241 Reintjes, WVS 2240 (K76157-K76160), Reduction Gear, Installation Instuctions

Installation Instructions
WVS 2240
K76157 – K76160
E – BV2381 – Version 1.0 / 03.06.2014

No part of this document may be reproduced in any form
(by printing, photocopying or other means) or processed,
dublicated or circulated electronically without prior written
approval of REINTJES GmbH.
© 2014 REINTJES GmbH

All Rights Reserved.
WVS 2240
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 assembly personnel ................................................................................................... 7
1.4 Safety information for installation ............................................................................................................ 8
1.5 Protective measures against fire and danger of explosion ................................................................. 9
2 Introduction to this Documentation .............................................................................................. 11

2.1 Maintaining the documentation ............................................................................................................. 12
2.2 Preconditions of warranty ....................................................................................................................... 12
2.3 Brief product description ......................................................................................................................... 13
2.4 Area of application and manner of intended use ................................................................................ 14
2.5 Use of the gearbox within the European Union .................................................................................. 14
3 Technical Data ........................................................................................................................................ 15
4 Transport, Storage and Preservation ........................................................................................... 17

4.1 Transport ................................................................................................................................................... 17
4.2 Storage ...................................................................................................................................................... 20
4.3 Preservation ............................................................................................................................................. 21
5 Description ............................................................................................................................................... 27
5.1 Gearbox standard execution .................................................................................................................. 27
5.2 Gearbox with trolling propulsion system ADS ..................................................................................... 34
6 Installation and Alignment ................................................................................................................ 35

6.1 Requirements for installation personnel ............................................................................................... 35
6.2 Steps in preparation ................................................................................................................................ 35
6.3 Setting up the gearbox ............................................................................................................................ 36
6.4 Alignment .................................................................................................................................................. 37
6.5 Connection of gearbox components ..................................................................................................... 45
Index ............................................................................................................................................................ 47
Installation Instructions 3
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Table of contents
4 Installation Instructions
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Safety
1 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
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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 mounting instruction 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 (WVS 2240 HL)
Dangerous places on the gearbox (WVS 2240 DR)
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Safety
Symbol Meaning Symbol Meaning

General Warning Sign Smoking and open fires prohibited!
These warnings must be
observed!
Danger of being drawn or caught Wear tightly fitting protective

in by rotating components clothing e.g. coverall
Danger of electric shock! Wear ear protectors

Do not disconnect or service this
device until power supply has been
disconnected!
Caution, hot components Read instructions carefully!
1
1.3 Requirements for assembly personnel

Assembly 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 assembly. 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” on page 17 and “Installation and
Alignment” on page 35.
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!
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Safety
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 mounting.
 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!
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.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Safety
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.
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.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Safety
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 waste.
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.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Introduction to this Documentation
2 Introduction to this Documentation
This documentation comprises one set of installation instructions and operation

! manual for gearboxes belonging to the WVS 2240 model series.
This installation instructions contain information about:
• Safety
• Technical data
• Transport, storage and preservation
• Description of gearbox models
• Installation and alignment
The operation manual contains information about:
• Putting the unit into operation

• Operation
• Maintenance
• Trouble-shooting
• Spare and replacement parts
• Drawings for installation, tubing and supervision
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.
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.
Constant improvement and continued development may result in changes to your gearbox
that is not yet mentioned in these instructions.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
2.3 Brief product description

The gearboxes of the WVS model series are horizontally (WVS 2240 HL/HR) or diagonally
(WVS 2240 DL/DR) offset reverse-reduction gearboxes with two built-in hydraulic disc
clutches. The gear reduction ratios are the same in the Ahead and Astern directions.
Marine gearboxes can be supplied with identical and counter rotation of the input and output
shafts. The thrust bearings built into the gearbox absorb the propeller thrust.
The gearbox has been designed under the assumption that a highly flexible coupling will be
employed between the engine and the gearbox.
Control is effected by means of electrical valves.
2.3.1 Illustration
WVS 2240 HL
Operation delay pot
Heat exchanger Oil filter

Control valve
Dipstick
Oil pump Output shaft Input shaft
WVS 2240 DR
Operation delay pot Control valve Dipstick
Heat exchanger
Oil filter
Input shaft
Oil pump
Output shaft
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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.
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.
2.5 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.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Technical Data
3 Technical Data
Type: WVS 2240 P HL/HR

Application group: L
Gearbox work no.: K76157 – K76158
Drawing of installation: 0-104-81671, 0-104-81672
Year manufactured: 2010
K76157 HL K76158 HR
Weight (not filled with oil) 2900 2900 kg
Gear reduction ratio i 3.565 : 1 3.565 : 1
Rotation direction input side Counter-clockwise Counter-clockwise
Rotation direction output side Counter-clockwise Clockwise
Engine power 4320 4320 kW
Min. engaging speed 500 500 min-1
Max. engaging speed 810 810
min-1
Oil volume 150 150 Litres
Oil type SAE 40 SAE 40
ISO VG150 ISO VG150
Operating oil pressure 21 – 25 21 – 25 bar
305 – 362 305 – 362 psi
Min. permissible oil temperature 15/59 15/59 °C/°F
Max. permissible operating oil temperature 70/158 70/158 °C/°F
Min. permissible ambient temperature -10/14 -10/14 °C/°F
Max. permissible ambient temperature 60/140 60/140 °C/°F
Max. humidity 80 80 %
permissible inclination athwartships; static 15° 15°
permissible inclination athwartships; dynamic 22.5° 22.5°
permissible inclination fore-and-aft; static 6° 6°
permissible inclination fore-and-aft; dynamic 13° 13°
Heat exchanger Type: Bloksma
Max. cooling water inlet temperature 35/95 35/95 °C/°F
Minimum cooling water quantity minimum 15,000 15,000 l/h
(pressure loss on water side 0.11 bar)
Maximum cooling water quantity 20,000 20,000 l/h
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Technical Data
Type: WVS 2240 UP DL/DR

Application group: L
Gearbox work no.: K76159 – K76160

Drawing of installation: 0-104-81730, 0-104-81731
Year manufactured: 2010
K76159 DL K76160 DR
Weight (not filled with oil) 6650 6650 kg
Gear reduction ratio i 3.529 : 1 3.565 : 1
Rotation direction input side Clockwise Clockwise
Rotation direction output side Clockwise Counter-clockwise
Engine power 4320 4320 kW
Min. engaging speed 500 500 min-1
Max. engaging speed 810 810
min-1
Oil volume 260 260 Litres
Oil type SAE 40 SAE 40
ISO VG150 ISO VG150
Operating oil pressure 21 – 25 21 – 25 bar
305 – 362 305 – 362 psi
Min. permissible oil temperature 15/59 15/59 °C/°F
Max. permissible operating oil temperature 65/149 65/149 °C/°F
Min. permissible ambient temperature -10/14 -10/14 °C/°F
Max. permissible ambient temperature 60/140 60/140 °C/°F
Max. humidity 80 80 %
permissible inclination athwartships; static 15° 15°
permissible inclination athwartships; dynamic 22.5° 22.5°
permissible inclination fore-and-aft; static 6° 6°
permissible inclination fore-and-aft; dynamic 13° 13°
Heat exchanger Type: Bloksma
Max. cooling water inlet temperature 35/95 35/95 °C/°F
Minimum cooling water quantity minimum 21,000 21,000 l/h
Maximum cooling water quantity 24,000 24,000 l/h
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Transport, Storage and Preservation
4 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,
attachment eyes or eye bolts approved for the gearbox weight.
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 pur-
pose 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!
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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 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.
WVS 2240 HL
Eyebolt
Eyebolt
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
WVS 2240 DR
Eyebolt
Eyebolt
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
4.2 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. (refer to "Measures against corrosion during storage" on page 22.)
 In cases of doubt, please contact the REINTJES service department.
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
(refer to "Measures against corrosion during storage" on page 22.)
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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:
• Conditions of storage
• Duration of storage
• Packaging
• Individual customer wishes
4.3.2 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
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.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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.
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 1: 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.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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.
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 1 on page 22 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 2: 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 24 in this regard!
For unpacked gearboxes, apply the measures mentioned above even if the stipulated storage
duration has expired.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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 2 on page 23 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:
• The concentration of VCI agents

• The amount of moisture that has entered
• How well the gearbox is resealed afterwards
4.3.4 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 3:
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.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Variant B: Flush with anticorrosive oil
 Drain the operating oil.
 Fill with 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 2 on page 23.
 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.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Corrosion protection of the heat exchanger
Follow the safety instructions provided in this installation instruction.

! (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.
 Afterwards, fill the water side of the heat exchanger with freshwater mixed with an
anticorrosive additive.
4.3.5 Product specifications for corrosion protection and preservation oils

Example: Fuchs Renolin, full-power anti-corrosion oil for gearboxes
BRANOROL 32/10, VCI preservation oil, mineral-oil-based
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Description
5 Description
5.1 Gearbox standard execution
5.1.1 Gearbox type

The gearboxes of the WVS model series are horizontally (WVS 2240 HL/HR) or diagonally
(WVS 2240 DL/DR) offset reverse-reduction gearboxes with two built-in hydraulic disc
clutches.
The gearboxes of the WVS model series are reverse-reduction gearboxes with two clutches.
The gear reduction ratios are the same in the Ahead and Astern directions.
Marine gearboxes can be supplied with identical and counter rotation of the input and
output shafts. The thrust bearings built into the gearbox 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 electrical valves.
5.1.2 Standard Execution
The propulsion engine is normally resiliently mounted; the gearbox may be rigidly or
resiliently mounted onto the foundation.
The torsionally flexible coupling used must also be capable of accommodating the axial
misalignment between the engine and gearbox shafts at the specified operating
speeds.
Referenced to the gearbox, the flexibility of the resilient engine mounts must be such
as to allow engine-to-gearbox alignment accuracy which ensures that there is no possibility
of appreciable reactive forces at the bearings of the connected gearbox shafts when
operating temperatures prevail.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Description
5.1.3 U-Drive and Universal Shaft
If a universal joint shaft is planned between engine and gearbox, ensure that the max.
allowable joint angle is not exceeded and that axial compensation is possible.
The alignment must be carried out especially carefully in order to minimize the forces
caused by the universal joint shaft.
5.1.4 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 identical rotation WVS 2240 HL

