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Operating Instructions Marine transmission ZF 9000 series
ZF 9000 NR, ZF 9050 NR, ZF 9065 NR. ZF 9300 NR, ZF 9311 NR, ZF$350NR, ZF 9351 NR, ZF 9355 NR, ZF 9356 NR ZF 9000 NR2, ZF 9050 NR2. ZF 9b% NRZ, ZF 9050 NK2 ZF 9000 NR2B. ZF 9050 NRZB, Zp 9055 NRZB, ZF 9080 NR2B ZF 5000 NUH, ZF 9050 NWH, ZF $055 N M H ZF 9000, ZF 9030, ZF 9055, ZF g300, ZF 931 I,ZF9350, ZF 9351, ZF 9355, ZF 9'358 ZF 9000 A, ZF 9050 A, ZF 9058 A ZF 9000 ANR, ZF 9050 ANR, ZF 9055 ANR ZF 90DO V, ZF 9050 V, ZF 9055 V ZF 0000 VNR, ZF G650 VNR, ZF 9066 VNR
Foreword
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FOREWORD This operating manual is a fundamental part of the transrnission and must accompany it. The operating rnanual is to be used for avoiding problerns and darnages during operation and should be rnade available for the rnaintenance and operating personnel. The warranty terms and conditions agreed upon with ZF Marine GmbH for the transrnission are to be applied accordingly. ZF Marine GmbH will only accept warranty claims when: - The transmission has been installed, controlied,
operated and maintained according to the instructions of this operating manual. - The ZF-approved lubricants have been used (ZF
TE-ML 04). - The rnaxirnum engine output speed ratio accord-
ing to the specification plate as well as the engine speed according to the transmission classification has not been exceeded. This operating rnanual applies to standard transrnissions. Differences due to customisation and operating conditions are possible. If the information in the operating manual deviates frorn the technical andlor comrnercial specifications then the information in these specifications is binding. This operating rnanual was issued in consideration of the following current Standards and regulations: DIN EN 62079; DIN EN ISO 12100-2; DIN EN 60204-1; DIN 31052
VDI guideline 4500
3103.758.101 1 Edition: 2009104
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Table of contents
TABLE OF CONTENTS
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FOREWORD
1 SAFETY 1. 1 Conventions for safety instructions in the text . 6 1.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . .6 1.3 Personnel and organisational requirernents . . 7 1.4 Safety regulations for s e ~ i c eand repair works 7 1.5 Consurnables and service fluids. fire and environrnental protection . . . . . . . . . . . . . . . .9 1.6 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . .10
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2 PRODUCT OVERVIEW 12 2.1 Transmission ovewiew . . . . . . . . . . . . . . . . .12 2.1 .1 General design principle . . . . . . . . . . . . .12 2.1.2 Installation position i n the ship . . . . . . . . 15 2.1.3 Direction of rotation of propeller during forward travel . . . . . . . . . . . . . . . . . . . . .17 2.1.4 Transmission views . . . . . . . . . . . . . . . . .18 2.2 Technical specifications . . . . . . . . . . . . . . . .32 2.2.1 Transmission description . . . . . . . . . . . . 34 2.2.2 Monitoring ZF 9000/9300 series without versions NR2. NR2B. and NR2H . . . . . . . 36 2.2.3 Monitoring values ZF 9000 NRZ/NRZB/ NR2H ZF 9050 NR2/NR2B/NR2Hr ZF 9055 NR2/NR2B/NR2H2ZF 9060 NR2/ NR2B . . . . . . . . . . . . . . . . . . . . . . . . . . .37
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3 DESCRlPTlON .BASIS TRANSMISSION AND VERSIONS 38 3.1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . .38 3.2 Application area . . . . . . . . . . . . . . . . . . . . . .41
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4 INITIAL INSTALLATION AND 43 COMMlSSlONlNG 4.1 Initial installation . . . . . . . . . . . . . . . . . . . . . .43 4.1 .1 Transmission support in the foundation . 44 4.1.2 Connection to the motor . . . . . . . . . . . . . 45 4.1.3 Connection to propeller shaft . . . . . . . . .45 4.1 3 . 1 Shaft installations with only one suppott for propeller shaft (fig. A) . . . 46 4.1.3.2 Shaft installations with t w o or more supports for the propeller shaft (fig. B) 46 4.1.4 Connection to the joint shaft . . . . . . . . . .47 4.1.5 Alignment of the transmission . . . . . . . . 49 4.1.6 Transmission cooling (cool systerns) . . . . 49 4.1.6.1 Open sea water circuit . . . . . . . . . . . .49 4.1.6.2 Closed sea water circuit . . . . . . . . . . .49 4.1.7 Transmission cooling (Design of the cooler) . . . . . . . . . . . . . . . . . . . . . . . . . 50 . 4.1.7.1 Requirernents for the cooling water circuit . . . . . . . . . . . . . . . . . . . . . . . .50 4.1.7.2 Earthing . . . . . . . . . . . . . . . . . . . . . . .51 4.1.7.3 Drainage of the transrnission oil cooler . . . . . . . . . . . . . . . . . . . . . . . .51 4.1.8 Transmission cooling (pipework) . . . . . . 51 4.1.8.1 Installation . . . . . . . . . . . . . . . . . . . . .51
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4.1.8.2 Screw-in nozzle . . . . . . . . . . . . . . . . .52 . 4.1 3 . 3 Flow velocity . . . . . . . . . . . . . . . . . . 52 4.1 3 . 4 Materials for the cooling-water pipe . . 52 4.1 3 . 5 Eatthing for the cooling-water pipe . . 52 4.1.9 Transmission cooling (general notes) . . . 52 4.1 3 1 Clearance for rnaintenance work . . . . 52 4.1 .10 Oil filling and oil level control . . . . . . . . .52 4.1 .11 Connection of rnonitoring equiprnent . . . 53 4.2 Installation control and cornrnissioning . . . . . 53 4.3 Cornrnissioning afterstandstill . . . . . . . . . . .54 4.3.1 Standstill of 3 t o 6 rnonths . . . . . . . . . . . 54 4.3.2 Standstill of 6 to 9 months . . . . . . . . . . .54 4.3.3 Standstill of 36 rnonths and rnore . . . . . . 54 4.4 Operation control . . . . . . . . . . . . . . . . . . . . 54 . 4.4.1 Minimum transrnission monitoring . . . . . 54 4.4.2 Additional transrnission rnonitoring . . . . . 55
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5 OPERATION 57 5.1 Operating controls . . . . . . . . . . . . . . . . . . . .57 5.1 . 1 Electric transmission control with three magnet valves (for ZF 900 series without NR. NR2. NR2B and NR2H) . . . . . . . . . . 58 5.1 . 1.1 Electric transrnission control elernents 58 5.1.1.2 Mechanical ernergency control with three magnet valves (for ZF 9000 series without NR. NR2. NR2B and NR2H) . . . . . . . . . . . . . . . . . . . . . . . .59 5.1.1.3 Operation using the rnechanical ernergency control . . . . . . . . . . . . . . .60 5.1.2 Electric transmission control with t w o rnagnet valves (for ZF 9000 series without NR. NR2. NR2B. and NRZH) . . . . . . . . . .62 5.1.2.1 Electric transrnission control elernents 62 5.1.2.2 Mechanical ernergency control with t w o rnagnet valves (for ZF 9000 series without NR. NR2. NR2B. and NR2H) . 63 5.1.2.3 Operation using the rnechanical ernergency controi . . . . . . . . . . . . . . .64 5.1.3 Electric transmission control (for ZF 9000 series without NR2. NR2B and NR2H) . . 65 5.1 3 . 1 Electric transrnission control elernents 65 5.1.3.2 Mechanical emergency controi (for ZF 9000 series without NR. NR2. NR2B and NR2H) . . . . . . . . . . . . . . . . . . . . 67 . 5.1 3 . 3 Operation using the rnechanical ernergency control . . . . . . . . . . . . . . .69 5.1.4 Electric transmission control (for ZF 9000 NR21NR2BINR2H series) . . . . . . . . . . . .70 5.1.4.1 Electric transrnission control elernents 70 5.1.4.2 Mechanical emergency control (for ZF 9000 NR2INR2BINR2H series) . . . 71 5.1.4.3 Operation using the rnechanical ernergency control . . . . . . . . . . . . . . .72 5.2 Switching operation . . . . . . . . . . . . . . . . . . .72 5.2.1 Switching Neutral > Forward and Neutral > Reverse . . . . . . . . . . . . . . . . . .73 5.2.2 Switching Forward > Reverse and vice versa . . . . . . . . . . . . . . . . . . . . . . . . . .73 .
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Table of contents
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5.2.3 Switching in case of Danger (crash stop) 73 5.3 Trailing operation . . . . . . . . . . . . . . . . . . . .73 5.3.1 Occasional trailing operation . . . . . . . . . 73 5.3.2 Regular trailing operation . . . . . . . . . . . 73 5.4 Operation by means of emergency circuit ("Come home screws") . . . . . . . . . . . . . . . . 7 4 5.4.1 Emergency circuit activation . . . . . . . . . 75 5.4.2 Emergency circuit deactivatio . . . . . . . . 75
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6 SPECIAL EQUIPMENTISPECIAL DESIGNS 77 6.1 Trolling . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 6.1 .1 Electrical trolling . . . . . . . . . . . . . . . . . . 77 6.1.2 ZFAUTOTROLL . . . . . . . . . . . . . . . . . . . 78 6.2 Trailing operation oil pump (trailing pump) . 78 6.3 PTO=Power Take Off . . . . . . . . . . . . . . . . . .79
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7 TROUBLESHOOTING 80 7.1 Troubleshooting information . . . . . . . . . . . . 80 7.2 Table of possible faults . . . . . . . . . . . . . . . . 81 7.2.1 Overall transmission . . . . . . . . . . . . . . . 81 7.3 Transmission oil cooler . . . . . . . . . . . . . . . . 83 7.4 Diagnosis for ZF AUTOTROLL (Special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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8 MAINTENANCE 86 8.1 Maintenance schedule . . . . . . . . . . . . . . . . 86 8.1 . 1 Maintenance schedule concept . . . . . . . 86 8.1.2 Maintenance work before taking out of operationlstandstill . . . . . . . . . . . . . . . . 87 8.1.2.1 For closed cooling circuit . . . . . . . . . 87 8.1.2.2 For closed cooling circuit . . . . . . . . . 87 8.2 Corrosion protection and conservation . . . . 90 8.3 Plan for rnaintenance work . . . . . . . . . . . . . 92 8.4 Tool kit . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 8.4.1 Tool kit W1 for maintenance . . . . . . . . . 93 8.5 Spare parts and spare part orders . . . . . . . . 94 8.6 Maintenance system work sheets . . . . . . . . 95
3103.758.101 / Edition: 2009/04
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Safety
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1
SAFETY
1.2
1.I
Conventions for safety instructions in t h e text
General
DANGERI In case of imminent Danger. Consequences: Death or very serious lnjury.
*
General notes
In addition to the present operating instructions the general applicable locai, legal, and other compulsoiy regulations on accident prevention and environmental protection are to be observed. This transmission was constructed according to the current state of the art and the applicable rules and regulations. However, the transmission can still present personal and physical risks, in case of:
* unintended use
Countermeasures
operating, s e ~ i c i n g and , commissioning by unqualified personnel
* changes or modifications WARNING!
*
noncornpliance with safety instructions
lntended use In possibly Dangerous situation Consequences: Death or very serlous injury.
*
Countermeasures
In Dangerous situation Consequences: Minor injuries or material damage.
The transmission is designed exclusively for the purpose defined in the contract andlcir as foreseen at delivery. Any other or further use is considered as unintended. The manufacturer of the transmission does not assume any liability for damages resulting of such use. The risk will be borne solely by the user. The intended use also comprises compliance with the operating instructions as weil as cornpliance with the service and repair instructions. Special and emergency modes must remain limited to the rnaximum admissible time or number of cycles according to the operating instructions.
Countermeasures Changes or modifications Note: This document specially highlights safety instructions according to US standard ANS1 2535 which are introduced by one of the signal words listed above according to the degree of Danger. Safety instructions: 1. Ensure that you read and understand all warnings prior to commissioning or repair the product. 2. Pass on all safety instructions also to the operating, service, and repair personnel andlor transport personnel.
Unauthorized changes to the transmission impair the safety. ZF Marine GmbH will not assume any liability or warranty obligations for damages resulting from unauthorized changes or modifications. Spare parts Oniy ZF original spare parts may be used for replacement of components or assembly groups. For darnages resulting from the use of other spare parts all liability and warranty ciaims against the manufacturer of the transmission will expire.
Note: Used to point out special procedures, methods, information, use of devices, etc.
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Safety
1.3
that all persons are clear of the Danger area of rnoving parts.
Personnel a n d organisational requirements
Personnel requirements Works on the transrnission rnust be left to trained and instructed quaiified personnel. Based on their appropriate training and experience the qualified personnel rnust be capable to recognize risks and to avoid possible hazards which rnay be caused by the operation or the repair of the transrnission.
lrnmediately after comrnissioning of the transrnission andlorthe piant, ensure that the operating and display instrurnents and the monitoring, signalling, and alarrn systerns operate properly. Safety regulations for operation 0 The operator rnust be farniliar with the operation and display elernents.
The legal minirnurn age rnust be observed
The operator rnust be aware of the effects of every operating sequence perforrned by him. The operator rnust perforrn the individual operating sequences according to the instructions.
The operating instructions rnust be read and under stood by the personnel. The responsibilities of the personnel for operation. service, and repair are to be defined.
0
Organisational measures The present operating instructions rnust be passed on to the operating. service, repair andlor transport personnel. They rnust be readily available at the site where the transrnission is operated at any time and be accessible to the operating. service, repair andlor transport personnel. The personnel rnust be introduced to the handiing and repair of the transrnission with the help of the present instructions and the safety-relevant instructions rnust be explained in particular. This particularly applies to personnel who are working on the transmission only occasionaliy. Such personnel shouid be instructed repeatedly.
