintenance
job no.: ---
Duration of job
in minutes: 360 = 6h
Description of the
maintenance job:
Screwed joints
Safety measures

DANGER!
Before performing these jobs, block and
secure the propulsion system!
Required tools

Allen wrench, torque wrench
Required parts
None
Other materials
--------
Test equipment
Torque wrench
Working procedure
Refer to the next page
Location:
Date:
52
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Maintenance
Gearbox type:
LAF
Maintenance job
no.: 011
Every 6000 hours of
To be performed if
time as maintenance
job no.: ---
Duration of job
in minutes: 360 = 6h

Before performing these jobs, block the propulsion system!
Check the tightening torque of bolts while the gearbox is cold.
In particular, check these connections:
Engine - flexible coupling - gearbox
Gearbox output flange - propeller shaft
Gearbox supports - foundation
Union nuts and banjo bolts of the pipe fittings
Check the rubber parts of the flexible coupling for brittleness, cracks or other damage.
Location:
Date:
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Maintenance
4.3
Check of tube bundle contamination in the heat exchanger

WARNING!
Prior working on the gearbox, stop the propulsion plant and prevent the
engine from being switched on!
Danger of injuries caused of hot oil and water!
CAUTION!
The operating oil is under pressure!
Danger of injury!
First bleed the pressure.
Be careful when loosening the cover!
4.3.1
Structure of tube plates

1. Tube plate
2. O-rings
3. Fixing plates
4. Jacket
5. Tube bundle
Both of the tube plates are the same
1 2
The outer o-rings seal the cover in each case.
The inner o-rings seal the jacket.

The four fixing plates are inserted in the groove at centre.
The fixing plates may be inserted either from the intake cover or the reverse cover end.
Both covers may be mounted rotated by 180 degrees (improved access to anodes).
In any case, avoid reversing the back and front when mounting the covers.
There is only one correct position for installing the tube bundle in the jacket.
Make sure not to install the tube bundle with the ends reversed or turned.
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Maintenance
4.3.2
Sight check of the tube bundle

The amount of dirt deposited on the tube bundle depends on conditions of installation
and operation.
Perform the first sight check 3 months after putting the gearbox into operation.
You can determine future intervals based on the results of the first inspections.
The bolts holding the cooling water coupling flange and the covers of the heat
exchanger must always be loosened and tightened in opposite pairs.
Sight check by removing the covers

The hydraulic oil in the heat exchanger does not need to be drained when performing
this simple sight check.
Close the valves for the water intake and water outlet
Drain the cooling water.
Unscrew the cooling water connectors.
Check whether the connector gaskets are still in good order.
Mark the position of intake
cover A with 1/1 and the
position of reverse cover B
with 2/2.
Loosen the bolts of the covers
in opposite pairs and remove
the bolts.
Intake cover A
Remove covers A and B.

A nylon separator is inserted at the centre of
intake cover A.
Take care not to damage this separator.
Reverse cover B
Secure the tube bundle in place with the fixing plates.

To do this, insert the cover bolts through the holes from the
back and bolt the fixing plates in place using the nuts.
Check to see how heavily the covers and tubes are soiled.
Clean the tube bundle using a nylon tube brush.
Wipe off the covers with a lint-free cloth.
Separator
Fixing plates
Tube cleaning brush
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Maintenance
4.3.3
Dismantling the tube bundle

If there is enough room on board, you can leave the heat exchanger mounted and remove the
tube bundle at the gearbox.
The tube bundle can be pulled out from either side. In this description, sides A and B should
be taken to be the intake cover side as A and the reverse cover side as B (see pictures above).
Loosen and remove the oil drain screw (SW19).
Drain the oil into a pan.
Mark the position in which the tube bundle is built in.
The tube bundle must afterwards be mounted in exactly
the same position.
Remove the separator on intake cover side A.
Remove the bolts and nuts from the flange holes.
Remove the 4 fixing plates.
Separator
Fixing plates
During the next step, be careful not to damage the edges by pounding them
with a hammer.
On the A side, push in the tube plate so that it is flush with the jacket.
Using a piece of wood and a rubber mallet, carefully drive in the tube plate.
On side B, remove both o-rings.
On the B side, push in the tube plate so that it is flush with the jacket.
On side A, remove both o-rings.
Push the tube bundle in on side B far enough so that you
are able to reach in behind the tube plate on side A.
Taking hold of the tube bundle, pull it out straight toward
side A.
Be careful not to bend the baffles on the tube bundle!
Pulling out the tube bundle
56
If you wish to clean the tube bundle using chemical agents, request from REINTJES
detailed information on cleaners and procedures.
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Maintenance
4.3.4
Mounting the tube bundle
The tube bundle and jacket have matching dimensions. The entire heat exchanger
therefore needs to be replaced in order to replace the tube bundle!
Never employ used or salvaged o-rings.