Input shaft A - Clutch A (open) -
Clutch B (closed) - Intermediate shaft B -
Wheel C - Output shaft C.
Output shaft and input shaft rotate in the same

direction.
Path of drive with counter rotation WVS 2240 HR

Input shaft A - Clutch A (closed) - Pinion shaft A -
Wheel C - Output shaft C.
Intermediate shaft B rotates without load.
Output shaft and input shaft rotate in the

opposite direction.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Description
Path of drive in identical rotation WVS 2240 UP DL

Input shaft A - Clutch A (closed) - Pinion shaft A -
Wheel C - Intermediate shaft C - Wheel D -
Output shaft D.
Intermediate shaft B rotates without load.
Output shaft and input shaft rotate in the same

direction.
Path of drive with counter rotation WVS 2240 UP DR

Input shaft A - Clutch A (open) -
Clutch B (closed) - Pinioin shaft B - Wheel C -
Intermediate shaft C - Wheel D - Output shaft D.
Output shaft and input shaft rotate in the

opposite direction.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Description
5.1.5 Auxiliary units and additionally mounted parts
The hydraulic system
WVS 2240 HL
Operation delay pot
The hydraulic system Oil filter Control valve
consists of: Valve block
• Oil pump
• Oil filter
Dipstick
• Heat exchanger
• Valve block with
pressure limiting valve
• Control valve
• Pressure oil system
• Lubrication oil system
The operating oil pressure is
controlled by the pressure
limiting valve.
Heat exchanger
Oil pump
WVS 2240 DR
Operation delay pot
Control valve Heat exchanger
Valve block
Dipstick
Oil filter
Oil pump
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Description
Hydraulic diagram
Clutch ahead
Lubrication oil
Trailing pump
Clutch astern
Heat exchanger
Oil filter
Oil pump
Dipstick
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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 operation
manual, from page 55.
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 operation manual,
beginning from page 60.
Control valve, electrical
Axial slide valves, which are brought into the desired position
of engagement by axially shifting the control piston.
WVS gearbox - 4/3 directional valve with return spring.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Description
Valve block with pressure limiting function
Operating pressure is regulated by a spring-loaded

pressure limiting valve.
Standard operating pressure is approx. 21 - 25 bar.
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 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 (option) and oil level (option). 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.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Description
5.2 Gearbox with trolling propulsion system ADS
5.2.1 Gearbox execution

The gearbox is basically the same as the standard execution (refer to 5.1).
This section therefore deals only with the components differing from the basic gearbox.
The minimum output shaft speed with the clutch engaged is usually nengine (idle) x igearbox
The electrical trolling propulsion system (ADS) additionally allows use of a low speed range for
a limited period of time.
(Please refer to operation manual chapter "ADS - trolling propulsion mode" on page 28).
5.2.2 Aggregates and additionally mounted parts
The hydraulic system with ADS
The hydraulic system additionally includes:
• A pressure build-up valve

• A proportional valve
Pressure build-up valve (ADS)

The pressure build-up valve is a directly Pressure build-up valve
controlled pressure limiting valve that is
Proportional valve
actuated hydraulically. Pressure is limited
by means of a spring-loaded piston.
Pre-pressure and operating pressure during

trolling propulsion mode depend to a limited
extent on oil viscosity and on the flow volume
of the oil pump.
The proportional valve is mounted on the

pressure build-up valve.
The current of the control oil in the proportional

valve determines the amount of pressure and,
in turn, the amount of operating pressure in
the engaged clutch during trolling propulsion
mode.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Installation and Alignment
6 Installation and Alignment
6.1 Requirements for installation personnel
• Installation and alignment are the responsibility of the yard.

! • 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.
6.2 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,
attachment eyes or eye bolts approved for the gearbox weight.
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 17 and the information provided above!
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
6.3 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
• Alignment calculation
Make sure that you have read and understood the descriptions and information
concerning alignment contained in the mounting instruction.
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
You will find the valid drawing number for your gearbox on the order confirmation.
The drawing of installation may be obtained from REINTJES by providing the commission
number.
service@reintjes-gears.de
On weekdays: Phone +49 5151 104 0
 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 from page 21).
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
6.4 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.
 For close-coupled gearboxes please note that the alignment and foundation of the
engine directly affects the output side of the gearbox.
 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
 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:
• the output shaft of the gearbox with the propeller shaft connection
• the engine with the input shaft of the gearbox
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
6.4.1 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:
• the propeller shaft and the intermediate shaft are in their bearings
• the propeller is mounted
• the intermediate shaft flanges are connected (if present)
• the flange facing the gearbox is in the alignment position (if necessary)
Steps in connecting to the propeller shaft
Alignment
screws
Hole
for screws
Surface for
collision chocks Surface for
lateral
collision chocks
Gearbox foot including fastening options
 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.
 In the case of close-coupeled gearboxes, please note that the alignment and foundation
of the engine has a direct effect on the output side of the gearbox.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
 With approved methods Example: Measuring of the GAP and SAG values:
(gauges, laser), measure the
horizontal and vertical GAP gearbox output
and SAG values between flange
the gearbox flange and the propeller shaft SAG
counterflange on the
propeller side. 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.
 Fix the gearbox to the foundation, as described in paragraph 6.4.2.
 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.
6.4.2 Fixing the gearbox to the foundation
 Ensure that the gearbox is installed distortion-free.

 Observe the following requirements for seat chocks and screws.
 Insert the seat chocks between the gearbox bases and the top plate.
 Loosen the alignment screws before tightening the foundation screws.
 After aligning the gearbox with the propeller shaft, screw the gearbox to the
foundation so that it is secured against shifting.
When cast resin is used, back off the alignment screws only after the thermosetting
! of the cast resin is finished.
Observe the regulations of the classification society as well as REINTJES’ operating

instructions for installation and alignment. You may also request from our factory REINTJES
operating instructions for your gearbox and foundation type (steel seat chocks or cast resin)
by providing your commission number.
Any other foundation methods must be approved by REINTJES.

!
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Foundation with steel seat chocks
Various combinations may be used for fastening the gearbox:
• Seat chocks with fitting bolts and collision chocks

• Seat chocks with fitting bolts but without collision chocks (only for steel seat chocks)
• Seat chocks with through bolts and collision chocks
 Observe the following requirements for seat chocks and screws in the table below.
Requirements for components used to fasten the gearbox

Seat chocks: Steel or cast steel is the preferred material for metal seat chocks.
Gray cast iron may also be used.
The height of the seat chock should be within the range of 20 to 80 mm.
The minimum height is 40 mm when using gray cast iron. The area of
the seat chock taken up by recesses should be less than 20% of the
total surface area of the seat chock.
Only rectangular seat chocks may be used.
The seat chock must be manufactured from one piece. Shims or lining
plates may not be used.
Metal seat chocks must be fitted by touching them up on both sides.
A contact marking area of at least 75% must be achieved.
The seat chocks may not be tack-welded.
Seat chocks must be adequately sized, closely fitted and designed in
accordance with the regulations of the classification society.
Fitting bolts: The strength of the fitting bolts that are used must comply with at least
ISO 898 property class 8.8.
The holes for the fitting bolts are pre-drilled.
Through bolts: The strength of the through bolts that are used must comply with at
least ISO 898 property class 8.8.
Through bolts must be tightened to the torque specified for the
particular thread size.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Foundation with cast resin
The following combinations may be used for fastening the gearbox:
• Cast resin with fitting bolts and collision chocks

• Cast resin with through bolts and collision chocks
 When a cast resin foundation is provided, commission a company authorized to

pour cast resin foundations to do planning and calculation and perform the work.
This company must also submit the required drawings, calculations and material data
to the classification society for approval.
The cast resin manufacturer will specify the type of foundation screws to use as well
as the tightening torque.
Responsibility for designing the collision chocks lies with the shipyard.
6.4.3 Connection to the engine

(does not apply when the gearbox is close coupled to the engine by means of a bell housing)
Pre-conditions for connection to the engine:
• The gearbox is aligned with the propeller shaft.

• The gearbox has been provided with a foundation and fastened to it.
• The motor is aligned axially to the gearbox.
The space between gearbox and motor must correspond to the mounting length of the
flexible coupling. The axial reaction forces exerted by the flexible coupling on the engine
and gearbox should be kept to a minimum. Observe the specifications provided by the
engine and coupling manufacturers.
Steps for connection to the 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. 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 values for GAP and SAG.
 Consider the thermal expansion of the engine, gearbox and foundation at operating
temperature.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
 Consider any possible shifting of the engine, the gearbox or any possible effects
due to the foundation.
 Consider the maximum permissible reaction forces exerted by the flexible coupling on
the gearbox input shaft (refer to figure 2).
 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.
Fig. 1: Variables for determining the reaction forces of the flexible coupling
 Determine the radial reaction force of the coupling FR:

FR = Δr x Cr dyn
Δr - radial shaft misalignment;

Cr dyn - radial stiffness of the flexible coupling
 Determine the corresponding bending moment MB:

MB = 0.5 x Cax x D x X1 (refer to figure 1)
Cax - axial stiffness of the flexible coupling;

D - diameter of the connection between the flange and the flexible coupling
X1 - measured angular misalignment (GAP)
 Check to make sure that FR and MB do not exceed the permissible load as shown in fig. 2.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Fig. 2: Allowable external forces on input shaft
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
6.4.4 Alignment check
Alignment check of the engine

(does not apply when the gearbox is close coupled to the engine by
means of a bell housing)
 Check the gearbox foundation bolts for tightness.

 Disconnect the flexible coupling on the engine.
 Finally, check the GAPand SAG values and compare them with the data specified
by the coupling manufacturer. In case of deviations, please contact REINTJES.
Propeller-side alignment check
 Check the gearbox foundation bolts for tightness.

