ZF 45 IV Operating Instructions Manual
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ZF 45 IV Operating Instructions Manual

ZF 45 IV Operating Instructions Manual

Marine propulsion systems
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OPERATING INSTRUCTIONS
ZF 45 IV
MARINE PROPULSION SYSTEMS

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Summary of Contents for ZF ZF 45 IV

  • Page 1 OPERATING INSTRUCTIONS ZF 45 IV MARINE PROPULSION SYSTEMS...
  • Page 3 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.
  • Page 4 EN 3201.758.001a 2016-02...

  • Page 5: Table Of Contents

    INDEX 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.
  • Page 6 INDEX EN 3201.758.001a 2016-02...

  • Page 7: Introduction

    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.

  • Page 8: Conventions For Safety Information In Text

    INTRODUCTION 1.1.2 CONVERSION TABLE S.I. INTERNATIONAL SYSTEM OTHERS [mm] 0.03937 [in] [mm] 0.3937 [in] 25.4 [mm] [in] 6.4516 [sq. in] 1550 [sq. in] 16.387 [cu. in] 0.473 [U.S. pint] 61.02 [cu. in] 0.2642 [U.S. gal] 1.772 [oz] 0.4536 [kg] [lb] 0.00070308 [kg/mm [lb/sq.

  • Page 9: General Information

    INTRODUCTION 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.
  • Page 10 Main Unit 40Vdrive Unit 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.
  • Page 11 INTRODUCTION • Pos. 1: Output shaft rotation opposite to engine rotation • Pos. N: Neutral • Pos. 2: Output shaft rotation same as engine rotation 1.3.4 ELECTRIC CONTROL VALVE The solenoid that corresponds to Pos. 1 of the control lever of the mechanical control valve, is the solenoid "A": the energization of said solenoid rotates the output shaft in C.E.R.
  • Page 12 INTRODUCTION 10 11 6 5 7 1. Breather Main Unit 2. From external cooler to control unit in Main Unit 3. 9/16 UNF control valve sensor connector 4. Valve control lever 5. From oil pump outlet to external cooler 6. Spline SAE Input Shaft 7.

  • Page 13: Installation And Options

    INSTALLATION AND OPTIONS INSTALLATION AND OPTIONS The gearbox must be filled with oil and the oil level checked before use. (see Maintenance (p. 18)) Using the gearbox with insufficient oil could damage the gears. Too much oil could cause leakages through the gaskets and breather and considerably increase the running temperature.

  • Page 14: Control Valve Shift Control Linkage

    INSTALLATION AND OPTIONS Check the condition of the oil coolers. Flush the oil circuit of the coolers and test the cooler for leaks, both in the oil and water chambers. Prior to removal of the gearbox from the boat the alignment of the engine to the shaft should be checked and noted. A shaft that is out of alignment can cause numerous problems inside the engine to the shaft should be checked and noted.

  • Page 15: Towing

    INSTALLATION AND OPTIONS 2.4 TOWING Towing can be done continuously for 8 hours. Check that the oil temperature does not go over 80°C. The position of the control lever is of no importance when the engine is off. DO NOT PERFORM ANY OPERATIONS ON THE TRANSMISSION DURING TOWING, AS THE PROPELLER MAY START TURNING.

  • Page 16: Gearbox Fastening

    INSTALLATION AND OPTIONS 2.5 GEARBOX FASTENING a. Gearbox fastening holes EN 3201.758.001a 2016-02...

  • Page 17: Technical Data

    TECHNICAL DATA TECHNICAL DATA 3.1 TECHNICAL DATA TYPE MASS (WITHOUT OIL) OIL TEMPERATURE [°C] OIL CAPACITY [DM3] Main Unit 40 to 80 1.1 to 1.3 40 V Drive / 41 V Drive 40 to 80 0.9 to 1.0 OIL PUMP FLOW RATE: 19 litres at 4500 rpm OPERATING PRESSURE AT 4500 RPM: 14 - 16 bar...

  • Page 18: Maintenance

    MAINTENANCE MAINTENANCE 4.1 MAINTENANCE SCHEDULE ANNUALLY / SIX MONTHS / AFTER THE FIRST 50 DAILY MAINTENANCE OPERATIONS 500 HOURS 250 HOURS HOURS OPERATION Check for oil leaks Check oil levels Check external threaded fasteners Check and adjust shift control linkage Clean gearbox externally Lubricate external moving parts Oil Change...

  • Page 19: Oil Level Check

    MAINTENANCE 4.2 OIL LEVEL CHECK CAUTION Do not work on the transmission when being towed, or anchoring in a river because the propeller may rotate. Transmission fluid level may be checked in cold or hot condition. NOTE: Always check fluid level before operating transmission. 1.
  • Page 20 MAINTENANCE – For V Drive Unit: insert dipstick without screwing in. Remove dipstick and check that fluid level is between mi- nimum and maximum marks. MAX. MIN. 4. Insert the dipstick and lock it by turning the grip clockwise. CAUTION According to the type and arrangement of the cooler and pipelines a certain amount of oil will collect after stopping the engine and will flow back into the transmission after a longer rest period.

  • Page 21: Adjusting Shift Control Linkage

    MAINTENANCE 4.3 ADJUSTING SHIFT CONTROL LINKAGE With the engine off, unplug the shift control linkage connecting cable with the control valve lever. Put the lever in the forward drive position. Select the same direction with the bridge console control lever and check that the positions of the respective couplers (lever/cable) coincide.

  • Page 22: Warranty

    WARRANTY WARRANTY The marine gearbox has an identification plate stating its characteristics. If this plate is tampered with in any way or removed the warranty will lose its validity. The data on the plate must be quoted each time a service centre is contacted. NOTE: THE GUARANTEE FORM IS ON PAGE 1.

  • Page 23: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING PROBLEM CAUSE POSSIBLE REMEDIES No oil in gearbox Fill with oil No oil pressure in gear position Suction filter completely clogged Remove and clean the internal filter Pump gear damaged Replace the pump gear Low oil level Restore oil level Incorrect position of the lever command valve Register the control linkage Low oil pressure in gear position...
  • Page 26 ZF Padova S.r.l. Via Penghe, 48 I - 35030 Caselle di Selvazzano (PD) ITALY Phone +39 049 8299 311 +39 049 8299 550 www.zf.com...

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