If a fault is detected or indicated by the systern.
*
inforrn the responsible supervisory personnel. evaluate the message. perforrn eventual ernergency rneasures, e.g operation by rneans of the ernergency circuit.
Operation of propulsion plant 0 Wear hearing protection while motor is running. 0
Ensure good ventilation of rnachine roorn. lrnrnediateiy wipe up leaked or spilled service fluids or absorb with corresponding absorbent.
Work clothing and protective equipment For all works work clothing corresponding to safety requirernents must be worn. Depending on the type of the work use additional protective equiprnent, e.g. goggles, protective gloves, safety helrnet, apron. Work clothing rnust fit tightly to ensure that it does not get caught by rotating or protruding parts. Do not wearje. weliery (rings, neckiaces, etc.).
During operation the display instrurnents and rnonitoring assemblies rnust be constantly monitored according to the rnomentary operational conditions to ensure cornpliance with the lirnit values and for warnings and aiarrns.
0
lnappropriate shielding of electrical parts can cause severe electric shock and subsequent injuries.
* Do never rernove water, oil, cornpressed air or hydraulic lines while rnotor is running. Servicing and repair
1.4
Safety regulations f o r service a n d repair works
Before using the product for the first time it rnust be installed and connected to the monitoring systern according to the present operating instructions.
An essential safetyfactor is the compliance with the service and repair instructions. Unless expressiy approved, servicing andlor repair works rnust not be per forrned while the rnotor is running. Secure rnotor against unintended Start. Attach "Do not operate" sign in the operator roorn or to the controi unit. Keep away uninvolved persons.
Ensure for every use of the transmission andlor plant
Note:
Safety regulations for commissioning
* that all service and repair works have been completed, that all lose parts of rotating machines have been removed,
3103.758.101 i Edition: 2009104
Do never rernove faults or perforrn repairs in case of absence of the required experience or speciai tools. Leave all service and repair works to authorized qualified personnel.
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Do only use tools that are suitable for the function and calibrated.
CAUTION!
* Do not work on transmissions or assemblies Take care when removing bleed screws or screw plugs from the transmission. In order to avoid leaking of liquids under pressure hold a cloth over the screw or the plug. The Danger of accident is even higher if the transmission was shut off only a short while ago and the liquids may still be hot.
which are held only by lifting devices or a crane. Always Support them according to regulations using appropriate means before beginning with servicing or repair works. @
Before turning the engine ensure that all persons are clear of the Danger area of the propulsion plant. Afte; performance of works on the transmission check if all protective equipment has been fitted and all tools and lose parts have been removed from the transmission.
* When removing or opening lines seal all openings
WARNING!
using caps and Covers. Do not damage pipes and tubes during servicing andlor repair works. For installation of connections between lines apply correct torque when tightening. Ensure that all brackets and dampers are installed properly.
Take care when draining hat Service fluids. Consequences: Danger of scalding!
Collect service fluids in a container, absorb spilled liquids using absorbent andlor wipe up.
Ensure that all electrical cables and pressure oil lines have enough clearance in order to prevent contact with other comoonents.
WARNING! Beware of hot liquids in lines, pipes, and rooms. Consequences: Danger of burning!
For works above body height use ladders and working platforms corresponding to safety requirements. Ensure stable positioning of transmission parts! In order to avoid back injuries when lifting components adults must not carry or lift more than a maximum of 10 kg to 30 kg, depending on age and Sex, thus: 0
use lifting equipment or get help ensure that all chains, hooks, eyes, etc. are tested and approved, have sufficient load capacity and that hooks are positioned correctly. lifting lugs must not be loaded from the side
WARNING! Obsewe cooling time of components which have been warmed u p for assembly or disassembly. Consequences: Danger of burningl
*
when performing service and repair works of the propulsion plant particularly ensure cleanliness. After completion of service and repair works ensure that no lose parts are inlnear the machine installation.
Welding works 0 Welding on the transmission or attached power units is not allowed. Never place welding cable above or near cable harnesses of the ZF plants. The welding currents can induce interference voltage in the cable harnesses which could result in damages to the electric installation.
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Edition 2009104 13103 758 101
Safety The ground connection of the welding device rnust not be connected in a distance of rnore than 60 crn frorn the welding location. Pressing on and off Only devices specified in the working plan and the assernbly instructions rnay be used for pressing an and off. The rnaxirnurn adrnissible slip-on pressure for the device for pressing on and off rnust not be exceeded. The high-pressure lines for pressing an and off are tested with 3800bar.
9
After cornpletion of the service andlor repair works reconnect and fasten any cables rernoved. After all repair works a functional inspection of the device andlor the installation rnust be petforrned by rneans of corresponding functional tests. A separate inspection of the repaired cornponent without integration in the cornponent assembly is not enough.
*
Cable ties rnust not be used for fastening since cable ties rnight be rernoved during service andl or repair works without being refitted.
Do not bend lines under pressure or apply force Before start of the pressing process observe the following:
*
Vent the device for pressing an and off, the purnps and the pipework at the positions intended for the relevant installation used (e.g. Open vent screws, pump until oil is free of air, tighten vent screws).
rernoved. In case of a device for pressing on and off with central expansion pressure application screw spindle in the shaft end until seal effect is achieved. 0
During hydraulic pressing on and off of cornponents ensure that all persons are clear of the component to be pressed on.
* While the systern is under pressure there is a risk of the cornponent to be pressed on abruptly corning off the pressure connection. 0
The devices rnust be checked in specified intervals prior to their use (crack detection test).
Works on electriclelectronic assembly groups * Prior to start of service and repair works andlor shutting off parts of the electronic system the authorization of the supervison/ personnel in charge rnust be obtained. Prior to perforrnance of works on assernbly groups the electric supply of the relevant areas rnust be disconnected. If specific rneasures require electric supply this will be rnentioned in the corresponding section of the docurnentation. Do not darnage cabling during dernounting works and install such that darnage to the cabling due to contact with sharp edges, rubbing an parts or contact with hat surfaces is excluded during operation. 0
Do not attach cables to liquid-carrying lines
Spare parts rnust be stored properly until used for replacernent. i.e. in particular protected against rnoisture. Defective electronic cornponents or assernbly groups rnust be properly packaged for transport to repair, i.e. in particular protected against rnoisture, in a shock-proof way, and where necessary in antistatic foii.
For press-on process Open device with plug inserted.
* For press-off process Open device with plug
If cables are near rnechanical cornponents and there is a risk of raying fasten thern using cable clarnps.
Operation of eclectic devices For Operation of electric devices certain parts of these devices are under electric voltage. Failure to cornply with the warnings applicable to the devices can result in severe injuries or material damages.
1.5
Consumables a n d service fluids, fire a n d environmental protection
Fire prevention Rernove oil leakages irnrnediately. Even srnall arnounts of oil or cleaning agent an hot Pans can cause fires.
* Thus, always keep transrnission clean. 0
Do not leave cloths irnpregnated with service fluids near the transrnission. Do not store cornbustible objectslrnaterial near the propulsion plant.
* Do not perforrn welding works on pipes and parts containing oil or fuel. Prior to all welding works clean with non-cornbustible liquid.
*
Always keep suitable extinguishing agent (fire extinguisher) ready and be aware and capable of its usage.
Noise Noise can result in an increased Danger of accident if irnpairing perception of acoustic signals, warning cries or noises indicating Danger.
10
satety At all work places with a sound pressure level exceeding 85db(A) wear hearing protection (protective Cotton, ear plugs or earmuffs).
Environmental protection * Dispose off used service fluids, cleaning agents, and filter in accordance with local regulations.
* *
Service fluids and cleaning agents rnust not enter soil, ground water or sewer System.
Paints and varnishes For painting works outside the Spray stands equipped with a suction System ensure sufficient ventilation.
* Ensure that adjacent work places are not irnpaired.
* No open flames. * Smoking is prohibited.
Request safety data sheets frorn the responsible environmental agency and for relevant products and observe them.
O b s e ~ eregulations or preventive fire protection. Wear protective rnasks against paint and solvent vapours.
Collect used oil in Container of sufficient size
*
When handling service fluids and cleaning agents obsewe regulations of the manufacturer.
Used oil Used oils can contain harrnful combustion residues. Apply Skin barrier cream to hands.
Service fluids and consumables
*
Do only use service fluids tested and approved by ZF (lubricant list TE-ML 04).
After contact with used oil clean hands.
1.6
Transport
Store sewice fluids and consumables in suitable and correctly labelled containers.
*
When handling sewice fluids and other chemical substances observe safety regulations applicable to the product.
* Do never use transrnission components, such as
*
Take care when handling hot, undercooled or caustic substances.
*
When handling flarnmable substances avoid contact with ignition sources, do not smoke.
Lead * When working with lead or lead-containing pactes avoid direct physical contact, do not breathe lead fumes.
Do always use lifting lugs or suspension angles to suspend transmission. cooler, oil pump, pipe works, brackets, Sensors, input or output shafts for attachment of lifting devices.
*
During lifting and lowering process do not stand under transrnission and stay clear of the Danger area. Observe centre of gravity of transrnission. For transport the transmission rnust always be in installation position, rnaximum adrnissible inclined hoist is 10 degrees.
*
Activate suction device
The lifting rope or chain should always be in a rninimum distance of 20mrn to the transmission components.
After contact with lead or lead-containing substances clean hands.
The load capacity of the lifting device rnust be at least 4,000kg.
Avoid occurrence of lead dust.
* Acids and bases When working with acids and bases wear goggles or face shield, gloves, and protective clothing.
Secure the transmission against tilting during transport. When using slopes and ramps particularly secure transrnission against slipping and tilting.
In case of cauterizations imrnediately remove contaminated clothing.
Transmission without suspension angles
Rinse injured body parts with plenty of water.
Lifting lugs are provided at the machined surfaces used for attachrnent of the sucpension angles.
lmrnediately wash eyes with eye bottle or clean tab water.
Do not use lifting lugs other than for transport of transmission. They rnust not be used for trancport of the overall propulsion unit (motor and transrnission).
* Prior to attachrnent of the suspension angles rernove lifting lugs.
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Edition: 2009104 1 3103.758.101
Safety
11
Transmission with suspension angles lf the transmission is supplied with original ZF suspension angles the outer load carriers are designed to be used as iifting lugs. Do always use these holes for all sling gear (e.g. shackle A4 according to DIN 82101, not supplied by ZF).
* lf suspension angles are not supplied by ZF the shipyard or the motor manufacturer must provide a corresponding transmission suspension. Lowering the transmission after transport 0 Do always lowertransmission on a flat. solid surface. Observe condition, load capacity of the floor andl or surface. Do never place transmission on oil sump unless expressly authorized by ZF for the individual transmission.
Fig. 1:
3103.758.101 1 Edition: 2009104
Transmission anchor and centre of gravity (S)
0 ZF
2
PRODUCT OVERVIEW
2.1
Transmission overview
2.1.1 General design principle
ZF marine transmissions are designed and manufactured in accordance with the regulations of the individual classification societies. The propuision power values approved by the classification society depend on the input Speeds, the class of the ship, and the various appiicable construction specifications. In most cases the maximum torques approved by ZF are also approved by the classification society up to the same rnaximum value. Full testing or rig acceptance by the classification society specified by the customer is possibie on request. The normal input direction in respect to the transmission input flange is clockwise. in the case of special design transmissions with anticlockwise input directions (with respect to the transmission input flange anticlockwise) a corresponding arrow is provided on the transmission input side. Transmissions of the ZF 9000 series are hypoid reverse transmission and reduction transmissions with triple gearing. One hydraulic multiple-disc clutch each is located on the input shaft and the intermediate shaft (also reversing shaft) of the transmission. The transmission versions NR2, NRZH, and NR2B are reduction transmissions with a specially designed double gearing which are not intended for reverse operation. A multiple-disc clutch is arranged on the input shaft. The output shaft rotates in opposite direction compared to the direction of rotation of the input shaft which is also described as "counter-engine wise rotation". The Cast iron housings of the transmissions are highly torsion-resistant and consist of a iargely sea-water resistant light alloy. The machined surfaces required for connection of transmission suspension angies and torque converter housing including threaded holes are provided as a standard. In ordert0 achieve a long Service life and a high degree of quietness in operation all power-transferring transmissions are designed to highest safety standards, case-hardened, polished, and subsequently submitted to a speciai treatment. The shafts rotate in antifriction bearings. Propeller thrust bearings are incorporated in the transmission to absorb the propeller thrust (no in the NR2 versions). The ciutch arranged on the input shaft is a multipie-disc clutch with steellsinter couple. It is pressured by oil pressure and thus closed.
0ZF
Oil supply and transrnission cooler The transmission housing is designed as oil container. A continuous delivery gear pump is used for delivery of the oil flow for transmission lubrication, transmission cooling, and for pressuring the multiple-disc clutch. The heiical gearing and corresponding gearing geometry of the pump wheeis ensure very iow sound ievel values and a low pressure pulse. The transmission housing provides threaded hoies for connection of Sensors for monitoring purposes as a standard. The following oil supply values can be measured at the transmission: transmission oil temperature, filter difference pressure (not for NRZ), lubricating oil pressure and clutch oil pressure. An oil cooler of sea-water resistant material is mounted to the transmission housing for cooling of the transrnission oii. This heat exchanger has a pipe bundle design. For cleaning of the transmission oil an exchange oil filter with filter cattridge is supplied. lt can be switched during operation (not for NR2). Control unit and transmission control The control unit is arranged as complete assembly group on the transmission housing and comprises the following essential components. - controi slide valve (fiiiing and venting of mul-
tiple-disc clutch) - control valve (clutch pressure value) - timer (modulation of clutch pressure)
The transmission control is made eiectrically or mechanically by means of a pilot valve which is located on top of the control unit. The electric operation is patt of the transmission basic design. Transmission design in A and parallel version The flange of the transmission shaft is always above the flange of the input shaft. The vertical axial distance between the two shafts is the measure "A. Transmission input and output are located on opposite sides of the housing. Parallel version Also referred to asvertical arrangement because of the verticai distance between input and output shaft (measure " A ) . The shafts in the transmission are arranged on parallel axes. The transmission description merely consists of the transmission type "ZF 9000" without being complemented by a letter.