 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.
DANGER!
Rotating Parts!
 After alignment mount covers to all rotating parts to prevent being
caught or drawn in.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
6.5 Connection of gearbox components
Connection of valve control and supervision

 Lay the cables for the control and supervision system to the gearbox terminal 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. (refer to operation manual page 15)
Connection of the heat exchanger
Please note that the input cross-section of the heat exchanger on the water side
! may not be varied!
 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
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.
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Index
Index
A Opening the gearbox 24
Alignment 37 Preservation oil
Alignment check 44 Volume to be filled 23
Preservation oils 26
B
Brief product description 13 R
Requirements for assembly personnel 7
C
Check of the propeller shaft 38, 41 S
Connection of the heat exchanger 45 Safety 5
Corrosion protection 22 Set-up 35, 36, 45
Interruptions in operation 24 Standard execution 28
Protective measures 24 Storage 20
Corrosion protection oils 26
T
D Technical data 15
Description 27 Transport and storage 17
Types of documentation 11
F
Foundation 39 U
Foundation with cast resin 40, 41 U-drive and universal shaft 28
Foundation with steel seat chocks 40
V
G Valves
Gearbox execution 34 Pressure limiting 33, 34
Gearbox type 13, 27 VCI preservation oil 21
Volatile corrosion inhibitors 21
H
Heat exchanger 32
Hydraulic system 30, 34
I
Illustration of the gearbox 13
Initial preservation 21
Installation and assembly 35
Introduction 11
L
Long interruptions in operation 24
O
Oil filter 32
Oil pump 32
Operation delay system 33
P
Packaging inspection intervals 22
Path of drive 29
Preservation 21
E – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Index
E – BV2381 – Version 1.0 / 03.06.2014
Operation Manual
WVS 2240
K76157 – K76160
B – BV2381 – Version 1.0 / 03.06.2014


WVS 2240
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 installation ............................................................................................................ 8
1.5 Protective measures against fire and danger of explosion ................................................................. 9
2 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
3 Operation .................................................................................................................................................. 23
3.1 Engaging procedures for standard gearboxes .................................................................................... 23
3.2 Special operating modes ........................................................................................................................ 26
3.3 Behaviour in emergency operation ....................................................................................................... 30
3.4 Setting the pressure limiting valve ........................................................................................................ 33
4 Maintenance ............................................................................................................................................. 35
4.1 Maintenance plan .................................................................................................................................... 37
4.2 Maintenance job cards ............................................................................................................................ 40
4.3 Additional work for gearboxes equipped for trolling propulsion mode ............................................ 59
4.4 Check of tube bundle contamination in the heat exchanger ............................................................. 60
4.5 Replacement of the mechanical gearbox oil pump ............................................................................ 65
4.6 Conversion factors and screw tightening torque values .................................................................... 69
4.7 Screw Locking .......................................................................................................................................... 70
4.8 Maintenance performed .......................................................................................................................... 71
5 Trouble-shooting ................................................................................................................................... 73
6 Spare and replacement parts ........................................................................................................... 77

6.1 Gearbox oil pump A001.00, Type KF2/.., KF3/.., KF4/.. .................................................................... 79
6.2 Heat exchanger A002.00, Type P ... .................................................................................................... 81
6.3 Duplex filter A003.00, Type PI 210 ....................................................................................................... 83
Operation Manual 3
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Table of Contents
6.4 Operation Delay Pot H426.00/H427.00/ Connection Plate V004.00 ...............................................85

6.5 Control valve V1 (4/3-way-valve), electrical ........................................................................................87
6.6 Control block V006.00, type HB4 C 0320 A DKF4O30 ......................................................................89
6.7 Pressure build-up valve V316.00, for ADS ..........................................................................................91
6.8 Proportional valve V304 for ADS (trolling operation) .........................................................................93
Index ............................................................................................................................................................95
4 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Safety
1 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
Operation Manual 5
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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 (WVS 2240 HL)
Dangerous places on the gearbox (WVS 2240 DR)
6 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Safety
Symbol Meaning Symbol Meaning

General Warning Sign Smoking and open fires prohibited!
These warnings must be
observed!
Danger of being drawn or caught Wear tightly fitting protective

in by rotating components clothing e.g. coverall
Danger of electric shock! Wear ear protectors

Do not disconnect or service this
device until power supply has been
disconnected!
Caution, hot components Read instructions carefully!
1
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 35.
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!
Operation Manual 7
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Safety
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!
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!
the remote starter.
8 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Safety
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.
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.
Operation Manual 9
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Safety
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 waste.
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 next to the gearbox

 Ensure that no used parts, dirt or foreign substances are in or near the gearbox.
10 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Putting the unit into operation
2 Putting the unit into operation
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).
Operation Manual 11
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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
• Operation manual (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 21).
!
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
12 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
 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.
This screw is labelled with .
 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.
Dipstick with two markings:

screw plug
 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 MAX
(measurable approx. 10 min. after shut down of
the system). MIN
 Screw on the venting filter as far as it will go.

Dipstick
 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.
Operation Manual 13
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
2.3.1 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 0,26 US gallons
litres 0,22 Imperial gallons
US gallons 3,79 litres
Imperial gallons 4,54 litres
US gallons 0,833 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.
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 to the other filter side.
This pressure loss can lead that the diesel engine is shut down by the pressure
switch "oil pressure too low, engine 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 for
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 manually filled with oil during the filter change.
14 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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.
Operation Manual 15
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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 °C (note)
2.5.1 Engine foundation
Type of foundation (indicate applicable items):

Seat chocks and fitting bolts
Cast resin
Flexible Type
Manufacturer
Model
2.5.2 Gearbox foundation
Type of foundation (indicate applicable items):

Cast resin
Foundation bolts, note Quantity: Dimensions:

Steel with
seat chocks and fitting bolts
Fitting bolts, note Quantity: Dimensions:
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), Take the sample using a clean sampling
label completed and attached glass, label it and send it to REINTJES.
16 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
2.5.4 Cooling system
Cooling system (indicate applicable items):

Seawater cooling Inlet temperature
of cooling water
Freshwater cooling (target)
______°C
2.5.5 Torsionally flexible coupling
Flexible coupling on engine side: Type

Manufacturer
Model
2.5.6 Gearbox alignment

Alignment protocol included as annex?
For engine - gearbox
For gearbox - propeller shaft
Alignment screws loosened?
2.5.7 Oil cooler

Plastic plug on cooling water inlet flange
removed?
Compensators for cooling water pipes
installed?
Operation Manual 17
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
2.5.8 Sight check

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(es)
No other defects?
2.5.9 Preservation

Was preservation performed during
storage?
Log recording preservation measures
completed regularly?
Protective layer completely removed
Paint layer undamaged?
Screw plug replaced with venting filter?
Internal inspection:
Sight check (through inspection
opening) performed?
Preservation oil completely drained?
18 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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

Gearbox terminal box correctly earthed?
Check to ensure that the sensors for the following are connected:
(if present)
Warning - oil pressure too low
Emergency stop main engine
Oil pressure present,
Gearbox clutch engaged
“Oil filter contaminated” switch
Start stand-by pump
Operation Manual 19
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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 Out __________°C
Both sides of oilfilter filled with oil? (see “Filling the oil filter” page 14.)

Clutch control valves can be actuated
mechanically?
Control valve 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)
20 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
2.8 Notes on the checklists for putting the unit into operation
Check Comments / Notes / Values Name/Initials

chapter
Operation Manual 21
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
22 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Operation
3 Operation
3.1 Engaging procedures for standard gearboxes
!
During normal operation and at idling speed, you must adhere to these values:
• 40-60 °C oil temperature as 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 17 bar.
 Set the engine to the required operating speed.
Operation Manual 23
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Operation
Reversing at slow speeds
The ship is travelling at up to 50 % of its nominal speed.
 Reduce the engine speed to engaging speed.
 Shift the gearbox to the NEUTRAL position.
 Wait approx. 1 second.
 Engage the gearbox for the other direction of travel.
Reversing at higher speeds
The ship is travelling within the range of 50-100% of its nominal speed.
 Reduce the engine speed to engaging speed.
 Wait until the speed of the ship has dropped to 50 %.
 Shift the gearbox to the NEUTRAL position.
 Wait approx. 1 second.
 Engage the gearbox for the other direction of travel.
24 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Operation
Stop manoeuvre with repeated engaging
The clutch has been designed and optimised to allow it to be engaged from AHEAD to
ASTERN several times during a stop manoeuvre. Experience reveals that this may become
necessary for stop manoeuvres from high speeds in order to prevent any damage to the diesel
engine.
During a stop manoeuvre the ship's control automatically interrupts engaging procedures in
order to prevent excessive strain on the engine.
 For this case, you should provide, in the ship's control, for a period of delay for engaging the
clutch and reversing the direction. (Not supplied with the gearbox)
 Please contact REINTJES for more detailed information.
Crash-stop
The object is to stop the ship from a high speed within the shortest possible distance.
!
NOTICE!
During a crash stop manoeuvre the propulsion system is subject to heavier wear and
greater strain due to heat build-up.
Perform a crash-stop manoeuvre in emergency cases only!
 Proceed as described under „Reversing at higher speeds”.
Operation Manual 25
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Operation
3.2 Special operating modes
3.2.1 Trailing operation, engine at STOP with propeller free to turn
!
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 trailing mode
Occasional trailing mode, i.e. in case of a one-engine system, means:
• Due to damage, the ship can no longer be propelled on its own power
• The propulsion system is shut down
• The ship is tugged with external aid
• The propeller shaft turns freely with the water flowing against it
With a standard gearbox, 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.
26 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Operation
Regular trailing mode
Regular trailing mode, i.e. in 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
Regular trailing mode without limitation is only possible:
• With the addition of a trailing pump
An additional pump mounted on the gearbox takes over the

function of supplying lubrication to the gearbox during trailing
mode. This pump is driven directly by the propeller shaft.
• With an electrical stand-by pump
Switch on the electrical stand-by pump for the entire duration of trailing mode.
Operation Manual 27
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Operation
3.2.2 ADS - trolling propulsion mode
The execution of the trolling propulsion control (ADS) is adapted to the parameters of
your propulsion system. In the following it is therefore only possible to provide general
information and descriptions of trolling propulsion mode.
!
Unsupervised operation of the trolling propulsion device is prohibited!
If a cable breaks or the electronic control unit breaks down, the gearbox automatically
switches to normal operating mode, i.e. the prevailing torque and corresponding
engine speed are transmitted.
!
NOTICE!
Risk of excessive strain to the clutch!
Trolling propulsion mode is not permissible in these cases:
• Travelling through ice

