OPERATING MANUAL - MANUALE D'USO

BETRIEBSANLEITUNG - MANUEL DE SERVICE

BW 155 family

ENVIRONMENTAL MANAGEMENT
SYSTEM CERTIFIED

RINA
UNI EN ISO 9001 (ISO 9001)

MARINE 32.70.155.6234
QUACER ISO 9001 ISO 9001 RINA
Certified Quality System Certificate Number: 30062 E M S C E R
I S O 1 4 0 0 1
ZF PADOVA spa Ed. 02/99
 We are glad to know
you have choosen the

ZF MARINE GEARBOX

This manual is intended to provide all the information necessary to install and use

correctly the gearbox.

Moreover, in this manual you will find the maintenance information that will

contribute to increase your gearbox life.

In this manual you will also find a list of the Aftersale Services where you can

apply for any information.

© 1999 The reproduction, even partial, of this manual is prohibited without a written authorization of ZF
MARINE S.p.A..

Printed in Italy

First publication: 01/03/98

Second publication: 01/02/99

Edition: 02/99

Code: 32.70.155.6234

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ZF PADOVA

NOTES

2
 CONTENTS

1 Introduction Pag. 5

1.1 Orders and manufacturer data ............................................................ ” 5

1.2 Gearbox data ....................................................................................... ” 5
1.3 How to use this manual ....................................................................... ” 6
1.4 Conventional signs .............................................................................. ” 6
1.5 Description of the gearbox .................................................................. ” 7
1.6 Functioning .......................................................................................... ” 8
1.6.1 BW 155 A ............................................................................. ” 8
1.6.2 BW 155 V ............................................................................. ” 9
1.7 Emergency devices ............................................................................. ” 10
1.7.1 Hydraulic system breakdown (“Come home system”) ......... ” 10
1.7.2 Electric system breakdown .................................................. ” 11
1.8 Part of the gearbox .............................................................................. ” 12
1.8.1 Trolling valve (T.V.) ............................................................... ” 12
1.8.2 Remote controls ................................................................... ” 13
1.9 Technical features ............................................................................... ” 14
1.9.1 Oil types ............................................................................... ” 14
1.9.2 Pressures and temperatures ................................................ ” 14

2 Installation Pag.15

2.1 Standard gearbox installation .............................................................. ” 15

2.2 Application with gearboxes and V-drive transmission ......................... ” 16
2.2.1 Alignment method with parallel faces flanges ...................... ” 16
2.2.2 Alignment method with counterpoint shafts ......................... ” 17
2.3 Connection to the propeller axle ......................................................... ” 17

3 Trouble shooting Pag.19

3.1 Symptoms, causes and remedies ....................................................... ” 19

4 Maintenance Pag.23

4.1 Maintenance program ......................................................................... ” 23

4.2 Ordinary maintenance operations ....................................................... ” 24
4.2.1 After 50 hours of operation .................................................. ” 24
4.2.2 Daily ...................................................................................... ” 25

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ZF PADOVA

4.2.3 Semi-annually and/or 250 hours .......................................... ” 25

4.2.4 Annually and/or 500 hours .................................................... ” 26

5 Warranty Pag.29

5.1 Warranty card ...................................................................................... ” 29

5.2 After Sale Network .............................................................................. ” 30

6 Maintenance certificate Pag.33

4
C H A P T E R

INTRODUCTION
1

1.1 ORDERS AND MANUFACTURER DATA

The gearbox is provided by ZF Padova S.p.A. together with this manual. If you want some more copies
of this manual or any technical documentation, please ask:

ZF Padova S.p.A.
Ufficio tecnico
Via Penghe 48,
35010 Caselle di selvazzano PD

Tel.: +39 - 0498299485

Fax + 39 - 0498299560

1.2 GEARBOX DATA

Identification plate

The gearbox is provided with the following identification plate:

• placed on the upper part of the back half housing.

TYPE

SERIAL No RATIO

PART LIST No CUSTOMER No MASS DRY (Kg)

Pleasure Light Medium Continous

OIL CLUTCH OIL

OIL TYPE CAPACITY (dm3) PRESSURE(bar)

OIL CHANGE: after first 50 hours of operation and every

1000 hours or 12 months, wichever occurs first.
CHECK OIL LEVEL WEEKLY

Fig. 1

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ZF PADOVA

1.3 HOW TO USE THIS MANUAL

This manual and the manuals provided by ZF Padova S.p.A. are part of the gearbox they refer to.

A copy of these manuals must be stored with care in an easily reachable and known place to allow
consultation to the personnel in charge of the gearbox use and maintenance operations.

Before proceeding to the gearbox installation, it is advisable to read this manual.

ZF cannot be responsible for any damages caused to people, things or data due to wrong installation,
use or maintenance. All these operations must be performed in accordance with the instructions given
in this and in the others manuals. The workshop and instruction manuals provided by ZF Padova have
been planned to facilitate consultation, they can be used by the operator at any time when he needs
specific information about an argument.

For further information, not included in this manual or in the technical manual, please consult ZF
Padova technical service center.

1.4 CONVENTIONAL SIGNS

In this manual we have used the following conventions:
Italic: It is used to mention a chapter, a section, a paragraph, a table or a figure of this manual or of
another publication.

The notes contain important information and are marked with this symbol in the margin.