Edition: 2009104 / 3103.758.101
Product overview
U version The shafts in the transmission are arranged on parallel axes. The transmission type is complemented by the description "U", for exarnple, ZF 9300 U.
Fig. 2:
Parallel version
Aversion The axis of the input shaft is inclined by the angle "?" towards the axis of the input shaft. The transmission type is complemented by the letter "A,for example, ZF 9000 A.
Fig. 4:
U version
V version The axis of the input shaft is inclined by the angle "?" towards the axis of the inout shaft. The transmission type is complemented by the letter " V , for example, ZF 9000 V.
Fig. 3:
A version
Transmission designs in V and U version In this design input and output flange are located an the Same transmission side. The flange of the transmission input shaft is always ebove theflange of the input shaft. The vertical axial distance between the two shafts is the measure "A.
Fig. 5:
V version
Transmission designs in N R 2 version The NR2, NR2H. and NR2B transrnission designs always have to parallel shafts. Reversing is not possible.
A switchable clutch allows interruption of the power flow in the transmission. The transmission input and output are located an opposite housing sides.
3103.758.101 1 Edition: 2009104
0 ZF
Product overview
NR2 version The input shaft is arranged above the output shaft. The vertical distance between the two shafts is the rneasure " A .
Fig. 8:
Fig. 6:
NR2 version
NR2H version in a distance equal to measure "A" the two shafts are located on a horizontal level "H". The transmission type is complemented by the description "L" or T',depending on the location of the output shaft (arranged left or right from the input shaft, looking at the output flange).
Fig. 7:
0ZF
NR2H version (side view)
NR2H version (top view)
NR2B version The input shaft is arranged below the output shaft. The verticai axial distance between the shafts is the measure "A". The transmission type is cornplemented by the description "B".
Fig. 9:
NR2B version
Edition: 2009104 I3103.758.101
Product ovewiew
15
This ensures good centring of rnotor and transrnission and the torsionally flexible ciutch rnust no cornpensate additional forces which could o t h e ~ l i s eoccur due t o the misalignrnent of the shafts.
2.1.2 Installation position i n the ship
Motor transmission arrangement "standard"
Motor-transmission arrangement i n U or V shape For arrangernent in U or V shape transmissions are used with input and output fiange on the sarne side. For U arrangernent the installation position of transrnission and rnotor is inclined towards the longitudinal axis by the angle and respectively.
U
Fig. 10: Veltical offset
006779.2
Fig. 12:
U propulsion (U orrangement)
In V arrangernent rnotor and propulsion are connected on one level by rneans of a joint shaft. The propeller shaft and the input flange of the transrnission re both inclined towards the longitudinal axis of the propulsion unit by the angle "Y. C476911
Fig. 1 7:
D o w n angle
The transrnission can be rnounted to the motor as "detached" or "flanged" installation. Detached installation The transrnission is rigidly or eiastically supported in the foundation; the rnotor is norrnally eiastically supported. The input conriection between rnotor and transrnission is realised by rneans of a torsionally flexible clutch. The ciutch serves as torsional vibration darnper and rnust cornpensate axial, angular, and, to a rninor extent, radial rnisalignrnents, in addition. The eiasticity of the motor bearing and the alignrnent of rnotor and transrnission rnust be selected such that the adrnissible loads acting on the transrnission in axial and radial direction due t o the restoring forces of the torsionally fiexible connection are not excseded. Flanged installation The rnotor is connected t o the transrnission through the torque converter housing.
3103.758.101 IEdition: 2009104
006719.3
Fig. 13:
Vpropulsion (V orrangement)
According t o the installation position of the joint shafts a distinction is rnade between t w o arrangernent types: W a n d Z arrangernent. each under the condition that both joint angles are equai = ?2). For installation instructions and aiignrnent guidelines see sections 4.1.2 Connection to the rnotor and 4.1.4 Connection t o the joint shaft.
@ ZF
Product overview
16
004971.1
Fig. 14:
W arrongement with
P, =ß2
OM-971.2
Fig. 15:
Z orrangement wirb ß, = ß2
V and U arrangernent are both subject to a detached installation of rnotor and transrnission. The transrnission is rigidly or elastically supported in the foundation. The motor is norrnally eiastically supported. Motor and transrnission are connected through a joint shaft allowing and cornpensating in all operational conditions offsets between the two power units. For vibrational decoupling frorn rnotor and transrnission a torsionally elastic clutch is attached on the rnotor side. Radial and axial forces occur at the joint shaft. According to the iength of the joint shafts used additional support points rnay be required. if a support point between elastic clutch of the rnotor and joint shaft is enough it is led out as torque convefier housing at the rnotor. Alternatively, the joint shaft can be supported directly in the foundation.
0ZF
Edition: 2009104 13103.758.101
Product overview 2.1.3
1/
Direction of rotation of propeller during forward travel
Normal motor arrangement One-motor installation
Two-motor installation
V arrangement
Note:
-
Input shafts rotating anti-clockwise (with respect to the input flange) require a special version.
(i) Admiirible
3103 758 101 1 Edition 2009104
0 ZF
Product overview
18 2.1.4 Transmission views
Transmissions ZF 9000 1 ZF 9050 1 ZF 9055 1 ZF 9300 1 ZF 931 1 1 ZF 9350 1 ZF 9351 1 ZF 9355 1 ZF 9356
Your transmission may vary from the images shown here with respect to structure, connections, and pipework 35136
0 ZF
35136
41
34
Edition: 2009/04 /
3103.758.101
Product o v e ~ i e w
19
Key to drawing:
1 2/21/27
26 Transmission fastening sutface 33 Measurina ooints for clutch ~ressure Filter chamber sludge blow off Input (input flange special equipment) Motor-dependent oil pump (primary oil pump) Measuring points for oil ternperature Water connection flange Oil cooler Connection facility for oil pressure of standby pump Connection facility for suction side of standby pump Oil drain Measuring point for lubricating oil pressure Transmission vent Oil gauge
Output Oil filter (duo filter switchable) Emergency circuit (counter-engine wise rotation) Cooling water inlet Cooling water outlet Measuring point for oil temperature Ernergency circuit (engine wise rotation) Oil filling hole lnspection hole Cover Oil drain cooler Measuring point for oil ternperature after cooler Differential pressure switch for filter contamination Neutral switch Measuring point for level control
20
Product o v e ~ i e w
Transmission views - transmissions ZF 9000 A I ZF 9050 A 1 ZF 9055 A I ZF 9000 ANR 1 ZF 9050 ANR I ZF 9055 ANR Your transmission may vary from the images shown here with respect t o structure, connections, and pipework.
0 ZF
Edition: 2009104 I3103.758.101
Product ovewiew
21
Key t o drawing:
1 Transmission fastening surface 2/21/27 Measuring points for clutch pressure Filter charnber sludge blow off Input (input flange special equiprnent) Motor-dependent oil pump (prirnary oil pump) Measuring points for oii ternperature Water connection flange Oil cooler Connection facility for oil pressure of standby pump Connection facility for suction side of standby pump Oil drain Measuring point for lubricating oil pressure Transmission vent Oil gauge
3103.758.101 1 Edition: 2009104
26 33 34 35 36 41 44 46 47
Output Oil filter (du0 filter switchable) Ernergency circuit (counter-engine wise rotation) Cooling water inlet Cooling water outlet Measuring point for oil ternperature Ernergency circuit (engine wise rotation) Oil filling hole lnspection hole Cover
50
Oil drain cooler
53 Measurina- .uoint for oil ternuerature after cooler 127 Differential pressure switch for filter contarnina tion 137 Neutral switch 171 Measuring point for level control
0 ZF
zz
Product o v e ~ i e w
Transmission views - transmissions ZF 9000 V 1 ZF 9050 V IZF 9055 V IZF 9000 VNR IZF 9050 VNR I ZF 9055 VNR Your transmission may vary from the images shown here with respect to structure, connections. and pipework
0ZF
Edition: 2009104 13103.758.101
Product overview
Key to drawing:
26 1 Transmission fastening surface 2/21/27 Measuring points for clutch pressure 33 Filter chamber sludge blow off Input (input flange special equipment) Motor-dependent oil pump (primaty oil pump) Measuring points for oil temperature Water connection flange Oil cooler Connection facility for oil pressure of standby pump Connection facility for suction side of standby pump Oil drain Measuring point for lubricating oil pressure Transmission vent Oil gauge
3103.758.101I Edition: 2009104
Output Oil filter (duo filter switchable) Emergency circuit (counter-engine wise rotation) Cooling water iniet Cooling water outlet Measuring point for oil temperature Emergency circuit (engine wise rotation) Oil filling hole Ins~ectionhole Cover Oii drain cooler Measuring point for oil temperature after cooier Differential pressure switch for filter contamination Neutral switch Measuring point for level control
0 ZF
Product overview
24
Transmission views - transmissions
ZF 9000 NR2 I ZF 9050 NR2 I ZF 9055 NR2 I ZF 9060 NR2
Your transrnission may vary frorn the irnages shown here with respect t o structure, connections, and pipework
0ZF
Edition: 2009104 13103.758.101
Product overview
25
Key to drawing: 1 2/21/27 5 7 8 10 11112 13 15 16 19 20
22 23
Transmission fastening surface Measuring points for clutch pressure Measuring point for oil pressure before filter Filter chamber sludge blow off Input (input flange special equipment) Motor-dependent oil pump (primary oil pump) Measuring points for oil ternperature Water connection flange Oil cooler Connection facility for oil pressure of standby pump Connection facility for suction side of standby pump Oil drain Measuring point for lubricating oil pressure Transmission vent
3103.758.101 [Edition: 2009104
Oil gauge Output Oil filter (du0 filter switchable) Emergency circuit (counter-engine wise rotation) Cooling water inlet Cooling water outlet Oil filling hole lnspection hole Cover Neutral switch
@ ZF
I 1
Zö
Transmission views - transmissions
Product ovewiew
ZF 9000 NR2B I ZF 9050 NR2B I ZF 9055 NR2B 1ZF 9060 NR2B
Your transmission may vary from the images shown here with respect to structure, connections, and pipework.
0 ZF
Edition: 2009/04 / 3103.758.101
Product overview
3103.758.101 i Edition: 2009104
27
0 ZF
rroauct overview
28 Kev t o drawing: Transmission fastening surface Measuring points for clutch pressure Measuring point for oil pressure before filter Filter chamber sludge blow off Input (input flange special equipment) Motor-dependent oil pump (primary oil pump) Measuring points for oil temperature Water connection flange Oil cooler Connection facility for oil pressure of standby pump Connection facility for suction side of standby pump Oil drain Measuring point for lubricating oil pressure Transmission vent Oil gauge Output Oil filter (gap filter) Emergency circuit (counter-engine wise rotation) Cooling water inlet Cooling water outlet lnspection hole Cover Measuring point for oil temperature Oil filling hole Neutral switch
0 ZF
Edition: 2009104 13103.758.101
Product ovewiew
ZY
-
Transmission views transmissions ZF 9000 NR2H I ZF 9050 NR2H I ZF 9055 NR2H Your transmission rnay vary from the irnages shown here with respect to structure, connections, and pipework. The figures show the transmission version ZF 9000 NRZHL,
>U
0 ZF
Product overview
Edition: 2009104 / 3103.758.101
Product overview Kev to drawing: Transmission fastening surface Measuring points for clutch pressure Measuring point for oil pressure before filter Filter charnber sludge blow off Input (input flange special equipment) Motor-dependent oil pump (primary oii pump) Measuring points for oil temperature Water connection flange Oil cooler Connection facility for oil pressure of standby pump Connection facility for suction side of standby pump Oil drain Measuring point for lubricating oil pressure Transmission vent Oil gauge Output Oil filter (gap filter) Emergency circuit (counter-engine wise rotation) Cooling water inlet Cooling water outlet lnspection hole cover Measuring point for oil temperature Oil filling hole Neutral switch
31
32
Product overview
2.2
Technical specifications
The normal input direction is - in respect to the transmission input flange - clockwise. In the case of speciai design transmissions with anticiockwise input directions (in respect to the input flange - left) a corresponding arrow is provided on the transmission input side.
Transmission
001 614
Fig. 16: Direction of rototion, tronsmission input shoft (standard design)
According to section 4.1.2 Connection to the motor maximum admissibie ioads (forces) must be obsewed et the transmission input. On the front side of the input shaft the additional forces must not exceed 8,000N in radial direction and 3.000N in axial direction. Section 4.1.3 Connection to propeller shaft describes the aiignment of transmission and propeiler shaft. For assembiy andlor centring of input fiange and propeiler shaft the meximum admissible radial force is 2,000N. The alignment accuracy of the propeller shaft varies between the individual transmission designs and is shown in the following table:
Measure " A according t o 2.1.1 General design principle, Page 12
Max. admissible misalignment
Max. shaft misalignment
"X"
"Y"
Smallest admissible bearing distance "C' - depending on propeller shaft diameter "d" (See 4.1.3 )
tmml A=O
imml
A=390
1000 für d/=I 50
2.000 für d 180 bis 250 3.000 für d>250 Tob. 1: Alignment accurocy ofpropeller shaft Cooler specifications for transmission versions:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13,000dm3/h . . - Minimum admissible cooiing waterflowvolume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5,000dm3/h - Pressure loss between cooling water inletloutiet at 13,00Odm3/h:. . . . . . . . . . . . . . . . . . . . . . . . . . . ..0.3 bar
- - Maximum admissible cooling waterflow volume. -
- - Maximum admissible water pressure at cooiing water inlet:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. bar
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35'C . .. - Maximum transmission ambient temperature: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60°C
- - Maximum cooling water inlet temperature for P, L, M applications. -
0 ZF
Edition: 2009104 13103.768.101
1
Product overview
33
Cooler specifications for transmission versions: ZF 9000NR2B IZF 9050NR2B IZF 9055NR2B IZF 9060NR2B IZF 9000NR2H IZF 9050NR2H 1ZF 9055NR2H -
- Maximum admissible cooling waterflow volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,000dm3/h
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,000dm3/h - - Pressure loss between cooling waterinletloutlet at 13,000dm3/h:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 bar - - Maximum admissible water pressure at cooling water inlet: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 bar - - Maximum cooling water inlet temperature for P, L. M applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35"C - - Maximum cooling water inlet temperature for C applications:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50°C - - Maximum transmission ambient temperature: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60°C - - Minimum admissible cooling waterflowvolume.