Always insert the tube bundle together with new o-rings.
Carefully clean the sealing surfaces.
At the same time check the sealing surfaces for damage.
Apply a soap-free lubricant (e.g. Molikote, silicone paste or
Parker O-lube) to the sealing surfaces.
Do not use vaseline or other lubricants containing soap.
Clean the grooves in the tube plate.

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

Mount the reverse cover in the same way.
Mount the cooling water connectors. When doing this, replace any damaged gaskets.
Clean the oil drain screw and screw it into the socket together with a new sealing ring.
Connect the oil pipes to the heat exchanger.
After completing assembly, fill the water circulating system and the hydraulic system
Vent the heat exchanger by loosening an anode.
At the same time check all connections to make sure they are water-tight.
4.3.5
Corrosion protection of the heat exchanger
Follow the safety instructions provided in this mounting instruction.

(see Safety from page 5.)
In addition, observe any applicable safety precautions when mounting or
dismantling equipment.
Draining the water side of the heat exchanger during interruptions in operation
of longer than 2 weeks:
Seawater circulating system:
Drain the seawater circulating system of the heat exchanger.
Flush the water side of the heat exchanger with freshwater.
Freshwater circulating system:
Drain the freshwater circulating system of the heat exchanger.
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Maintenance
4.4
Replacement of the mechanical gearbox oil pump
4.4.1
Oil pump mounted on the PTO K12

Steps in dismantling and reassembling the oil pump
A001.00
A001.01
Overview of positions for the following steps

(drawing may vary from the mounted parts - subject to technical changes)
Dismantling the pressure pipe
Using an open-ended spanner, loosen the fittings
fastening the pressure pipe to the pump and the
non-return valve.
Remove the pipe and store it for reassembly
later on
.
Loosening the suction pipe
Using an allen wrench, completely loosen the
flange connection of the suction pipe to the pump.
Using an allen wrench, only loosen slightly the
flange connection of the suction pipe to the housing
in order to swing it away from the pump.
This prevents residual oil from leaking into the bilge.
Loosen the 4 fastening bolts and
remove them
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Maintenance
Pull out the pump.

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

residual adhesive.
Take the new pump out of the package.

Remove the plastic plugs from the connectors.
Apply liquid surface sealant to the pump flange

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

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

Insert the pump as far as possible into the
pump flange.
Make sure that the fitting key fits into the groove on
the drive shaft.
Tighten the pump against the flange
evenly by means of the bolts.
Fasten the pressure pipe.
Fasten the suction pipe.
Check the fittings to ensure they are well seated.

Check the flanges to ensure they are tight.
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Maintenance
4.4.2
Oil pump mounted on the pump drive

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

(drawing may vary from the mounted parts - subject to technical changes)
Dismantling the pressure pipe
Using an open-ended spanner, loosen the fittings
fastening the pressure pipe to the pump and the
non-return valve.
Remove the pipe and store it for reassembly
later on.
Loosening the suction pipe
Using an allen wrench, completely loosen the
flange connection of the suction pipe to the pump.
Using an allen wrench, only loosen slightly the
flange connection of the suction pipe to the housing
in order to swing it away from the pump.
This prevents residual oil from leaking into the bilge.
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Maintenance
Labelling the pump flange

Mark the position at which the pump drive housing
and the bearing housing are installed with two
punch marks.
Mark the punch marks additionally with a felt
marker to be able to find them more easily.
Withdrawing the tapered pins E122.03