This symbol indicates that the partial or total non-respect of the procedure could cause damages to
the gearbox or to the devices connected to it.

This symbol indicates that the partial or total non-respect of the procedure could cause physical hurt
to the operator.

6
1.5 DESCRIPTION OF THE GEARBOX

The gearbox is provided with or without accessories (heat exchanger, flexible coupling, brackets, trolling valve).
As if it is possible to calibrate all the gearbox devices, these are pre-adjusted at the manufacturer’s
and do not require any further adjustment. The gearbox is provided without oil.

11 15 BW 155 – BW 155 A
14 8
10
18 12
9 18

13 7

9
7

8
16 1 2

6 4
5
4

5
17 6
Fig. 2 3 5

Tab. 1

POS. DESCRIZIONE POS. DESCRIZIONE

1 PTO cover 11 Oil filling plug

2 Oil pump/countershaft 12 Remote control bracket
3 Output shaft 13 Control valve
4 Suction screen filter 14 Control lever
5 Drain plugs 14A Solenoid valve
6 Rear half housing 15 Main pressure plug 1/8 N PTF
7 Front half housing 16 Lubrication pressure plug M10 x 1
8 Oil dipstick 17 Pump pressure plug M14 x 1.5
9 Breather 18 Oil filter
10 Heat exchanger

BW 155 V

18
10 18
14A
8
13
13
9
16

11
1
7
2

17
7
6
3
4
5
Fig. 3

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ZF PADOVA

1.6 FUNCTIONING

1.6.1 BW 155 A

The main functions of a marine gearbox are the following:

• to reduce the motor revolutions permitting a better propeller functioning;
• to invert the boat movement by means of two hydraulic clutches;
• to stop the propeller shaft movement (neutral).

The three possible functioning modes are the following:

Neutral
The movement is not transmitted from the
motor [1] to the propeller shaft [4], because
both clutches are disengaged (2-3) Fig. 4.

Fig. 4

Enginewise
(propeller shaft [4] and motor shaft [1] with
the same rotation sense), this is possible by
engaging the countershaft clutch [3] (counte-
renginewise to the motor), as shown in fig. 5.

Fig. 5

Counterenginewise
(propeller shaft [4] and motor shaft [1] with
different rotation sense), this is possible by
engaging the input shaft clutch [2] (enginewi-
se to the motor), as shown in fig. 6.

Fig. 6

8
1.6.2 BW 155 V

The main functions of a marine gearbox are the following:

• to reduce the motor revolutions permitting a better propeller functioning;
• to invert the boat movement by means of two hydraulic clutches;
• to stop the propeller shaft movement (neutral).

The three possible functioning modes are the following:

Neutral
The movement is not transmitted from the
motor [1] to the propeller shaft [4], because
both clutches are disengaged (2-3) Fig. 7.

Fig. 7

Enginewise
(propeller shaft [4] and motor shaft [1] with
the same rotation sense), this is possible by
engaging the countershaft clutch [3] (counte-
renginewise to the motor), as shown in fig. 8.

Fig. 8

Counterenginewise
(propeller shaft [4] and motor shaft [1] with
different rotation sense), this is possible by
engaging the input shaft clutch [2] (enginewi-
se to the motor), as shown in fig. 9.

Fig. 9

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ZF PADOVA

The clutches engagement occurs hydrauli-

HYDRAULIC BASIC SCHEME
cally. This scheme (fig. 10) shows the
hydraulic system in a simplified way.

Fig. 10

1.7 EMERGENCY DEVICES

1.7.1 HYDRAULIC SYSTEM BREAKDOWN (“COME HOME” SYSTEM)

If the hydraulic system breakdowns, and con-

BW 155 / 155A
sequently the pressure of the high pressure
circuit for the clutches engagement control
falls down, there is a mechanical system that
compresses the clutches pack.To engage
this system, it is necessary to remove the
PTO cover or the PTO unit itself, if installed,
so with a 10 mm hexagonal wrench [1] (Fig.
11) for TCE screws 300 mm long, tighten the
three screws after placing them on the
respective holes. This is for the input shaft
clutch. 1

Fig. 11

For “V” version, simply remove the cap as

shown (Fig. 12).
1
BW 155 V

1 Fig. 12

10
 For the output shaft clutch, it will be enough
to remove the M14 x 1,5 plug from the clut-
ches cover on the side of the hydraulic pump
and then proceed as for the input shaft (the
control valve must be placed in its neutral
position). After the breakdown has been eli-
minated, before starting the gearbox, loosen
completely the screws [2] and lock in position
with Loctite 242 (Fig. 13).

Fig. 13 2

1
For “V” version, simply remove the cap as
shown (Fig. 14).

1
2
1 Fig. 14

1.7.2 ELECTRICAL SYSTEM BREAKDOWN

If there is a breakdown to the electrical

system or to the solenoid valves (EB30), it is
possible to perform mechanically the clut- 2
ches engagement, operating as follows:
remove the cap [2] (Fig. 15), press pushbut- 1
ton [3] (Fig. 16) and rotate anticlockwise.

Fig. 15

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ZF PADOVA

Under no circumstances this operation is

allowed to both valves contemporaneously,
because the engagement of both clutches at 3
B A
the same time would lock the transmission.

A= closed valve (regular position);

B= open valve (emergency position).