Cooler specifications for transmission versions: ZF 9000 1ZF 9050 1ZF 9055 1ZF 9300 1ZF 9311 1ZF9350 IZF 9351 1ZF 9355 1ZF 9356
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,000dm3/h - Minimum admissible cooling water flow volume. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,000dm3/h - Pressure loss between cooling water inletloutlet at 13,000dm3/h: . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 bar - Maximum admissible water pressure at cooling water inlet: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 bar - Maximum cooling water inlet temperature for P, L, M applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5 T - Maximum cooling water inlet temperature for C applications:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50°C - Maximum transmission ambient temperature: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60°C
- - Maximum admissible cooling waterflow volume -
Oil types The valid ZF lubricant list TE-ML 04 is binding for ZF marine transmissions. This list is available from all ZF service branches. It can be downloaded free of charge on the internet under www.zf-marine.com in PDF format. The "List of Lubricants" can be found in various languages under the heading "SupportlDealers". Viscosity class SAE 30 or SAE 40 for oil sump temperatures < 80°C Viscosity class SAE 40 for oil sump temperatures > 80°C Oil quantities
. . . . . . . . . . . . . . . . . . . . . . . . approx. 80dm3 - ZF 9000AIZF 9050NZF 9055NZF 9000ANRIZF 9050ANRlZF 9055ANR . . . . . . . . . . . . . . . . . approx. 80dm3 - ZF 9000VIZF 9050VIZF 9055VlZF 9000VNRIZF 9050VNRIZF 9055VNR . . . . . . . . . . . . . . . . . . approx. 80dm3 - ZF 9000NRZlZF 9050NRZlZF 9055NRZlZF 906ONRZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 60dm3 - ZF 9000NRZBlZF 9050NR2BIZF 9055NRZBlZF 906ONRZB. . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 60dm3 - ZF 9000lZF 9050lZF 9055lZF 9000NRIZF 9050NRlZF 9O55NR
- ZF 9300lZF 931 1lZF9350lZF 9351lZF 9355lZF 9356lZF 9300NRIZF 931 INRIZF 9350NRl
. . . . . . . . . . . . . . . . . . . . approx. 90dm3 ZF 9000NRZHlZF 9050NR2HlZF 9055NRZH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 55dm3
- ZF 9351 NRIZF 9355NRlZF 9356NRIZF 9300UIZF 9350UlZF 935511. -
3103.758.101 / Edition: 2009104
0 ZF
34
Product o v e ~ i e w
Transmission ratio The relevant ratio is indicated on the type plate at the transmission. (For details see section 2.2.1 Transmission description) Transmission weight The overall weight of the transmission depends on the transmission version and the special equipment supplied. The overall weight is indicated an the type plate on the transmission. 2.2.1 Transmission description
The type plate is located an the upper housing half an the same side of the housing as the output flange and is clearly visible also in installed condition. An exception are the NR2H version transmissions where the type plate is attached to the transmission top.
Type platelcla~sification
Fig. 78: Tronsmission ZF 9000 NR2H
If the transmission is subject to a classification the certificate number and seal of the classification society are embossed in the housing next to the type plate. Type platelcla~sification
Fig. 79: Type plate Specifications on the type plate:
Fig. 17:
@ ZF
Trcinsmission ZF 9000 NR2
1)
Design
2)
Serial number
3)
ltem list number
4)
Customer reference nurnber
5)
Overall transmission ratio and code letter for oil pump ratio
5a)
Main transmission ratio
5b)
Primary transmission ratio (if applicable)
6)
Oil volurne
7)
Weight (dry)
9)
Clutch pressure (nominal)
10 )
Maximum performance ratiotspeed ratio for intermittent operation with very strongly differing motor sueeds
Edition: 2009/04 / 3103.758.101
I
I
Product overview
35
11 )
Maximum petformance ratiolspeed ratio for intermittent operation with strongly differing motor speeds
12 )
Maximum performance ratiolspeed ratio for intermittent operation with differing motor speeds
13)
Maximum perforrnance ratiolspeed ratio for continuous operation with maxirnurn motor perforrnance
In case of questions concerning transmission, troubleshooting, servicing, spare part orders, order of optional equipment, etc. the fields 1 to 3 and 5 are obligatory. For further details concerning fields 10 to 13 see section 3 Description - basis transmission and versions. The relevant ratio installed is embossed in the type plate. The code letter entered in field 5 after the overall ratio refers to the prirnary oil pump ratio. Oil pump ratio A is standard design.
t Code letter
Target rnotor speed at continuous perforrnance [rpm]
speed [rpm]
1.650 bis 2.300
1.100 bis 1.650
Tab. 2:
Prirnaty oil pump ratios
3103.758.101 / Edition: 2009104
0 ZF
2.2.2 Monitoring ZF 900019300 series without versions NR2, NR2B. and NR2H Filter contamination
Clutch oil pressure
Lubricating oll pressure
Oil temperature
Measuring point ')
127
2, 21, 27
22
11.12.41
Ooerational condition
. . .
Switch position
Transmission Input speed "n„"
"Neutral, "counter-engine wise rotation or engine wise
mode
rotation" Nominal value
...
Target
...
...
PKN 7,
...
PK = PKN-2 bar 4, ''I
0.4bar
PK = PKN+3 bar 4, 19)
20bar
value Warning Switching off motor: 15.5bar
7
/
1
0.5 bar
V
)' 5, 800-1200
3.2 bar
V
)' 5, 1600-2000
4.5 bar V 2 ) 5, > 2000 Minimum rnonitoring 14'
Pressure switch
Additional rnonitoring
. . .
'141
Manometer 0 to 25 bar
...
Thermometer 0 to 120°C
Pressure switch or pressure transrnitter ")
Pressure switch or
Temperature switch )' or
0 to 25 bar
manometer 0 t o 25 bar
temperature transmitter 16' 0 t o 120°C
for armngement of the measuiing Points at the transmission - see 2.1.4 Transmission views. Page 18
dunng operation with motor switched off and propeiler driven by the current (section 5.3 Traiiing operation)
19)
when switching short-term pressure drop to below 10 bar (C2.5~)
for optical and acoustic warning
during normal opemtion
20)
Warning must be disabled in trolling operation
not inciuded in the above table
not included in the above tabie
21)
for pump ratio A, for pump mtio B on request
at 6DPCto 80°C oil temperature
without trailing pump
increasing
warning with time delay of 3 to 10s (the monitonng devices described in the monitoring plan are supplied by ZF. For processing of these signais (e.g. for warning purposes) a superordinate monitoring system is required. which is not suppiied by ZF)
with trailing pump (not supplied by ZF as a Standard)
decreasing
not included in the above table the nominal clutch pressure isspecified in the binding, o r derspecific technicai documents and also embossed in the rype piate
not inciuded in the above table
PK
Clutch oii pressure
not supplied by ZF as a Srandard
PKN
Nominal ciutch pressure
not included in the above table for remote dispiay not included in the above table warning point is rneasured by a pressure tmnsmitter
2.2.3
Monitoring values ZF 9 0 0 0 NRZINRZBINR2H, ZF 9 0 5 0 NRZINR2BINR2H, ZF 9 0 5 5 NR21NRZBINR2H. ZF 9 0 6 0 N R Z I N R Z B
Measuring point ') Operational condition
Filter contamination 5
Clutch oil pressure 2, 21. 27
Switch position
Switch position
"counter-engine
Lubricating oil pressure
22 Switch
Transmission input speed
Oil temperature 1 1.. 1 2 . 4 1 D i v i n g mode
.21)
"counter-engine wise rotation"
"neutral"
z
PK = PKN-1 bar 4,
4.5 bar
1 bar
pK = PKN+3 bar 4,
1 4 bar
1 5 bar
Trailing rnode 8)
nan
wise rotation" Nominal value
...
Target display
PVF= Pi Forward and Neutral > Reverse
5.2.1
1. Set motor speed adjusting device to idle speed 2. Select required direction and remain in this position for approx. 1 to 2s. 3. lncrease motor speed to the required operating
speed. 5.2.2
Switching Forward > Reverse and vice versa
1. Set motor speed adjusting device to idle speed. 2. Maintain switch position in order to use the motor braking effect on the propeller until the motor speed has decreased to approximately 1.2 times the idle speed (max. 720rpm). 3. Move control lever in "neutral" position and remain
in this position for approx. 0.5s. 4. Switch control leverfurther in the opposite direction and remain in this position for approx. 1 to 2s.
5. lncrease motor speed to the required operating speed. Note: Not applicable to reduction transmission NR2! 5.2.3
Switching in case of Danger (crash stop)
In the event of an emergency reversing from "forward" to "reverse" is of evidently also possible for higher motor speed (20% above idle speed, however, rnax. 720rpm).
ZF Marine GmbH recommends to use the motor braking effect also in this case and not to increase the motor speed until after selection of the "return" switch position. During such operations you should consider that in many cases (among others depending on the ship type) no or only little reduction of the stopping distance is achieved in respect to the switching sequence described above. Note: Crash stop manoeuvres mean extreme stress for the overall propulsion plant with particuiar stress on the re. Verse clutch.
If crash stop manoeuvres are performed during first trial of the ship a time interval of half an hour should be provided between the manoeuvres. This allows the components, subjected to extreme thermal load during the crash stop manoeuvre, to cool down to normal temperature. Note: ZF Marine GmbH recommends not to perform more than 1 to 5 crash stop manoeuvres for test purposes,
5.3
Trailing operation
Trailing operation refers to operation with the motor off and the propeller being driven by the current. According to the transmission design regular or occasional trailing operation is possible. Note: For trailing operation with the motor off and the propeller shaft rotating the transmission control must be switched in "neutral" switch position.
5.3.1 Occasional trailing operation The basic transmission design (without trailing oil pump) allows occasional trailing operation. The transmission oil temperature must be monitored (measuring points 11 and 12 are located in the oil sump). The maximum oil temperature must not exceed 7 5 T If the temperature exceeds this limit value the ship speed must be reduced. If necessary, the motor may operated for a short period until the transmission oil temperature has fallen below the maximum admissibie value due to the cooling water circulation (transmission in "forward" or "neutral" switch position). Note: In case of an emergency trailing operation for up to 15 hours is admissible. 5.3.2
Regular trailing operation
If regular trailing operation is intended orthis condition continues for more than 5 hours without interruption installation of a trailing oil pump is required. See chapter 6 special equipmentlspecial designs. lf the motor is off with the output shaft rotating such oil pump ensures the lubricating oil supply of the transmission. This allows unlimited operation with the motor off and the propeller rotating. The oil temperature must be monitored and must not exceed a maximum of 105°C (the oil surnp temperature roughly corresponds to the plate temperature). If the oil temperature is too high either reduce the ship speed or pass water through the transmission oil cooler.
74
Operation
The cooling water volurne can either be taken through a special valve of the rnotor installations in operation or by a separately driven water pump. For dirnensioning a cooling water volurne can be expected corresponding t o a rnaxirnurn of 25% of the watervolurne required for normal operation.
The openings of the housing are sealed by rneans of screw plugs. Ernergency circuit Ernergency circuit Counter-engine wise Counter-engine wise rotation 1441 rotation (34)
If the transrnission oil ternperature should increase above 90°C it rnust be considered that after starting the rnotor the transrnission rernains in "neutral" switch position until the transrnission oil ternperature has fallen below 90°C. Normal operation is not adrnissible until then.
5.4 Operation b y means o f emergency circuit ("Come h o m e screws") If in spite of using the rnechanical ernergency operation (section 5.1 .I .2 Mechanical ernergency operation with three rnagnet valves (for ZF 9000 series without NR, NR2, NR2B. and NRZH), 5.1 2 2 Mechanical ernergency operation with two rnagnet valves (for ZF 9000 series without NR, NR2, NRZB, and NRZH), 5.1.3.2 Mechanical ernergency operation (for ZF 9000 NR series without NR2, NR2B. and NR2H) or 5.1.4.2 Mechanical ernergency operation (for ZF 9000 NR2INR2Bl NR2H series) no force transrnission takes place a fault in the transrnission occurred. In such cased the clutch discs of the shifting clutch can be pressed together rnechanically by rneans of clarnping bolts integrated in the transrnission. Note: In the case of transrnission configurations with, for exarnple. power take offs on the intermediate shaft access to these clarnping bolts rnight not be possible. Four clarnping bolts each are available for the clutch for engine wise rotation and for the clutch for counter-engine wise rotation and can be accessed frorn the outside through the transrnission output side. Note: For double-shaft transmissions (NR21NR2BINR2Hversions) only counter-engine wise rotation is possible during operation by rneans of ernergency circuit due to the fact that double-shaft transrnissions have only one multiple-disc clutch at the input shaft.
