ZF ZF 45 IV User manual

OPERATING INSTRUCTIONS
ZF 45 IV
MARINE PROPULSION SYSTEMS

3
EN 3201.758.001a 2016-02
Copyright
Copyright © 2014 ZF Padova S.r.L.
All Rights Reserved
No part of this publication may be copied or reproduced in any form, including an electronic retrieval system or be
made available on the Internet, a public network, by satellite, or otherwise without the prior written permission of ZF
Padova S.r.L.
Legal Information
The information in this manual is believed to be accurate at the time of publication, but no responsibility, direct or con-
sequential, can be accepted for damage resulting from the use of this information. ZF Padova S.r.L., reserves the right
to make changes to any of its products without notice.
ZF Padova S.r.L.
Via Penghe, 48
I - 35030 Caselle di Selvazzano (PD)
ITALY
Phone [phone]
Fax [phone]
e-mail: [e-mail]
www.zf.com

4EN 3201.758.001a 2016-02

INDEX
5
EN 3201.758.001a 2016-02
INDEX
1. INTRODUCTION ...............................................................................................................7
1.1. INTRODUCTION ....................................................................................................................................7
1.2. CONVENTIONS FOR SAFETY INFORMATION IN TEXT ...........................................................................8
1.3. GENERAL INFORMATION ......................................................................................................................9
2. INSTALLATION AND OPTIONS .........................................................................................13
2.1. STANDARD INSTALLATION AND ASSEMBLY ........................................................................................13
2.2. PROPELLER SHAFT CONNECTION ........................................................................................................13
2.3. CONTROL VALVE SHIFT CONTROL LINKAGE .........................................................................................14
2.4. TOWING ................................................................................................................................................15
2.5. GEARBOX FASTENING ..........................................................................................................................16
3. TECHNICAL DATA ............................................................................................................17
3.1. TECHNICAL DATA .................................................................................................................................17
3.2. OIL TYPE ...............................................................................................................................................17
4. MAINTENANCE ................................................................................................................18
4.1. MAINTENANCE SCHEDULE ..................................................................................................................18
4.2. OIL LEVEL CHECK ..................................................................................................................................19
4.3. ADJUSTING SHIFT CONTROL LINKAGE .................................................................................................21
4.4. CHECKING FLEXIBLE COUPLINGS .........................................................................................................21
5. WARRANTY ......................................................................................................................22
6. TROUBLESHOOTING ........................................................................................................23

INDEX
6EN 3201.758.001a 2016-02

INTRODUCTION
7
EN 3201.758.001a 2016-02
1INTRODUCTION
1.1 INTRODUCTION
Notes to application support work of ZF
Propulsion System Competence Centre.
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 Marine Propulsion System 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 Marine Propulsion System keeps the right to modify procedures, shapes, equipment, optionals, material, etc. men-
tioned 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
1.1.1 NOTICE
Read this handbook before proceeding with the installation.
The following symbols are used to highlight important information on technical reliability and safety:
NOTE:
When this symbol is displayed, the text alongside contains important information.
This symbol denotes a procedure that could damage the gearbox or associated equipment if not followed cor-
rectly.
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.
CAUTION
DANGER

INTRODUCTION
8EN 3201.758.001a 2016-02
1.1.2 CONVERSION TABLE
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!
S.I. INTERNATIONAL SYSTEM OTHERS
1 [mm] = 0.03937 [in]
10 [mm] = 0.3937 [in]
25.4 [mm] = 1 [in]
6.4516 [cm2]= 1 [sq.in]
1[m
2] = 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]
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
9
EN 3201.758.001a 2016-02
1.3 GENERAL INFORMATION
1.3.1 MANUFACTURER'S ADRESS AND CONTACT
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
Tel. +39 - 049 8299485
Fax +39 - 049 8299560
1.3.2 GEARBOX DATA
IDENTIFICATION PLATE
The data of the gearbox will be found on the identification data plate:
the plate is located on top of the casing as shown.
This type of gearbox have been designed for high speed crafts such as example leisure boats and sport boats
It must be stored in a dry and temperate environment with its packs.
If the packing is removed, it's must be provided to the painting with anti-rust (if not present) of all outer surfaces gear-
box.
The gearbox is delivered without oil.

INTRODUCTION
10 EN 3201.758.001a 2016-02
1.3.3 TYPE GEARBOX IDENTIFICATION
The ZF 40 IV is different from ZF 41 IV for the unit "V drive":
In version 41 ZF V the propeller shaft passes through output flange.
The Main Unit is the same in both versions and in it there is the group clutches and the control unit
E.R.
• Rotation same as direction of rotation of engine
C.E.R.
• Rotation opposite to direction of rotation of engine
THE GEARBOX IS DESIGNED TO FUNCTION NORMALLY AND PRINCIPALLY IN E.R.
The gearbox should operate normally and principally in the E.R. and occasionally in C.E.R. (in reverse) .
The reverse function is performed through a planetary gear
The E.R. clutch is applied by the level of selector valve when it is placed in the [1] position (see fig. below). The engaged
clutch connects the input shaft to the output shaft that turn in C.E.R.
The output shaft rotation is transmitted in C.E.R. at 1.462:1 speed reduction ratio. The reverse clutch is applied by the
selector valve when it is placed in the reverse position.
The engaged clutch locks the planefary gear carrier. The input shaft rotation is transmitted to the output shaft through
ring gear and the three planetary pinions.
The Output shaft rotation is less than input shaft rotation at a 2.203:1 speed reduction ratio
Main Unit 40Vdrive Unit
Main Unit 41Vdrive Unit