Fit the thread with a suitable sleeve or with two M10
nuts and screw on an M8 nut.
Using a ring spanner, pull the pin out of
pump drive case E122.00.
Dismantling the pump drive case

Loosen the Allen screws, labelled E122.01, of the
pump housing.
Carefully remove the pump drive housing and
place it on a workbench with the pump downward.
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Maintenance
Using a ring spanner, loosen bolt R104.01 of the

pump drive gear.
Place the bolt and washer aside for reassembly.
Loosen the 4 bolts, labelled A001.01, of the pump

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

Put a three-armed extractor over the
pump drive gear and pull it off.
Now screw out the 4 bolts, labelled A001.00, of the

pump flange.
Remove the defective pump.
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Maintenance
Mounting the mechanical oil pump

Apply oil to the pump shaft.
Place the fitted key into the groove.
Place cover E122.00 of the pump drive

onto a working surface.
Coat the contact surface of the pump
flange with liquid surface sealant like
shown.
Take the new pump out of the package.

Remove the plastic plugs from the connectors.
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Maintenance
Mount oil pump A001.00 on the cover using the

A001.01 bolts.
Ensure that the pump is positioned properly
(i.e. by the markings) when setting it on the cover.
Heat pump drive gear

R104.00 to approx. 80C/
176F.
Caution! Hot parts!
Danger of injury!
Wear protective gloves!
Place the pump drive gear on the pump shaft.
Put a drop of bolt-locking fluid on bolt R104.01.

Lock pump drive gear R104.00 in place using the
bolt.
Seal the sealing surface of cover

E122.00 using liquid surface sealant.
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Maintenance
Place the cover onto the bearing housing.

Fix the cover in place with the E122.03 tapered pins.
Fasten cover E122.00 using Allen screws E122.01.
Fasten the pressure pipe.

Fasten the suction pipe.
Check the fittings to ensure they are well seated.

Check the flanges to ensure they are tight.
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Maintenance
4.5
Conversion factors and screw tightening torque values

Approximate values for conversion
factors
equals
Be careful never to mix metric screws and nuts with imperial

screws and bolts. The use of improper or improperly fitting
screws and nuts results in damage or faulty operation of the
gearbox or even personal injury.
Multiply
by
mm
inch
kg
lb
kPa
psi
psi
bar
Nm
lb ft
Nm
lb in
litres
US gallons
US gallons
0.03937
inch
Any replacement screws and nuts required must be of the
25.4
mm
same size and of the same property class as the originals.
2.2
lb
The head of the screw usually has a label identifying the
0.454
kg
property class. This is identified with the digits 8.8, 10.9 etc.
0.145
psi
The following tables list tightening torque values for screws
6.89
kPa
and nuts of the property classes 8.8 and 10.9.
0.0689
bar
14.5
psi
0.74
lb ft
1.36
Nm
8.9
lb in
0.113
Nm
0.26
US
3.79
litres
0.833
Imperial
Temperature conversion C = (F - 32) : 1,8 / F = (C x 1,8) + 32
Metric ISO thread 1)

Thread
Tightening torque for

property class 8.8
size
Metric
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M36
M39
M42
M45
M48
1)
68
Metric ISO thread 1)
Nm
lb ft
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
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
Thread
Tightening torque for

property class 10.9
size
Metric
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M36
M39
M42
M45
M48
Nm
lb ft
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
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
ISO= International Organisation for standardisation
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Maintenance
4.6
Screw Locking
For assembly use screws with screw-locking glue only.
The glue is applied either as a coating by the screw manufacturer,

or you must use a usual medium-strength screw glue.
After dismantling and before re-assembling these screws, free
nuts and shaft nuts from glue remains. The threaded holes have
to be cleaned as well.
Free threaded holes from glue remains by using a corresponding tap.
Pay attention to the charts for tightening torques.

Screws are only sufficiently secured by using glue if they are tightened with the
proper torque (assembly torque). (See Conversion factors and screw tightening
torque values on page 68.)
2 threads without glue
3 threads with glue
Use always screw-locking, medium-strength metal glue for locking:
fixing screws for heat exchanger, filter, pump etc.

