ZF 400 Series, Operating Instructions Manual

Page 1: ...ZF 400 Family Operating Instructions...

Page 2: ...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 prose...

Page 3: ...1 6 8 Tugging 15 2 Technical data 16 2 1 Types of oil 16 2 1 1 Lubricant class 04A 16 2 1 2 Lubricant class 04B 16 2 1 3 Lubricant class 04C 16 3 Emergency devices 17 3 1 Electrical circuit failure 1...

Page 4: ...4 Index EN_3224 758 102d_2021_12...

Page 5: ...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 reliab...

Page 6: ...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 mino...

Page 7: ...zano PD Italy Tel 39 049 8299485 Fax 39 049 8299560 1 4 Reverse transmission identification The identification plate is affixed to the reverse transmission Before proceeding with the installation we r...

Page 8: ...es of operation Neutral The output shaft 2 connected to the propeller axle does not transmit any rotation The clutches are disengaged Engine rotation The output shaft 2 connected to the propeller axle...

Page 9: ...f emergency the direction of motion can be reversed with the engine at full speed Motion reversals with the engine at full speed significantly reduce the working life of the clutches Before putting th...

Page 10: ...shaft 3 Drain plugs 4 Rear half carcass 5 Front half carcass 6 Heat exchanger 7 Lifting eyebolt 8 Level rod 9 Oil control block 10 Solenoid valve 11 Oil filter 12 Oil pump 13 Mesh filter 14 Load plug...

Page 11: ...r 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 pre...

Page 12: ...il 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 conn...

Page 13: ...ON 1 PTO cover 2 Output shaft 3 Drain plugs 4 Rear half carcass 5 Front half carcass 6 Heat exchanger 7 Lifting eyebolt 8 Level rod 9 Oil control block 10 Solenoid valve 11 Oil filter 12 Oil pump 13 M...

Page 14: ...es with maximum rotation speed above 2000 rpm Depending on the reverse transmission s reduction ratio the propeller s dimensions and the features of the watercraft the actual rotation speed of the pro...

Page 15: ...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 remote controls make sure that the...

Page 16: ...e 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...

Page 17: ...n 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 This operation must never be performed on th...

Page 18: ...element capable of absorbing the vibrations caused by imperfect alignment 4 1 Connection of the propeller axle We recommend using a thrust support to ease the axial stresses that inevitably bear on th...

Page 19: ...agrams 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...

Page 20: ...install the universal joint make sure that the longitudinal axes of the flexible coupling alignment shafts and reverse transmission input shaft are aligned on the same vertical plane Make sure that th...

Page 21: ...x x x Lubricate external moving parts x x x x Oil change x x x x x Replace oil filter clean gap filter and filter housing x x Torsionally flexible clutch visual inspection x Clutch discs visual inspec...

Page 22: ...day of operation 3 months A2 all 500 hrs 1 year A3 all 2 000 hrs 2 years A4 P according to operating hrs limit of duty 8 years L M C according to operating hrs limit of duty 5 years A5 all starting 12...

Page 23: ...perated for two minutes Subsequently check the oil level again two minutes after the engine is switched off 5 3 Oil change Remove the fill cap 3 and extract the oil level rod 1 as shown in the picture...

Page 24: ...ean the filter The cap 5 must be tightened with a torque of 100 Nm 5 5 Oil filter replacement Turn the cartridge 7 counter clockwise using an appropriate tool until it has been completely removed Clea...

Page 25: ...ral position of the stator lever Perform the same check on the Flying Bridge if present This opera tion must be verified also after the first few hours of operation INSPECTION OF THE FLEXIBLE COUPLING...

Page 26: ...osition of the gear enga gement selection lever Adjust the gear shift linkage 3 Intake filter partially clogged Remove the filter and clean it 4 Use of a non recommended oil Replace the oil with a rec...

Page 27: ...o support its customers 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 cent...

Page 28: ...rift A B Ore lavoro Heures de marche Horas de trabajo Arbeitsstunden Data timbro firma Date timbre signature Fecha sello firma Datum Stempel Unterschrift A B Ore lavoro Heures de marche Horas de traba...

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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...