ZF 400 Family User manual

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. [phone]
Fax [phone]
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
10 EN_3224.758.102c_2020_02
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

Introduction
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1.6.2 ZF 400 IV
POS. DESCRIPTION
1PTOcover
2 Oil pump
3Outputshaft
4 Strainer / Screen filter
5Drainplugs
6 Rear half housing
7 Front half housing
8 Oil dipstick
9Breather
10 Oil cooler
11 Filler plug
12 Shift control linkage bracket
13 Control valve
14 Control valve lever
15 1/8 NPTF pressure connector
16 M14x1.5 plug
17 Lifting eyebolt
18 Oil filter
ZF 400 IV
11
12
6
6
5
4
2
16
1
17
814
14
15 13
3
3
7
7
9
2
17
17
18

Introduction
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1.6.3 ZF 400 V
POS. DESCRIPTION
1PTOcover
2 Oil pump
3Outputshaft
4 Strainer / Screen filter
5Drainplugs
6 Rear half housing
7 Front half housing
8 Oil dipstick
9Breather
10 Oil cooler
11 Filler plug
12 Control valve
13 1/8 NPTF pressure connector
14 Oil filter
ZF 400 V
11
11
10
10
16
12
12
6
6
5
5
4
2
2
1
8
8
14
13
3
3
7
7
9
9

Introduction
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1.6.4 Mechanical trolling valve (MTV)
The trolling valve is a device that allows for varying the speed of the propeller, regardless of the engine's rotation spe-
eds. The MTV is commonly applied in the following cases:
1. the boat speed is too high even though the engine is at minimum power.
2. the rotation speed of the PTO must exceed the propeller's rotation speed.
• Maximum rotation speed = (max engine revolutions x 0.5) rpm, for engines with maximum rotation speed below
2000 rpm.
• Maximum rotation speed = (1000) rpm, for engines with maximum rotation speed above 2000 rpm.
Depending on the marine gearbox's reduction ratio, the propeller's dimensions and the features of the boat, the actual
rotation speed of the propeller can be reduced by a percentage varying between 30% and 70% of the useful speed.
Recommended range of use: 60-80°C.
a. Clutch slipping
b. Clutch pressure
c. pressure gauge fitting (15)
The MTV can be used in both directions of motion and the maximum running speeds are:
NOTE:
Mode of use
Verify that the MTV is excluded before engaging the gear. After engaging the gear, gradually move the MTV lever until reaching the
desired maneuver speed.
The number of revolutions can be varied during operation in trolling mode within the limits mentioned above.
It is forbidden to reverse the direction of motion with the MTV engaged.
CAUTION
CAUTION
c (15)
Fig. 5
a
b

Introduction
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1.6.5 Electrical trolling valve (ETV)
An electrical device with the same functions and mode of use as the MTV.
The ETV is activated by means of a proportional solenoid valve.
1.6.6 Control valve shift control linkage
1.6.7 Towing
Towing can be performed continuously for 8 hours. Check that the oil temperature does not exceed 80°C. When the
engine is off, the position of the operating lever is irrelevant.
When installing the shift control linkage, make sure the travel on the lever takes it right to the travel limit, when
operated from the bridge console. If it doesn't, this could result in the burning of the clutches because the oil
flow rate will be too low.
Do not perform any work on the transmission during towing, as the propeller may rotate.
CAUTION
Fig. 6
DANGER

Technical data
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2 Technical data
• * ) marine gearbox without accessories; (for further details, see chapter "Oil level inspection" (p. 21));
• ** ) reference rpm: 1500.
The values must be measured using holes (5) and (15), indicated on page "Main subgroups" (p. 10).
2.1 Types of oil
Use the following oils (refer to the ZF-TLM 04 standard):
2.1.1 Lubricant class 04A
Single-grade engine oils (API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/SF/SG/SH/SJ/SL or ACEA categories, A/B/E)
Viscosity classes: SAE 30, in warm countries or when the temperature in the oil pan exceeds +80°C SAE 40 is also
accepted.
2.1.2 Lubricant class 04B
Single-grade engine oil
Viscosity class: SAE 30, in warm countries or when the temperature in the oil pan exceeds +80°C, SAE 40 is also ac-
cepted.
2.1.3 Lubricant class 04C
Multi-grade engine oil
Viscosity classes: SAE 5W-40 / 10W-40 / 15W-40
TYPE *OIL QUANTITY
(DM3)
PUMP FLOW RATE
(L/MIN AT 1000 RPM)
**OPERATING PRESSURE
(BAR) TEMPERATURE (°C)
ZF 400 A 8,5 ÷ 9,5 19 23 ÷ 24 40 ÷ 80
ZF 400 IV 9 ÷ 10 19 23 ÷ 24 40 ÷ 80
ZF 400 V 12 ÷ 14 22 23 ÷ 24 40 ÷ 80
NOTE:
We suggest installing a pressure indicator (range 0-50 bar) on hole (15) and an oil temperature sensor on hole (5).
All commercial products formulated with mineral oil that meet the above-mentioned specifications are allo-
wed. No product list is available.
As for gearboxes certified by DNV, class 04A lubricants cannot be used. Therefore, these gearboxes must be
filled with class 04B or 04C lubricants.
WARNING
WARNING