CAUTION!
Possible destruction risk!
Valid for screws and bolts with mechanical stress.
All screws and bolts connecting parts with torque transmission
must not be re-used after disassembly.
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Maintenance
4.7
Maintenance performed
Gearbox type: ____________________
Gearbox no.
____________________
Hours of operation
70
Maintenance level/job
Date
Initials
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Trouble-shooting
Trouble-shooting
Fault
Cause
Repair
Oil temperature too

high
Cooling water flow rate too low
Increase the water flow rate using the

water valve.
Heat exchanger soiled
Clean the heat exchanger
Oil flow rate too low
Check the gearbox oil pump and the pipes

for any leaks.
Check to see if the oil pump is intaking air.
Carefully tighten the pipe fittings.
Clutch slips; operating pressure too

low
Check the items listed under Operating

pressure too low, variable.
Oil temperature too

low
Water flow rate through heat

exchanger too high
Decrease the water flow rate using the

water valve.
Operating pressure
too low, variable
Gearbox oil pump intakes air
Check the items listed under Gearbox oil pump

intakes air.
Pressure limiting valve blocked
Replace the pressure limiting valve.
Check valve of electrical stand-by

pump is defective
Check whether oil flowing back through the

electrical stand-by pump causes it to rotate.
This is a sign that the check valve is not closing.
Clean the check valve to remove any dirt and
rinse if necessary.
Wrong type of operating oil
Compare the type of operating oil used with

lubrication chart.
Use only oil types listed in this chart.
Change the oil if the gearbox was filled with an
inappropriate oil type
(see Change the operating oil on page 46.)
Operating pressure
falls strongly after
switching over the
filter element
Filter bell of the oil filter not complete

filled with oil
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Filling filter housing completely with oil.

(see Filling the Oil filter on page 15.)
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Trouble-shooting
Fault
Cause
Repair
Operating pressure
too high
Defective pressure limiting valve
Replace the pressure limitng valve.
Cold operating oil
Let the gearbox idle until it reaches operating

temperature.
Idle periods in cold waters result in a higher oil
viscosity.
Wrong type of operating oil
Compare the type of oil used with lubrication

chart.
Use only oil types listed in the lubrication chart.
Change the operating oil if the gearbox was filled
with an inappropriate oil type (see Change the
operating oil on page 46.)
Oil loss
Shaft sealing rings (normal wear)
In this case, consult

REINTJES customer service.
In the pipe system
Carefully tighten the fittings.

Immediately replace any leaking or cracked
pipes.
Screw plug, oil drain screw
Tighten the screw.

Replace the screw gasket
Replace the screw
Gearbox noise
Heat exchanger leaking
Replace the heat exchanger gaskets. Use gasket

set A002.50 in this case (see Heat exchanger
A002.00, Type P ... on page 79.)
Idling speed is in critical range
Increase the idling speed.
Torsional vibration resonance of the

engine is transmitted to the gearbox
Change the speed in order to avoid critical speed

ranges.
Check the flexible coupling on the input side.
Hydraulic noises, gearbox oil pump

intakes air
72
Check the items listed under Gearbox oil pump

intakes air.
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Trouble-shooting
Fault
Cause
Repair
Gearbox oilpump
intakes air
Gearbox oil level too low
Check the gearbox for leakage.

Repair the cause of oil loss. (E.g. replace sealing
rings, tighten screws or fittings on pipes.)
Suction pipe leaks
Carefully tighten the suction pipe fittings.

Replace the gaskets on the flange fittings.
Tighten the flange screws.
Clutch slips
Operating oil pressure too low

Clutch slips at high

engines speeds
Operating oil pressure too low

Reduce engine speed until the clutch no longer
slips.
Clutch does not

engage
Control valve not properly engaged
From the control room, shift from OFF to ON

several times.
Shift the gearbox by hand in order to check valve
functioning.
-or For electrical shifting valve, check the shifting

position using the pressure switches:
LAF: Clutch engaged A74
Clutch does not

disengage
Oil pressure too low

Control defective
From the control room, shift into the OFF

position several times.
Disengage the gearbox by hand in order to check
valve functioning.
Discs are defective or seized
Check whether the emergency screws are tight.

