ZF 400 - Family
ZF 400 - Family
ZF 400 - Family
ZF 400 Family
MANUALE DI RIPARAZIONE
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
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
7 Service centers............................................................................................................. 25
EN_3224.758.102c_2020_02 3
Index
4 EN_3224.758.102c_2020_02
Introduction
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:
DANGER
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
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.
EN_3224.758.102c_2020_02 5
Introduction
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.
NOTICE
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.
• 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!
6 EN_3224.758.102c_2020_02
Introduction
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.
NOTE:
The notes contain important information, to which the user must pay careful attention.
TYPE
SERIAL No RATIO
Fig. 1
EN_3224.758.102c_2020_02 7
Introduction
Fig. 2
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).
8 EN_3224.758.102c_2020_02
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).
The marine gearbox is supplied without oil.
CAUTION
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.
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
DANGER
Make sure the engine and propeller are at a standstill before carrying out any kind of operation on the gearbox.
EN_3224.758.102c_2020_02 9
Introduction
1.6.1 ZF 400 A
ZF 400 A
11 10 7
9 15
8 6 16
14
14
12 7
11
1
5
2 17
3 4 13
3
Fig. 4
POS. DESCRIPTION
1 PTO cover
2 Output shaft
3 Drain plugs
4 Rear half housing
5 Front half housing
6 Oil cooler
7 Lifting eyebolt
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
10 EN_3224.758.102c_2020_02
Introduction
1.6.2 ZF 400 IV
15 13 ZF 400 IV
14 18
8
17 14
17
11 17
1
12 9
16 7
2 2
4
3
3
6
5 6
7
POS. DESCRIPTION
1 PTO cover
2 Oil pump
3 Output shaft
4 Strainer / Screen filter
5 Drain plugs
6 Rear half housing
7 Front half housing
8 Oil dipstick
9 Breather
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
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Introduction
1.6.3 ZF 400 V
12 11 13
10 ZF 400 V
11 10
16
14
1 8
8 9
9
12
7
2 7 6
3
4
6 2 3
5 5
POS. DESCRIPTION
1 PTO cover
2 Oil pump
3 Output shaft
4 Strainer / Screen filter
5 Drain plugs
6 Rear half housing
7 Front half housing
8 Oil dipstick
9 Breather
10 Oil cooler
11 Filler plug
12 Control valve
13 1/8 NPTF pressure connector
14 Oil filter
12 EN_3224.758.102c_2020_02
Introduction
CAUTION
The MTV can be used in both directions of motion and the maximum running speeds are:
• 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.
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.
CAUTION
It is forbidden to reverse the direction of motion with the MTV engaged.
a
c (15)
Fig. 5
a. Clutch slipping
b. Clutch pressure
c. pressure gauge fitting (15)
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Introduction
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. If it doesn't, this could result in the burning of the clutches because the oil
flow rate will be too low.
Fig. 6
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.
DANGER
Do not perform any work on the transmission during towing, as the propeller may rotate.
14 EN_3224.758.102c_2020_02
Technical data
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).
NOTE:
We suggest installing a pressure indicator (range 0-50 bar) on hole (15) and an oil temperature sensor on hole (5).
WARNING
All commercial products formulated with mineral oil that meet the above-mentioned specifications are allo-
wed. No product list is available.
WARNING
As for gearboxes certified by DNV, class 04A lubricants cannot be used. Therefore, these gearboxes must be
filled with class 04B or 04C lubricants.
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Emergency control
3 Emergency control
3
2 B A
Fig. 2 Fig. 3
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.
16 EN_3224.758.102c_2020_02
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.
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.
Fig. 1
Fig. 2
CAUTION
X = max. 0.05 mm
CAUTION
Y = max. 0.1 mm
CAUTION
L = [mm]
min. 500 for d < 60 mm
min. 1000 for d 60-90 mm
min. 2000 for d > 90 mm
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Installation
CAUTION
The engine and marine gearbox must be installed so that flanges A and B lie parallel to each other.
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.
CAUTION
Make sure that the longitudinal axes of the flexible coupling, universal joint and marine gearbox input shaft
are aligned on the same vertical plane.
Fig. 3
18 EN_3224.758.102c_2020_02
Installation
Fig. 3
CAUTION
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.
Verify that the oil drain plug is easily accessible.
LONGITUDINAL
PITCH MODE ROLL MODE
STATIC
ALLOWED INSTALLATION ANGLES DURING NAVIGATION
(°)(With reference to the perpendicular and longitudinal axes -5 ÷ +10 -10 ÷ +25 -15 ÷ +15
of the input shaft with respect to the horizontal plane)
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Maintenance
5 Maintenance
MAINTENANCE INTERVENTIONS
OF OPERATION
DAILY
Oil change
Flexible supports
Heat exchanger
20 EN_3224.758.102c_2020_02
Maintenance
Fig. 1
1
3
2
Fig. 2 Fig. 3
Fig. 4
EN_3224.758.102c_2020_02 21
Maintenance
Fig. 5 4
Fig. 6
Turn the cartridge (7) counter-clockwise using an appropriate tool until it has been completely removed. Clean the filter
attachment base. Dampen the seal of the new cartridge with oil, then tighten it firmly using the hands alone.
Storage
If the transmission must be stored away for an extended period of time, it must be completely filled with oil through
the oil dipstick. Change the oil when the transmission is put into operation.
22 EN_3224.758.102c_2020_02
Maintenance
DANGER
Remove the ignition key before proceeding with the operation.
NOTE:
Do not use chemical compounds on rubber parts. Make sure that you adjust the tightness of the screws and couplings. Periodically
lubricate the external control mechanisms according to the manufacturer's recommendations.
EN_3224.758.102c_2020_02 23
Troubleshooting guide
6 Troubleshooting guide
To resolve errors marked with the aforementioned symbol, we recommend contacting the ZF authorized service
centers.
24 EN_3224.758.102c_2020_02
Service centers
7 Service centers
EN_3224.758.102c_2020_02 25
Maintenance certificates
8 Maintenance certificates
A A
Ore lavoro / Heures de marche Ore lavoro / Heures de marche
Horas de trabajo / Arbeitsstunden Horas de trabajo / Arbeitsstunden
B B
Data, timbro, firma / Date, timbre, signature Data, timbro, firma / Date, timbre, signature
Fecha, sello, firma / Datum, Stempel, Unterschrift Fecha, sello, firma / Datum, Stempel, Unterschrift
A A
Ore lavoro / Heures de marche Ore lavoro / Heures de marche
Horas de trabajo / Arbeitsstunden Horas de trabajo / Arbeitsstunden
B B
Data, timbro, firma / Date, timbre, signature Data, timbro, firma / Date, timbre, signature
Fecha, sello, firma / Datum, Stempel, Unterschrift Fecha, sello, firma / Datum, Stempel, Unterschrift
a. Work hours
b. Date, stamp, signature
26 EN_3224.758.102c_2020_02
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