ZF 400 Family Bedienungsanleitung
ZF 400 Family
Operating Instructions
MANUALE DI RIPARAZIONE
Copyright © ZF Padova S.r.l.
This document is protected by copyright. Complete or partial reproduction
or dissemination of this document is prohibited without the consent of
ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution.
This document is a translation of the Italian original.
Index
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1 Introduction .................................................................................................................... 5
1.1 Conversion table ........................................................................................................................... 5
1.2 Conventions for safety information in text ..................................................................................... 6
1.3 Responsibilities ............................................................................................................................. 7
1.3.1 Manufacturer's address and contact info ...................................................................................................... 7
1.4 Marine gearbox identification........................................................................................................ 7
1.5 Operating principles...................................................................................................................... 8
1.6 Main subgroups .......................................................................................................................... 10
1.6.1 ZF 400 A .................................................................................................................................................... 10
1.6.2 ZF 400 IV ................................................................................................................................................... 11
1.6.3 ZF 400 V .................................................................................................................................................... 12
1.6.4 Mechanical trolling valve (MTV).................................................................................................................. 13
1.6.5 Electrical trolling valve (ETV)....................................................................................................................... 14
1.6.6 Control valve shift control linkage ............................................................................................................... 14
1.6.7 Towing ....................................................................................................................................................... 14
2 Technical data .............................................................................................................. 15
2.1 Types of oil ................................................................................................................................. 15
2.1.1 Lubricant class 04A .................................................................................................................................... 15
2.1.2 Lubricant class 04B .................................................................................................................................... 15
2.1.3 Lubricant class 04C .................................................................................................................................... 15
3 Emergency control ....................................................................................................... 16
3.1 Electrical system breakdown....................................................................................................... 16
4 Installation.................................................................................................................... 17
4.1 Connection of the propeller shaft ................................................................................................ 17
4.2 V-DRIVE marine gearbox............................................................................................................. 18
4.3 Alignment method ...................................................................................................................... 18
4.3.1 Alignment method with parallel-face flanges.............................................................................................. 18
4.3.2 Alignment method with counterpoint shafts ............................................................................................... 19
5 Maintenance................................................................................................................. 20
5.1 Maintenance schedule................................................................................................................ 20
5.2 Oil level inspection...................................................................................................................... 21
5.3 Oil change .................................................................................................................................. 21
5.4 Suction filter check ..................................................................................................................... 22
5.5 Oil filter replacement .................................................................................................................. 22
5.6 Remote control adjustment ......................................................................................................... 23
6 Troubleshooting guide ................................................................................................. 24
7 Service centers............................................................................................................. 25
8 Maintenance certificates ............................................................................................. 26
Index
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Introduction
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1 Introduction
This document is to be intended only as a support material for the design and analysis of the Vessel Designer and Shi-
pyard in their role of unique Responsible of the final performance analysis, design, selection and decisions.
ZF Padova S.r.l. accept no liability for lack of performance for any expressed or unexpressed result. In no way, this
document is to be intended as a performance and/or commercial promise.
ZF Padova S.r.l. keeps the right to modify procedures, shapes, equipment, optionals, material, etc. mentioned or
shown in the attached figures. Also, some mentioned equipment might be optional.
The actual scope of supply will be limited to that mentioned in the offers issued by ZF Sales Dept
Notice
Read this handbook before proceeding with the installation. The following symbols are used to highlight important in-
formation on technical reliability and safety:
1.1 Conversion table
This symbol denotes a procedure that could result in physical injury to the operator or to other persons in the
vicinity if not followed correctly.
This symbol denotes a procedure that could damage the gearbox or associated equipment if not followed cor-
rectly.
NOTE:
When this symbol is displayed, the text alongside contains important information.
S.I. INTERNATIONAL SYSTEM (OF UNITS) OTHERS
1 (mm) = 0.03937 (in)
10 (mm) = 0.3937 (in)
25.4 (mm) = 1 (in)
6.4516 (cm2) = 1 (sq. in)
1 (m2) = 1550 (sq. in)
16.387 (cm3) = 1 (cu. in)
0.473 (dm3) = 1 (U.S. pint)
1 (l) = 61.02 (cu. in)
1 (l) = 0.2642 (U.S. gal)
1.772 (g) = 1 (oz)
0.4536 (kg) = 1 (lb)
0.00070308 (kg/mm2) = 1 (lb/sq. in)
1 (bar) = 14.51 (psi)
1 (kg·m) = 7.246 (lb·ft)
30.48 (cm) = 1 (feet)
DANGER
CAUTION
Introduction
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1.2 Conventions for safety information in text
The following conventions apply for the safety information in these Operating Instructions:
•Ensure you read and understand all warnings prior to commissioning or repairing the product!