If the clutch still does not disengage even though
the screws are loose, you need to have the discs
replaced. In this case, consult REINTJES
customer service.
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Trouble-shooting
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The installation and use of non-original parts may pose a safety hazard or impair
functioning of the gearbox. REINTJES assumes no liability whatsoever for damage
arising from the use of such parts.
We require this information when ordering spare parts:
1. Gearbox type
e.g. LAF ....
2. Commission number
e.g. K80 000
3. Input power
4. Input speed
Providing these details avoids having to request further information and speeds
up delivery.
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6.1
Gearbox oil pump A001.00, Type KF2/.., KF3/.., KF4/..
Pos.- No.
Qty.
Designation
A 001.50
Set of seals consisting of:

A Shaft sealing ring (1)
B O-ring (1)
C O-ring (1)
D Gasket (1)
A 001.51
Bearing
Note: Mark the position of the cover before dismantling.
When re-assembling, make sure that the cover and
gasket D are correctly seated.
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6.2
Heat exchanger A002.00, Type P ...
Pos.- No.
Qty.
Designation
A 002.50
Set of seals consisting of

4 O-rings
A 002.53
Intake cover
A 002.54
Reverse cover
A 002.55
Tube bundle
A 002.56
Anode
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6.3
Duplex filter A003.00, Type RFLD
Pos.- No.
Qty.
Designation
A 003.50
Filter element with o-ring
A 003.08
Contamination indicator electrical standard
A 003.51

A O-ring (2)
B O-ring (2)
A 003.52
Switch lever, complete
A 003.53
Drain plug, magnetical
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6.4
Control valve V1 (4/2-way-valve), electrical
Pos.- No.
Qty.
Designation
V 223

A O-ring (5)
B O-ring (2)
C O-ring (2)
D O-ring (2)
V 259
Solenoid
V 260
Plug-in connector
V 261
Plug-in connector
V 262
Manual emergency control for 4/2 NG 10 without spring-return
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6.5
Control valve V114 (4/2-way-valve), electrical, for PTO
Pos.- No.
Qty.
Designation
V 102

A O-ring (5)
B O-ring (2)
C O-ring (2)
D O-ring (2)
V 368
Solenoid
V 369
Plug-in connector
V 370
Plug-in connector
V 393
Manual emergency control for 4/2 NG 10 without spring-return
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6.6
Control valve V189 (4/2 way-valve), pneumatical, for shaft brake
Pos.- No.
Qty.
V 356
Designation
A O-ring (5)
B O-ring (2)
C O-ring (2)
D Turcon-Step seal (2)
O-ring (2)
E Quadring (1)
F Turco-Glyd ring (1)
O-Ring (1)
V 358
Pneuko piston, complete
V 357
Seal ring for piston

D and F consisting of 2 parts one fitting into the other
Detail X disc installed as STOP.
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6.7
Operation Delay Pot H426.00
Pos.- No.
Qty.
Designation
H 426.50

A O-Ring (1)
B O-Ring (1)
V 403.00
Non-return valve (Aeration valve)
Pos.- No.
Qty.
Designation
V 004.50
O-Ring
V 004.51
O-Ring
V 004.52
Threaded pin
V 004.53
Adjusting screw
V 004.54
Seal lock nut
V 004.55
Spring
V 004.56
Ball
V 004.57
Sealing ring
V 004.58
Plug screw
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6.8
Pos.- No.
Qty.
Designation
V418.50
Non-return valve (Aeration valve) ; depending on Potsize
V418.51
Sealing ring
Operation Manual
B BV2311 Version 1.1 / 06.02.2013
91
LAF 2346 4575

92
Operation Manual
B BV2311 Version 1.1 / 06.02.2013
LAF 2346 4575

6.9
Pos.- No.
Qty.
Designation
V 401.00
Non-return valve (Aeration valve) ; depending on Potsize
V 402.00
Sealing ring
Operation Manual
B BV2311 Version 1.1 / 06.02.2013
93
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94
Operation Manual
B BV2311 Version 1.1 / 06.02.2013
LAF 2346 4575

6.10
Control block V006.00, type HB4 D 0327 A
Pos.- No.
Qty.
Designation
V006.00
Control block HB 4 D 0327 A, ordering only completely:
V006.50
Set of seals
Pilot valve
Operation Manual
B BV2311 Version 1.1 / 06.02.2013
95
LAF 2346 4575