Fig. 60: Position of clamping bolts for parallel und counter-engine wise rotation (ZF 9000 A, exarnple) Operation by rneans of the ernergency circuit is adrnissible under the foliowing conditions: a) For ZF 9000 NR21NR2BINR2H versions the oil pressure at rneasuring point 2 rnust be at least 6.Obar at rnotor idle speed and warrned up transrnission. In this case operation at 50% of the rnaxirnurn rnotor speed is adrnissible. b) For all other ZF 9000 versions the oil pressure at the rneasuring point rnust be 2>PKN-I bar. In this case operation at 50% of the normal rnotor speed is possible. The special wrench required for operation of the ernergency circuit (hollow hexagon wrench, width 8, length 280rnrn) is available frorn ZF Marine GmbH under parts nurnber 1x56 137 055.
lnadrnissible operetional condition due to blocked transrnission. Consequences: Component damage, significant material damage!
-
0ZF
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75
Operation Only one shifting clutch rnay be closed at every transrnission at a time since otherwise both output directions are force-closed and the transrnission will block. For this reason the normal transrnission control device rnust be disabled during operation by rneans of emergency circuit.
CAUTION! Jarnrned clutch piston due to uneven tightening of clarnping bolts. Consequences: No or insufficient torque transmission due to jammed clutch piston.
CAUTION! During operation by rneans of ernergency circuit the control lever is deactivated. "Neutral" switch position is not possible. Consequences: Danger of injury, significant material damage i
When operated by rneans of ernergency circuit the transrnission cannot be switched to "neutral" or reversed by rneans of the control iever. The steerrnan rnust be aware of this condition all the time. The way of navigation rnust be adapted to this condition. In the port area and in narrow or busy waters the rnotor rnust thus be switched off and the ship is to be trailed. 5.4.1
Emergency circuit activation
1. Turn off rnotor and ensure that the rnotor cannot be restarted while switching an the ernergency circuit. 2. Disable control of pilot valve. In the case of electrical transmission control this is rnade by removal of the plugs. 3. Deterrnine clutch to be switched 4. Loosen screw plugs and rernove. 5. Insert wrench in one of the four opening untii end position is reached. Rotate rnotor or transrnission shaft slowly until head of clarnping bolt contacts wrench. Note: The direction of rotation is irrelevant; the said position should be reached after rnax. 90" rotary displacernent. 6. Withdraw wrench by approx. 30rnrn and rotate rnotor ortransrnission shaft slightly (approx. 1') until the wrench can be introduced in the clarnping bolt hexagon.
7. Tighten clamping bolt by several clockwise rotations until end position is reached. 8. Repeat this procedure for the otherthree clarnping bolts through the corresponding housing openings. Further rotation of the transrnission input shaft is not required.
9. In a second cycle tighten all four clarnping bolts with approx. 50Nrn tightening torque. 10. Seal housing openings with screw plugs After the ernergency circuit has been set up in such way the rnotor can be statted and the ship navigated to the closest service station. 5.4.2
Emergency circuit deactivatio
11. Turn off rnotor and ensure that the rnotor cannot be restarted while switching an the ernergency circuit. 12. Deterrnine switched clutch. 13. Loosen screw plugs and rernove. 14. Insert wrench in one of the four openings until end position is reached. Continue to rotate rnotor or transrnission shaft until the head of the clarnping bolt contacts the wrench. Note: The direction of rotation is irrelevant; the said position should be reached after rnax. 90" rotary displacement. 15. Withdraw wrench by approx. 30rnrn and rotate rnotor or transrnission shaft slightly (approx. 1") until the wrench can be introduced in the clarnping bolt hexagon.
76
Operation
CAUTION! Jammed clutch piston due to uneven tightening of clamping bolts. Consequences: No or insufficient torque transmission due to jammed clutch piston.
16. Loosen clamping bolt by several clockwise rotations until end position is reached. 17. Repeat this procedure forthe otherthree ciamping bolts through the corresponding housing openings. Further rotation of the transmission input shaft is not required. 18. In a second cycle tighten ali four clamping bolts with approx. 10Nm tightening torque. 19. Seal housing openings with screw plugs. 20. Enable control of pilot valve. In the case of electrical transmission controi this is made by fitting the plugs.
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Special equipmentlspecial designs 6
SPECIAL EQUIPMENTISPECIAL DESIGNS
A variety of parts and accessories is available on the rnarket which is not manufactured or recommended by ZF. Unauthorized modifications and alterations which impair the function and safety are not allowed. Note: Do not use accessories authorized by ZF only. Mainly the operating data approved by ZF for the application classes M and C are fully accepted by the major classification societies. Deliveiy of a type approval or certificates for the classification is possible on request. Note: If special deliveries or special designs result in variations in operation and maintenance and these are not described in the following sections, please see specifications applicable to the relevant order for such details.
6.1
Trolling
Note: For transmissions with mounted and controlied trolling valve (special equipment) only.
A trolling system facilitates operation and manoeuvring at slow speed. This installation allows selection of propeller speeds below the minimum propeller speed resulting from the transmission ratio and the motor idle speed. This enables operation at lower ship speeds as for a norrnally switched transmission at the smallest admissible motor speed. Typical applications are:
77 Functional description Trolling operation allows operation at propeller speeds which are smaller than possible with non-trolling operation. Consequently, trolling operation is used for travelling at lo ship speed. In trolling operation. the propelier speed can be reduced by up to 0.3 - 0.7 times of the propeller speed of non-trolling operation. The reduction of the propeller speed is achieved by a defined slipping process of the clutch discs. For this purpose, in trolling operation, the clutch pressure (oil pressure with which the clutch discs are pressed against each other) is decreased until a defined slipping process is caused. The transmission oil circuit is designed such that the friction heat occurring in the clutch is removed. The trolling valve for adjusting the clutch oil pressure is arranged in the clutch control centre. Note: Trolling refers to operation with slipping clutch. Trolling operation allows reversing and manoeuvring in the port area. However, it is pointed out that the propeller thrust generated by the low propeller speed in trolling operation might not be enough for sufficient movernent of the ship. Manoeuvring of bigger displacement boats with a relatively weak motor in trolling operation is not possible or only slowly. Light sport boats with strong motor and planing hull, however, show good reactions. Note: ZF Marine GmbH consequently recornmends that the reaction of the ship during manoeuvring in trolling operation is tested in free water. If the results are not satisfying the steerman or approval officer in charge must prohibit the use in the port area.
* Passages at limited speed, e.g. canal passages
* *
Manoeuvring in ports and at landing places
6.1 .I
Holding position for police boats, life boats
In trolling operation the clutch oil pressure at the transmission is adjusted by means of an electrical control signal. The required operating controls are not part of the transmission.
Towing of srnalier boats Sport fishing at optimum trolling speed For the ZF 9000 series transmissions the following trolling devices are available: Electrical trolling
* ZF AUTOTROLL
Electrical trolling
Note: For operation of trolling controls see operating instructions by control manufacturer. The trolling device can be used for forward or reverse travel without time limit provided that the admissible rnotor speed values and lubricating oil temperature are not exceeded.
Max. admissible motor speed for trolling operation For submerged standard propellers (with parabolic propeller curve): 45% of rnaxirnum admissible operating speed (motor speed), however up to a maximum of 700min-1
1
Special equiprnent/special designs
78
For surface propellers: rnotor idle speed up to the maximurn operating speed (rnotor speed) of 700min-1 Max. admissible lubricating oll temperature: 90°C
Transmissions with electrical trolling are not secured against excessive motor speeds in trolling operation. If the adrnissible rnotor speed values or lubricating oil temperature is exceeded the trolling operation must be stopped.
6.1.2 ZF AUTOTROLL
In connection with the electrical transrnission control ZF AUTOTROLL may be used. ZF AUTOTROLL is a controlled trolling device. In trolling operation the propeller speed deterrnined by the operating controls is adjusted through the degree of power take off (i.e. through the clutch slip) by the transrnission. The operating controls thernselves are not part of the transmission.einrichtung selbst ist nicht Teil des Getriebes. Note: For operation of the trolling controls refer to operating instructions by operating controls' rnanufacturer. It is recornmended to examine these instructions in regular intervals.
* Easy manoeuvring even of displacement boats with a weak rnotor by a reversing sequence (short-terrn raise of the clutch pressure during reversing).
*
Operating errors are excluded.
Note: The transmissions with ZF AUTOTROLL are delivered in fully assernbled and tested condition. The delivery of ZF AUTOTROLL includes the following:
a trolling valve rnounted to the transrnission
* an electronic control device rnounted to the transmission application-based prograrnming of the control speed sensor at the input shaft
* speed sensor at the output shaft * a cable harness for connection of all AUTOTROLL components rnounted to the transrnission a rnounted plug socket with counterplug as electrical interface to the ship control The delivery of ZF AUTOTROLL does not include:
* the ship-based operating controls for the electric transrnission control the ship-based operating controls for the trolling control
* the voltage supply * all indicator lamps * eventual dimmer devices for indicator iarnps the ship-based cabling up to the electrical interface at the transrnission
Fig. 61: Control unit with trolling valve for ZFAUTOTROLL
In ZF AUTOTROLL operation the ship can be reversed even during operation. In this case the reaction of the ship is significantly improved by the reversing aid integrated in the electronic system. The ZF AUTOTROLL system has the following main characteristics:
* The propeller set through the trolling control lever is automatically rnaintained at a constant rate.
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Special equipmentlspecial designs
79
6.2 Trailing operation oil pump (trailing p u m p )
6.3
Regular trailing operation is adrnissible only with a trai. ling operation oil pump in place. For all transmission designs in parallel, V, and Aversion optional retrofitting with such trailing operation oil pump is possible.
The power take offs are used for propulsion of Pumps, hydraulic Systems for water jet applications or even of generators. All ZF 9000 series transmissions are available as special design with power take off (PTO). In general, the power take offs cannot be switched but are permanently driven by the transmission. This is reasonable for most pump transmissions since the hydraulic systern rnust be ready to operate imrnediately after stait-up of the rnotor.
According to the motor speed in continuous operation two transmission ratios are offered for the trailing operation pump (analog to the primary oil pump). Code letter Design motor speed for continuous operation [rpm]
1
A
I
B
1.650
1.100
2.300
1.650
I
Motor idle speed [rpm]
Tob. 6:
Transmission ratio o f trailing operation oil pump
The oil pump is mounted to the transmission housing on the transmission side opposite to the input (parallel and Aversion) or to the input side (V version), respectively. It is driven via a spur gear by the transmission output shaft. Pump delivery to the oil circuit is always in the Same direction, irrespective of the input direction. If the motor is off with the output shaft rotating this oil pump ensures the lubricating oil supply of the transrnission. This aliows uniirnited operation with the motor off and tha propeller rotating. Note: For trailing operation with the motor off and the propeller shaft rotating the transmission control must be switched in "neutral" switch position. The oil pressures do not require monitoring while the motor is off. The transrnission oil ternperature rnust be monitored, the instructions in section 2.2.2 Monitoring values apply. An additional measuring point (41) for the oil temperature is available (see section 4.4 Opera tional monitoring).
PTO=Power
Take Off
The dirnensions of the powertake offs ara designed for various output performances and the rnounting dirnensions are standardized according to SAE standard (A, B, B-B, C, C-C or D). The power take off is located at the input andlor intermediate shaft or is implemented in a separate housing as top PTO, according to customer requirements and the maximum torque to be picked off. PT0 at input or intermediate shaft The transrnissions in basic design are equipped with a mounting facility for a power take off at the input and the intermediate shaft. This makes retrofitting with a PT0 possible at any time. Note: In the case of transrnissions in V design the power take off cannot be mounted to the input shaft. Top PT0 with separate housing For implementation of the power take via the constant gearing of the input or intermediate shaft an additional housing is required. Such housing is mounted to the top of the transmission housing. The description Top PT0 results from the top iocation of the mounting position. Note: A top PT0 is factorymounted, retrofitting is not possible.
The maintenance works 101 and 102 must be performed on a daily basis also for operation with the motor off and propeller rotating (see chapter 8 Maintenance)
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Troubleshooting
80
7
Troubleshooting
7.1
Troubleshooting information
Faults in the propulsion plant frequently suggest a defect of the transmission. even though in many cases the fault is caused by external impacts on the transmission. The minimum monitoring specified in section 2.2 Technical specifications is required and must be installed. Every transmission in basic design provides the measuring points for the minimum monitoring. Note: Monitoring devices, such as Sensors, warning equiprnent, and display instruments are not supplied by ZF Marine GmbH as a standard.
It is expressly pointed out that fault signals can be indicated only if the connection options are used by the transmission. If removal of the faults based on the following information is not possible please refer to your closest ZF service branch. If you would like to remove faults of the transmission yourself or pelform repairs yourself we recommend that you request the sewice manual and the spare parts catalogue from our ZF plant customer s e ~ i c ein the Friedrichshafen plant.
@ZF
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Troubleshooting
81
7.2
Table o f possible f a u l t s
7.2.1
Overall transmission
Fault Transmission oil temperature too high (measuring point 11 *, 12*, and 41 * )
Possible cause
Counter measures
Water flow rate through cooler is too
lncrease waterflow rate
low Oil cooler clogged
Transmission oil
Water flow rate through cooler is too
temperature too low
high
Clean oil cooler
Reduce water flow rate
Oil pressure before oil cooler and filter too
Oil cooler contaminated
Clean oil cooler oil side
high
Oil filter contaminated
Replace filter
No oil filled in transmission
Fill with oil
lncorrect transmission input direction
Use special transmission design
Display device defective
Remove fault
Oil pump defective
Replace oil pump
(measuring point 5 ' ) No oil pressure (measuring point 2*, 21 * and 27*)
Oil type used has too iow viscosity Oil pressure too low (measuring point 2*, 21 *, and 2 7 * )
Use specified oil type (see lubricant list) Oil pump defective
Replace oil pump
Pressure relief valve leaking
Remove fault
Timer for pressure modulation does not
See fault: Clutch slipping
work correctlv If the fault cannot be removed the lubrication supply of the transmission is also at risk. Continued operation only at reduced input speed intil next reoair facilitv. Oil pressure too high (measuring point 2*,
Oil type used has to high viscosity
Use specified oil type (see lubricant list)
21 *, and 27') No powertransmission from the transmission input to the transmission output, clutch does not transfer torque
For electrical transmission control. Fault in the electric system Test facility: When operating the transmission by
Remove fault in the electric system
means of the manual iever normal power transmission. No oil pressure
See fault: no pressure or pressure too low
* see monitoring values (sections 2.2.2 und 2.2.3) and transmission views (section 2.1.4)
Tab. 7:
Table o f possible faults (overali transrnission)
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Troubleshooting
Fault
Possible cause
Counter measures
Power transrnission frorn transmission input to output cannot
Possible causes and Counter rneasures see fault: clutch does not transrnit toraue
be interrupted; clutch does not oDen Counter measure as for fault: "Oil pressure too low (rneasuring point 2'. 21 *, and 27*)". If the fault cannot be rernoved on board the Operation rnay be continued at Clutch siipc at high
Oil pressure too low (rneasuring point
reduced speed - at which the clutch does
rnotor speed
2*, 21 *, and 27')
not slip
- until the next repair facility is
reached. Avoid reversing and perforrn only with propeller alrnost standing and at the smallest possible rnotor idle speed. Oil level decreases strongly (deterrnined according to the
Leaks at housing parting lines or oil
rneasuring marks of
pipes, oil leaks at shaft seal rings
the oil gauge).