• Towing operation
Trolling propulsion mode with multi-engine systems
• With multi-engine systems, do not switch to trolling propulsion mode as long as one
or more gearboxes are running in normal operating mode.
• Do not switch any gearbox of a multi-engine system to normal mode as long as one
or more gearboxes are being run in trolling propulsion mode.
• No combination of operating modes is permissible, e.g. one gearbox in trolling propulsion

mode and one gearbox in normal mode.
28 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Operation
3.2.3 Switching trolling propulsion mode ON and OFF
!
Switch trolling propulsion mode on only when the engine speed is within the
permissible range.
!
NOTICE!
Risk of irreparable clutch damage!
Under no circumstances should you run the system in trolling propulsion mode with
a soiled filter element by using “Bypass” to circumvent filtering.
 Switch over filters immediately when the “contaminated filter” warning appears.
 Replace the soiled filter element immediately.
!
Note in particular the following:
For trolling propulsion mode, use only oil types listed in our lubricant table BV2060/1
(oil types for trolling propulsion mode).
You must adhere to the oil change intervals specified in the maintenance plan.
The specified oil change intervals apply when trolling propulsion mode makes up
a maximum of 10 % of operating time. If this 10 % amounts to more than 200 hours,
a limit of 200 hours applies. You must consult the factory if the proportion of trolling
propulsion mode is higher.
In contrast to the information in the operating instructions, if the engine has been
operated in trolling propulsion mode, oil change intervals may not be extended
following an oil analysis.
Gearboxes with an electrical trolling propulsion device are equipped with a

20 µ / 25 µ filter. Ensure that you have replacement filter elements on board.
These fine filter elements cannot be cleaned.
Operation Manual 29
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Operation
3.3 Behaviour in emergency operation
3.3.1 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 150 °C during
permanent operation!
Danger of burnings!
 Wear protective gloves during manual emergency operation!
Emergency operation of the 4/3-way control valve for type WVS
In cases of failure of the electrical clutch control WVS
 Note the signs on the valve indicating direction of travel.

 Push end cap (handle) inwards and turn radial for fixation.
30 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Operation
3.3.2 Emergency operation in case of failure of the pressure oil supply
In cases of failure of the pressure oil supply, emergency operation may be continued by
mechanically immobilising one of the clutches.
WARNING!
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.
 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.
You can no longer reverse on the gearbox the direction in which the propeller rotates.
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 imput torque when employing the K8 emergency screws.
After operation in emergency mode (failure of the pressure oil supply) you must
have the gearbox parts checked thoroughly for any damage.
Operation Manual 31
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Operation
Tightening the emergency screws
 Determine which clutch must be immobi-

WVS 2240 HL
lised for travelling AHEAD.
 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!) Note! Tighten the emergency
screws on only one clutch.
 Loosen the counter-nuts of all emergency

screws. WVS 2240 DR
 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).
 For safety reasons, do not engage the control valves

any more afterwards!
 Close the inspection opening.
 Start the engine.
The ship can then head to the nearest harbour for K107.02
repairs.
32 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Operation
3.4 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 B set-screw 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 35) before adjusting the setting!
To set the pressure limiting valve, proceed as follows:

 Loosen counter nut A using Allen wrench.
 Carefully turn set-screw B using Allen wrench -

- turning clockwise means an increase in
pressure,
- turning counter-clockwise means a
decrease in pressure.
 During adjustment, observe the manometer

mounted on the gearbox.
With the engine speed at full power and the

clutch engaged and gearbox in operating tem- A B
perature, the pressure must be within the
manometer markings.
 Tighten counter nut A using Allen wrench.
Operation Manual 33
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Operation
34 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
4 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 manufacturer‘s 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.
Operation Manual 35
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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.
36 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
4.1 Maintenance plan

The maintenance schedule summarizes the maintenance services which are sub-divided into
maintenance stages. Particular arduous service conditions may require modification of the
maintenance schedule (reduced intervals).
On the gearbox name plate the application group letter is stamped in.
According to the application group the maintenance interval (operating hours) must be
taken into consideration for the maintenance tasks. The operating hours specified have
been determined in accordance with our experience. They can, therefore, only be considered
as guideline values.
Maintenance level Control- and working step description Maintenance intervals acc. to
application group
P L M
Maintenance level 1 Daily: X X X
 With the engine at a standstill, check the
oil level (upper dipstick marking =
operating 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: X X X

 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 hours of operation: 100 200 200
 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 connnections 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.
Operation Manual 37
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
Maintenance level 4 After every hours of operation or after 500 1000 1000
months: 6 6 6
 Change the operating oil after this interval.
 Replace the filter elements.
Maintenance level 5 After every hours of operation or 500 2500 4000

after year(s): 1 2 2
 Check the seat of all bolts
including those on the foundation, engine
and propeller connnections and on the bell
housing.
 Check the pipe fittings.
If there is any leakage, tighten the fittings.
Replace any leaky gaskets.
38 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
Basic overhaul The following tasks must be performed by

skilled REINTJES staff after:
hours of operation or after years.
3000 9000 20000
The following checks are performed: 10 10 10
• 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
• Manometer for functioning
worn or damaged parts must be replaced.
The following need to be replaced:
- Clutch discs
- Square section rings, screws and return
springs of the annular piston
- O-rings
- Circlips
- All clutch housing screws
- Roller bearings
- 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)
Operation Manual 39
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
4.2 Maintenance job cards
Maintenance job card
Gearbox types: WVS 2240
Maintenance Maintenance level 1 To be performed if Duration of job

job no.: 001 Daily possible at the same in minutes: 5
time as maintenance
job no.: 002-005
Description of the
maintenance job: Check operating oil level (Dipstick with two 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: Page: 1 of 2
40 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
Maintenance Maintenance level: 1 To be performed if Duration of job

job no.: 001 Daily possible at the same in minutes: 5
time as maintenance
job no.: 002 - 005
Description of the maintenance job:
 Check the operating oil level using the dipstick only when the pro-
pulsion system is at a standstill.
The operating oil level must be between the “Min” and “Max” mark-
ings shown on the dipstick (measurable approx. 10 min. after shut-
MAX
down of the system).
MIN
Dipstick
 If the operating oil level is too low:
 Unscrew 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.
 Screw on 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.
 If you notice any oil loss, determine the cause.
Seal any leaks immediately so as to avoid damage to the gearbox.
Venting filter
Operation Manual 41
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance

job no.: 002 Daily, with engine running possible at the same in minutes: 5
time as maintenance
job no.: 001 - 005
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 the next page
42 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance

time as maintenance
job no.: 001 - 005
 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 approx. 21 - 25 bar.
If the value is outside of this range refer to “Trouble-shooting” on page 71.
Operation Manual 43
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance

time as maintenance
job no.: 001 - 005
Description of the
maintenance job: Check the oil temperature (with the gearbox warm from operation)
Safety measures Observe all current, generally applicable job safety regulations.
Required tools None
Required parts None
Test equipment None
44 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance

time as maintenance
job no.: 001 - 005
 Read off the oil temperature from the thermometer.

The operating temperature is between 40 and 60 °C
when measured after the oil cooler.
The maximum operating oil temperature is 70 °C.

(Temperature alarm at > 70 °C)
If the temperature exceeds this value refer to “Trouble-shooting” on page 71.
Thermometer
Operation Manual 45
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance

time as maintenance
job no.: 001 - 005
Description of the
maintenance job: Check the contamination indicator for the oil filter
Required tools None
Required parts None
Test equipment None
46 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance

time as maintenance
job no.: 001 - 005

 A contaminated filter element causes the electrical
contamination indicator (pressure sensor detecting
differential pressure) to continuously show
contamination.
 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 posi- Active filter side
tioned, 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. Pressure sensor detecting
differential pressure
Operation Manual 47
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance

time as maintenance
job no.: 001 - 004
Description of the
maintenance job: Sight check and running noise check
Required tools None
Required parts None
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.
48 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
Maintenance Maintenance level: 3+4 To be performed if Duration of job

job no.: 006 /009 possible at the same in minutes: 40
time as maintenance
job no.: 010
Description of the
maintenance job: Change the operating oil
Safety measures Safeguard the engine against starting. (Note the safety information on page 35
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
Operation Manual 49
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
Maintenance Maintenance level: 3+4 To be performed if Duration of job

job no.: 006 / 009 possible at the same in minutes: 40
time as maintenance
job no.: 010
These intervals apply to operating temperatures of up to 70°C as measured after the oil cooler.
Higher operating temperatures require shorter exchange intervals.
Please consult with REINTJES service in this case.
After the first 200 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 venting filter from the upper surface of the gearbox in order to pour in operating oil.
The venting filter is labelled with .

 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.
 Screw on 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, 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 or electrical stand-by pump once again.
 After 10 minutes, check the oil level once again using the dipstick.
Add oil and fill to the upper dipstick marking.
 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.
50 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance

job no.: 008 possible at the same in minutes: 20
time as maintenance
job no.: ---
Description of the
maintenance job: Check the oil cooler anodes
Safety measures DANGER! Hot water!

Danger of scalding
Shut down propulsion system and secure it for restarting!
Switch off cooling water pump!
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
Operation Manual 51
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance

time as maintenance
job no.: ---

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.
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 aluminium sealing ring. Anode with copper 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 one thereafter. A002.56
We recommend performing a monthly check during the first six months.
14
 Based on the amount of wear to the anodes, determine future inspection

and exchange intervals.
Repeat this job at least every six months or every time the heat exchanger 83 mm
is cleaned.
52 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance

time as maintenance
job no.: 006/009
Description of the
maintenance job: Filter element exchange
Safety measures Caution! The filter is under pressure!

