Professional Documents
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OPERATING MANUAL
Reduction: 4.500 : 1
Work no.: 76 643
Direction of rotation
Input: clockwise
Output: anticlockwise
Contents
Operating manual BV2179.en 2007-10
Appendix
0-104-83450 Drawing of installation
0-211-83684 Supervision plan
Service manual
76643.en_T.doc
BV2179.en
MARINE GEARBOXES 2007-10
BV2179.en_2007-10.doc 1 / 26
REINTJES BV2179.en 2007-10
1 General Information
1.1 Introduction
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.
Constant improvement and continued development may result in changes to your gearbox
that is not yet mentioned in these instructions.
Please address any questions about your gearbox or about this documentation to REINTJES
customer service:
service@reintjes-gears.de or on
working days: Phone (+49) 05151 104 0
In emergencies and on weekends: Phone (+49) 05151 104 237
Note!
REINTJES strongly recommends that you have a torsional vibration calculation
performed for the entire system.
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REINTJES BV2179.en 2007-10
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.
NOTE!
Incorrect operation, lubrication, maintenance or repair of this product can be
dangerous and may even lead to injury.
1.4.2 General protective measures and personal protection in the machine room
The gearbox may be operated and maintained only by qualified staff knowledgeable in its
operation and maintenance.
⇒ Prior to the trial run, mount coverings over all openly accessible rotating parts.
⇒ Immediately repair any faults that pose a safety hazard!
⇒ Ensure that no foreign objects enter the inside of the gearbox during assembly.
⇒ Wear protective eyewear when cleaning with compressed air.
Danger of eye injuries due to dirt particles.
⇒ While the engine is running, wear ear protectors to prevent hearing 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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REINTJES BV2179.en 2007-10
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.
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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REINTJES BV2179.en 2007-10
1.5.3 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.
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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REINTJES BV2179.en 2007-10
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REINTJES BV2179.en 2007-10
The gear dry weight (without oil but with special accessories) is stamped onto the name
plate. The lifting rig must be attached to the lifting eyes provided by means of shackles.
Under no circumstances must lifting equipment be attached to shaft ends, pipework
or other externally-mounted equipment. The lifting equipment must be secured
against tilting.
2.2 Alignment
A basic prerequisite for trouble free operation of a propulsion plant is careful alignment of
engine and gearbox to the propeller shaft. Accurate alignment to the engine is also
necessary if torsionally elastic couplings are used, since every alignment error has a
disadvantageous effect on the service life of the driving elements or accesories. Only high
flexible couplings must be used.
On request, REINTJES will supply all data required for alignment calculation (such as
temperature expansion curve, mass and stiffness distribution of the gearbox output shaft and
allowable bearing loads).
If the customer, or shipyard, is in possession of an alignment calculation for the complete
propulsion plant, then plant alignment must be completed in accordance with such
calculation. A copy of the alignment calculation should, however, be submitted to REINTJES
for information.
Propulsion plant alignment diagrams are generated by superimposing the fullload
temperature characteristics of the engine crankshaft, the gearbox input and output shafts and
the propeller shaftline.
These full-load temperature shaft-displacement characteristic curves permit precision cold-
state alignment for optimized fullload operating conditions.
If alignment calculation for the complete propulsion plant has not been made, it is mandatory
to comply with REINTJES instructions when aligning the marine gear.
During gearbox installation it is essential to ensure that sufficient free space provided for
disassembly of housings, shafts, etc during later maintenance. The gearbox has to be
installed onto an adequate strengthened foundation so that no housing distortion can occur.
The installation, or foundation, drawing includes all necessary marine gear mounting face
dimensions. Application-specific deviations must be confirmed in consultation with the
factory.
For propulsion plant alignment, it is mandatory that the vessel be afloat with
absolutely noground-contact with the sea bed.
Alignment of the gear output shaft-to-propeller shaftline connection, the engine PTO to the
gear input shaft and the auxiliary units to the additional gearbox (PTO) shafts must be made
in compliance with manufacturer's instructions.
Vertical alignment of gearbox to propeller or intermediate shaft is effected by alignment
screws located in the gearbox seating. For horizontal alignment we recommend to fix
alignment screws on the foundation.
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REINTJES BV2179.en 2007-10
Engine power transmission from the engine to the marine gear must be via a torsionally
resilient coupling. Based on our experience we recommend that, when selecting a torsionally
resilient coupling for the propulsion plant, the torsional resilience factor chosen be such as to
ensure that the resonance speed, of the 1. grade vibrational form exited by the main
rotational harmonics of the engine, is so far below the lowest specified operational speed
that it is only transgressed during engine startup and shutdown. Alternatively care must be
taken to ensure that, within reasonably acceptable limits, the plant operating range be kept
free of torsionally-critical speeds.
Selection of the torsionally resilient coupling is generally made by the engine manufacturer.
The gearbox data required for torsional vibration calculation is supplied by REINTJES
together with the associated order-referenced torsional vibration diagram.
If the coupling is specified by the engine manufacturer or the shipyard and is supplied
assembled with the marine gear; then REINTJES cannot accept responsibility for the
suitability or durability of the torsionally resilient coupling. Compliance with the appropriate
instructions is mandatory for assembly / dismantling of the coupling flange (hub).
The propulsion engine is normally resiliently mounted; the gearbox may be rigidly or
resiliently mounted onto the foundation. The torsionally resilient coupling used must also be
capable of accommodating the the axial misalignment between the engine and gearbox
shafts at the specified operating speeds.
Referenced to the gearbox, the flexibility of the resilient engine mounts must be such as to
allow engine-to-gearbox alignment accuracy which ensures that there is no possibility of
appreciable reactive forces at the bearings of the connected gearbox shafts when operating
temperatures prevail.
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REINTJES BV2179.en 2007-10
Seat Chocks
Rectangular seat chocks must be used only. Round discs or shim plates arranged one
upon the other are not permissible.
Seat chocks must be adequately dismensioned and closely fitted. They are to be made in
accordance with the rules of the classification societies.
Fitting Bolts
The fitting bolts used must be of tensile strength 8.8 in accordance with ISO 898.
The fitting bolt bores are pre-drilled.
Through Bolts
Through bolts must be of the same tensile strength as the fitting bolts.
The foundation bolts must comply with application- specific requirements and be tightened to
the specified torque.
On completion of alignment, the gear must be attached to the foundation in such a manner
that it is secured against displacement and that the propeller thrust is transmitted and led into
the foundation.
Important
Planning, calculation and installation of cast-resin foundation should only be carried out by
an authorized company which is also in a position to submit the necessary drawings,
calculations and materials to the Classification Societies for approval.
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REINTJES BV2179.en 2007-10
On completion of alignment and after the engine and marine gear foundation bolts have been
finally tightened to specified torque, a check of the mating accuracy of both marine gear
flanges is recommended whereby the flange securing screws must be removed.
We accept no claims under warranty arising from exceeding alignment tolerances of
both gearbox connecting flanges.
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REINTJES BV2179.en 2007-10
REINTJES marine reduction gearboxes of type VA are vertically offset, single stage spur
wheel gearboxes.
The direction of rotation marked on the name plate is the direction of rotation of input and
output shaft looking in the direction of AHEAD travel.