Fig. 16

1.8 PARTS OF THE GEARBOX

1.8.1 TROLLING VALVE (T.V.)

The trolling valve is a device that permits a variable control of the speed (Fig. 17). It permits to make
the propeller work at a lower speed in comparison with the system without T.V.
The typical applications are:
1) Reduce the boat speed when the engine is already at idle speed.
2) When a PTO (power-take-off) controlled by the motor works with a constant speed and the boat
speed must be necessarily reduced.
The trolling valve system can be used for forward and backward movements, observing the peak rpm
indicated below.

Peak rotating running = (max motor rev. x 0,5) RPM, for the motors which peak rotating running is
lower than 2000 RPM.
Peak rotating running = (1000) RPM, for motors which peak rotating running is higher than 2000 RPM.

Use
Reduce the motor revolutions to the minimum, then engage the gear checking that the trolling valve
has been excluded.
Move the T.V.lever as to obtain the desired speed.
When the trolling is on, it is possible to modify the revolution number up to 1000 RPM using the requi-
red graduality

It is forbidden manoeuvring (forward → reverse and viceversa) when in trolling mode.

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1.8.2 REMOTE CONTROLS
Tab. 2

BW 155 family
X[°] L[mm] L1[mm] R[mm] R1[mm]
45 70.7 56.5 50 40

For the remote controls installation, it is

necessary to make sure that the lever, con-
trolled from the dashboard, can reach the
limit stop.
If this limit is not observed, the clutches can
burn because the oil flow is not sufficient.
Fig. 18

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ZF PADOVA

1.9 TECHNICAL FEATURES

1.9.1 OIL TYPE

OIL: For all the models Tab. 3

+ Olio Specif. Viscosity i.v. Specification

MIL - L 2104C API classes

SAE 30* SAE 30 102 cst (40oC) 1.6 cst (40oC) 100 MIL - L 2104D CC-CD-SC
MIL - L 46152 SD-SE-SF

MIL - L 2104C API classes

SAE 40** SAE 40 145 cst (40oC) 14.5 cst (40oC) 99 MIL - L 2104D CC-CD-SC
MIL - L 46152 SD-SE-SF

* = recommended ** = alternative for hot countries

Tab. 4

BW 155 14÷16 litres – Filling: through the oil filling plug (see p. 7
pos. 11).
+ Oil quantity BW155 A 14÷16 litres

BW155 V 16÷18 litres

Oil pump flow: 22 litres/min. for 1000 RPM

1.9.2 PRESSURE AND TEMPERATURE

Tab. 5

BW 155 23÷24 bar • The value must be measured using holes

15/17, marked on the drawing p. 7.
OPERATING
BW155 A 23÷24 bar
PRESSURE
BW155 V 23÷24 bar

OPERATING OIL
65÷85° C
TEMPERATURE

IF THE VALUES MEASURED DO NOT CORRESPOND WITH THE ONE EXPECTED, CONSULT
ZF AFTERSALE SERVICE.

It is advisable to install a pressure gauge (field 0-50 bar) in position 15 (Fig. 2 page 7 and Fig. 17 page
13) on the control valve cover or on the trolling valve body with dashboard indicator.
If an oil temperature sensor has been installed in position 5 (Fig. 2-3 page 7), check that the oil tem-
perature does not deviate from its steady state value. The steady state temperature value is indica-
ted in table 5.

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C H A P T E R

INSTALLATION
2

2.1 STANDARD GEARBOX INSTALLATION

Normally the gearbox is flanged to the motor. In this case, the two units are centered in an adequate
way. If the gearbox is installed separately with a universal joint, it can be fixed to the base either on
elastic mounts or on rigid mounts.
In addition to the normal universal joint applied to the motor, it could be necessary to install, another
element to absorb the unperfect alignement. See the following installation schemes.

Fig. 1 Fig. 2

Make sure the gearbox has been installed leaving the necessary space for the heat exchanger, the
pump and oil filter substitution and to permit the access to the oil dipstick.

The oil drain plug must be reached easily.

Tab. 7

INSTALLATION ANGLES PERMITTED Static longitudinal Pitching Rolling

FOR NAVIGATION (°)
(Refering to input shaft orthogonal and longitudi- – 5 ÷ + 10 – 10 ÷ + 25 – 15 ÷ + 15
nal axis in comparison with the ground plane)

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ZF PADOVA

2.2 APPLICATION WITH GEARBOXES AND V-DRIVE TRANSMISSION

The advice given in the preceeding paragraph are also valid in this case. If the gearbox is installed
separately, it is necessary to use a universal joint with variable lenght. To make the joint work in the
best conditions (omokinetic transmission) and to avoid damaging the gearbox or the motor, it is neces-
sary to respect some rules for the installation, as indicated in the following schemes.

2.2.1 ALIGNMENT METHOD WITH PARALLEL FACES FLANGES

The motor and the gearbox must be installed

so that flanges A and B are parallel.

1 Motor

2 Flexible coupling

3 Universal joint with variable lenght.

– Selected in accordance with the manu-
facturer advice.
– In compliance with the instructions for
the installation.
Fig. 3
4 Propeller axle.

5 Marine gearbox with input and output on

the same face.

Make sure the longitudinal axis of the flexible coupling, the universal joint and the gearbox input shaft
are aligned on the same vertical plane.