Oil lass through oil cooler in cooling
Note: Maintenance
water svstem
Remove mechanical fault
Rernove fault, replace oil cooler, if required
work no. 101 "Oil level control"
0il level increases (see maintenance work 101 "Oil level control") Transmission in some speed ranges too loud
Water enters oil circuit from cooling system Torsional vibration resonances of propulsion plant in rnotor idle speed range
Transmission in motor
Torsional vibration resonances of
idle speed range too
propulsion plant in rnotor idle speed
loud
range
Motor stalls when
Motor idle speed too low
changing frorn
Reversing rnanoeuvre is perforrned too
"forward" to "reverse"
quickly or at too high ship speed
Rernove mechanical fault
Avoid critical speed ranges. Use rnore suitable torsionally flexible clutch
lncrease motor idle s ~ e e d
lncrease rnotor idle speed Reverse as recornrnended i n 5.2.3
* see monitoring values (sections 2.2.2 und 2.2.3) and transrnission views (section 2.1.4)
Tab. 8:
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Table o f possible faults (overall tronsmission, continued)
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I
I
Troubleshooting
7.3
83
Transmission oil cooler Possible cause
-ault
Counter measure Drain and disassemble the cooler Disassemble receiverlcover Secure pipe bundle with fixing plate and bolt
l i l esCaDes into the water
3il level too low
Pipes in the cooler
Give 5bar compressed air onto the
leaking
lacket Locate defective pipe on the pipe olates Seal the defective pipe by means of 3 copper plug
Drain the cooler on the water and on (Iisible oil leakage at
0-ring on pipe platel
the cover
housing is defective
the oil side and disassemble it Disassembly receiverlcover
l i l escapes from the
Extract pipe bundle
ransmission oil cooler
Replace all o-rings Visible oil leakage at the transmission
0-ring transmission
Drain the cooler on the water and on
flange connection
the oil side and disassemble it
defective
Replace all 0-rings Drain cooler on the water and on the
VVater leakage into the oil; oil level too high, milky sppearance
0-ring on pipe platel water chamber is defective
3il side and disassemble it Disassembly receiverlcover Secure pipe bundle with fixing plate snd bolt Repiace all o-rings Drain cooler on the water and on the
Nater escapes from the :ooler
oil side and disassemble it Visible water
0-ring on pipe platel
Disassembly receivericover
leakage at the cover
cover is defective
Secure pipe bundle with fixing plate and bolt Replace all o-rings
Visible water leakage at the pipe connection Tab. 9:
Sealing pipe connection defective
Replace seal at pipe connection
I
Tabie o f possible faults (transmission oil cooler)
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Troubleshootina
84
Fault
Possible cause
Counter measure
Cooling water intake
Water intake temperature is too high
temperature is too
Observe target values in the
iigh
transmission installation drawing
Cooling water
Delivery rate of the cooling water
outflow
pump too low
temperature too high Temperature
J\later flow rate is too OW
transmission instaliation drawing lncrease delivery rate
measurement by
Gland for the bleed off too iarge
means of click-on
Use smaller gland or throttle valve
Sensor
Foreign material in the pipe or in the
Determine whether
cooler, which causes clogging
water intake and
Clean pipelpipe bundle
water outflow have
Water side is more contaminated
a temperature
Nater flow in the
than usual (e.g. due to thick
difference of
:ooler is i m ~ a i r e d
deposits)
approx. 2°C to 5°C
rransmission oil
Obse~e target values in the
Clean pipe bundle More than 10% of the pipes are
:emperature too high
leaking Replace pipe bundle. Oil side is more contaminated than usual (e.g. due to thick deposits) Clean fins Is divider correctly assembled on the two-way receiver and are the fixing plates mounted on this side
Cooling water D U ~ ~ ~ O W
ieat transfer from oil
temperature not too
o water is impaired
high
if this is not the case, assemble divider correctly Pipe bundle installed correctly? Check identification mark X If this is not the case install pipe bundle correctly All pressure chambers vented? If this is not the case vent all Dressure chambers
I
Tab, 10: Table o f possible faults (transmission oil C I
0ZF
er, continued)
Editon: 2009104 / 3103.758.101
Troubleshooting
7.4
85
Diagnosis for ZF AUTOTROLL (Special equipment)
Apart from the control functions the ZF AUTOTROLL is equipped with an intelligent diagnosis system. The diagnosis system has the following functions: System monitoring, monitoring of operating values, fault detection, generation of emergency operation properties Warning of the steerrnan Registration of occurred faults in the fault memory and communication with ZF diagnosis device *TESTMAN" Alarm messages for warning of the steerman in case of faults are indicated by the aiarm lamp (red). In case of operating values being below or exceeding limit values this is indicated by the alarm lamp (yellow) and the control lamp (green). As soon as the operating voltage is connected to the AUTOTROLLcontrol the diagnosis is active. This means that system faults can be diagnosed even in non-trolling operation and indicated by the alarm system. For suppott of the system service a diagnosis device "TESTMAN" can be adapted to the ZF AUTOTROLL control. The relevant works should be left to the trained qualified personnel of the Friedrichshafen service centre. The diagnosis device "TESTMAN" which is not supplied as a standard with ZF AUTOTROLL is also available from the Service centre.
WARNING! Unintended speed increase of the ship. Consequences: Danger of accident, significant material damage!
In case of faults which do not result in autornatic transfer of the system into trolling operation a sudden increase of the ship speed is possible.
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86
Maintenance
8
MAINTENANCE
8.1
Maintenance schedule
8.1 .I
Maintenance schedule concept
The rnaintenance system for ZF ship transmissions is based on a preventive rnaintenance concept. The preventive maintenance facilitates advance planninn and secures high availability,
7 Maintenance level
After respective operational
Groups of application
hours
I
l
all
L
The time intervals, according to which maintenance work is to be carried out, as well as the scope of the inspection and maintenance work described are the average result of operational experience and therefore rnay only be regarded as guidelines. In case of special conditions of application as well as for technical requirements, additional rnaintenance work andlor changes in the rnaintenance intervals rnay become necessary
for every day of operation
Limit value 3 months
(see also K1; K2)
all
500 h
6 months
all
...
annual
all C and M Land P
2000 h
2 years
all
. . .
5 years
. . .
8 years
For every major
Operational condition of the transmission
Tab. 11: Periodical maintenance works Maintenance level Z1 22
After respective operational hours 50 to 100h .--
Limit value 12 rnonths 2 months
Tab. 12: Additional one-time rnaintenance works for new or reconditioned transmission
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Maintenance
87
8.1.2
Maintenance work before taking out of operationlstandstill
8.1.2.1
For closed cooling circuit
8.1.2.2
lf the cooling circuit is closed the cooler mav rernain in a filled state.
For closed cooling circuit
If the standstill of the plant onlv lasts for a short period of time (< 2 weeks) the coolermay remain in a filled state. if the system is taken out of operation for a longer period of time, the cooler rnust be drained on the water side. Note: This is only required if the cooler is not autornatically drained when the cooling-water pump is in standstill.
Measures Drain cooler on the water side. Additionally rinse with clean water. If possible, dry pipe bundle from inside with compressed air. Tob. 13: Standstill tirne/droining cooling w o t e ~
Maintenance
88
Maintenance information For specifications of the Service fluids and list of the rnanufacturers refer to ZF lubricant list TE-ML 04 for ZF marine transmissions. This list is available frorn every ZF Service branch. It can be downloaded free of charge on the internet under www.zf-rnarine.com in PDF forrnat. The "List of Lubricants" can be found in various languages under the heading "SupporilDeaiers". The following list rnainly lists the consurnables (cleaning agents, iubricants, and sealants) recornrnended by ZF Marine. The applicable service fluid regulations are available frorn the respective rnanufacturers. Only consurnables and service fluids which cornply with the ZF specification andlor which were approved by the respective rnanufacturer rnay be used. The instructions of use by the respective rnanufacturer are binding. For maintenance of all cornponents which are not li sted in the rnaintenance schedule the rnanufacturer specifications apply. After cornpletion of the rnaintenance works a functional test rnust be perforrned. It is also recornrnended to keep a rnaintenance protocol providing the following information: 0
Person in charge of and perforrning the rnaintenance work rnaintenance level
*
time of maintenance work (date, operating hours)
Cleaning agents for removal of grease of cone surfaces for comprecsed oil structures. Acetone, Spirit (caution flarnrnable) or conventional cieaning agent without regreasing. Glycerine For pressing on the cornpressed oil structures. As an alternative, oil can be used for pressing on. Grease See ZF lubricant list!
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Edition: 2009104 13103.758.101
Sealant Manufacturer
Description
/
Use
seal SO 32M Spezial Temperature resistant: -50°C up to +250°C (CHC f ree)
(HYLOMAR CLEANER) and apply HYLOMAR
Company Marston-Domsel
Use for sealing surfaces of
to both sides. After venting (approx. 10
GmbH, 53909 Zülpich,
housing and Cover
minutes) perform assembly. Tighten bolts
Germany, Tel. +49 (0)22
after 10-15 minutes. Forface ground surfaces
52-9414-0
I
one-sided application is enough.
-
Locite
Supply source
Degrease sealing surfaces prior to use
Non-hardening universal HYLOMAR
lnstructions of use
Locite no. 640 and
Clean parts Apply sufficient product for gaps to be filled
Locite no. 275
-
Joint parts
-
Leave ~ r o d u cto t harden
Henkel Locite Deutschland GmbH, Munich Henkel Central Eastern Europe GmbH. Vienna
Iarnishes and oaints for representation of tooth Dykem Red
Dykem Red
flank surface appearances
DX-29618 oz
for transmissions with
(Made in Germany)
acceptance specification by classification societies
Tab. 14: Recommended consumabies und service fluids
Company Helling GmbH, Spökerdamm 2,24536 Heidgraben (near Hamburg), Germany Tel. +49 (0)4122-922-0 Fax t 4 9 (0)4122-922-201
90
8.2
Maintenance
Corrosion protection and conservation
Serial transmissions delivered by ZF have corrosion protection according to level I of "Richtlinien für Schiffsgetriebe über Korrosionsschutr, Verpackungsarten, Lagerbedingungen und -reitenr' [Guidelines for marine transmissions concerning corrosion protection. packaging types, storage conditions and timesl F 43258lRT 3332-289. Conservation measures for long-terrn storage rnust be specified in the transrnission order. If transmissions are stored at ZF branches and ZF distributors the measures according to the guideline for conservation of marine transmissions shall be binding. The conservation measures described in the guideline must be performed by personnel authorized by ZF since otherwise the warranty claim will expire. The corrosion protection measures for a transrnission installed in the ship required in case of longer downtirnes strongly depend on the ternperature variations, the air hurnidity, and the salt content of the air in the engine room. Therefore, the recomrnended rneasures and time indications may only be regarded as rough guidelines. In case of doubt we recomrnend to perform the corrosion protection rneasures for the transmission analog to those for the motor. Downtirne periods of up to 3 rnonths do normally not required corrosion protection measures. If the downtime period is less than 6 months we recommend to perforrn corrosion protection measure K1 every 10 to 20 days. Depending on the condition of the lubricating oil in the transmission an oil exchange according to maintenance level Z1 may be necessaty prior to re-commissioning. K2 is a conservation rneasure and should be perforrned in case of downtirne periods of more than 6 months after completion at the end of the operating period. K2 can also be performed for shorter downtime periods instead of K1. K3 is a long-term conservation rneasure and allows to take out of operation the installed transrnission for a maxirnum of 36 rnonths. In place of K3 the conservation can be irnplemented according to K2. In this case the conservation has to be repeated every 9 months.
0 ZF
Edition 2009104 13103 7 5 8 101
I
Maintenance
91
Maintenance level K1
Performance
Shut down periods
Note (annex)
eveiy 10 to 20 days
up to 6 months
"Richtlinien für Schiffsgetriebe
at the end of the operating oeriod
9 months
über Korrosionsschutz, Verpockungsarten, Logerbedingungen und
i
at the end of the operating oeriod
Tab. 15: Corrosion protection measures forlongershut down periods
K1 Corrosion protection Start motor and operate at motor idle speed or slightly increases speed for at least 5 rninutes to ensure lubrication of the transmission. The transmission can be in "neutral" or "counter-engine wise rotation" or "engine wise rotation" switch position. Repeat this process eveiy 10 to 20 days. Prior to re-cornmissioning, check oil for condensed water (emulsion). The checking hast to take place immediately after switching off the motor; oil must not be clouded.