Bleed the contaminated filter side before exchanging the filter!
Observe all current, generally applicable job safety regulations

Allen wrenches
Required parts Filter element with o-ring A003.50

Gasket set A003.51
Other materials Flat oil pan
Test equipment None
Operation Manual 53
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance

time as maintenance
job no.: 006/009
1 Aeration screw
2 Changeover lever
3 Filter element
1
4 Filter bowl
5 Pressure equalizing lever
6 O-Ring Filter element 5
2 6
7 O-Ring Filter bowl
Description of the maintenance job: 3
7
 Changed over to the other filter element, when contaminationsignal has
been established.
 Operate and hold pressure equalizing lever (5) located in the changeover
lever (2). At the same time swivel changeover lever and engage the catch 4
on the other side.
Now the lever is positioned at the same side as the element to be replaced.
 Place trough or drip pan underneath to collect leaking oil.
 Loosen vent screw (1) maximum back out against safety stop (filter support).
 Unscrew filter bowl (4) anticlockwise and empty it into an appropriate
used oil container.
 Clean the filterbowl (4) inside and outside.
 Pull down filter element (3) by slight movements to and fro, replace element.
 Before assembling the element check O-rings (6+7) for damage. Replace,
if necessary.
 Push a new element (3) onto the seat.
 Firmly screw in the bowl (4) with O-ring (7).
 Care must be taken to ensure that the filter bowl (4), after it has been
tightened up, is slackened off by 1/8 turn.
 Operate only the pressure equalizing lever (5) long enough until the oil emerge
bubble-free from the vent bore.
 Tighten vent screw (1).
 Check filter for leaks by operating the pressure equalizing lever once again (5).
54 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance

job no.: 011 possible at the same in minutes: 360 = 6h
time as maintenance
job no.: ---
Description of the
maintenance job: Screwed joints
Safety measures Observe all current, generally applicable job safety regulations
WARNING!
Prior working on the gearbox, stop the propulsion plant and
prevent the engine from being switched on!
Danger of injuries caused by hot oil and water!

Allen wrench, torque wrench
Required parts None
Test equipment Torque wrench
Operation Manual 55
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance

job no.: 011 possible at the same in minutes: 360 = 6h
time as maintenance
job no.: ---
 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.
56 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
4.3 Additional work for gearboxes equipped for trolling propulsion mode
Additional maintenance for gearboxes equipped for trolling propulsion mode

Oil change
 Make sure to adhere precisely to the intervals for changing operating oil specified in the
maintenance plan for trolling propulsion mode.
The specified oil change intervals apply when trolling propulsion mode makes up a
maximum of 10 % of operating time.
If this 10 % amounts to more than 200 hours, a limit of 200 hours applies.
If you operate the unit in trolling propulsion mode more of the time, consult with
REINTJES to determine the necessary measures.
It is not permissible to extend oil change intervals even if an oil analysis reveals
positive results.
 Immediately replace any contaminated filter elements.
Gearboxes with electrical trolling propulsion devices are equipped with a finer filter.
Ensure that you have replacement fine filter elements on board.
These fine filter elements cannot be cleaned.
 If you notice an increase in engagement time,
check the sinter filter element in the pressure
Sinter filter
build-up valve.
Exchange the sinter filter once it has become
clogged.
!
Our customer service will be glad to assist on any other questions:
Email service@reintjes-gears.de Tel. +49 5151 104-0
Operation Manual 57
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
4.4 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!
4.4.1 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 3 4 5
• 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.
Either of the covers may be rotated by 180 degrees when mounted (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.
58 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
4.4.2 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 posi-
tion of reverse cover B with 2/2.
 Loosen the bolts of the covers
in opposite pairs and remove
the bolts.
Intake cover A Reverse cover B

 Remove covers A and B.
A nylon separator is inserted at the centre
of intake cover A.
Take care not to damage this separator.
 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.
Separator Fixing plates
Clean the tube bundle using a nylon tube brush.
Wipe off the covers with a lint-free cloth.
Tube cleaning brush
Operation Manual 59
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
4.4.3 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
!
If you wish to clean the tube bundle using chemical agents, request from REINTJES
detailed information on cleaners and procedures.
60 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
4.4.4 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
Operation Manual 61
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
 Take out the bolts and insert them from the other side.
 Tighten the nuts with spring washers as much as possible by hand.
 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.
4.4.5 Corrosion protection of the heat exchanger
!
Follow the safety instructions provided in this operation 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.
 Afterwards, fill the water side of the heat exchanger with freshwater mixed
with an anticorrosive additive.
Freshwater circulating system:
 Drain the freshwater circulating system of the heat exchanger.

 Afterwards, fill the water side of the heat exchanger with freshwater
mixed with an anticorrosive additive.
 Observe the areas of application recommended by the additive manufacturer
62 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
4.5 Replacement of the mechanical gearbox oil pump
4.5.1 Oil pump mounted directly on the drive shaft

Steps in dismantling and reassembling the oil pump
Overview of positions for the following steps

(drawing may vary from the mounted parts - subject to technical changes)
Dismantling the pipes

 Loosen the fittings of the suction and pressure
pipes using open-ended spanners.
 Using open-ended spanners, also loosen the

fittings fastening the control pipe to the pump
and filter.
 Remove the pipes and store them for reassembly
later on.
 Loosen the 4 fastening bolts and remove them.
Operation Manual 63
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
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.
 Place the defective pump on a working surface.

 Loosen and remove the fittings on the control, suction
and pressure sides. These are needed for the new
pump.
64 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
 Take the new pump out of the package.

 Remove the plastic plugs from the connectors.
Prior to mounting the pump, make sure that the

connectors are mounted properly. Note the rotating
direction!
 Screw the fittings into the connector threads on the
new pump applying liquid sealant.
 Apply liquid surface sealant to the pump flange as

shown.
 Make sure that the contact surface of the flange and

the holes are clean.
 Lightly lubricate the pump shaft and the drive shaft
hole.
Operation Manual 65
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
 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.
 Mount the suction, pressure and control pipes on the

pump using open-ended spanners.
66 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
4.6 Conversion factors and screw tightening torque values
Approximate values for conversion Be careful never to mix metric screws and nuts with imperial
factors screws and bolts. The use of improper or improperly fitting
screws and nuts results in damage or faulty operation of the
Multiply by equals
gearbox or even personal injury.
mm 0.03937 inch Any replacement screws and nuts required must be of the
inch 25.4 mm same size and of the same property class as the originals.
kg 2.2 lb The head of the screw usually has a label identifying the
lb 0.454 kg property class. This is identified with the digits 8.8, 10.9 etc.
kPa 0.145 psi
The following tables list tightening torque values for screws
psi 6.89 kPa
and nuts of the property classes 8.8 and 10.9.
psi 0.0689 bar
bar 14.5 psi
Nm 0.74 lb ft
lb ft 1.36 Nm
Nm 8.9 lb in
lb in 0.113 Nm
litres 0.26 US
US gallons 3.79 litres
US gallons 0.833 Imperial
Temperature conversion °C = (°F - 32) : 1,8 °F = (°C x 1,8) + 32
Metric ISO thread 1) Metric ISO thread 1)

Thread Tightening torque for Thread Tightening torque for
size property class 8.8 size property class 10.9
Metric Nm lb ft Metric Nm lb ft
M5 5+1 4+1 M5 7+1 5+1
M6 9+1 7+1 M6 13+1 10+1
M8 21+2 16+2 M8 30+3 22+2
M10 41+4 30+3 M10 60+6 44+4
M12 71+7 52+5 M12 104+10 77+8
M14 113+12 84+8 M14 165+16 122+12
M16 170+20 126+13 M16 250+25 185+19
M18 245+25 181+18 M18 350+35 259+26
M20 350+35 259+26 M20 490+50 363+36
M22 470+47 348+35 M22 670+67 496+50
M24 600+60 444+44 M24 850+85 630+63
M27 880+90 650+65 M27 1250+125 925+93
M30 1190+120 880+90 M30 1700+170 1260+126
M36 2100+210 1550+155 M36 3000+300 2210+221
M39 2700+270 1990+199 M39 3800+380 2800+280
M42 3300+330 2442+244 M42 4700+470 3478+348
M45 4100+410 3034+303 M45 5800+580 4292+429
M48 5000+500 3700+370 M48 7000+700 5180+518
1)
International Organisation for standardisation
Operation Manual 67
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
4.7 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 following 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 67.)
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.
68 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
4.8 Maintenance performed

Gearbox type: __________________
Gearbox no. ___________________
Hours of operation Maintenance level/job Date Initials
Operation Manual 69
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Maintenance
70 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Trouble-shooting
5 Trouble-shooting
Fault Cause Repair

Oil temperature too Cooling water flow rate too low  Increase the water flow rate using the
high 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  Check the items listed under “Operating
too low pressure too low, variable”.
Oil level too high  Check the oil level with the dipstick. If the oil level
is too high, drain oil until the oil level is between
the “MIN” and “MAX” marking of the dipstick.
Oil temperature too Water flow rate through heat  Decrease the water flow rate using the water
low exchanger too high valve.
Operating pressure Gearbox oil pump intakes air  Check the items listed under “Gearbox oil pump
too low, variable intakes air”.
Pressure limiting valve blocked  Replace the pressure build-up valve.
Check valve of electrical stand-by  Check whether oil flowing back through the
pump is defective 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 the
lubrication chart.
 Use only oil types listed in this chart.
 Change the operating oil if the gearbox was filled
with an inappropriate oil type (see ”Change the
operating oil” on page 49.)
Operating pressure Filter bell of the oil filter not complete  Filling filter housing completely with oil.
falls strongly after filled with oil (see ”Filling the oil filter” on page 14.)
switching over the
filter element
Operation Manual 71
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Trouble-shooting
Fault Cause Repair

Operating pressure Defective pressure limiting valve  Replace the pressure limiting valve.
too high
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 49.)
Oil loss Shaft sealing rings (normal wear)  In this case, consult REINTJES 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.
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.)
Gearbox noise Idling speed is in critical range  Increase the idling speed.
Torsional vibration resonance of the  Change the speed in order to avoid critical
engine is transmitted to the gearbox speed ranges.
 Check the flexible coupling on the input side.
Hydraulic noises, gearbox oil pump  Check the items listed under “Gearbox oil pump
intakes air intakes air”.
Gearbox oilpump Gearbox oil level too low  Check the gearbox for leakage.
intakes air  Repair the cause of oil loss (e.g. replace sealing
rings, tighten screws or fittings on pipes).
 Add oil and fill to the upper dipstick marking.
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  Check the items listed under “Operating
pressure too low, variable”.
72 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Trouble-shooting
Fault Cause Repair

Clutch slips at high Operating oil pressure too low  Check the items listed under “Operating
engines speeds pressure too low, variable”.
 Reduce engine speed until the clutch no longer
slips.
 Avoid switching directions of rotation.
-or-
 Change the direction of rotation only with the
propeller at a standstill and the engine at idling
speed.
Clutch does not Control valve not properly engaged  From the control cabin, shift from “Neutral” to the
engage desired direction of travel several times.
 Shift the gearbox by hand in order to check valve
functioning.
-or-
 For electrical shifting valves, check the shifting
position using the pressure switch signals:
WVS: (optional) AHEAD and ASTERN A74/A75
Oil pressure too low  Check the items listed under “Operating
pressure too low, variable”.
Clutch does not Control defective  From the control cabin, shift into the “Neutral”
disengage 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 service.
Operation Manual 73
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Trouble-shooting
74 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
Spare and replacement parts
6 Spare and replacement parts
!
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. WVS 2240

2. Commission number e.g. K76157
3. Input capacity
4. Input speed
Providing these details avoids having to request further information and speeds up
delivery.
Operation Manual 75
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
76 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
6.1 Gearbox oil pump A001.00, Type KF2/.., KF3/.., KF4/..
Pos. no. Qty. Designation

A 001.50 1 Set of seals consisting of:
A Shaft sealing ring (1)
B O-ring (1)
C O-ring (1)
D Gasket (1)
A 001.51 1 Bearing
Note: Mark the position of the cover before dismantling.
When re-assembling, make sure that the cover and
gasket D are correctly seated.
Operation Manual 77
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
78 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
6.2 Heat exchanger A002.00, Type P ...