The installer is responsible for any damage caused by the breaking of the connecting cardan
shaft and to avoid them he must used protective structures.

16
2.2.2 ALIGNMENT METHOD WITH COUNTERPOINT SHAFTS

1 Motor
2 Gearbox
3 Universal joint with variable lenght.
– Selected in accordance with the manu-
facturer advice.
– In compliance with the instructions for
the installation.
4 Propeller axle.
To facilitate the correct alignment of the motor
and the gearbox, that is to say to obtain iden-
tical connecting angles: ß1 and ß2:
install two alignment shafts 6 instead of the
universal joint;
– the shafts must have the same lenght;
– align the two units so that the heads of
the shafts meets each other, to ensure the
Fig. 4
angles identity (ß1 and ß2);
– then remove the alignment shafts and
install the universal joint;
– make sure the longitudinal axis of the THE ALIGNMENT METHODS DESCRIBED CAN
flexible coupling, the gearbox alignment BE APPLIED FOR BOTH KIND OF INSTALLA-
and input shafts are aligned on the same TION.
vertical plane.

The installer is responsible for any damage caused by the breaking of the connecting cardan
shaft and to avoid them he must used protective structures.

2.3 CONNECTION TO THE PROPELLER AXLE

It is possible to install propeller axles with or without thrust bearing support. The thrust bearing is
necessary to lighten the axial strains that operate inevitably on the gearbox.The real axial load value
that can be borne by the gearbox depends on many factors. Therefore we advise you to consult the
nearest ZF Marine Design Engineering Department.
The performance of the propeller axle support depends on the operative loads and must be specified
by the shipyard.

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ZF PADOVA

X [mm]
max. 0,05

Y [mm]
max. 0.1

L [mm]
min. 500 for d < 60 mm
min. 1000 for d 60 ÷ 90 mm
min. 2000 for d > 90 mm

Fig. 5

The alignment must be checked before delivering the boat to the client taking into account that:
1 The boat must be completed in the water because the hull deformation in the water can modify the
alignment performed out of the water.
2 The propeller axle must be removable to permit the flange substitution.

An alignment fault could cause irreversible damages to the gearbox and to the hull sealing
system, and provoke noise, vibrations.
ZF Padova S.p.A. assumes no warranty liability for failures caused by improper use and impro-
per installation.

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C H A P T E R

TROUBLE SHOOTING
3

3.1 SYMPTOMS, CAUSES AND REMEDIES

SYMPTOMS CAUSES REMEDIES

1) No Oil Pressure 1 - Empty sump – Fill marine gear sump

(Neutral or Engaged
2 - Wrong rotation ] – See application specifications
position)
3 - Fully clogged suction filter screen ] – Remove and clean filter screen
4 - Damaged oil suction tubes ] – Disassemble and inspect suction tubes.
Replace parts as required
5 - Damaged or worn oil pump assembly ] – Remove and replace oil pump assembly
6 - Broken oil pump drive ] – Remove pump and replace drive
7 - Broken input or intermediate shaft ] – Remove and replace the shaft
8 - Coupling broken ] – Replace the coupling

2) Low Oil Pressure 1 - Pressure control valve stuck in open posi- – Remove and clean control valve carefully
Engaged position tion
2 - Low level oil – Fill oil level
3 - Selector valve lever not properly set – Adjust remote controls
4 - Oil lekas on clutch oil line (worn segments, ] – Overhaul gearbox and replace worn parts
damaged oil distribution supports, faulty
piston rings)
5 - Partially clogged filter screen – Remove and clean filter screen
6 - Damaged or worn oil pump assembly ] – Remove and replace oil pump assembly
7 - Scored valve bore on pressure control ] – Remove valve assembly. Disassemble
valve damaged valve assembly and inspect valve bore
8 - Pressure control valve spring worn or ] – Inspect and replace worn spring and adju-
broken st the pressure
9 - Improper oil – Drain gearbox and fill with proper oil
10 - Trolling control valve lever in trolling mode – Put the lever in no trolling range
11 - High oil temperature – See sympton 4

] To make the operations marked with this sign, it is advisable to ask ZF Aftersale Services.

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ZF PADOVA

SYMPTOMS CAUSES REMEDIES

3) High Oil Pressure 1 - Pressure control valve stuck in closed – Remove and clean control valve carefully
position
2 - Internal lines and pipes obstructed ] – Overhaul gearbox and clean pipes
3 - Oil side cooler fulded ] – Clean internal oil cooler

4) High Oil Temperature 1 -Insufficient heat exchanger capacity ] – Replace present heat exchanger with heat
exchanger of suitable capacity
2 - Insufficient cooling water flow ] – Replace valves and lines with larger inside
diameter ones
3 - Dirty heat exchanger ] – Clean heat exchanger
4 - Oil level too high or too low – Restore normal level
5 - Improper oil – Drain gearbox and fill with proper oil
6 - Clutches slipping – Check main pressure
7 - Oil pump cavitation – Add oil
8 - Improper bearing preload adjustment or ] – Check bearings preload and eventually
demage bearing replace
9 - Clutch piston locked ] – Remove and overhaul clutches
10 - Clutch plates warped ] – Overhaul gearbox and replace plates
11 - Insufficient oil flow to the cooler ] – Check oil pump

5) Excessive noise 1 - Air leaks in suction side of system – Tighten all fittings and/or replace damaged
tubes. Check filter screen
2 - Improper bearing end play adjustment ] – Check end play for bearings and make
(excessive end play) proper shim adjustments
3 - Damaged bearings ] – Overhaul gearbox and replace damaged
parts
4 - Worn gear teeth ] – Overhaul gearbox and replace worn gears
5 - Improper elastic coupling or damaged ] – Remove coupling and replace it with a sui-
table one

6) No neutral 1 - Selector valve lever not properly set – Adjust remote controls
2 - Clutch plates warped ] – Overhaul gearbox and replace plates
3 - Clutch piston seized ] – Remove and overhaul the clutch

] To make the operations marked with this sign, it is advisable to ask ZF Aftersale Services.