The gearbox output shaft is turning in the opposite direction to the input shaft.
The service life of the gearbox depends upon the correct completion of the recommended
operating and maintenance services and the use of recommended lubricants.
The hydraulic system comprises a geartype pump, an oil filter, heat exchanger, pressure
limiting valve, and lubrication oil system.
Oil supplied by the pump is filtered and cooled, so that the oil temperature does not rise
above the normal operating temperature. The cooling water flows through the tube bundle
and the oil flows between the tube bundle and the outer housing. The cooling water
connections can be reciprocally used for inlet, outlet resp.
Warning
The adjustment screw is not secured against turning out of the valve block and must not be
removed by screwing it out anticlockwise. Oil will leak out if screw V13 is removed while oil is
under pressure (engine STOP)!
The setting screw should only be screwed in until the top is even with the lock nut, so
that the valve is not blocked. (At valves with hexagon screw, the screw can be turning
in so that the hexagon head is against the lock nut).
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REINTJES BV2179.en 2007-10
Hot oil can cause personal injury. Do not allow hot oil or hot parts to contact skin.
Before a re-setting of the pressure limiting valve is intended due to changed pressure
readings, possible causes must be checked carefully.
The pressure gauge on the gearbox indicates the operating pressure. At nominal engine
speed and the gearbox at operating temperature, the normal operating pressure is approx. 5
bar.
The engine power is transmitted to the input shaft via the engine-to-marine gear coupling.
When the input shaft rotates, the oil pump provides oil pressure for gearbox lubrication.
The output shaft and propeller shaft are turning in the opposite direction to the input shaft.
The path of drive is from input pinion shaft R1 via gear R2 to output shaft P1 connected with
the propeller shaft. These parts are turning as soon as the input shaft is force locked
engaged to the running engine.
The oil companies are responsible for determination of the oil types stated in the lubrication
chart.
REINTJES is not liable for correctness of these data nor for any amendments occuring.
REINTJES does not accept responsibility for any damages due to the use of unsuitable oils.
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REINTJES BV2179.en 2007-10
Oil Filling
Prior to shipment, the marine gear is preserved internally. In the case of units which have
been hermetically sealed, the sealing plug must be removed and the venting filter (supplied
loose) must be installed. The preservation oil must be drained, minor oil residues will mix
with the service oil.
The amount of oil required is stamped into the name plate. Fill oil as specified into the marine
gear until the upper mark on the dipstick is reached. The oil level can only be checked with
the plant shut down and using the dipstick.
After installation check and prior to sea trial a short test run under limited load must be
carried out. As the hydraulic system will be filled with oil then, the oil level must be re-
checked on the dipstick and if necessary oil must be filled up.
Dipstick markings
The dipstick for the gear unit has 3 markings:
• The top mark shows the maximum oil level when the gear unit is stationary.
• The centre mark shows the minimum oil level when the gear unit is stationary.
• The bottom mark shows the minimum level when the gear unit is running.
Refer also to the adhesive label "Dipstick markings" near the dipstick.
Installation Check
In the course of the last check prior to initial operation, it is essential to ensure that all
necessary connections have been made as specified. All necessary data must be recorded
on the "Alignment Certificate" which must be signed.
Having confirmed that the gearbox is in an operationally safe condition and that the
propulsion plant is ready for service, initial operation may be done.
On completion of the test-run the propulsion plant alignment should be checked and the
foundation bolts must be checked for tight fit.
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REINTJES BV2179.en 2007-10
Safety and maintenance are prerequisites for troublefree operation, maximum performance
and a long service life.
Safety is, initially, an abstract definition and can not, in all cases, be defined by regulations.
The necessary safety measures can normally be determined by experience and intelligence.
Be alert at all times.
Observe possible danger sources.
Take all necessary precautions.
Safety is EVERYBODY'S business.
This Operation Manual includes descriptions of maintenance services which have to be
completed periodically. Familiarize yourself with the "Maintenance" chapter.
Periodic supervision and registration of measured parameters provides a duty profile for the
engine and marine gear. If certain conditions change then a changed display may indicate a
potential problem. The necessary repairs can be laid down before an actual failure occurs
with resultant non-scheduled down time.
This condition covers all operating conditions in which the propulsion plant is shut
down and the propeller, the shaftline and the gearbox shafts are caused to rotate by
entrained water.
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REINTJES BV2179.en 2007-10
4 Maintenance
Operational safety, reliability and low maintenance costs can only be achieved by
maintenance and care in compliance with our instructions. Furthermore, only trained
maintenance personnel, should work on the gearbox, and only correct tools, original spare
parts and lubricants in accordance with our recommendation should be used.
Filter elements and waste oil must be disposed of as recyclable material or special
waste.
If required, our Service Department is available at all times to provide advice and assistance.
Has the "Function and Operation" chapter been read and understood?
Operator alertness provides the best protection against possible dangers.
The operator must comply with safety instructions and be familiar with all precautionary
measures. Run a maintenance log book. Regular registration of recorded data can provide
indication of internal changes. Rectify minor faults before they can develop into major
repairs.
Keep the marine gear clean and dry at all times, this facilitates early recognition of any
possible leaks thus preventing subsequent extensive damage. As a matter of principle, never
use chemical detergents to clean rubber or synthetic components. Wipe with a dry cloth only.
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REINTJES BV2179.en 2007-10
Thread Size Grade 8.8 Standard Torque Thread Size Grade 10.9 Standard Torque
Metric Nm )
1
lb ft Metric N m 1) lb ft
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REINTJES BV2179.en 2007-10
The Maintenance Schedule summarizes the maintenance services which are sub-divided
into Maintenance Stages.
Particularly arduous service conditions may require modification of the Maintenance
Schedule (reduced intervals).
Maintenance Stage 1 Daily
• Check oil level (lower dipstick marking -- operation oil level)
Maintenance Stage 2 Daily with engine running, check:
• operating pressure,
• oil temperature,
• heat exchanger temp cooling water,
• duplex filter contamination indicator,
• visual checks and running noises
• Ball valve (oil sucking) for tightness
Maintenance Stage 3 After first 300 operating hours:
• Perform an oil analysis, acc. to this result possible oil cleaning or oil
change.
• Replace filter element
• Check threaded connections incl. foundation, check connection to
engine and propeller and bolts of intermediate housing
• Tighten swivel nuts and banjo bolts of threaded pipe connections in
case of leakage
• Check heat exchanger for leakage
Maintenance Stage 4 After each operating period of 3000 hours or 6 months:
• Change oil
• Replace filter elements
Maintenance Stage 5 After each operating period of 6000 hours or 1 year:
• Check threaded connections incl. foundation, connection to engine
and propeller and bolts of intermediate housing
• Check heat exchanger for leakage and replace seals, if necessary,
check control valve actuation
Maintenance Stage 6 After each operating period of 60000 hours or 10 years or in
conjunction with an engine major overhaul
Check:
• shafts for run-out
• bearing seats for damage
• carriers
• gear and pinion teeth
• annular piston carrier
• pins oil distributor
• pressure gauge
• Ball valve (oil sucking) for tightness
Replace:
• clutch discs
• rectangular rings, screws and return springs for annular piston
• O-rings, snap rings,
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REINTJES BV2179.en 2007-10
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REINTJES BV2179.en 2007-10
Maintenance stage 1
4.5.1 Daily before engine start
Oil Level Check The dipstick for the gear unit has 3 markings:
• The top mark shows the maximum oil level when the gear unit is
stationary.