96
Operation Manual
B BV2311 Version 1.1 / 06.02.2013
LAF 2346 4575

6.11
Control block V006.00, type HB 4 A 0328 B
Pos.- No.
Qty.
Designation
V006.00
Control block HB 4 A 0328 B, ordering only completely:
Set of seals
Operation Manual
B BV2311 Version 1.1 / 06.02.2013
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LAF 2346 4575

98
Operation Manual
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LAF 2346 4575

6.12
Control block, type HB 4 B 0320A + DKF4O30
Pos.- No.
Qty.
Designation
Control block, ordering only completely:
10
DKF4O30-Mounting group
100
O-Ring
Operation Manual
B BV2311 Version 1.1 / 06.02.2013
99
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100
Operation Manual
B BV2311 Version 1.1 / 06.02.2013
Index
Index
B
fill 12
Behaviour in cases of fault 27
C
Checklist
Preservation 18
Sensor connections 19
Checklist before starting the engine 19

Checklist for gearbox after engine start 20
Checklists for putting into operation 15
Connection to the engine 27, 68
Conversion factors (oil) 14
Oil drain screw 13

Operation modes 23
P
Power Take Off PTO K51 23
Pressure limiting valve 30
set 30
Putting the unit into operation 11
R
Requirements for assembly personnel 7
Dipstick marking 14
Safety 5
Service repair sets 77
Shaft brake 24
Special operating modes 25
E
Emergency operation 27, 28
Emergency screws 28
Engaging the gearbox 23
F
Failure of pressure oil supply 28
Fresh oil sample 13
T
Tighten of the emergency screws 29
Tightening torque 68
Trailing operation 25
Trouble-shooting 71
H
Handling the checklists 15
Heat exchanger
Maintenance 35, 37
I
Installation check 12
L
Lubricant amount 14
Lubricant recommended 14
M
Maintenance 31
Maintenance job card 35, 37
Maintenance level 33
Maintenance plan 33
Manual emergency operation 27
N
Notes on the checklists 21
O
Oil
Operation Manual
B BV2311 Version 1.1 / 06.02.2013
101
Index
102
Operation Manual
B BV2311 Version 1.1 / 06.02.2013

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Installation Instructions

LAF 2346 4575

E BV2311 Version 1.1 / 06.02.2013

No part of this document may be reproduced in any form

2013 REINTJES GmbH

LAF 2346 4575

Introduction to this Documentation .............................................................................................. 17

Technical Data ........................................................................................................................................ 21

Transport, Storage and Preservation ........................................................................................... 25

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

LAF 2346 4575

6.13 Alignment Check ......................................................................................................................................65

LAF 2346 4575

Meaning of Warnings and Notes

Note without signal word:

Additional information and recommendations

LAF 2346 4575

Basic measures of caution

Dangerous places on the gearbox

These warnings must be

Wear tightly fitting protective

Danger of electric shock!

Wear ear protectors

Do not disconnect or service this

Caution, hot components

Read instructions carefully!

LAF 2346 4575

Requirements for installation personnel

LAF 2346 4575

Safety information for installation

LAF 2346 4575

Protective measures against fire and danger of explosion

LAF 2346 4575

Cables connected to the gearbox

LAF 2346 4575

Introduction to this Documentation

This installation instructions contains information about:

The operating instruction contains information about:

Putting the unit into operation

The procedures described in this documentation are of a general nature.

Please read the Installation instructions before installing the gearbox!

LAF 2346 4575

Maintaining the documentation

REINTJES strongly recommends that you have a torsional vibration calculation

LAF 2346 4575

Brief product description

Pressure build-up system

LAF 2346 4575

Area of application and manner of intended use

Use of the gearbox within the European Union

LAF 2346 4575

Requesting spare parts

e.g.: LAF ...

GEAR REDUCTION RATIO - e.g.: 4.05 : 1

Item number of the part

LAF 2346 4575

LAF 2346 4575

LAF 2346 4575

LAF 2346 4575

Transport, Storage and Preservation

LAF 2346 4575

During transport, make sure:

Not to damage packaging, if further storage is intended afterward.