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SYMPTOMS CAUSES REMEDIES

7) Irregular 1 - Air in oil – Check oil level.

engagement or Correct air leaks on tubes and replace
no engagement emulsified oil
2 - Clutch piston seized ] – Remove and overhaul the clutch
3 - Misfunctioning of the rate of rise system ] – Check control valve
4 - Wrong linkage position ] – Adjust remote control
5 - Internal oil leak circuit – Check oil circuit
6 - Improper oil temperature – Check heat exchanger
7 -Electrical circuit or solenoid damaged – Check electrical circuit
(for electrical control valve only)

8) External oil leakage 1 - Seals or shafts damaged ] – Replace seals or shafts

2 - Breather fulded – Clean the breather and check the seat
3 - Oil dipstick leak – Replace oil dipstick
4 - Plugs and connectors loosening – Lock the plugs and connectors
5 - Demaged hoses – Replaces hoses
6 - Leakage from the housing ] – Replace gasket or sealant

9) Oil level variation 1 - Exchange water-oil through the cooler ] – Replace the cooler

] To make the operations marked with this sign, it is advisable to ask ZF Aftersale Services.

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C H A P T E R

4 MAINTENANCE

4.1 MAINTENANCE PROGRAM

Semi-annually / 250 hours

After 50 hours of operation

Annually / 500 hours

MAINTENANCE OPERATIONS
Daily

3 3 3 3 Check for oil leaks

3 3 3 3 Oil level check

3 3 3 3 Hose connections, nuts, fittings and bolts tightening

3 3 3 3 Shift position adjustment

3 3 3 3 Suction filter check

3 3 3 3 External transmission cleaning

3 3 3 3 Lubrication of external moving parts

3 3 3 3 Oil change

3 3 3 3 Replace oil filter cartridge

3 3 3 3 Check for flexible coupling

3 3 3 3 Check flexible mounting pads

3 3 3 3 Clutch disc inspection

3 3 3 3 Gear inspections

3 3 3 3 Indicator devices

3 3 3 3 Replace zinc anodes

3 3 3 3 Oil cooler cleaning

3 3 3 3 Bearing visual check

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ZF PADOVA

4.2 ORDINARY MAINTENANCE OPERATIONS

4.2.1 AFTER 50 HOURS OF OPERATION

• First oil change
• Hose connection,nuts, fittings and bolts tightening
Ensure all hose connections, external nuts and bolts are tight.
• Remote control adjustment
When the engine is off, remove the connecting plug of the remote control cable from the lever of
the distributor, then place it in the forward speed position.
Place the lever in its forward speed position and check that the lever cable connectors coincide.
Repeat the operation for the reverse speed and, if there are irregularities, adjust the linkage as
necessary.
Then check that the neutral position of the lever on the dashboard coincides with the
neutral position of the distributor lever
Note: to be checked after the first 50
hours of operation. Fig. 1

• Oil change 2 1

Take out the oil dipstick [1] and remove

the drain plug [2] (fig. 1) .

Drain lube oil by removing the drain plugs Fig. 2

[1] (fig. 2). Collect plugs seals.
Collect exhaust oil.
Tighten the plugs [1] with a torque of 90
Nm, fill oil through plug [2] (fig. 1) and
screw in it with a tightening torque of 80
Nm.

24
 • Suction filter check Fig. 3
The suction filter should be inspected and
cleaned at 50 hours of operation then
semy annually and/or 250 hoursof opera-
tion. This is located on the suction side of
the oil pump.
Removal procedure:
– remove plug [1] (fig. 3);
– remove suction filter [2], copper seal,
clean and reassemble with a new cop-
per seal;
– tighten plug with a torque of 100 Nm. 2

4.2.2 DAILY

• Check for oil leaks

Start the engine and check for any external oil leaks. Ensure that all connections are tight.

• Oil level check

The oil level must be checked only when the motor is off, 2 minutes after it has been turned off.

The right oil level is between the upper

and lower sign on the measuring stick
(fig. 4). For the first oil filling and after
maintenance operations or oil filter clea-
ning, it is necessary to remember that
some oil stays in the cooler, in the pipes
or in the filter chamber and does not flow
in the gearbox. So after the gearbox has
been working for some time, moreover 2
minutes after the motor has been turned
off, check the oil level on the measuring
stick.

Pull out the dipstick only when the motor

is off, otherwise the boiling oil could
sprinkle out from the reduction gear and
Fig. 4
provoke dangerous burns.