• The centre mark shows the minimum oil level when the gear unit is
stationary.
• The bottom mark shows the minimum level when the gear unit is
running.
• Refer also to the adhesive label "Dipstick markings" near the
dipstick.
• The oil level must be between the marks on the dipstick.
• If the oil level is low, fill up suitable oil until the level reaches the
upper mark on the dipstick.
• Determine and rectify the cause of oil loss.
• For filling in the oil screw out the venting filter marked OEL (OIL).
Maintenance stage 2
4.5.2 Daily with engine running
Operating Pressure • With the engine running and clutch engaged, the maximum
Check operating pressure is indicated on the gearbox-mounted pressure
gauge.
• Oil viscosity, operating temperature and different delivery rates of
the oil pump, due to varying engine speeds, have only a minor affect
on the operating pressure.
Oil Temperature • The normal operating oil temperature after the heat exchanger will
Check be in the range of approx. 40 - 60 °C and can be read off at the
thermometer.
• If the oil temperature is higher than the normal operating
temperature, determine the possible cause and initiate the
appropriate remedial measures.
Cooling Water • Normally the cooling water temperature difference across the oil
Temperature heat exchanger should be 3 to 5 °C (5 to 9°F).
• An increase of the cooling water temperature difference indicates
contamination of the water side of the oil heat exchanger or an
insufficient cooling water flow rate.
Oil Filter • Experience has shown that the contamination indicator must be
Contamination closely observed during the first 100 operating hours.
indicator
• With high viscosity or cold oil a high pressure difference may be
effective during the warm-up phase. This can lead to a temporary,
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REINTJES BV2179.en 2007-10
Maintenance stage 3
4.5.3 After first 300 operating hours
This oil change with changing filter elements is to be firstly carried out on all new or
completely overhauled gearboxes. All following oil changes are to be completed at the
intervals specified for Maintenance Stage 4.
Oil check • The first oil check or cleaning professionally of the oil (e.g. by a
separator) must be carried out after 300 operation hours.
• We recommend to have carried out an oil analysis and to clean
professionally or to replace the oil if required according to the
results.
• The intervals apply to the further regular oil changes to servicing
step 4.
• We independently of the oil change intervals recommend a monthly
check of the Hose lines on crack formation and mechanical
damages.
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REINTJES BV2179.en 2007-10
Maintenance Stage 4
4.5.4 After each operating period of 3000 hours or 6 months
This maintenance stage determines the Standard intervals of oil change and oil filter
element replacement. Adhering to these intervals the oil sludge must be checked for
metallic residues.
Oil Change • Change the oil when engine is shut down and the oil is warm
(cooled down from operating temperature).
Caution! • Hot oil or components can cause injury. Avoid skin contact with hot
oil and components.
Oil change cont. • Remove the oil drain plug and allow oil to drain into a suitable
container or pump the oil from the gearbox into the container. Clean
the drain plug and reinstall it with a new sealing ring. Tighten plug to
specified torque.
• Refill recommended oil into the gearbox until the oil level reaches
the upper mark on the dipstick. The oil capacity is indicated on the
gearbox name plate.
• Replace the oil filter elements.
• On completion of all maintenance tasks, start the engine and run for
5 to 10 min. Shut down the engine and recheck the oil level. The
level must remain at the upper mark on the dipstick. Do not overfill
the gearbox.
• Compliance with the oil change intervals specified in the
Maintenance Schedule is mandatory; especially the first,(or initial)
oil change. Prolongation of the oil change intervals is only
permissible when regular and reliable analyses are carried out.
• In addition to ageing checks the lubricating capability must be
checked.
• The above mentioned intervals rely on a operating temperature after
the heat exchanger of approx. 60°C. If these temperatures are
exceeded, the oil change intervals are reduced and must be
determined in consultation with REINTJES.
• Independent of the oil change intervals we recommend to check the
flexible hoses monthly for cracks and damage.
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REINTJES BV2179.en 2007-10
Filter Element • Prior to carrying out the following maintenance tasks, the filter
Replacement element to be replaced must be taken out of service. The change
over lever is at the side of the filter element which is in operation.
• Direct the oil flow to the currently inoperative filter by moving the
lever away from the filter element to be replaced.
• Slowly release the vent screw and allow all pressure to escape.
Remove the vent screw and O-ring.
• Remove the drain plug and O-ring from the filter housing. Allow the
oil and contaminant deposits to drain from the filter housing.
• Remove the cover securing screws. Turn the cover through 45° and
carefully remove the cover and O-ring.
• Remove the filter element and contaminant strainer. Remove the
filter element out of the housing by turning it clockwise. The
contaminant strainer will become loose and remain in the housing
when lifting out the element by turning it anticlockwise.
• Clean the filter housing, contaminant strainer and drain plug.
• Prior to filter system re-assembly, check all O-rings for damage;
replace damaged O-rings.
• Install the drain plug and O-ring.
• Install the new filter element with O-ring and the contamination
strainer. Take care not to damage the O-ring. Install the filter cover
and O-ring. Ensure that the O- ring is correctly seated. Insert the
vent screw with O-ring loosely.
• With the vent screw loose, move the change-over lever approx. 10°
towards the centre; in this position the filter housing will be filled with
oil. Hold the lever in this position until bubble-free oil is discharged
at the vent screw.
• Tighten the vent screw to specified torque and set the change over
lever for single-filter operation.
Maintenance stage 5
4.5.5 After each operating period of 6000 hours or 1 year
Threaded • The screw tightening torques should be checked with the gear cold.
Connections Particular attention must be paid to the following connections:
• Engine - flexible coupling – gearbox,
• Gearbox output shaft flange - propeller shaft,
• Gearbox mountings - foundation.
• Swivel nuts and banjo bolts of threaded pipe connections.
• Check the rubber elements of the flexible coupling for porosity,
cracking or other signs of damage.
• Check the heat exchanger for leakage and replace the seals, if
necessary.
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Maintenance stage 6
4.5.6 After each operating period of 60000 hours or 10 years
or in conjunction with engine major overhaul
Matching to the engine maintenance intervals is permissible provided that the operating
hours specified are not excessively exceeded.
Part Checks - Shafts for run-out,
- Bearing seats for damage,
(and replacement - Carriers,
as necessary):
- carrier pins for annular piston,
- Gear and pinion teeth,
- Oil distributor,
- Pressure gauge.
Replace - Rectangular rings,
- screws and return springs for annular piston,
- O-rings,
- Snap rings,
- All clutch housing screws
- Anti-friction bearings,
- Thrust bearing screws and springs,
- Shaft seals and bushes,
- Oil filter elements and seals,
- Oil pump,
- Inspection cover gaskets,
- O-rings for pressure limiting valve,
- Flexible hoses,
thoroughly clean the gear housing, vent filter and all other parts which are to be reused.