K2 Conservation At the end of operation, drain transmission oil and fill in corrosion protection oil at least until the bottom measuring rnark of the oil gauge (for implementation See rnaintenance work), use corrosion protection oil C 642 or C 644 according to MIL-L-21 260.
max. 36 months
-zeitenr', extract from:
F 43258/'RT 3332 K3 Long-term conservation At the end of operation, drain transmission oil and fill in corrosion protection oil at least until the bottom measuring rnark of the oil gauge (for implementation See maintenance work). Use corrosion protection oil C 642 or C 644 according to MIL-L-21 260. lmmediately afterwards, operate motor in "counter-engine wise rotation" or "engine wise rotation" switch position at increased motor idle speed (max. 50% of nominal operating speed) for approx. 5 to 10 rninutes. Switch off motor. Then fill transmission completely with corrosion protection oil. Protect outer steel parts against corrosion. Re-comrnissioning according to K3 iong-term conservation. Drain corrosion protection oil until normal oil level. Then operate rnotor for approx. 5 minutes. Subsequently drain corrosion protection oil completeiy and fill transmission with specified oil type (see "Maintenance work 141").
lmmediately afterwards, operate motor in "counter-engine wise rotation" or "engine wise rotation" switch position at increased motor idle speed (max. 50% of nominal operating speed) for approx. 5 to 10 rninutes. Switch off motor. Protect outer steel parts against corrosion. To extend the conservation by another 9 months operate rnotor for approx. 5 minutes. Then drain conservation oil and fill the transrnission with oil type and volume specified for operation and restart motor and operate for at least 15 rninutes. Operate the transmission clutches several times during this time. Then perform ""K2 conservation. Commissioning after K2 consetvation. Start rnotor and operate for approx. 5 minutes to mix any condensed water eventually accumulated in the transmission with the corrosion protection oil. Drain corrosion protection oil and fill transmission with specified oil type (see "Maintenance work 141").
3103.758.101 1 Edition: 2009/04
0 ZF
92
8.3
Maintenance Plan for maintenance work
perlodic
Required tools
Maintenance works
Maintenance level
1 one-time Check oil level Turn change lever on duplex-switch filter or rotate rotary handle of oil filtei Visual inspection Clean transmission externally Re-tighten all bolts accessible from the outside Oil exchange Replace filter elements; clean gap filter and filter housing Torsionally flexible clutch: visual inspection Flexible motor and transmission support; visual inspection Clutch discs; visual inspection Running gears: visual inspection Check oil pump Check control unit Check operating controls Recalibrate indicators Visually inspect oil cooler and clean Check shaft seal ring of input shaft Check shaft seal ring of output shaft Major transmission overhaul
without without without without on-board tools on-board tools on-board tools without without on-board tools on-board tools W1 W1 W1 ...
W1 without without W2
Required spare parts
Tab. 16: Maintenance levels and maintenance works
= for
NB
@ ZF
implementation see service manual
= Spare parts according to requirement
T l , T2
=
W1
= Tool kit, see operating instructions
W2
= Tool
Part kits, see spare part list
kit, see setvice manual
Edition: 2009104 13103.758.101
Maintenance
8.4 8.4.1
93
Tool kit Tool kit W1 for rnaintenance
Tool kit W1 is composed of commercial tools. Commercial irnplies, for exarnpla: General hand tools
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63mm . Flat ring wrenches up to width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46mm . . Offset ring wrench up to width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46rnm Setofsockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13mm .. Setofsockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32mm .. Setofsockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-5Omm .. Set of sockets for hexagon socket screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5-22mm . Tongs (flat) for locking rings (internal securing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. I. 1-4 (no.) Tongs (flat) for locking rings (external securing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. 1-4 (no.) Screwdriver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .u. p. t.o l 3 r n m Hammcrs (metal + piastic), punches Open-end wrenches up to width
Hammers (metal + plastic), punches Torquewrench Calliper square,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-35ONm .. depth gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .measurement . range up to 300mm
Thickness gauge
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .rneasurement . ranga 0.5-1.0mm
Other Oil filter wrenc Tools for emergency control of transmission
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3rnrn Wrench for hexagon socket screws (Allen wrench) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8mm Wrench for hexagon socket screws (Allen wrench)
Wrench for hexagon socket screws (ZF item no. 1X56,186,369,80mm long) . . . . . . . . . . . . . . . . . . . . . . . .1Omm Wrench for hexagon drive screws (ZF item no. IX56.137.055,280mm long) . . . . . . . . . . . . . . . . . . . . . . . . .8mm Tools for cleaning of oil cooler nylon brush (ZF itam no. lX56.190.838)
3103.758.101 IEdition: 2009104
0 ZF
Maintenance
94
8.5 S p a r e p a r t s and s p a r e P a r t o r d e r s Spare part orders For maintenance works and repairs requiring replacement of cornponents or assembly groups ZF original spare parts rnust be used exclusively. For spare part orders and inquiries keep the following details, which can b e found on the transmission type plate, at hand: MODEL
(field no. 1)
SERIAL NO
(field no. 2)
* PARTS LIST NO
(field no. 3)
* RATIO TOTAL
(field no. 5)
For all inquiries concerning the transmission, troubleshooting, rnaintenance, order of special equiprnent, etc. the details of the fields 1 t o 3 ere essential. For transrnissions with classification please note that in general, spare parts without classification are delivered under the specified itern number. Note: If a niodel with classification is required pleas specify the required test type in addition t o the itern nurnber for the spare parts. This is also required if the transrnission itern list is specified during order and when requesting replacernent transmissions. For implementation of the periodic maintenance works the parts required according t o the rnaintenance level can be ordered as rnaintenance kit or on-board kits. For major overhaul of a transrnission or an assernbly group the required spare parts are also offered as repair andlor spare Part kits.
ZF service branches If a transrnission fault cannot be rernoved with the Counter rneasures listed in chapter Troubleshooting pleas contact your closest ZF branch. The repair instructions applicable t o your transrnission type and up-to-date technical information, such as ZF service letters are available form both, the ZF service branches and the ZF dealers. You can find the ZF Sales and Service Organization responsible foryour region on www.zf-rnarine.com in the top navigation bar, under the pull-down rnenu "Support" and "Find dealer". A list with the ZF service branches with up-to-date telephone and fax nurnbers is available frorn ZF Marine GmbH i n Friedrichshafen, on request.
0ZF
Edition: 2009/04 / 3103.758.101
95
Maintenance
8.6
M a i n t e n a n c e System job sheets
Table of contents w o r k sheets Maintenance works
page
101
Checkoillevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 ..
102
Turn change lever on duplex-switch fiiter or rotate rotary handle of oil filter . . . . . . . . . . . . . . . . . . . . . . . . 98
103 Visualinspection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I00 .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 .
121
Clean transmission externally
122
Re-tighten all bolts accessible from the outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 .
141
Oilexchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 .
142
Replace filter elements; clean gap filter and filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
161
Torsionally flexible clutch: visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 .
162
Flexible motor and transmission support; visual inspection
163
Clutch discs; visual inspection .
164
Running gears: visual inspection
165
C h e c k o i l p u m p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 ..
166
Checkcontrolunit
167
Checkoperatingcontrois .
168
Recalibrate indicator
169
Visually inspect oil cooler and clean
173
Check shaft seal ring of input shaft
174
Check shaft seal ring of output shaft
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 .
3103.758.101 / Edition: 2009104
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148 .
0 ZF
Maintenance
96
iransmission type:
ZF 9000 Series
rfter switching motor off wait for 10 minutes until removing oil gauge since otherwise Danger
iafety measures f burns due to ejected hat oil. io always switch off motor to refill oil since otherwise Danger of burns due to ejected hat oil
.............................
nt-free cloths
-est equipment
.............................
ee opposite Page
0ZF
Edition: 2009104 / 3103.758.101
Maintenance
97
Fig. 62: Oil gouge (25) ot tronsmission (example) For first fiiling after repair or cleaning of the oil filter consider that patt of the oil rernains in the oil cooler and the oil pipes and does not flow back in the transrnission housing. Thus, check oil level again after a shott period of operation.
Fig. 64: Oilfillscrew (46) ot tronsmission ZF9000 NR2 (exomple)
Fig. 65: Oil fillscrew (46) o t tronsmission ZF 9000 (exomple) If oil needs to be refilied, Open oil fill screw and refill oil.
Fig. 63: Oil gouge (exomple) The correct oii level is between the top and the bottorn rneasuring rnark of the oil gauge.
Note: After switching off rnotor wait for approx. 10 minutes until the oil gauge has settled. Now rernove oil gauge and read.
3103.758.101 / Edition: 2009104
0 ZF
Maintenance
98
Transmission type: Z
I
Maintenance job no-
F 9000 Series Maintenance level
-1
If periormed possibleTfoTe in conjunction with maintenance job no.
Time required ir minutes
7
Safety measure:
Parts
Test equipment
ee opposite Page
0ZF
Edition: 2009104 13103.758.101
Maintenance
Fig. 66: Switch lever at duplex-oil filter (ZF9000 series without NR2, NRZB, and NRZH, exomple) The contamination indicator controls the respective filter side in operation. The switch lever points towards the filter side taken out of operation. Move switch lever to other filter side until locked in place.
Fig. 67: Rotary handle at gap filter (ZF 9000 series NR2/NR2B/NRZH series, example) Siowly rotate rotary handle of gap filter clockwise by 1 to 2 rotations.
3103.758.101 i Edition: 2009104
Maintenance
100
Transmission type:
Safety measures
( Z F 9000 Series
arforrn visual inspection o n rotating Part from sufficient distance since otherwise Da being caught by rotating part.
Fest equipment
!e opposite Page
0 ZF
Edition: 2009104 13103.758.101
Maintenance '01
Fig. 68: Transmission Z F 9000 A (example)
Fig. 70: Transmission ZF 9000 NR2 (example)
Fig. 69: Transmission Z F 9000 V (example) Check outlet points of input and ouipui shaft from the transrnission housing, connections to the oil pipes and monitoring devices, cooling water connections, and transmission oil cooler for leaks (visual inspection). First the oil level (water leaking in oil or oil leaking in water when moior is switched off) must be checked.
1
Maintenance
102
rransmission type:
iafety measures
ZF 9000 Series
io only use cleaning agents that cornply with the accident prevention regulations valid at i e site of operation.
n-board tools
:leaning agents
.............................
............................. 'est equipment
ee opposite Page
0 ZF
Edition: 2009104 13103.758.101
Maintenance
103
Fig. 71: Transmission ZF 9000 A (exomple)
Fig. 73: Transmission ZF 9000 NR2 (exomple)
Fig. 72: Transmission ZF 9000 V (example) Use cleaning agent to clean transrnission externally to facilitate visual inspection - see maintenance work sheet 103. Caution:
Avoid contact of rubber Parts, flexible conduits, and shaft seal rings with cleaning agents.
i
Maintenance
104
'ransmission type:
ZF 9000 Series
iafety measures
30 not perform re-tightening works while transrnission is in operation.
Test equipment
-..-..- - - -- - - - -.--.- .- - .--.
;ee opposite page
0 ZF
Edition: 2009104 I3103.758.101
Maintenance
Fig. 74: Transmission ZF 9000 A
Fig. 76: Transmission ZF 9000 NR2 Re-tighten all accessible screw connections Pay particular attention to the following connections: O
*
Motorltorsionally flexible clutch Flywheel housingltorque converter housing of transrnission Angle plateltransrnission Angle platelfoundation
Also check the connections "frorn" and "to" the transmission oil cooler and the rnonitoring device connections and re-tighten, if possible.
Fig. 75: Transmission ZF 9000 V
3103.758.101 i Edition: 2009104
Note: The re-tightening of the screws according to tightening torque should be perforrned while the transrnission is cold (approx. 20°C).
@ ZF
Maintenance
106
Transmission type: ZF 9000
41
Series
Oil exchange
--
P -
ock motor starting device.
3afety rneasures
'erform oil exchange at 40-50°C maximum, since otherwise Danger of burns :ollect used oil in oil coliection containers of sufficient size, since otherwise Danger of envimmental oollution.
n-board tools
e w sealslseal rings
III
type:
,dmissible are oils according to the currently applicable "ZF lubricant list TE-ML 04 for ZF iarine transmissions". A lubricant list valid at the time of deliveiy of the transmission is enc~ s e dwith the transmission. it is available from all ZF service branches, on request.
rest equipment
ee opposite page
0ZF
Edition: 2009/04 / 3103.758.101
Maintenance
107
If possible, periorm this operation in combination w i t h maintenance works 142, 163, and 164. 1. Rernove oil gauge, Open oil drain screw (20) and drain oil. 2. Suck off oil, if an oii suction device has been fitted to the transrnission. 3. Insert new seal rings at oil drain screw (20). insert screw and tighten.
4. If oil suction device is used, close suction device. 5. For filling with of oii open oil fill screw (46) or rernove inspection hole cover (37 andlor 47).
Fig. 78: Oil drain screw (201, ZF 9060 NR2 (exomple)
6. Fill with new oil. Oil volumes
47
ZF9000 / ZF9050 / ZF9055 1 ZF 9000NR / ZF 9050NR 1 ZF 9055NR
\
46
approx. 80 dm3
ZF 9000A / ZF 9050A / ZF 9 0 5 5 A l ZF 9000ANR IZF 905OANR I ZF 9055ANR approx. 80 dm3 ZF 9000V / ZF 9O5OV 1 ZF 9055V 1 ZF 9000VNR / ZF 9050VNR IZF 9055VNR approx. 80 dm3 ZF 9000 NR2 / ZF 9050 NR2 / ZF 9055 NR2 IZF 9060 NR2
approx. 60 dm3
ZF 9000 NR2B / ZF 9050 NR2B 1 ZF 9055 NR2B 1 ZF 9060 NR28
approx. 55 drn3
ZF 9000 NR2H / ZF 9050 NR2H / ZF 9055 NR2H
approx. 55 dm3
ZF 9300 1 ZF $31 1 / ZF $350 / ZF 9351 / ZF 9355 / ZF 9356 1 ZF 9300NR / ZF 931 1NR / ZF 9350NR / ZF 9351NR / ZF 9355NR / ZF 9356NR 1 ZF 930011 I ZF 935011 1 ZF 935511
Fig. 79: Oildroin screw (46) andlnspection hole cover (471, for ZF 9000 (exomple)
approx. 90 dm3
7. Fit oil fili screw (46) with new seal ring andlor inspection hole cover (37 andlor 47) and re-tighten. 8. Subsequently, check oil level, according to rnainte-
nance work 101. Note: The rneasurernent by rneans of the oil gauge is relevant.