4.2.3 SEMI-ANNUALLY AND/OR 250 HOURS

• Check for oil leaks

• Oil level check

• Hose connections, nuts, fittings and bolts tightening

• Shift position adjustment

• Suction filter check

25
ZF PADOVA

• External transmission cleaning

The transmission should be throughly cleaned externally with a cleaning agent semi-annually.

Caution: do not allow the rubber components to come in contact with the cleaning agent.

• Lubrication of external moving parts

Lubricate the moving parts of the shifting mechanism as recommended by the manufacturer.

4.2.4 ANNUALLY AND/OR 500 HOURS

• Check for oil leaks

• Oil level check

• Hose connections, nuts, fittings and bolts tightening

• Shift position adjustment

• Suction filter check

• External transmission cleaning

• Lubrication of external moving parts

• Oil change

• Replace oil filter cartridge Fig. 5

The oil filter has to be replaced by the fol-
lowing procedure: 1
1) turn the oil filter [1] (fig. 5) in an anti-
counterclockwise direction and remo-
ve the filter from its place;
2) place new filter element;
3) lock the filter with hands power only
after giving oil on the gasket.

• Check for flexible coupling

The flexible coupling/damper plate/rubber block drive can be checked by the following procedure:
1) rotate engine slowly and check rubber components for cracks, embrittlement and signs of
overheating or oil contamination;
2) a starting point should be marked on the coupling with chalk to ensure complete rotation.

Caution: disconnect starter prior to jacking over engine.

• Check for flexible mounting pads

Follow the manufacturers suggested maintenance annually.

26
• Clutch disc inspection
The clutch disc have to be chacked for wear and signs of overheating annually (where it is possi-
ble through an inspection access cover).

• Gear inspection
The gears have to be checked for wear annually.

• Indicator devices
All indicators must be checked annually for accuracy.

• Replace zinc anodes

On oil coolers, zinc anodes are fitted near raw water inlet and outlet of cooler. This must be
checked at 500 hours or annually. Replace zinc anodes if water leakage occurs.

• Oil cooler cleaning

The oil cooler has to be inspected and/or cleaned annually. Also if operational performance is out-
side of normal operating specifications.

27
C H A P T E R

5 WARRANTY

The gearbox has an identification plate which shows important information. Don’t tamper with
or remove this plate or the warranty is void.

The data stamped on the plate must be quoted whenever you require Aftersale Service.

WARRANTY CARD
ZF PADOVA S.p.A. within the period of validity specified in the warranty card, is liable for all defecti-
ve components of the new unit due to poor materials used by ZF PADOVA S.p.A. and incorrect machi-
ning, but not for failures caused by improper use and improper installation, inaccurate or missing main-
tenance, accidents. ZF PADOVA S.p.A. assumes no liability for components (e.g. oil seals, gaskets,
driving belts, rubber bellows, guards and diaphgrams) which, because of their material composition,
are subject to continuos fatigue or premature wear, except when assembling, application or original
faults are uniquivocal. The units or their parts must absolutely be installed in compliance with ZF
PADOVA S.p.A. specifications or exlusively with the approval from ZF PADOVA S.p.A, Design
Engineering or Application Department. ZF PADOVA S.p.A. will provide free of charge either new com-
ponents or components repaired at its own Works or at a ZF-Service workshop for really defective
units or elements, provided all shipment costs have been prepaid by the owner of the boat or of the
vehicle.
All expenses concerning the operations carried out by ZF PADOVA S.p.A. authorized technicians to
get access to the unit or its components are and remain at the exclusive charge of the owner of the
boat of the vehicle. ZF PADOVA S.p.A. assumes no liability for consequent damages, expenses, com-
pensations of any kind whatsoever. All unauthorized expenses will not be reimbursed. ZF PADOVA
S.p.A. is intitled to cancel the warranty if repairs of modifications are carried out without its previous
approval or if such works are carried out by staff not previously authorized by ZF PADOVA S.p.A. or
if ZF PADOVA S.p.A. genuine parts are not used.
In signing the attached warranty card the User agrees to comply with the above clauses as well as
with those set by ZF PADOVA S.p.A. General Sales Conditions.
Damage to transmissions caused by torsional vibrations, repeated or continuos emergency maneu-
vres or abnormal operation is not covered under Warranty.

NOTE: THE PERIOD OF VALIDITY OF THE WARRANTY IS SPECIFIED IN THE WARRANTY

CARD, THAT MUST BE KEPT TOGETHER WITH THE BOAT DOCUMENTS.

29
ZF PADOVA

5.2 AFTER SALES SERVICE

ARGENTINA + ZF FAE - FABRICA ARGENTINA FRANCE + ZF FRANCE S.a.r.l.