Our Service Department is available at all times, to answer any questions you may have:
Email service@reintjes-gears.de Tel. +0049 5151 104-0
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Gearbox No.
Type
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4.7 Troubleshooting
4.7.1 Disturbance
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Preservation Measures
From outside the gearbox is protected from corrosion by adequate packaging for
transportation and the storage period stated in the contract.
All openings of the gearbox are sealed.
For preservation of the inner parts the gearbox is operated with preservation oil during the
test run. After the test run BRANOROL (VCI preservation oil) is filled into the gearbox. This is
indicated by the plate on the gearbox:
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0 1 2 3 4 5 6 7 8 9
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
Gearbox VA 4851 K41
Classification GL AUT
Working pressure
Project agent ROT
Commission Created on 16.04.2010
Instructions by
Number of pages 13
=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Cover sheet
0-211- 83684 +
Page
F1
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9
Table of contents
Page Page description supplementary page field
1 Cover sheet
2 Table of contents
3 Hydraulic diagram
4 Pressure switches
5 Pressure switches / Oil level controller
6 Temperature after oil cooler
7 Temperature Thrust bearing
8 Terminal diagram =+-X000
9 Terminal diagram =+-X000
10 Measuring points list
11 Monitor list
12 Terminal box
13 Pressure test valve
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Table of contents
0-211- 83684 +
Page
F2
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9
-A113
/6.3 /13.1
-A480 -A55
T
Oil cooler
/7.3
-A490
T
Oil filter
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
-A43.1 P P -A43.2
/5.1 Δ Δ /5.2
Stand by pump
=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Hydraulic diagram
0-211- 83684 +
Page
F3
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9
Pressure switches
1-2 Pressure low
1-3 Pressure high
Lube oil pressure too low - Alarm Start - Stand by pump Main engine slow down Main engine shut down
1 2 3 1 2 3 1 2 3 1 2 3
1 2 3 1 2 3 1 2 3 1 2 3
-R1 -R2
24k 24k
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
-X000 1 2 3 4 5 6 7 8
Alarm system Starter - Stand by pump Engine safety system cabinet Engine safety system cabinet
=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Pressure switches
0-211- 83684 +
Page
F4
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9
Filter element 1 - contaminated Filter element 2 - contaminated Oil level too low
BN GY(BU) BK
1 2 3 1 2 3
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
-X000 9 10 11 12 13 14 15 16 17 18 19
=
Ed.
Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Pressure switches /
Oil level controller 0-211- 83684 +
Page
F5
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9
-A480.2
-A480.1
2L / 2x Pt100 Θ Θ
Pt100
Pt100
1 3 2 4
-W480 BN BU WH BK
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
-X000 20 21 22 23 -X000 24 25 26 27
=
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Appr
ROT
DAJ
16.04.2010 Gearbox
Commission
VA 4851 K41 Temperature after oil cooler
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0 1 2 3 4 5 6 7 8 9
-A490.2
-A490.1
2L / 2x Pt100 Θ Θ
Pt100
Pt100
1 3 2 4
-W490 BN BU WH BK
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
-X000 28 29 -X000 30 31 32 33 -X000 34 35 36 37 38 39 40
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VA 4851 K41 Temperature Thrust bearing
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Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9
Terminal diagram
-W103
-W105
-W461
-W125
-W43.1
-W43.2
-W57
-W480
Strip
Cable name
Cable name
=+-X000
Page / column
Connection
Connection
cable type
cable type
terminal
jumper
point
point
Function text Target designation Target designation
Lube oil pressure too low - Alarm -AS 1 -A103 1 BN /4.0
= -AS 2 -A103 3 BU /4.1
Start stand by pump -SP 3 -A105 1 BN /4.3
= -SP 4 -A105 2 BU /4.3
Main engine slow down -MAN X58:3 5 -A461 1 BN /4.5
= -MAN X58:4 6 -A461 2 BU /4.6
Main engine shut down -MAN X58:1 7 -A125 1 BN /4.8
= -MAN X58:2 8 -A125 2 BU /4.8
Filter element 1 -AS 9 -A43.1 1 BK /5.1
Filter element 1 - ready -AS 10 -A43.1 2 BN /5.1
Filter element 1 - contaminated -AS 11 -A43.1 3 BU /5.1
Filter element 2 -AS 12 -A43.2 1 BK /5.2
Filter element 2 - ready -AS 13 -A43.2 2 BN /5.3
Filter element 2 - contaminated -AS 14 -A43.2 3 BU /5.3
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
Oil level -AS 15 -A57 BN BN /5.7
Oil level too low - Alarm -AS 16 -A57 GY(BU) BU /5.7
Oil level ready -AS 17 -A57 BK BK /5.7
18 /5.8
19 /5.9
Lube oil temperature -Alarm (Pt100) -AS 20 -A480 1 BN /6.3
= -AS 21 -A480 3 BU /6.3
Lube oil temperature -Engine slow down (Pt100) -MAN X59:9 22 -A480 2 WH /6.5
-MAN X59:8
Lube oil temperature -Engine slow down (Pt100) -MAN X59:10 23 -A480 4 BK /6.6
-MAN X59:11
24 /6.8
25 /6.9
26 /6.9
27 /6.9
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VA 4851 K41 Terminal diagram =+-X000
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0 1 2 3 4 5 6 7 8 9
Terminal diagram
-W490
Strip
Cable name
Cable name
=+-X000
Page / column
Connection
Connection
cable type
cable type
terminal
jumper
point
point
Function text Target designation Target designation
28 /7.1
29 /7.1
Thrust bearing temperature -Alarm (Pt100) -AS 30 -A490 1 BN /7.3
= -AS 31 -A490 3 BU /7.3
Thrust bearing temp. -Engine slow down (Pt100) -MAN X59:5 32 -A490 2 WH /7.5
-MAN X59:4
Thrust bearing temp. -Engine slow down (Pt100) -MAN X59:6 33 -A490 4 BK /7.6
-MAN X59:7
34 /7.8
35 /7.8
36 /7.8
37 /7.8
38 /7.8
39 /7.8
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
40 /7.9
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VA 4851 K41 Terminal diagram =+-X000
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Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9
Measuring points list Note XX = sequence alarm Time delays are not supplied by Reintjes
Pos. Measuring point Abbre. Responding value Function Function Function Alarm value Time delay Comment Function text
Low High Alarm slow down shut down
-A10 Pressure suction pipe P connection 1 -for gauge
-A11 Pressure suction pipe P connection 2 -for gauge
-A35 Operating pressure P Visual indication at gearbox 0 - 10bar Manometer_Operating pressure
-A43.1 Differential pressure PDAH X X DP > 5bar Filter element 1 - contaminated
-A43.2 Differential pressure PDAH X X DP > 5bar Filter element 2 - contaminated
-A55 Oil temperature T Visual indication at gearbox 0 - 100°C Temperature after oil cooler
-A57 Oil level NW X X 10sec Oil level too low
-A103 Oil pressure low PAL X X P < 1bar Lube oil pressure too low - Alarm
-A105 Oil pressure low PAL X XX P < 1.2bar Start - Stand by pump
-A125 Oil pressure low PALL X X P < 0.6bar Main engine shut down
-A461 Oil pressure low PAL X X P < 0.8bar Main engine slow down
-A480-A480.1 Oil temperature TAH X X T > 65°C Lube oil temperature -Alarm (Pt100)
-A480-A480.2 Oil temperature TAHH X X T > 70C° Lube oil temperature -Main engine slow down (Pt100)
-A490-A490.1 Oil temperature TAH X X T > 90°C Thrust bearing temperature -Alarm (Pt100)
-A490-A490.2 Oil temperature TAHH X X T > 95C° Thrust bearing temperature -Main engine slow down (Pt100)
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
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Commission
VA 4851 K41 Measuring points list
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Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9
Monitor list
Pos. Manufacturer Designation Type number Measuring range Degree of protection
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
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VA 4851 K41 Monitor list
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11
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0 1 2 3 4 5 6 7 8 9
360 mm
160 mm
Cover
-A120
91 mm (Gesamthöhe)
-A21
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
Box
-A119
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VA 4851 K41 Terminal box
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12
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9
BAR
-A113
/3.6
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
Pressure test valve
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VA 4851 K41 Pressure test valve
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13
Modification Date Name Original Replaced by Replaced by Supervision Page 13
BV1945.en
MARINE GEARBOXES 2008-03
Gearbox Preservation
1 Safety Information
• The established safety rules have to be observed when handling operating and auxiliary
materials!