A 002.50 4 O-ring
A 002.53 1 Intake cover
A 002.54 1 Reverse cover
A 002.55 1 Tube bundle
A 002.56 3 Anode
Operation Manual 79
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
80 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
6.3 Duplex filter A003.00, Type PI 210

A003.50 2 Filter element
A003.08 1 Contamination indicator electrical, standard
A003.51 1 Set of seals consisting of
A O-ring (2)
B O-ring (2)
C O-ring (1)
D O-ring (1)
A003.52 1 Switch lever, complete
Additional order:
A003.08 1 Contamination indicator, visual
Operation Manual 81
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
82 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
6.4 Operation Delay Pot H426.00/H427.00/ Connection Plate V004.00
Pos. no. Pos.- No. Qty. Designation

H 426.50 H 427.50 1 Set of seals consisting of:
A O-Ring (1)
B O-Ring (1)
V 403.00 V 404.00 1 Non-return valve (Aeration valve)

V 004.58 2 O-Ring
V 004.52 2 Plug screw, Threaded pin, O-Ring
V 004.56 4 Ball
V 004.55 2 Spring
V 004.54 2 Seal lock nut
V 004.53 2 Adjusting srew
V 004.51 2 O-Ring
Operation Manual 83
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
84 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
6.5 Control valve V1 (4/3-way-valve), electrical

V 223 1 Set of seals
Operation Manual 85
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
86 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
6.6 Control block V006.00, type HB4 C 0320 A DKF4O30

V006.00 Control block type HB4C 0320, ordering only completely:
10 1 DKF4O30-Mounting group
100 2 O-Ring
Operation Manual 87
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
88 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
6.7 Pressure build-up valve V316.00, for ADS

V 316.50 1 Sinter filter-element
V 316.51 1 Set of seals consisting of:
A O-Ring (1)
B O-Ring (1)
C O-Ring (2)
D O-Ring (2)
E O-Ring (1)
F O-Ring (1)
V 316.52 1 Sealing nut
Operation Manual 89
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
90 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
6.8 Proportional valve V304 for ADS (trolling operation)
V 304

V 304 1 Proportional valve complete
with two o-rings and connecting plug
Operation Manual 91
B – BV2381 – Version 1.0 / 03.06.2014
WVS 2240
92 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
Index
Index
A Maintenance job card 40, 42
ADS - trolling propulsion mode 28 Maintenance level 37
Maintenance plan 37
B Manual emergency operation 30
Behaviour in cases of fault 30
O
C Oil
Change the operating oil 51 fill 12
Check the contamination indicator for the oil Oil drain screw 13
filter 48
Check the oil cooler anodes 53 P
Check the oil temperature 46 Pressure limiting valve 33
Check the operating pressure 44 set 33
Checklist Putting the unit into operation 11
Preservation 18
Checklist before starting the engine 19 R
Checklists for putting into operation 15 Requirements for assembly personnel 7
Connection to the engine 30, 69 Reversing at higher speeds 24
Conversion factors 69
Crash-stop 25 S
Safety 5
D Safety information for assembly 8
Dipstick marking 13 Screwed joints 57
Service repair sets 79
E Sight 50
Emergency operation 30, 31 Sight check and running noise check 50
Emergency screws 31
Engaging the gearbox 23 T
Tightening torque 69
F Trailing operation 26
Failure of pressure oil supply 31 Trolling propulsion mode 28
Fresh oil sample 12 Maintenance 42
Trouble-shooting 73
H
Handling the checklists 15
Heat exchanger
Maintenance 40, 42
I
Installation check 12
L
Lubricant amount 14
Lubricant recommended 14
M
Maintenance 35
Maintenance intervalls acc. to application
group 37
Operation Manual 93
B – BV2381 – Version 1.0 / 03.06.2014
Index
94 Operation Manual
B – BV2381 – Version 1.0 / 03.06.2014
Spare Parts Lists and Drawings
WVS 2240
K76157 – K76160


K76157
0-102-69065
Pos. for Designation Quantity Part no. Document

E 8 cover 1 A984740 2-041-68311/01
E 13 anti-friction bearing 1 A1000112
E 40 cover 1 A984903 2-041-68307/01
E 56 washer 16 A210285 DIN 125
E 56 hexagon screw 12 A10987 DIN 933
E 205 washer 12 A210285 DIN 125
E 367 clamping sleeve 1 A13579 DIN 1481
E 705 bearing housing 1 A984536 2-021-68314
E 722 oil distributor 1 A984840 2-051-50516/01
E 1015 bearing housing 1 A984782 2-021-68353/01
E 1030 washer 1 A981471 2-051-49768/12
E 1031 countersunk screw 3 A1003042 DIN 7991
E 1032 bush 1 A632244 2-051-49767/04
E 1333 retaining ring 1 A452289 DIN 472
E 1389 bush 1 A649856 2-051-50511/01
E 1399 o-ring 3 A21644
E 1502 o-ring 1 A21610
E 1603 clamping sleeve 1 A1003185 4-052-69507/12
G 90 allen screw 1 A17264 DIN 912
K 119 allen screw 6 A8850 DIN 912
K 120 o-ring 1 A48690
K 125 carrier cover 1 A558290 2-181-46180/01
K76157
0-102-69065

R 119 pinion shaft 1 A1003242 2-191-80905/04
W 17 intermediate shaft 1 A984843BW 2-131-68653/01
W 103 retaining ring 1 A12866 DIN 471
W 395 bush 1 A649830 2-101-50513/01
W 396 allen screw 4 A8745 DIN 912
K76157
0-102-69066

E 104 hexagon nut 12 A12610 DIN 934
E 104 washer 12 A210706 DIN 125
E 115 washer 12 A210277 DIN 125
E 193 cover 1 A984747 2-041-68308/01
E 202 cover 1 A984705 2-041-68309/01
E 203 spring 16 A69302 7-091-24321
E 219 shaft sealing ring 1 A705322
E 251 trailing pump 1 A983089
E 372 bush 1 A984640 2-021-68528/01
E 374 bush 1 A984643 2-021-68306/01
E 407 cover 1 A982512 2-041-67430/01
E 408 washer 7 A437417 DIN 125
E 408 allen screw 7 A572250 DIN 912
E 915 washer 1 A984762 2-051-68312/01
E 1681 o-ring 1 A980261
E 1688 cover 1 A983092 2-041-67680/01
G 273 stud 12 A719455 DIN 835
P 1 output shaft 1 A1003203 2-151-79870/01
P 20 anti-friction bearing 1 A7757
P 84 clamping sleeve 1 A13676 DIN 1481
P 166 connecting shaft 1 A984776 2-101-68529/01
P 168 allen screw 8 A9296 DIN 912
P 220 hexagon nut 1 A12599 DIN 934
P 220 washer 1 A210293 DIN 125
Optional
Optional
K76157
0-102-69066

R 2 wheel 1 A1003245 2-191-80058/03
R 184 wheel 1 A982510 4-273-67433
Optional
Optional
K76157
0-102-96404

A001.00 *S oil pump 1 A984793 11 15417/4
E 7 cover two part 1 A984719 2-041-68310
E 15 anti-friction bearing 2 A984874 4-655-62506/20
E 186 washer 12 A210285 DIN 125
E 206 cover 1 A984907 2-041-68352/01
E 244 washer 12 A210285 DIN 125
E 451 v-ring 1 A657832
E 452 sealing ring 1 A984724 2-051-48951/17
E 452 spring 1 A984725
E 585 bush 1 A632244 2-051-49767/04
E 586 washer 1 A981471 2-051-49768/12
K76157
0-102-96404

E 1069 intermediate ring 1 A983941 2-219-68125/01
E 1266 spring 12 A14249 SK4-001124
E 1267 washer 1 A984717 2-053-68535/01
E 1501 o-ring 1 A21610
E 1595 v-ring 1 A657832
E 1659 stud 4 A920886 DIN 835
K 5 bolt 12 A75043 DIN 1445
K 5 bolt 12 A75043 DIN 1445
K 6 spring 12 A551074 7-091-46330
K 6 spring 12 A551074 7-091-46330
K 7 rectangular ring 1 A170488 7-238-86228/04
K 8 hexagon screw 8 A50296 DIN 933
K 8 locking wire 1 A45128
K 8 wire-rope grip 2 A45110
K76157
0-102-96404

K 17 annular piston 1 A346985 2-181-36186/01
K 40 carrier cover 1 A558265 2-181-46174/01
K 59 cover 1 A347000 2-181-36186/02
K 59 cover 1 A347000 2-181-36186/02
K 128 o-ring 1 A48690
K 165 washer 1 A984726 2-181-68593/01
K 165 washer 1 A984726 2-181-68593/01
R 1 pinion shaft 1 A1003241 2-191-80905/03
R 32 shaft nut 1 A33723 RN 0049
R 32 shaft nut 1 A33723 RN 0049
R 33 threaded pin 1 A11754 DIN 916
R 44 retaining ring 1 A12882 DIN 471
R 64 bush 1 A984544 4-103-43065/06
R 64 bush 1 A984544 4-103-43065/06
W 1 input shaft 1 A1003198BW 2-121-68483
W 7 shaft nut 1 A21563 RN 0049
W 8 threaded pin 1 A11711 DIN 916
W 12 bush 1 A984491 4-103-46151/21
K76157
0-102-96404