DE ENGRANAJES S.A.I. y C. Z.I.
Hipolito Yrigoyen 1628 - 6° piso 3-11 Rue Henri Poincaré
1344 Buenos Aires F-92 167 Antony Cédex
ARGENTINA FRANCE
Tel. +54 (0)1 498 806 Tel. +33 (0)1 4096 4273
Fax +54 (0)1 492 517 Fax +33 (0)1 4096 4285

AUSTRALIA + ZF AUSTRALIA PTY. LTD. GERMANY + ZF MARINE GmbH *

Locked Bag 13, 23 Foundry Road Ehlerstrasse 50
Seven Hills NSW 2147 D-88038 Friedrichshafen
AUSTRALIA GERMANY
Tel. +61 (0)2 9674 6222 Tel. +49 (0)7541 77 - 2207
Fax +61 (0)2 9674 6445 Fax +49 (0)7541 77 - 4222

BRAZIL + ZF DO BRASIL S.A. * + ZF MARINE GmbH - ZF HURTH

Avenida Conde Zeppelin, 1935 MARINE **
CEP 18103-000 Sorocaba-SP Zamdorferstrasse 90
BRASIL D-81677 München
Tel. +55 (0)15 235 2586 / 2389 GERMANY
Fax +55 (0)15 235 2233 Tel. +49 (0)89 930094 63/64
Fax +49 (0)89 930094 21
CHINA + ZF SHANGHAI Representative
Office + SCHIFFSDIESELTECHNIK KIEL
Room 6E, Yi-Dian Building, No. 746 Grasweg 26 b
Zhaojiabang Road, Xuhui D-24118 Kiel
District, Shanghai 200030 GERMANY
P.R. CHINA Tel. +49 (0)431 542029
Tel. +86 (0)21 6445 9745 / 9746 Fax +49 (0)431 542382
Fax +86 (0)21 6445 9748
GREECE + TEKMAR Ltd
+ FOILBORN ENTERPRISE Ltd. 15 Ethn. Makarioy Str.
Unit A8-9, 13/F GR-185 47 Piraeus
GREECE
Veristrong Ind. Ctr
Tel. +30 (0)1 4820814
34 - 36 Au Pui Wan. St.
Fax +30 (0)1 4118938
Fo-tan, Shatin
N.T. Hong Kong
Tel. +852 (0)2 687 2988 + THEODOR MALERDOS & C. **
Fax +852 (0)2 687 1996 55 Dragatsaniou Street
GR-18545 Piraeus
+ JEBSEN & CO LTD GREECE
Tel. +30 (0)1 4172488
12/F., Scomber Building, Fax +30 (0)1 4175441
1 Yip Fat Street,
Wong Chuk Hang, Hong Kong
Tel. +852 (0)2 9262179
+ ARIEXPO ENGINEERING S.A.
Fax. +852 (0)2 28821588 60, Alimou Ave.
GR-17455 Alimos
Athens
CYPRUS + CHAR. PILAKOUTAS Ltd. ** GREECE
P.O. Box 1168, 7 Larnaca Road Tel. +30 (0)1 981 1237
1503 Nicosia Fax +30 (0)1 983 1346
CYPRUS
Tel. +357 (0)2 349572 INDIA + BHARAT GEARS Ltd.
Fax +357 (0)2 349952 Hoechst House, 14 Floor
Nariman Point
DENMARK + ZF DANMARK ApS Bombay 400 021
Hesselager 21 - P.O. Box 97 INDIA
DK-2600 Glostrup Tel. +91(0) 22-2 83-11 14
DENMARK Fax +91(0) 22-2 87-02 97
Tel. +45 (0)43 436243
Fax +45 (0)43 432643 ISRAEL + NIMDA CO. Ltd.
1 Korazin Street
EGYPT + MAPSO Givatayim 53583
5 Ahmed Orabi Street, Manshia ISRAEL
Alexandria Tel. +972 (0)3 571 2161
EGYPT Fax +972 (0)3 571 5022
Tel. +20 (0)3 4833 453
Fax +20 (0)3 4833 486 ITALY + ZF PADOVA S.p.A. *
ZF MARINE
FINLAND + ATOY OY ATOCO Via Penghe, 48
Lauttasaarentie 54 I-35030 Caselle di Selvazzano (PD)
FIN-00200 Helsinki ITALY
FINLAND Tel. +39 049 8299 311
Tel. +358 (0)9 6827 1 Fax +39 049 8299 550
Fax +358 (0)9 6827 303

30
 + ZF HURTH MARINE S.p.A. * SINGAPORE + ZF SOUTH EAST ASIA Pte.
Via S. Andrea, 16 51 Tuas Ave. 1, Jurong Town
I-38062 Arco (TN) Singapore 639501
ITALY Rep. of SINGAPORE
Tel. +39 0464 580555 Tel. +65 (0)8 610177
Fax +39 0464 580544 Fax +65 (0)8 621311

+ ZF ITALIA S.r.l. SOUTH AFRICA + ZF of SOUTH AFRICA Pty. Ltd.

Via Donizetti, 11 P.O. BOX 2098, Kempton Park 1620
I-20090 Assago (MI) Rep. of SOUTH AFRICA
ITALY Tel. +27 (0)11 453 1818
Tel. +39 02 4884 2778 Fax +27 (0)11 453 8588
Fax +39 02 4884 3260

JAPAN + ZF JAPAN CO. Ltd. SPAIN + ZF ESPAÑA, S.A.