• Check all lines, hoses and threaded connections for leakage before putting the gearbox into
operation!
• Smoking is generally prohibited when working with inflammable operating materials!
• Be careful when handling oil and fuel vapors! There is high risk of fire!
• Be careful when handling hot or caustic operating and auxiliary materials!
There is risk of getting burned or scalded!
• Be careful with liquids coming out under high pressure! Risk of injury!
• Relieve pressure from all operating materials systems and pressure lines according to
manufacturer's instructions before starting work!
• Let gearbox cool down before commencing maintenance work! For cleaning of gearbox use
only non-flammable cleansing liquid or liquid with flash point over 65°C!
Use only operating and auxiliary materials recommended by the manufacturer!
2 General Information
Preservation is the protective treatment of sliding and bright metal parts against corrosion.
After the test run the gearbox undergoes specific preservation before being shipped to the
customer. The preservation measures to be taken depend on the period until initial operation, the
storage conditions and special wishes on the part of the customer.
For tropical climates the preservation has to be adjusted to the local conditions. Specific
preservation measures become also necessary for the gearbox and its auxiliary units, if they are
taken out of service for a longer period.
As a matter of course, all spare part shipments and gearbox accessories underwent adequate
preservation.
First preservation measures are taken by the manufacturer based on the provisions of the contract.
If the instructions and measures described in this document are not observed, REINTJES will not
accept responsibility for corrosion and resulting damages.
3 First Preservation
For preservation of the interior the gearbox is operated with preservation oil during the test run at
the factory. After the test run a VCI preservation oil (VCI = volatile corrosion inhibitor) is filled into
the gearbox. VCI inhibitors are agents which evaporate very slowly and in enclosed space settle
down on bright metal surfaces as an invisible film. Due to their polarity they interrupt electro-
chemical corrosion reactions.
BV1945.en_2008-03.doc Page 1 / 5
REINTJES BV1945.en 2008-03
In order to ensure that the VCI inhibitors are effective as long as possible all openings of the
gearbox are closed and the shafts are sealed with acid-free grease.
During transportation and, in addition, for the storage period stated in the contract the gearbox is
corrosion-protected from outside through preservatives forming a wax-like film after evaporation of
the solvent, as well as through adequate packaging.
If the gearboxes are to be stored longer than stated or under different conditions, additional
measures will have to be taken in order to guarantee sufficient corrosion protection.
If storage will be continued upon expiration of the guaranteed conservation time, the condition of
the packaging respectively the condition of the gear has to be checked by a company specialized
in long duration packaging. These checks and measures have to be discussed with REINTJES in
each single case.
The effectiveness of the preservation measures depends on the packaging, the storage conditions
and the storage period.
Damages to the packaging, which must also be avoided during storage, and unfavorable storage
conditions, e.g. high atmospheric humidity, saliferous or polluted air, extremely changing
temperatures etc., will have a negative effect on the permissible storage period. Generally, the
gearbox must not be stored in the open.
High-quality packaging with sufficient drying agent and storage in air-conditioned space with low
atmospheric humidity will have a positive effect on corrosion protection. The better the gearbox is
sealed, the less humidity can penetrate and the longer the VCI agents can protect the interior of
the gearbox against corrosion.
The period after removal of the original packaging and before initial operation has to be kept as
short as possible. During this period adequate measures have to be taken to ensure optimum
protection of the gearbox from environmental influences and external damage.
Generally, all openings of the gearbox have to be kept sealed until initial operation. If, however,
prior opening of the gearbox cannot be avoided, afterwards all openings will have to be
hermetically sealed again. In addition, further measures described in Section 5 will become
necessary.
The measures described in the following sections represent general instructions for certain
conditions. In case of doubt, it is recommended to agree on the measures to be taken with
REINTJES.
If corrosion damages are found during checks or maintenance REINTJES Customer Service will
have to be informed immediately.
On reception the gearbox packaging has to be checked for transport damages immediately.
Page 2 / 5
REINTJES BV1945.en 2008-03
If the packaging is damaged, water and harmful environmental influences can act directly on the
gearbox. Due to changing temperatures more humidity can penetrate the interior of the gearbox.
Measures:
• Dry gearbox, if necessary
• Check and, if necessary, replace drying agent
• Check and, if necessary, restore preservation at shaft ends
• Repair packaging, better: take off old foil and shrink-wrap gearbox with drying agents again in
foil of comparable quality
• Regular outward check of packaging and, if possible, drying agents
Check intervals: European climatic zone every 4 weeks, tropical climate every 2 weeks
Immediately after removing the original packaging additional preservation measures will become
necessary in order to ensure sufficient corrosion protection for the gearbox.
Measures:
• Provide best possible protection of the gearbox against water and harmful environmental
influences. When covering the gearbox with awnings make sure that there is a distance to the
gearbox, they must not become steam domes.
• At regular intervals check gearbox for corrosion damages from outside, check and, if
necessary, restore preservation and sealing of shaft ends (for check intervals see 5.2)
• At regular intervals top up VCI preservation oil Branorol;
The time for the first topping-up is dependent on the storage conditions. The standard
calculation says that by removing the packaging the remaining, agreed storage period is
halved. However, the period until the first topping-up must not exceed 12 weeks (Europe) and
8 weeks (tropics).
The above mentioned measures will have to be taken correspondingly, if the agreed storage
period of unpacked gearboxes (only European climatic zone) expired.
When the gearbox is opened, the VCI agents of the preservation oil escape. Whether a protective
agent atmosphere can develop again after the gearbox has been sealed anew, depends on the
residual quantity of VCI agents in the preservation oil, the quantity of humidity which penetrated
and the quality of the subsequent sealing of the gearbox.
Measures: top up preservation oil Branorol; for quantity and further service intervals see 5.3
Page 3 / 5
REINTJES BV1945.en 2008-03
Prior to initial operation drain off VCI preservation oil, residual quantities may mix with the
operating oil.