Emergency control
16 EN_3224.758.102c_2020_02
3 Emergency control
3.1 Electrical system breakdown
In the event of failure of the electrical circuit or of the solenoid valve's solenoids, a mechanical system can be used to
manually engage the clutches. To activate this system, remove the protection cap (2) (Fig. 2), press button (3) (Fig. 3)
and turn it counter-clockwise.
a. valve closed (normal position)
b. valve open (emergency position)
To reset the electrical control valve, tighten the protection cap (2) to 7 Nm.
Tighten the solenoid valves to 27 Nm if they have been replaced or removed.
This operation must never be performed on the two valves simultaneously, as this would cause the transmis-
sion to lock due to the simultaneous engagement of the two clutches.
1
2
Fig. 2
3
BA
Fig. 3
DANGER

Installation
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4 Installation
V-DRIVE gearbox is not flanged directly on to the engine. Make sure that the connecting cardan shaft does not transmit
vibration which could damage the transmission. V-DRIVE gearbox is installed separately, with a drive shaft and the
foundation mounting can be either rigid or elastic.
If necessary, in addition to the normal flexible coupling fitted to the engine, fit an extra damper to absorb the vibration
caused by an imperfect alignment.
4.1 Connection of the propeller shaft
We recommend using a thrust support to ease the axial stresses that inevitably bear on the marine gearbox. The per-
formance of the propeller shaft support depends on the operating loads and must be specified by the shipbuilding yard.
The alignment must be verified with the boat in the water, since the deformations of a submerged hull are capable of
altering the alignment made with the boat on the cradle.
X = max. 0.05 mm
Y = max. 0.1 mm
L = [mm]
min. 500 for d < 60 mm
min. 1000 for d 60-90 mm
min. 2000 for d > 90 mm
Fig. 1
Fig. 2
CAUTION
CAUTION
CAUTION

Installation
18 EN_3224.758.102c_2020_02
4.2 V-DRIVE marine gearbox
The above considerations apply. If the marine gearbox is mounted separately, a universal joint of variable length is
used. For the joint to work in optimal conditions (homokinetic transmission) and without damaging the marine gearbox
or the engine, it is necessary to follow a few simple installation rules, as shown in the following diagrams.
4.3 Alignment method
4.3.1 Alignment method with parallel-face flanges
1. Engine.
2. Flexible coupling.
3. Variable-length universal joint.
Selected according to the instructions of the manufacturer.
In compliance with the installation instructions.
4. Propeller axle.
5. Marine marine gearbox with input and output on the same face.
The engine and marine gearbox must be installed so that flanges A and B lie parallel to each other.
Make sure that the longitudinal axes of the flexible coupling, universal joint and marine gearbox input shaft
are aligned on the same vertical plane.
CAUTION
CAUTION
Fig. 3

Installation
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EN_3224.758.102c_2020_02
4.3.2 Alignment method with counterpoint shafts
1. Engine.
2. marine gearbox.
3. Variable-length universal joint.
- Selected according to the instructions of the manufacturer.
- In compliance with the installation instructions.
4. Propeller shaft.
To facilitate the correct alignment of the engine and marine gearbox, that is to obtain identical connection angles
ß1 and ß2:
- install two alignment shafts 6 in place of the universal joint;
- the shafts must have the same length;
- align the two units so that the ends of the shafts meet, to ensure that angles ß1 and ß2 are identical;
- at the end, remove the alignment shafts and install the universal joint;
- make sure that the longitudinal axes of the flexible coupling, alignment shafts and marine gearbox input shaft are
aligned on the same vertical plane.
Make sure that the transmission was installed by leaving enough space for performing proper maintenance to replace
the filter, oil and pump, and for accessing the oil dipstick.
Verify that the oil drain plug is easily accessible.
Defective alignment can cause irreversible damage to the transmission, noise, vibrations, and damage to the
hull's sealing systems.
ZF Padova S.r.l. is relieved of all liability for breakage under warranty.
LONGITUDINAL
STATIC PITCH MODE ROLL MODE
ALLOWED INSTALLATION ANGLES DURING NAVIGATION
(°)(With reference to the perpendicular and longitudinal axes
of the input shaft with respect to the horizontal plane)
-5 ÷ +10 -10 ÷ +25 -15 ÷ +15
Fig. 3
CAUTION

Maintenance
20 EN_3224.758.102c_2020_02
5 Maintenance
5.1 Maintenance schedule
YEARLY - 500 HOURS 6 MONTHS - 250 HOURS DAILY AFTER THE FIRST 50 HOURS OF OPERATION
MAINTENANCE INTERVENTIONS
 Oil leakage inspection
   Oil level inspection
   Tighten all the screw connections accessible from the out-
side
   Remote control adjustment
   Intake filter check
  Transmission external cleaning
  Lubrication of external moving parts
  Oil change
Oil filter replacement
Visual inspection of the flexible coupling
Flexible supports
Control indicators and tools
Replacement of the zinc anodes
Heat exchanger
Shaft line check