Bungakudo Bldg. 5th Flr. Avenida Fuentemar, 11 -
1-7-1, Isago, Kawasaki-Ku E-28820 Coslada, Madrid
Kawasaki-City SPAIN
Kanagawa 210 Tel. +34 (0)91 485 2698
JAPAN Fax +34 (0)91 673 3931
Tel. +81 (0)44 246 3017
Fax +81 (0)44 246 3020 SWEDEN + KGK TRANSMISSIONS AB
Hammarbacken 8
+ YOKE CO., LTD. ** S-191 81 Sollentuna
Taguchi Bldg. 6F SWEDEN
3-16-3 Ueno, Taito-Ku Tel. +46 (0)8 923 000
Tokyo 110 Fax +46 (0)8 929 599
JAPAN
Tel. +81 (0)3 3834 2871 TURKEY + NIVEKO Makina Ticaret Limited
Fax +81 (0)3 3834 2872
Takkeci Sokak No. 3
TR-80820 Arnavutköy - Istanbul
KOREA + ZF KOREA CO. Ltd. TURKEY
422-2 Chongchon-dong Tel. +90 (0)212 287 2780
Bupyong-Gu, Incheon 403-032 Fax +90 (0)212 287 6571
Rep. of KOREA
Tel. +82 (0)32 505 1530 UNITED KINGDOM + ZF GREAT BRITAIN Ltd.
Fax +82 (0)32 505 1514
Abbeyfield Road, Lenton
Nottingham NG7 2SX
+ ZF-HURTH MARINE UNITED KINGDOM
KWANG-NAM Tel. +44 (0)115 986 9211
10Fl Hyundai Bldg. Fax +44 (0)115 986 9261
80 Jeok Sun-Dong
Jong Ro-KU - Seoul UNITED ARAB
Rep. of KOREA
Tel. +82 (0)32 738 0151 EMIRATES + ZF MARINE MIDDLE EAST
Tel. +82 (0)32 738 0158 Office No. 16 Main Office Block
Lamnalco Oilfield & Marine Supply Base
MALAYSIA + AJENSI TULEN SDN. Bhd. Creek Road, Sharjah
U.A.E.
35 A Jalan Anggerek 36
Tel. +971 6 5722 455
Taman Johor Bahru, Johor
Fax +971 6 5741 745
MALAYSIA (WEST)
Tel. +60 (0)7354 7755
Fax +60 (0)7354 7757 U.S.A. + ZF INDUSTRIES INC
ZF MARINE U.S. HEADQUARTERS *
MALTA + LANCING MARINE 3131 Southwest 42nd Street
Fort Lauderdale, FL 33312
9, Main Street
U.S.A.
Zurrieq
Tel. +1 954 581 4040
MALTA
Fax +1 954 581 4077 (SERVICE / PARTS)
Tel. +356 (0)6 82244
Fax +1 954 581 4078 (SALES)
Fax +356 (0)6 11223

NETHERLANDS + AMW MARINE + ZF INDUSTRIES INC.

ZF MARINE GULF COAST FACILITY
Veersedijk 99 161, James Drive West, Suite 120
NL-3341 LL St. Rose, LA 70087
Hendrik-Ido Ambacht U.S.A.
THE NETHERLANDS Tel. +1 504 443 0501
Tel. +31 (0)78 6810100 Fax +1 504 443 0504
Fax +31 (0)78 6818878
+ ZF INDUSTRIES INC:
+ DACO B.V. ** ZF MARINE WEST COAST BRANCH
Avelingen - West 30 1095 Andover Park East,
NL - 4202 MS Gorinchem Seattle, WA 98188
THE NETHERLANDS U.S.A.
Tel. +31 (0)183 637577 Tel. +1 206 574 0375
Fax +31 (0)183 632906 Fax +1 206 574 0868

NORWAY + ZF NORGE AS
Casper Storms Vei 19
N-0664 Oslo
NORWAY
Tel. +47 (0)22 720 575
Fax +47 (0)22 720 902

POLAND + MARCO MOTORS

ul. Lady 2
PL-71-605 Szczecin
POLAND
Tel. +48 (0)91 4500552
Fax +48 (0)91 223942 * MANUFACTURING LOCATIONS
** ZF HURTH REPRESENTATIVE

31
C H A P T E R

MAINTENANCE CERTIFICATES
6

Hours work Hours work

Date, stamp, signature Date, stamp, signature

Hours work Hours work

Vigonza (Padova) - Italy

Date, stamp, signature Date, stamp, signature

33
 OPERATING MANUAL - MANUALE D'USO
BETRIEBSANLEITUNG - MANUEL DE SERVICE

IRM 312 TS

MARINE
ZF PADOVA spa

ZF Marine GmbH ZF Padova S.p.A. ZF-HURTH Marine S.p.A. ZF do Brasil S.A.

Via Penghe, 48 ENVIRONMENTAL MANAGEMENT

SYSTEM CERTIFIED
I-35030 Via S. Andrea, 16 Avenida Conde Zeppelin, 1935
D-88038 Friedrichshafen Caselle di Selvazzano (PD) I-38062 Arco (TN) Cep. 18103-000 Sorocaba - SP
RINA
UNI EN ISO 9001 (ISO 9001)

GERMANY ITALY ITALY BRASIL MARINE 32.70.312.5273

QUACER ISO 9001 ISO 9001 RINA
Phone +49 (7541) 77-2207 Phone +39 - 049 8299-311 Phone +39 - 0464 580-555 Phone +55 (15) 235 2586/2389 Certified Quality System Certificate Number: 30062 E M S C E R
ZF PADOVA spa Ed. 07/99
Fax +49 (7541) 77-4222 Fax +39 - 049 8299-550 Fax +39 - 0464 580-544 Fax +55 (15) 235 2233
I S O 1 4 0 0 1