After that fill in the quantity of operating oil indicated on the name plate and replace the plug screw
with the supplied venting filter (see also Operating Manual).
Fill up the system and lubricate the gear by shortly starting the engine or by the electrical oil pump.
Stop the pump or the engine.
Check the oil level again and top up oil up to the upper mark of the dip stick.
IMPORTANT: Foreign substances must not get into the interior! For this reason never clean the
gearbox with water or chemicals inside or outside.
Remove the preservative from the functional surfaces of the shaft ends with the help of plastic
scrapers, cloths, brushes and adequate solvents. Do not damage the functional surfaces.
If the ship is to be taken out of service for several weeks, anti-corrosion measures will become
necessary for the gearbox. If these measures are not taken, corrosion damages may occur on the
gearbox.
The type and extent of the measures to be carried out is dependent on the possibilities available.
Anti-corrosion measures will have to be taken not later than after a standstill of
4 weeks in the European climatic zone and 2 weeks in the tropical zone.
The following measures are adequate for protecting the gearbox against corrosion:
Page 4 / 5
REINTJES BV1945.en 2008-03
Important: If the gearbox is turned in the meantime, for types A and B the sealing of the housing at
the shaft sealings will have to be restored after turning.
Remark: When draining off the operating oil residual quantities may remain in the gearbox. The
effectiveness of the anti-corrosion measures taken subsequently will not suffer from this.
Conversely, residual quantities of the anti-corrosion oils may mix with the operating oil when the
gearbox is put into operation again.
Note: If a heat exchanger is installed, its water circuit should be drained and flushed according to
Operating Manual BV 1758. Then the heat exchanger should be filled with fresh water containing
an anti-corrosion additive. The sort of additive is dependent on the cooling system.
Page 5 / 5
Schmierstofftabelle / Lubrication Chart BV 1597/4
2010-06
Schiffsgetriebe ohne eingebauter Lamellenkupplung / Marine Gears without disc clutch
Energol DS-3 154 Castrol MLC 40* Delo 1000 Marine 40 Mobil DTE 19M
Energol DL-MP 40 Castrol MHP 154 Taro 16 XD 40 Mobilgear 600 XP 150
Vanellus C3-40 Castrol HLX 40 Taro 20 DP 40 Mobil Delvac 1640
Energol HPDX 40 Rivermax SX 40* Meropa 150* Mobilgard ADL 40
Energol GR-XP 150 Castrol Alpha SP 150 Pinnacle EP 150# Mobil SHC 629#
Hyspin AWH-M 150* Gear Compound EP 150* Mobilgear XMP 150*
Castrol MPX 40 Mobilgear SHC XMP 150*#
Mobilgard 412
Reintjes GmbH
D-31785 Hameln
Phone: +49 (0)5151 104 0
Fax: +49 (0)5151 104 300
www.reintjes-gears.de
Bitte beachten Sie auch die Hinweise auf der Rückseite / Please see remarks on the backside
Für die Ölauswahl in REINTJES- To be observed in selecting oil for
Getrieben ist zu beachten: use in REINTJES gears:
1. Eine Öltemperatur unter 1. If oil temperature is lower than
+ 10 °C / 50 °F (SAE 30) + 10 °C / 50 °F (SAE 30)
+ 15 °C / 59 °F (SAE 40)erfordert eine + 15 °C / 59 °F (SAE 40)a sump heating
Sumpfheizung im Getriebe installation is required
(Sonderausstattung). (special equipment must be fitted to the gearbox).
3. Hochalkalisch eingestellte Motorenöle (TBN > 20) 3. Highly alkaline engine oils (TBN > 20) must not
dürfen bei eingebauter Lamellenkupplung nicht be used.
verwendet werden.
2. Beim Ölwechsel sind die Ölfilter-Elemente 2. Filter elements must be replaced when changing
auszutauschen. Der Entlüftungsfilter ist sorgfältig zu oil. The air filter (venting filter) should be carefully
reinigen. Erste Verschmutzungskontrolle ca. 12 cleaned. First check for contamination should be
Stunden nach Inbetriebnahme. made approx. 12 hours after starting up.
3. Der Ölstand muss zwischen den Markierungen des 3. The oil level must be between the dipstick
Peilstabes liegen. Die auf dem Typenschild markings. The oil quantity indicated on the name
angegebene Ölmenge ist ein Anhaltswert. plate is a reference value.
4. Erforderliche Getriebespülungen möglichst mit dem 4. For flushing and cleaning of the gearbox the
Betriebsschmierstoff vornehmen. Das Spülöl ist operating lubricant should be used. Remove
weitgehend aus Getriebe, Filter und Wärmetauscher cleansing oil from gearbox, filter and heat
zu entfernen. exchanger as thoroughly as possible
5. Das Getriebe ist im Anlieferungszustand konserviert 5. The gearbox will be delivered in preserved state
(Konservierungsmittel ablassen). Reste des (corrosion preventive). Residual corrosion
Konservierungsmittels sind im Betriebsöl mischbar. preventive may be mixed with oil used in the
gearbox.
Achtung ! Attention!
• Die in der Schmierstofftabelle aufgeführten • The oil types listed in the lubrication chart
Ölsorten werden von den Ölgesellschaften are defined by the responsibility of the oil
verantwortlich festgelegt. Die Öle sind für den companies. The oils are suitable for the
Gebrauch in Getrieben geeignet und entsprechen use in gearboxes and are in accordance
der REINTJES Spezifikation. Für die Einhaltung with the REINTJES specification.
der der Empfehlung zu Grunde liegenden The oil companies are responsible to keep
Spezifikation des Produktes ist der the compositions of the oils are identical
Mineralölhersteller verantwortlich. as specified for this oil chart.
• REINTJES übernimmt keine Haftung für die • REINTJES is neither liable for correctness
Richtigkeit dieser Angaben sowie aller of these data nor for any amendments
eintretenden Änderungen. occurring.
• Bei Verwendung anderer Schmieröle ist vor dem • If other lubrication oil shall be used please
Einsatz Rücksprache mit REINTJES zu halten. contact REINTJES first.
• Für alle Schäden, die durch die Verwendung nicht • REINTJES does not accept responsibility
geeigneter Öle entstehen, übernimmt REINTJES for any damages due to use of unsuitable
keine Haftung. oils.
Änderungen vorbehalten Subjects to alterations
MARINE GEARBOXES
WARTUNGSHANDBUCH
SERVICE MANUAL
Inhalt
Contents
BV1755.de 2001-05 Allgemeine Hinweise / Schraubensicherung
BV1755.en 2001-05 General information / screw locking
76643.de-en_W.doc 1/2
REINTJES WARTUNGSHANDBUCH / SERVICE MANUAL
0-102-67836 Antriebswelle
Input shaft
0-102-66700 Abtriebswelle
Output shaft
0-102-61342 PTO-Welle
PTO-Shaft
V8 Druckbegrenzungsventil
V8 Pressure limiting valve
2/2
BV1755.en
MARINE GEARBOXES 2001-05
General Information
Seals
Some parts have been fitted with O-rings, e.g. the control valve.
Flat gaskets have been used for the inspection covers.
