ZF 400 Series Operating Instructions Manual
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ZF 400 Series Operating Instructions Manual

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Operating Instructions
ZF 400 Family

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Summary of Contents for ZF 400 Series

  • Page 1 Operating Instructions ZF 400 Family...
  • Page 2 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 Z F Friedrichshafen AG. Infringements lead to civil and criminal prosecution.

  • Page 3: Table Of Contents

    1.3.1 Manufacturer's address and contact info ...................... 7 Reverse transmission 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 ZF 400 ............................... 13 1.6.5...
  • Page 4 Index EN_3224.758.102d_2021_12...

  • Page 5: Introduction

    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 equi- pment 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.

  • 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

    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 reverse transmission include: • coupling the engine with the propeller axle 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 Fig. 3 ZF 400 V E.R. The rotation direction matches the engine rotation. C.E.R. The rotation direction is contrary to the engine rotation. The reverse transmission can be supplied with or without accessories (heat exchanger, flexible coupling, brackets, trol- ling 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-carcass Front half-carcass Heat exchanger Lifting eyebolt Level rod Oil control block 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_3224.758.102d_2021_12...
  • Page 13 Introduction 1.6.4 ZF 400 POS. DESCRIPTION PTO cover Output shaft Drain plugs Rear half-carcass Front half-carcass Heat exchanger Lifting eyebolt Level rod Oil control block Solenoid valve Oil filter Oil pump Mesh filter Load plug Pressure socket Bleed M14x1.5 plug...

  • Page 14: Mechanical Trolling Valve (Mtv)

    Introduction 1.6.5 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 watercraft's speed is too high even though the engine is at minimum power. 2.

  • Page 15: Electrical Trolling Valve (Etv)

    Introduction 1.6.6 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. 1.6.7 Remote controls for oil control block CAUTION When installing remote controls, make sure that the stroke of the lever, activated from the control on the brid- ge, is suitable for reaching the limit switches.

  • Page 16: 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, edition 02/2009): 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 17: Emergency Devices

    Emergency devices 3 Emergency devices 3.1 Electrical circuit failure Fig. 3 Fig. 2 A. valve closed (normal position) B. valve open (emergency position) To reset the electrical oil control block, tighten the protection cap (2) to 7 Nm. Tighten the solenoid valves to 27 Nm if they have been replaced or removed. DANGER 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.

  • Page 18: Installation

    Installation 4 Installation If the reverse transmission is not flange-mounted directly onto the engine, check that the connecting cardan shaft does not transmit dangerous vibrations to the transmission. If the reverse transmission is installed separately with the universal joint, it can be fastened to the base both elastically and rigidly (V-DRIVE).

  • Page 19: V-Drive Reverse Transmission

    Installation 4.2 V-DRIVE reverse transmission The above considerations apply. If the reverse transmission 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 reverse tran- smission or the engine, it is necessary to follow a few simple installation rules, as shown in the following diagrams.

  • Page 20: Alignment Method With Tailstock 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 not required to perform warranty repairs in case of ruptures. 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 level rod.

  • Page 21: Maintenance

    Maintenance 5 Maintenance 5.1 Maintenance schedule MAINTENANCE LEVEL MAINTENANCE DESCRIPTION Check oil level Rotate rotary handle of oil filter General conditions visual inspection Clean transmission externally Re-tighten all bolts accessible from the outside Check control position settings Lubricate external moving parts Oil change Replace oil filter;...
  • Page 22 5 years For every major reconditioning of the en- starting 12.000 hrs gine 50 hrs After commissioning • P = Pleasure* • L = Light Duty* NOTE: * For any additional information please refer to the ZF Product Selection Guide. EN_3224.758.102d_2021_12...

  • Page 23: Oil Level Inspection

    Maintenance 5.2 Oil level inspection The oil level check must be performed two minutes after the engine is switched off. The oil level must be between the upper and lower marks on the control rod, as shown in the picture. After the first top-up, or after performing repairs or oil filter cleaning, the reverse transmission must be operated for two minutes.

  • Page 24: Intake Filter Check

    Maintenance 5.4 Intake 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 upstream of the pump. Removal procedure: remove the cap (5), the filter (4) and the seal (6), replacing it with a new one, then clean the filter. The cap (5) must be tightened with a torque of 100 Nm.

  • Page 25: Remote Control Adjustment

    Maintenance 5.6 Remote control adjustment With the engine switched off, remove the plug connecting the remote control cable to the oil control block 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 26: 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_3224.758.102d_2021_12...

  • Page 27: 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 28: 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 30 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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