•Pass on all safety information to personnel involved in operating, maintenance, repair and transport!
Describes a dangerous situation that can lead to serious injuries or death when not avoided.
Describes a dangerous situation that can lead to serious injuries or death when not avoided.
Describes a dangerous situation that can lead to minor o moderate injuries when not avoided.
Describe a situation which can lead material damage when not avoided.
NOTE:
Serves to draw attention to special procedures, methods, information, use of aids and tools, etc. This document specially highlights
safety information according to US standard ANSI Z535 by marking the text with the above signal words according to the degree
of danger.
DANGER
WARNING
CAUTION
NOTICE
Introduction
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1.3 Responsibilities
The customer/operator is responsible for carrying out the maintenance checks described in this handbook to ensure
the efficient and safe operation of the marine gearbox.
Each marine gearbox is covered by warranty, which is only valid if the instructions in this manual are strictly adhered to.
1.3.1 Manufacturer's address and contact info
All gearboxes supplied by ZF Padova S.r.l. are accompanied by the relative operating manual.
Further copies of this manual or of other technical documentation can be obtained from:
ZF Padova S.r.l.
Via Penghe 48,
35010 Caselle di Selvazzano (PD), Italy
Tel. +39 049 8299485
Fax +39 049 8299560
1.4 Marine gearbox identification
The identification plate is applied to the marine gearbox. Before proceeding with the installation, we recommend rea-
ding the instruction manual.
NOTE:
The notes contain important information, to which the user must pay careful attention.
SERIAL No RATIO
TYPE
OIL TYPE
CHECK OIL LEVEL WEEKLY
OIL
CAPACITY (dm3)
CLUTCH OIL
PRESSURE(bar)
CUSTOMER No MASS DRY (Kg)
PART LIST No
ContinousMediumLightPleasure
Fig. 1
Introduction
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1.5 Operating principles
The main functions of a marine marine gearbox include:
• coupling the engine with the propeller shaft and reducing the propeller speed;
• inverting the direction of motion;
• interrupting the movement of the propeller shaft (idling mode).
Below is a simplified diagram of the hydraulics.
The marine gearbox allows for obtaining the following three types of operation:
Neutral
The output shaft (2) connected to the propeller shaft does not transmit any rotation.
The clutches are disengaged.
Engine rotation
The output shaft (2) connected to the propeller shaft rotates in the same direction as the input shaft (1).
Counter engine rotation
The output shaft (2) connected to the propeller shaft rotates in the opposite direction to the input shaft (1).
The transmission ratio, for both the engine and counter-engine rotation modes, is stated on the identification plate. The
three types of operation are controlled by the control valve [3] (mechanical or electrical).
Fig. 2
Introduction
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E.R.
The rotation direction matches the engine rotation.
C.E.R.
The rotation direction is contrary to the engine rotation.
The marine gearbox can be supplied with or without accessories (heat exchanger, flexible coupling, brackets, trolling
valve).
The marine gearbox is supplied without oil.
In normal operating conditions, the direction reversals must be made with the engine at minimum power.
In case of emergency, the direction of motion can be reversed with the engine at full speed.
Repeatedly reversing the drive with the engine running at maximum speed will considerably shorten the life of
the clutches
Before putting the marine gearbox into operation, the oil must be topped up and its level checked. (Refer to
section "Maintenance" (p. 20)).
Using the marine gearbox with too little oil can damage the gears.
Excessive oil can cause sealing rings leakages and bleedings and can considerably increase the operating tem-
perature.
Make sure the engine and propeller are at a standstill before carrying out any kind of operation on the gearbox.
ZF 400 A
Fig. 3
ZF 400 IV
ZF 400 V
CAUTION
DANGER
Introduction
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1.6 Main subgroups
1.6.1 ZF 400 A
POS. DESCRIPTION
1PTOcover
2Outputshaft
3Drainplugs
4 Rear half housing
5 Front half housing
6 Oil cooler
7Liftingeyebolt
8 Oil dipstick
9 Control valve
10 Solenoid valve
11 Oil filter
12 Oil pump
13 Strainer / Screen filter
14 Filler plug
15 1/8 NPTF pressure connector
16 Breather
17 M14x1.5 plug
ZF 400 A
15 16
17
3
3
7
2
1
4
5
6
7
8
9
13
11
14
12
14
10
11
Fig. 4
Inhaltsverzeichnis
Andere ZF Motor Handbücher