All other single parts are assembled with a liquid surface sealant (anaerobic sealant) having
almost no influence on the dimensions. These sealing areas must be cleaned and dried
before assembly. The sealing material must be applied on one part in the form of a
continuous band (2-3 mm - 0.1") along the centre line and inside past the drill holes.
Screws
All screws connecting parts with torque transmission, e.g.
input shaft - clutch housing or
output shaft - counter flange on propeller side,
must not be reused after disassembly. They are marked *8 in the spare parts lists.
BV1755.en_2001-05.doc 1/2
REINTJES BV1755.en 2001-05
Screw Locking
For assembly use screws withscrew-locking glue. The glue is applied either as a green
coating on the screws, or medium-strength screw glue must be used.
Prior to using the new screws the threaded holes have to be freed from glue remains by
using the corresponding tap.
Note:
Use always screw-locking, medium-strength metal glue for locking:
- shaft nuts, screws (without green coating), nuts mounted in the gearbox without securing
elements
- all external screws connecting the housing parts (near bearings)
- all screws which are transmitting force to other parts, e.g. bearing housing
- fixing screws for heat exchanger, filter, pump etc.
-
Pay attention to the following charts for tightening torques. Screws are only sufficiently
secured by using glue if they are tightened with the proper torque (assembly torque).
After dismantling and when re-assembling these screws, nuts and shaft nuts have to be free
from glue remains. The threaded holes have to be cleaned as well.
2/2
BV1778.en
MARINE GEARBOXES 2001-05
Glued Connection
Input Shaft - Clutch Housing
The contacting surfaces of the connection input shaft - clutch housing have to be assembled
using a liquid sealant (anaerobic glue).
First the contact surfaces are cleaned with a solvent. Then an activator is sprayed onto both
sides. After the activator evaporated the contact surface of the input shaft is coated with the
anaerobic glue.
Then the parts are assembled and screwed up.
BV1778.en_2001-05.doc 1/1
BV1174.en
MARINE GEARBOXES 2001-05
Attention
Operations involving pressurized oil involve no danger provided strict compliance with
operating instructions is observed and correctly-fitting accessories in perfect condition are
used.
Please observe the following instructions:
- Prior to service, carefully check the pump,H.P. pipe and all other accessories. Do
not,under any circumstances, use pump components which show even the slightest
signs of damage or damaged accessories which are not designed for pressures of at
east 300 MPa (3000 bar).
- Make sure that the pump and the high- pressure pipe are completely filled with oil and
that all air has been expelled from the pump.
- The pipe must not be bent or otherwise subjected to violent treatment when pressurized.
Mishandling of the pipe can lead to accidents.
- The pressures required for expansion and force-on must permanently be checked with
pressure gauges.
- Ensure that adequate safety precautions are taken when working with high- pressure
hydraulic systems.
- Oil under extreme pressure can cause injuries.
- Always wear protective goggles.
- Oil under pressure must not be allowed to come into contact with the skin.
Prior to assembly of the individual components (e.g. shaft and gear, shaft and flange) it is
necessary to carefully inspect the taper surfaces. Ensure that taper surface and oil
distribution groove transitions are free of burrs. Remove all burrs and rectify any other
damage found.
Instructions for Repair:
During repair operations, the nature and extent of the damage may require that shaft
concentricity, taper surface and bearing seating be checked.
BV1174.en_2001-05.doc 1/4
REINTJES BV1174.en 2001-05
Information for force-on dimension and expansion pressure will be given by REINTJES
service department on request.
The force-on dimension is stated in mm and comprised the nominal dimension and a
permissible tolerance, e.g. 13.3 + 1.2 mm.
To determine the force-on dimension push the component to be mounted (gear, flange, etc.)
onto the shaft.
The first checking dimension, required to establish the force-on dimension of the component
to be mounted, is calculated from that point at which the taper faces are in full contact with
each other without any pressure applied.
In order to be able to complete further force- on dimension checks it is now necessary to
select an additional reference point. A reference lip (shoulder) on the shaft is recommended
for this purpose.
Note the checking dimension thus obtained.
Position the assembly jig (hydraulic nut) handtight against the component to be mounted;
ensure that all threaded assembly jig elements are fully engaged with each other and that the
piston of the hydraulic nut is in its original position.
Connect hydraulic pumps as follows:
pump for expansion pressure to connection „B“
pump for force-on pressure to connection „A“
Pressure Connections
when starting the force-on process
2/4
REINTJES BV1174.en 2001-05
NOTE
In this case of components with two connecting points for expansion pressure one of
these must be effectively plugged.
Attention
Hydraulically assembled components are under extremely high pressure and can
cause injury when released. As the component to be removed can be suddenly
released at great force it is mandatory that this part be provided with a stop (hydraulic
nut) as a safety measure.
In order to remove the subject component (gear, flange, etc.) from the shaft, the installation /
removal jig (hydraulic nut) and hydraulic pumps must be assembled in the same positions
and manner as used for component assembly.
As a function of the max. force-on dimension, the annular piston must be forced out of the
hydraulic nut 3-4 mm (see sketch) and, with a force-on pressure of 100 bar applied at
connection "A", brought into contact with the component to be removed.
The force-on pressure in the hydraulic nut must then be released and the hydraulic pump
valve to the hydraulic nut connection "A" must be closed.
In order to be released, the component to be removed must first be expanded via
connection "B".
In order to achieve this, hydraulic oil is forced slowly between the component taper faces.
Expansion pressure increases should not exceed 100 bar over a period of 3 minutes.
Component release is indicated by a rise in pressure in the hydraulic nut which is indicated at
the pressure gauge of the hydraulic pump assigned to connection "A".
3/4
REINTJES BV1174.en 2001-05
When the pressure rises in the hydraulic nut, the oil pump valve to connection "A" must be
opened and the pressure released. The expansion pressure must, however, be mantained
by continuous operation of the hydraulic pump assigned to connection "B" until the
component is completely released from its tapered seat.
Attention
The component being removed may be released suddenly when the pressure at
connection "A" is released to zero, for this reason it is mandatory that the hydraulic
nut (safety stop) be correctly installed.
Pressure Connections
4/4
BV1758.en
MARINE GEARBOXES 2003-04
1 Introduction
In order to identify the heat exchanger please check the rating plate for the "BLOKSMA "
marking. The rating plate of the heat exchanger is located on one of the two cams of the oil
inlet and/or outlet.
We recommend having spare parts for maintenance work on board. Anodes and sealing
rings can be obtained from the REINTJES service department upon specifying the gearbox
number and type.
ATTENTION:
Checks of 2 Anodes and 3 Contamination Control shall be performed only with the
propulsion system shut down and the cooling water pump switched-off.
The gearbox and the heat exchanger shall have cooled down to lukewarm temperature.
2 Anodes
For protecting the water chamber and the tube bundle from corrosion the heat exchangers
are equipped with 3 anodes (A292): at water inlet, end cover and water outlet.
The anode consumption can differ. It is dependent on the installation and operating
conditions.
Based on the results of the first checks the precise intervals can be determined. Preventive
inspections have to be carried out regularly, as before.
The anodes have to be renewed when 60 % of their original volume have been consumed.