W 57 hexagon screw 4 A10596 DIN 933
W 58 hexagon nut 4 A12548 DIN 934
W 166 *8 allen screw 35 A507008 DIN 912
W 169 carrier pin 6 A51276 0-720-20939/01
W 169 carrier pin 6 A51276 0-720-20939/01
W 179 non-return valve 2 A868795
K76157
0-211-82116

A104 pressure transmitter 1 A934844
A113 pressure test valve 1 A861898
A113 connection plate 1 A995386 2-092-74118/01
A113.1 pressure test valve 1 A863599
A119 cable entrance 18 A186830 DIN 89280
A119 sealing ring 18 A572730 DIN 7603
A121 shut-off valve 1 A112399
A125 pressure switch 1 A808938
A206.1 speed take-up 1 A879070
A206.5 reducing fitting 1 A982538 4-734-67401
A21 terminal box 1 A982796 2-788-67637A
A35 pressure gauge 1 A506214 EN 837
A35 screwed union 1 A861901
A35 joining piece 1 A861871
A43 contamination indicator 1 A488445 0-705-54624
A485 protection tube 1 A945030
A485 temperature sensor 1 A984317 0-210-70663
A55 thermometer 1 A25240 0-714-27251
A57A connection piece 1 A848271 2-319-59734/01
A57B allen screw 2 A8966 DIN 912
A635 adapter 1 A967068 4-734-65648
0 1 2 3 4 5 6 7 8 9
Monitor list
Pos. Manufacturer Designation Type number Measuring range Degree of protection
-A35 VDO Pressure gauge 63/0-40bar (0-550 PSI) 0-40bar (0-550PSi)

-A43 Mahle Difference pressure switch PIS 3003 ∆-P 5bar IP 65
-A55 Wika Thermometer 32..212°F
-A57 Bedia Oil level controller PLCA-50 24VDC +/- 25% / time delay 7s, internal
-A74 Danfoss Pressure switch MBC 5100-3231-1DB04 5 - 20bar IP 65
-A104 Danfoss Pressure transmitter MBS 5100-XX11-1DB04 0-30 bar /4..20mA IP 65
-A206.1 Noris Speed sensor FA-2H-3E-70 IP 65
-A206.5 MTU Speed sensor DM22-A2 520 530 51 69 IP 66
-A485 Noris Temperature sensor 2TPT81 0-120°C IP 67
-V1 Kracht Control valve WL4 SF1 P1 E1 E6 Z02 400-K3 24VDC +/- 10%; 41W; spring returned
-V304 Kracht Proportional valve SOV 4A 0117 C IP 65
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
04.11.2009 Gearbox WVS 2240 HL-HR & DL-DR Monitor list =
Ed. ROT 0-211- 82116 + DOC
Appr DAJ Commission Page 5
Modification Date Name Original Replaced by Replaced by Supervision Page 23
K76157
0-211-82116

V1 control valve 1 A935786 0-705-64278
V10 allen screw 4 A19186 DIN 912
V304 proportional valve 1 A529664
W205.1 supply cable 1 A842052
W485 supply cable 1 A842052
X000 serial terminal 1 A982591
0 1 2 3 4 5 6 7 8 9
Monitor list

Ed. ROT 0-211- 82116 + DOC
K76157
List of spare parts, footnotes

*10 consisting of G1/G2 can only be ordered completely
*11 consisting of G1/G82/G2 can only be ordered completely
*12 consisting of G1/G82/G2/G433 can only be ordered completely
*15 consisting of G020.00/G030.00/G040.00 can only be ordered completely
*17 consisting of G020.00/G040.00 can only be ordered completely
*18 consisting of G020.00/G030.00/ G040.00/ G050.00 can only be ordered completely
*2 Pay attention to assembly and dismantling instructions for taper press hubs 1:30 (stated in the appendix)
*20 consisting of E927/E932 can only be ordered completely
*3 must be mounted in hot condition
*4 must be ordered as bearing combination
*5 Supplied in single Parts only. Have to be matched and finished on the Gearbox.
*8 have to be renewed on dismantling (special screws)
*9 Housing Pump Drive and Bearing Housing Pump Drive can only be ordered together.
*S Service Repair Kit

K76158
0-102-69065

E 8 cover 1 A984740 2-041-68311/01
E 40 cover 1 A984903 2-041-68307/01
E 56 washer 16 A210285 DIN 125
E 205 washer 12 A210285 DIN 125
E 1030 washer 1 A981471 2-051-49768/12
E 1032 bush 1 A632244 2-051-49767/04
E 1389 bush 1 A649856 2-051-50511/01
E 1399 o-ring 3 A21644
E 1502 o-ring 1 A21610
K 120 o-ring 1 A48690
K 125 carrier cover 1 A558290 2-181-46180/01
K76158
0-102-69065

R 119 pinion shaft 1 A1003234 2-191-80905/02
W 395 bush 1 A649830 2-101-50513/01
K76158
0-102-69066

E 104 washer 12 A210706 DIN 125
E 115 washer 12 A210277 DIN 125
E 193 cover 1 A984747 2-041-68308/01
E 202 cover 1 A984705 2-041-68309/01
E 203 spring 16 A69302 7-091-24321
E 372 bush 1 A984640 2-021-68528/01
E 374 bush 1 A984643 2-021-68306/01
E 407 cover 1 A982512 2-041-67430/01
E 408 washer 7 A437417 DIN 125
E 915 washer 1 A984762 2-051-68312/01
E 1681 o-ring 1 A980261
E 1688 cover 1 A983092 2-041-67680/01
G 273 stud 12 A719455 DIN 835
P 1 output shaft 1 A1003203 2-151-79870/01
P 220 washer 1 A210293 DIN 125
Optional
Optional
K76158
0-102-69066

R 2 wheel 1 A1003237 2-191-80014/03
R 184 wheel 1 A982510 4-273-67433
Optional
Optional
K76158
0-102-96404

A001.00 *S oil pump 1 A984793 11 15417/4
E 7 cover two part 1 A984719 2-041-68310
E 186 washer 12 A210285 DIN 125
E 206 cover 1 A984907 2-041-68352/01
E 244 washer 12 A210285 DIN 125
E 451 v-ring 1 A657832
E 452 sealing ring 1 A984724 2-051-48951/17
E 452 spring 1 A984725
E 585 bush 1 A632244 2-051-49767/04
E 586 washer 1 A981471 2-051-49768/12
K76158
0-102-96404

E 1266 spring 12 A14249 SK4-001124
E 1267 washer 1 A984717 2-053-68535/01
E 1501 o-ring 1 A21610
E 1595 v-ring 1 A657832
E 1659 stud 4 A920886 DIN 835
K 5 bolt 12 A75043 DIN 1445
K 5 bolt 12 A75043 DIN 1445
K 6 spring 12 A551074 7-091-46330
K 6 spring 12 A551074 7-091-46330
K76158
0-102-96404

K 40 carrier cover 1 A558265 2-181-46174/01
K 59 cover 1 A347000 2-181-36186/02
K 59 cover 1 A347000 2-181-36186/02
K 128 o-ring 1 A48690
K 165 washer 1 A984726 2-181-68593/01
K 165 washer 1 A984726 2-181-68593/01
R 1 pinion shaft 1 A1003233 2-191-80905/01
R 32 shaft nut 1 A33723 RN 0049
R 32 shaft nut 1 A33723 RN 0049
R 64 bush 1 A984544 4-103-43065/06
R 64 bush 1 A984544 4-103-43065/06
W 1 input shaft 1 A1003198BW 2-121-68483
W 12 bush 1 A984491 4-103-46151/21
K76158
0-102-96404

W 169 carrier pin 6 A51276 0-720-20939/01
W 169 carrier pin 6 A51276 0-720-20939/01
K76158
0-211-82116

A21 terminal box 1 A982796 2-788-67637A
A55 thermometer 1 A25240 0-714-27251
A635 adapter 1 A967068 4-734-65648
0 1 2 3 4 5 6 7 8 9
Monitor list

Ed. ROT 0-211- 82116 + DOC
K76158
0-211-82116

V1 control valve 1 A935786 0-705-64278
0 1 2 3 4 5 6 7 8 9
Monitor list

Ed. ROT 0-211- 82116 + DOC
K76158


K76159
0-102-83800

E 104 washer 12 A210706 DIN 125
E 115 washer 12 A210277 DIN 125
E 193 cover 1 A984747 2-041-68308/01
E 202 cover 1 A984705 2-041-68309/01
E 203 spring 16 A69302 7-091-24321
E 407 cover 1 A982512 2-041-67430/01
E 408 washer 7 A437417 DIN 125
E 915 washer 1 A984762 2-051-68312/01
E 1681 o-ring 1 A980261
E 1688 cover 1 A983092 2-041-67680/01
G 65 shielding sheet 1 A1003229 2-051-38633/17
G 163 washer 4 A705268 DIN 440
G 163 hexagon screw 4 A10693 DIN 933
G 658 clamping sleeve 1 A150134 DIN 1481
P 1 output shaft 1 A1003203 2-151-79870/01
P 220 washer 1 A210293 DIN 125
K76159
0-102-83800

R 2 wheel 1 A1003294 2-191-81042
R 184 wheel 1 A982510 4-273-67433
K76159
0-102-83805

A001.00 *S oil pump 1 A984793 11 15417/4
E 7 cover two part 1 A984719 2-041-68310
E 186 washer 12 A210285 DIN 125
E 206 cover 1 A984907 2-041-68352/01
E 244 washer 12 A210285 DIN 125
E 451 v-ring 1 A657832
E 452 sealing ring 1 A984724 2-051-48951/17
E 452 spring 1 A984725
E 585 bush 1 A632244 2-051-49767/04
E 586 washer 1 A981471 2-051-49768/12
E 1266 spring 12 A14249 SK4-001124
E 1267 washer 1 A984717 2-053-68535/01
E 1501 o-ring 1 A21610
E 1595 v-ring 1 A657832
E 1659 stud 4 A920886 DIN 835
G 316 retaining ring 1 A452289 DIN 472
K76159
0-102-83805

