ZF 400 Family Operating Instructions Manual
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ZF 400 Family Operating Instructions Manual

ZF 400 Family Operating Instructions Manual

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Operating Instructions
ZF 400 Family

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Summary of Contents for ZF 400 Family

  • Page 1 Operating Instructions ZF 400 Family...
  • Page 2 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.

  • Page 3: Table Of Contents

    1.3.1 Manufacturer's address and contact info ...................... 7 Marine gearbox identification......................7 Operating principles........................8 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...
  • Page 4 Index EN_3224.758.102c_2020_02...

  • Page 5: Introduction

    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.

  • Page 6: Conventions For Safety Information In Text

    Introduction 1.2 Conventions for safety information in text The following conventions apply for the safety information in these Operating Instructions: DANGER Describes a dangerous situation that can lead to serious injuries or death when not avoided. WARNING Describes a dangerous situation that can lead to serious injuries or death when not avoided. CAUTION Describes a dangerous situation that can lead to minor o moderate injuries when not avoided.

  • Page 7: Responsibilities

    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.

  • Page 8: Operating Principles

    Introduction 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.
  • Page 9 Introduction ZF 400 A ZF 400 IV ZF 400 V Fig. 3 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).

  • Page 10: Main Subgroups

    Introduction 1.6 Main subgroups 1.6.1 ZF 400 A ZF 400 A Fig. 4 POS. DESCRIPTION PTO cover Output shaft Drain plugs Rear half housing Front half housing Oil cooler Lifting eyebolt Oil dipstick Control valve Solenoid valve Oil filter Oil pump...

  • Page 11: Zf 400 Iv

    Introduction 1.6.2 ZF 400 IV ZF 400 IV POS. DESCRIPTION PTO cover Oil pump Output shaft Strainer / Screen filter Drain plugs Rear half housing Front half housing Oil dipstick Breather Oil cooler Filler plug Shift control linkage bracket Control valve...

  • Page 12: Zf 400 V

    Introduction 1.6.3 ZF 400 V ZF 400 V POS. DESCRIPTION PTO cover Oil pump Output shaft Strainer / Screen filter Drain plugs Rear half housing Front half housing Oil dipstick Breather Oil cooler Filler plug Control valve 1/8 NPTF pressure connector Oil filter EN_3224.758.102c_2020_02...

  • Page 13: Mechanical Trolling Valve (Mtv)

    Introduction 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.

  • Page 14: Electrical Trolling Valve (Etv)

    Introduction 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 CAUTION 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.

  • Page 15: Technical Data

    We suggest installing a pressure indicator (range 0-50 bar) on hole (15) and an oil temperature sensor on hole (5). 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...

  • Page 16: Emergency Control

    Emergency control 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.

  • Page 17: Installation

    Installation 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.

  • Page 18: V-Drive Marine Gearbox

    Installation 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.

  • Page 19: Alignment Method With Counterpoint Shafts

    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. 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.

  • Page 20: Maintenance

    Maintenance 5 Maintenance 5.1 Maintenance schedule MAINTENANCE INTERVENTIONS    Oil leakage inspection    Oil level inspection Tighten all the screw connections accessible from the out-    side    Remote control adjustment  ...

  • Page 21: Oil Level Inspection

    Maintenance 5.2 Oil level inspection The oil level check must be done two minutes after turning off the engine. The correct oil level is between the upper and lower marks on the dipstick (see Fig.1). After the initial filling or after carrying out repairs or changing the oil filter, run the gearbox for about two minutes. Fol- lowing this, recheck the oil level two minutes after turning the engine off.

  • Page 22: Suction Filter Check

    Maintenance 5.4 Suction filter check The intake filter must be inspected and cleaned after the first 50 hours of navigation, and subsequently every 250 hours and/or 6 months. The filter is located on the inlet side of the oil pump. Removal procedure: remove the plug (5), the filter (4) and the seal (6), replacing it with a new one, then clean the filter.

  • Page 23: Remote Control Adjustment

    Maintenance 5.6 Remote control adjustment With the engine switched off, remove the plug connecting the remote control cable to the control valve lever. Put the lever into the forward drive position. Put the lever on the control bridge in the forward drive position and check that the connectors (cable-lever) match.

  • Page 24: Troubleshooting Guide

    - Check the operating pressure 1 - Water-oil exchange through the - Check and replace the heat exchan- 4) Oil level variation heat exchanger To resolve errors marked with the aforementioned symbol, we recommend contacting the ZF authorized service centers. EN_3224.758.102c_2020_02...

  • Page 25: Service Centers

    Roughly 400 partners worldwide are dedicated to sales, after-sales services and assistance for ZF marine products. To find the nearest ZF support center, contact the regional center of competence from the following list, or visit the website www.zf.com and go to: Products and services / network services to find a ZF partner in your country.

  • Page 26: Maintenance Certificates

    Maintenance certificates 8 Maintenance certificates Ore lavoro / Heures de marche Ore lavoro / Heures de marche Horas de trabajo / Arbeitsstunden Horas de trabajo / Arbeitsstunden Data, timbro, firma / Date, timbre, signature Data, timbro, firma / Date, timbre, signature Fecha, sello, firma / Datum, Stempel, Unterschrift Fecha, sello, firma / Datum, Stempel, Unterschrift Ore lavoro / Heures de marche...
  • Page 28 ZF Padova S.r.l. 35010 Caselle di Selvazzano (PD) Via Penghe 48, Telefono/Phone +39 - 049 8299485 Telefax/Fax +39 - 049 8299560 www.zf.com...

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