BV1758.en_2003-04.doc 1/5
REINTJES BV1758.en 2003-04
schematic drawing
1 Tube plate
2 O-rings
3 Fixing plate
4 Shell
5 Tube bundle
Important
Never mount the covers to the wrong side.
The tube bundle has only one correct mounting position in the shell.
Never mount the tube bundle laterally inverted or twisted.
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The contamination of the tube bundle depends on the installation and operating conditions.
Based on the results of the first inspections further intervals can be determined.
Note
Always loosen and tighten the bolts of the cooling water connection flanges and the covers of
the heat exchanger crosswise.
For this simple visual inspection the hydraulic oil in the heat exchanger need not be drained.
The tube bundle can be pulled out to either side. In this description the indication of sides A
and B analogously applies to the corresponding side of open end cover and end cover.
Heat exchanger Drain oil, dependent on installation conditions
Tube bundle Mark mounting position and check marking on open end cover side
Open end cover side Take partition from tube bundle
Fixing plates Screw off bolts and nuts, take off fixing plates
A • Push in tube plate flush with shell
(or drive it in slightly using a piece of wood)
• Attention: Do not damage edges by hammer blows!)
B • Take off both O-rings
• Push in tube plate flush with shell
(or drive it in slightly using a piece of wood)
A Take off both O-rings
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REINTJES BV1758.en 2003-04
B Push in tube bundle so far as to be able to seize the tube plate from
behind on side A
(A) Pull out tube bundle carefully
Note:
Lift and straighten tube bundle,
take care not to bend the baffles on the tube bundle
Note
Never use Vaseline or other, unsuitable types of grease.
If unsuitable grease is used, any warranty claims will be refused.
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REINTJES BV1758.en 2003-04
First screw on the side with the fixing plates (example with open end cover).
Open end cover • Clean sealing surfaces, check for damages
• Apply thin layer of suitable lubricant to sealing surfaces
• Fit cover without applying force
• Take out bolts, insert them from the other side,
screw on nuts (with spring washer) hand-tight
• Screw bolts tight crosswise
End cover As above (insert bolts from outside to inside)
Cooling water connections Fit, check for damaged sealings
After finishing the assembly fill and vent water circuit and hydraulic system and check for
tightness.
If the system has been out of operation for more than two weeks, the water circuit should
be drained and flushed. After that the heat exchanger should be filled with fresh water
containing an anti-corrosion additive.
NOTE:
- The type of additives depends on the cooling system.
In case of doubt please contact
BLOKSMA, Holland, Phone: +31 36 549 23 00, Fax: +31 36 549 23 90.
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BV1756.en
MARINE GEARBOXES 2008-02
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:
⇒ Please provide this additional information, listed in the spare parts lists,
when ordering spare parts:
BV1756.en_2008.02.doc 1/1
MARINE GEARBOXES PL 76643
Ersatzteilliste
Spare Parts List
Getriebe-Nr
Gearbox No. 76643
Getriebetyp
Gearbox Type VA 4851 V K41B
Untersetzung
4,500
Reduction
Drehsinn Antrieb
CLOCKWISE
Input Rotation
Drehsinn Abtrieb
ANTICLOCKWISE
Output Rotation
MotorHersteller
MAN
Engine Make
MotorTyp
7 L 32/40
Motor Type
Leistung
3500 kW
Engine Power
Motor Drehzahl
750 min-1
Engine Speed
Leistungsmoment Motor
4,667 kW/min-1
Power/Speed Ratio - Engine
zul. Leistungsmoment Getriebe
4,667 kW/min-1
allowable Power/Speed Ratio - Gearbox
MotorDrehmoment
44.563,4 Nm
Engine Torque
zul. Drehmoment Getriebe
44.566,6 Nm
Allowable Torque - Gearbox
Lieferdatum
03.Aug.2010
Delivery Date
Abnahme
GL/KUNDE
Marine Society
Einbauzeichnung
0-104-83450
Installation Drawing
Drehschwingungsschema
0-111-83464
Torsional Information
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0-211-83684
A103 A861880 DRUCKSCHALTER pressure switch 1
A105 A861880 DRUCKSCHALTER pressure switch 1
A113 A879096 DRUCKPRÜFVENTIL pressure test valve 1
A113 A980813 ANSCHLUSSPLATTE connection plate 1
A119 A186830 KABELEINFÜHRUNG cable entrance 9
A119 A572730 DICHTRING sealing ring 9
A120 A186856 KABELEINFÜHRUNG cable entrance 3
A120 A632643 DICHTRING sealing ring 3
A121 A112399 KUGELHAHN shut-off valve 1
A125 A861880 DRUCKSCHALTER pressure switch 1
A159 A74357 ROHRSCHELLE pipe clamp 2
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*10 besteht aus G1/G2 kann nur komplett bestellt werden consisting of G1/G2 can only be ordered completely
*11 besteht aus G1/G82/G2 kann nur komplett bestellt consisting of G1/G82/G2 can only be ordered completely
werden
*12 besteht aus G1/G82/G2/G433 kann nur komplett bestellt consisting of G1/G82/G2/G433 can only be ordered
werden completely
*13 besteht aus G1/G144/G34 kann nur komplett bestellt consisting of G1/G144/G34 can only be ordered
werden completely
*14 besteht aus G1/G2/G98 kann nur komplett bestellt consisting of G1/G2/G98 can only be ordered completely
werden
*15 besteht aus G020.00/G030.00/G040.00 kann nur consisting of G020.00/G030.00/G040.00 can only be
komplett bestellt werden ordered completely
*16 besteht aus G1/G2/G433 kann nur komplett bestellt consisting of G1/G2/G433 can only be ordered
werden completely
*17 besteht aus G020.00/G040.00 kann nur komplett bestellt consisting of G020.00/G040.00 can only be ordered
werden completely
*18 besteht aus G020.00/G030.00/G040.00/G050.00 kann consisting of G020.00/G030.00/ G040.00/ G050.00 can
nur komplett bestellt werden only be ordered completely
*19 besteht aus G1/G82/G2/G107 kann nur komplett bestellt consisting of G1/G82/G2/G107 can only be ordered
werden completely
*2 Beachte Montage- und Demontageanleitung für Pay attention to assembly and dismantling instructions
Kegelpreßverbände mit Kegel 1:30 (siehe Anhang). for taper press hubs 1:30 (stated in the appendix)
*20 besteht aus E927/E932 kann nur komplett bestellt consisting of E927/E932 can only be ordered completely
werden
*21 besteht aus E620/E627 kann nur komplett bestellt consisting of E620/E627 can only be ordered completely
werden
*5 Nur in Einzelteilen lieferbar. Muß am Getriebe angepaßt Supplied in single Parts only. Have to be matched and
und fertiggestellt werden. finished on the Gearbox.
*8 müssen nach Demontage erneuert werden have to be renewed on dismantling (special screws)
(Spezialschrauben)
*9 Gehäuse Pumpentrieb und Lagergehäuse Pumpentrieb Housing Pump Drive and Bearing Housing Pump Drive
können nur zusammen bestellt werden. can only be ordered together.
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MARINE GEARBOXES 2004-08
Additional order:
A 43 Contamination indicator 2
visual
alternatively
A 43 Contamination indicator 2
electrical