K 40 carrier cover 1 A558265 2-181-46174/01
K 128 o-ring 1 A48690
R 1 pinion shaft 1 A1003286 2-191-80905/07
W 1 input shaft 1 A1003196BW 2-121-68483
W 12 bush 1 A984491 4-103-46151/21
K76159
0-102-83814

E 8 cover 1 A984740 2-041-68311/01
E 40 cover 1 A984903 2-041-68307/01
E 56 washer 16 A210285 DIN 125
E 205 washer 12 A210285 DIN 125
E 1030 washer 1 A981471 2-051-49768/12
E 1032 bush 1 A632244 2-051-49767/04
E 1389 bush 1 A649856 2-051-50511/01
E 1399 o-ring 3 A21644
E 1502 o-ring 1 A21610
K 5 bolt 12 A75043 DIN 1445
K 5 bolt 12 A75043 DIN 1445
K76159
0-102-83814

K 6 spring 12 A551074 7-091-46330
K 6 spring 12 A551074 7-091-46330
K 59 cover 1 A347000 2-181-36186/02
K 59 cover 1 A347000 2-181-36186/02
K 120 o-ring 1 A48690
K 125 carrier cover 1 A558290 2-181-46180/01
K 165 washer 1 A984726 2-181-68593/01
K 165 washer 1 A984726 2-181-68593/01
R 32 shaft nut 1 A33723 RN 0049
R 32 shaft nut 1 A33723 RN 0049
K76159
0-102-83814

R 64 bush 1 A984544 4-103-43065/06
R 64 bush 1 A984544 4-103-43065/06
R 119 pinion shaft 1 A1003287 2-191-80905/08
W 169 carrier pin 6 A51276 0-720-20939/01
W 169 carrier pin 6 A51276 0-720-20939/01
W 395 bush 1 A649830 2-101-50513/01
K76159
0-102-83853

E 1586 cover 1 A984903 2-041-68307/01
E 1587 washer 12 A210285 DIN 125
E 1833 bush 1 A632244 2-051-49767/04
E 1834 washer 1 A981471 2-051-49768/12
R 41 wheel 1 A1003290 2-191-81037/03
R 201 pinion carrier 1 A1003292 2-191-80024/01
R 202 shaft nut 1 A33723 RN 0049
R 204 bush 1 A984544 4-103-43065/06
K76159
0-211-82116

A21 terminal box 1 A982796 2-788-67637A
A55 thermometer 1 A25240 0-714-27251
A635 adapter 1 A967068 4-734-65648
0 1 2 3 4 5 6 7 8 9
Monitor list

Ed. ROT 0-211- 82116 + DOC
K76159
0-211-82116

V1 control valve 1 A935786 0-705-64278
0 1 2 3 4 5 6 7 8 9
Monitor list

Ed. ROT 0-211- 82116 + DOC
K76159


K76160
0-102-83800

E 104 washer 12 A210706 DIN 125
E 115 washer 12 A210277 DIN 125
E 193 cover 1 A984747 2-041-68308/01
E 202 cover 1 A984705 2-041-68309/01
E 203 spring 16 A69302 7-091-24321
E 407 cover 1 A982512 2-041-67430/01
E 408 washer 7 A437417 DIN 125
E 915 washer 1 A984762 2-051-68312/01
E 1681 o-ring 1 A980261
E 1688 cover 1 A983092 2-041-67680/01
G 65 shielding sheet 1 A1003229 2-051-38633/17
G 163 washer 4 A705268 DIN 440
G 163 hexagon screw 4 A10693 DIN 933
G 658 clamping sleeve 1 A150134 DIN 1481
P 1 output shaft 1 A1003203 2-151-79870/01
K76160
0-102-83800

P 220 washer 1 A210293 DIN 125
R 2 wheel 1 A1003293 2-191-80067/01
R 184 wheel 1 A982510 4-273-67433
K76160
0-102-83805

A001.00 *S oil pump 1 A984793 11 15417/4
E 7 cover two part 1 A984719 2-041-68310
E 186 washer 12 A210285 DIN 125
E 206 cover 1 A984907 2-041-68352/01
E 244 washer 12 A210285 DIN 125
E 451 v-ring 1 A657832
E 452 sealing ring 1 A984724 2-051-48951/17
E 452 spring 1 A984725
E 585 bush 1 A632244 2-051-49767/04
E 586 washer 1 A981471 2-051-49768/12
E 1266 spring 12 A14249 SK4-001124
E 1267 washer 1 A984717 2-053-68535/01
E 1501 o-ring 1 A21610
E 1595 v-ring 1 A657832
E 1659 stud 4 A920886 DIN 835
K76160
0-102-83805

K 40 carrier cover 1 A558265 2-181-46174/01
K 128 o-ring 1 A48690
R 1 pinion shaft 1 A1003278 2-191-80905/05
W 1 input shaft 1 A1003196BW 2-121-68483
W 12 bush 1 A984491 4-103-46151/21
K76160
0-102-83814

E 8 cover 1 A984740 2-041-68311/01
E 40 cover 1 A984903 2-041-68307/01
E 56 washer 16 A210285 DIN 125
E 205 washer 12 A210285 DIN 125
E 1030 washer 1 A981471 2-051-49768/12
E 1032 bush 1 A632244 2-051-49767/04
E 1389 bush 1 A649856 2-051-50511/01
E 1399 o-ring 3 A21644
E 1502 o-ring 1 A21610
K 5 bolt 12 A75043 DIN 1445
K 5 bolt 12 A75043 DIN 1445
K76160
0-102-83814

K 6 spring 12 A551074 7-091-46330
K 6 spring 12 A551074 7-091-46330
K 59 cover 1 A347000 2-181-36186/02
K 59 cover 1 A347000 2-181-36186/02
K 120 o-ring 1 A48690
K 125 carrier cover 1 A558290 2-181-46180/01
K 165 washer 1 A984726 2-181-68593/01
K 165 washer 1 A984726 2-181-68593/01
R 32 shaft nut 1 A33723 RN 0049
R 32 shaft nut 1 A33723 RN 0049
K76160
0-102-83814

R 64 bush 1 A984544 4-103-43065/06
R 64 bush 1 A984544 4-103-43065/06
R 119 pinion shaft 1 A1003279 2-191-80905/06
W 17 intermediate shaft 1 A1003189 2-131-68653/02
W 169 carrier pin 6 A51276 0-720-20939/01
W 169 carrier pin 6 A51276 0-720-20939/01
W 395 bush 1 A649830 2-101-50513/01
K76160
0-102-83853

E 1586 cover 1 A984903 2-041-68307/01
E 1587 washer 12 A210285 DIN 125
E 1833 bush 1 A632244 2-051-49767/04
E 1834 washer 1 A981471 2-051-49768/12
R 41 wheel 1 A1003282 2-191-80033/03
R 201 pinion carrier 1 A1003292 2-191-80024/01
R 202 shaft nut 1 A33723 RN 0049
R 204 bush 1 A984544 4-103-43065/06
K76160
0-211-82116

A21 terminal box 1 A982796 2-788-67637A
A55 thermometer 1 A25240 0-714-27251
A635 adapter 1 A967068 4-734-65648
0 1 2 3 4 5 6 7 8 9
Monitor list

Ed. ROT 0-211- 82116 + DOC
K76160
0-211-82116

V1 control valve 1 A935786 0-705-64278
0 1 2 3 4 5 6 7 8 9
Monitor list

Ed. ROT 0-211- 82116 + DOC
K76160


241 Reintjes, WVS 2240 (K76157-K76160), Reduction Gear, Installation Instuctions

Uploaded by

Copyright:

Available Formats

You might also like

241 Reintjes, WVS 2240 (K76157-K76160), Reduction Gear, Installation Instuctions

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

241 Reintjes, WVS 2240 (K76157-K76160), Reduction Gear, Installation Instuctions

Uploaded by

Copyright:

Available Formats

Installation Instructions

E – BV2381 – Version 1.0 / 03.06.2014

© 2014 REINTJES GmbH

2 Introduction to this Documentation .............................................................................................. 11

3 Technical Data ........................................................................................................................................ 15

4 Transport, Storage and Preservation ........................................................................................... 17

6 Installation and Alignment ................................................................................................................ 35

1.1 Meaning of Warnings and Notes

Note without signal word:

Additional information and recommendations

1.2 Basic measures of caution

Accidents may often be avoided by recognizing potential hazard situations in advance.

Input side Output side

Dangerous places on the gearbox (WVS 2240 HL)

Dangerous places on the gearbox (WVS 2240 DR)

Symbol Meaning Symbol Meaning

Danger of being drawn or caught Wear tightly fitting protective

Danger of electric shock! Wear ear protectors

1.3 Requirements for assembly personnel

General protective measures and personal protection in the engine room

 Immediately repair any faults that pose a safety hazard!

1.4 Safety information for installation

Observe the following procedures!

Safety prior to working on the gearbox

1.5 Protective measures against fire and danger of explosion

Pipes and tubes

Cables connected to the gearbox

 Make sure that all cables are maintained in an undamaged condition.

Foreign substances near to the gearbox

2 Introduction to this Documentation

This documentation comprises one set of installation instructions and operation

This installation instructions contain information about:

The operation manual contains information about:

• Putting the unit into operation

Please read the Installation instructions before installing the gearbox!

Anyone responsible for transport, installation, operation or maintenance of this equipment

2.1 Maintaining the documentation

2.2 Preconditions of warranty

REINTJES will only accept warranty claims when:

REINTJES strongly recommends that you have a torsional vibration calculation

2.3 Brief product description

Control is effected by means of electrical valves.

Heat exchanger Oil filter

Oil pump Output shaft Input shaft

2.4 Area of application and manner of intended use

These details must be absolutely adhered to!

2.5 Use of the gearbox within the European Union

Type: WVS 2240 P HL/HR

Type: WVS 2240 UP DL/DR

Gearbox work no.: K76159 – K76160

4 Transport, Storage and Preservation

 Report any transport damage to the freight carrier immediately.

During transport, make sure:

 In cases of doubt, please contact the REINTJES service department.

To avoid damage, the gearbox must be stored in an enclosed area.

These factors have a positive effect on the permissible storage period:

• High-quality packaging including an adequate amount of drying agent

These factors have a negative effect on the permissible storage period:

• Damage to the packaging