Fig. 80: Oil fill screw (46) und inspection hole cover (37) for ZF 9000 NR2 (exomple)
Fig. 77: Oil d r o h screw (201, ZF 9000 A (exomple)
3103.758.101 1 Edition:
2009104
0 ZF
1
Maintenance
108
-ransrnission type:
1 ZF 9000 Series
For reasons of safety do not perform filter exchange until 30 minutes after motor has stopi~ e d . lf this is not obsewed hot oil under pressure will abruptly escape from the sealing to the 0 !I filter. Danger of burning.
;afety rneasure!
Perform cleaning and replacement of elements at a maximum oil temperature of 40-50°( ,. Lock motor starting device. Collect used oil in oil containers of sufficient size, since o t h e ~ r i s eDanger of environmen.tal pollution. P
on-board tools P
Filter elements, sealslseal rings
Oil type: Admissible are oils according to the currently applicable "ZF lubricant list TE-ML04 for Z F marine transmissions". A lubricant list valid at the time of delivety of the transmission is 6mclosed with the transmission. It is available from all ZF s e ~ i c ecentres, on request.
rest equiprnent
see opposite Page
P
Location: 0 ZF
Edition: 2009104 l3103.758.101
Malntenance
109
if possible, periorm operation in combination with maintenance works 141, 163, and 164. Replacement of oil filter element (ZF 9000 series without NR2, NRZB, and NR2H) lf in the case of filters with optical and electrical contarnination indicator start up is perforrned in cold condition the red button of the indicator rnay pop out and an electrical signal rnay be ernitted. Do no press the butTon back in until the operating temperature is reached. If it irnrnediately pops out again andlor if the electrical signal does not stop afterthe operating ternperature has been reached the filter elernent must be replaced after end of shift.
CAUTION! Oil is very hot and under pressure. Consequences: Danger of injury and risk of burns.
The oil filer rnust not be replacernent imrnediateiy after switching of the rnotor. For reasons of safety do not perform filter exchange until 30 rninutes after rnotor has stopped. lf this is not observed hot oil under presSure will abruptly escape from the sealing to the oil filter. Avoid skin contact and to not inhale oii vapours.
Fig. 82: Duplex-switch filter (exomple) Caution:
The contamination indicator controls the respective filter side in operation. The switch lever points towards the filter side taken out of operation. Therefore, prior to filter maintenance, the filter must be changed over, whereupon the signal for the contamination indicator goes out and the red button can be pushed in again.
1. Operate pressure balance vaive in the switch lever until locked in piace. Place pan or drip plate underneath to collect leaking oil. 2 . Unscrew vent screw on filter side taken out of operation by 2-3 rotations. 3 . Open screw for sludge drain and drain filter charn-
ber. Collect leaking oil with container. 4. Unscrew filter hood in clockwise direction and clean in suitable medium. 5. Remove filter element towards the bottorn by carefully rnoving frorn side to side. 6. Check o-rings on filter hood and elernent rnount
for darnages. Replace defective parts. 7. Insert screws for sludge drain in filter hood. Use new seal ring.
8. Slightly oil thread of filter hood and screw into filter head until end position is reached. Subsequently, ioosen filter hood by 118 to 112 rotations. 9. Forfilling of filter chambers operate pressure cornpensation lever until the medium leaves the air bleeder hole free of bubbles. 10. Tighten vent screw. Operate pressure cornpensation lever again to check filter for tightness.
Fig. 81: Duplex-switch filter ot transmission ZF 9000 A (exomple)
110
Maintenance
Cleaning of gap filter and filter housing (NR2, NR2B and NR2H)
1. Rotate rotary handle of oil filter as described in rnaintenance work 102 with transrnission out of operation. 2. Loosen screw for sludge drain and drain filter charnber. Collect leaking oil with container. 3. Rernove the four fixing screws at the filter head (3) and rernove filter (4) towards the top. Ensure that no dirt enters the pure oil charnber of the filter housing. 4. Disrnantle filter housing (5) using a oil filter wrench or open-end wrench width 32. Caution:
Do only use brushes for cleaning, never linting cloths or mechanical tools, such as screw drivers, scrapers, etc.
5. Clean housing interior and filter(4) thoroughly using diese1 oil or cleaner's naphtha. For this purpose rotate rotary handle several tirnes (do not disrnantle filter).
Note: For instaliation of filter, filter housing, and sludge drain screw use new filter seal and seal ring. Assernbly is rnade in reverse order of disrnantling Fig. 83: Gap filter ot transmission ZF 9000 NR2 (example)
Fig. 84: Gap filter 1 Screw 2 Filter head 3 Filter housing
0 ZF
4 Seal 5 Filter
Edition: 2009104 / 3103.758.101
Maintenance
3103.758.101 IEdition: 2009104
11 1
0 ZF
Maintenance
112
Transmission type:
IZF
9000 Series
maintenance work
Safety measures
3ck motor starting device.
Parts
Test equipment
ae opposite Page
Location:
0ZF
Edition: 20091041 3103.758.101
Maintenance
113
Check tyres of torsionally flexible clutch for flawless condition. For this purpose slowly rotate motor and check rubber parts through inspection hole of torque converter housing.
Check rubber parts for cracks, embrittlement, and overheating symptoms.
Check identification marks (if available) for distortion.
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i
Maintenance
114
rransmission type: ~ Z F 9000 Series
iafety measures
'est equiprnent
heck rubber-bonded metal Supports at motor and transmission for flawless condition. Ruber parts rnust not show cracks. ernbrittlement, and overheating symptorns.
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Maintenance
3103.758.101 1 Edition: 2009104
115
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i
Maintenance
116
I i
Transmission type: ZF 9000
Series
Lock rnotor starting device.
Safety measures Remove all parts which couid enter the transmission interior after opening of the inspection Cover (empty chest pockets of technician).
on-board tool
Parts
Test equipment
see opposite Page
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Maintenance
117
It is advisable t o perform this work together with the oil exchange (maintenance work 141). 1. Remove inspection cover.
Fig. 85: lnspection hole cover - top view (example)
2. Check multiple-disc clutch. The external disc sup Port must no show any overheating symptoms.
Fig. 86: Extern01 disc support (tronsmission ZF 9000, exomple)
The axternal disc-clutch support has holes through which the disc set of the clutch is visible. Axial moving of the discs must be possible.
Fig. 87: View on the disc set (transmission ZF 9000, exomple) 3103.758.101 1 Edition: 2009104
@ ZF
Maintenance
118
AINTENANC Transmission type: ZF 9000
Series
Lock motor starting device.
, Safetv measures Rernove all parts which could enter the transmission interior after opening of the inspection Cover (empty chest pockets of technician).
on-board tools
Parts
.....................
see opposite Page
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Edition: 2009/04 / 3103.758.101
119
Maintenance It is advisable t o perform this work together with the oil exchange (maintenance work 141). 1. Rernove inspection cover.
Fig. 88: lnspection hole cover - top view (example) 2. Check aearina of wheels on inwut shaft. reverse shaft, a i d o u k u t shaft. The to&h flank; rnust not show pittings or sirnilar signs of wear.
Fig. 89: Wew on the gears (tronsmission ZF 9000, example)
Fig. 90: Tooth flanks without pittings (example)
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0 ZF
1
120
Maintenance
Transmission type:
Safety measures
ZF 9000 Series
ock motor starting device, if oil pump is dismantled
ool kit W1
eal kit
rest equipment
3e opposite page.
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Edition: 2009/04 13103.758.101
Maintenance Motor-dependent oil p u m p (primary oil pump) Correct dirnensioning in accordance with operating conditions and correct installation of the gear purnps provide structural conditions ensuring long and trouble-free operation. They have low rnaintenance requirernents which, however, are indispensible for a trouble-free operation since, according t o experience, a high proportion of the occurring faults and darnages are due t o dirt and insufficient rnonitoring.
Motor-dependent oil pump (primary oll pump)
-
ZF 9000 series without NR2, NRZB, and NR2H
Maintenance Regular checking of all operating data, such as filter contarnination degree, pressure, ternperature, etc. can help t o detect faults at an early stage. Note: The oil pump is a cornplete Part and is norrnaily not disrnantled. However, inspection or cleaning works rnight require disrnantling of the pump. Measures f o r dismantling of oil p u m p Ali works require highest cleanliness standards. Before rernoving screw connections the external environrnent rnust be cleaned.
Fig. 91: Primary o i l p u m p a t ZF 9000 A (example)
* Prior to disrnantling the connection lines are to be depressurized.
* Leaking fluids rnust be coilected and disposed off such that all risks for persons and the environrnent are excluded.
*
Seal pump connections and pipe lines against entry of dirt. Always use lint-free cloths for cleaning pump Parts.
Commissioning of the oil pumps Prior to starting a plant ensure that a sufficient arnount of transrnission oil is available in order to avoid dry running.
Fig. 92: Primafy oil p u m p design (example) 1 2 3 4
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Shaft wheel Bolt wheel Housing Cover
5 Bearing bushing 6 Radial shaft seal ring 7 Locking ring
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122
Maintenance Cleaning and testing of oil pump
Definition of direction of rotation The foliowing definition applies to the direction of rotation of a pump:
7. Thoroughly clean parts. 8. Check gear set (1, 2) for wear and indentation
9. Check front side of gear set for groves. 10. Check cover (4) and housing (3) for groves. 11. Check bearing bushings (5) for wear and groves. side
12. Apply thin layer of oii to movable parts. Assembly of oil pump 1. lnstall radial shaft seal ring (6) and locking ring (7).
Direction of rotation clockwise
2. lnstall long shaft with shaft wheel (1)
Fig. 93: Pump direction o f rotation clockwise (example)
*
3. lnstali short shaft with bolt wheel (2).
With view on the pump shaft end the flow direction is from left to right, for a shaft moving clockwise.
4. lnsert o-ring in cover (4) and mount cover (4) on housing. 5. Mount centring pins 6. Tighten fixing screws of cover with a torque of 49Nm.
7. Rotate pump manually. Pressure side
side
8. lnsert o-ring. 9. lnsert pump in pump flange and assemble by tightening fixing screws crosswise (torque = 23Nm). 10. lnsert o-rings.
Direction of rotation anti-clockwise
Fig. 94: Pump direction o f rotation anti-clockwise (example)
*
11. Mount suction and pressure lines by mounting the bracket and tightening the fixing screws crosswise (torque = 79 Nm).
With view on the pump shaft end the flow direction is from right to left, for a shaft moving anti-clockwise.
Removal and dismantling of oil pump 1. Dismantle suction and pressure lines by loosening the fixing screws at both connections and by removai of the bracket. 2. Take o-rings. 3. Dismantle pump by rernoving fixing screws 4. Take o-ring. 5. Mark position of pump parts 6. Remove screws on cover (4) and dismantle pump.
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123
Motor-dependent oil pump (primaty oil pump) NR2, NR2B. and NR2H
-
Removal and dismantling of oil pump 1. Dismantle suction and pressure pipe.
2. Take o-rings. 3. Dismantle pump by removing fixing nuts 4. Take o-ring.
5. Mark position of pump parts. 6. Remove screws on pump cover (9) and dismantle pump. Cleaning and testing of oil pump 1. Thoroughly clean parts using a lint-free cioth. 2. Check double bearing (4) for groves. 3. Check gear Set (I I) for indentation and groves. 4. Apply thin layer of oil to movable parts. Assembly of oil pump 1. Press shaft seal ( I ) in mounting plate (2) from front side of centring coiiar to bottom. Fig. 95: Primaly oil pump ot ZF 9060 NR2B (example)
2. lnsert housing (5) in mounting plate (2). 3. lnstall support ring (7) and rubber pressure filed seal (8) in first double bearing. 4. lnstall double bearing (4) in a way that the axial pressure field is orientated towards the high-presSure side direction. 5. Mount both gear sets (1 1) 6. lnsert support ring (7) and rubber pressure field seal (8) in second double bearing. 7. lnstall double bearing (4) such that axial pressure field is orientated towards the high-pressure side. 8. lnsert seal element (6) in housing 9. Mount pump cover (9) to housing (5), 10. Mount pump cover (9) to housing (5) by tightening fixing screw crosswise (torque = 79Nm). 11. lnsert o-ring
Fig. 96: Primaly oilpump design (NR2, NRZB, NRZH, example) 1 Shaft seal 2 Mounting plate 3 4 5 6
Set screw Double bearing Housing Seal element
3103.758.1 01 i Edition: 2009i04
7 Support ring 8 Rubber pressure field seal 9 Pump cover 10 Hexagon screw 11 Gear set (shaft)
12. lnsert pump in pump flange and assemble by tightening fixing nuts (torque = 79Nm). 13. lnsert o-rings. 14. Mount suction line to the pump by tightening the fixing screws (torque = 46 Nm). 15. Mount pressure line to pump by tightening the fixing screws (torque = 46).
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124
Maintenance
Trailing operation oil pump (Trailing pump)
9050 V (example)
Fig. 99: Trailing operation pump design (exmple) 1 Reverse housing 2 Inner rotor 3 Outer rotor 4 Steel ball 5 Pressure spring
6 Parallel key 7 Housing 8 Piston non-return valve 9 Bearing bushing 10 Cover
Removal and dismantling of trailing operation oil pump 1. Remove suction and pressure pipe, if required.
Fig. 98: Trailing operation pump ot transmission ZF 9060 NR2B (exomple)
2 . Dismantle traiiing pump by loosening the fixing screws.
3. Dismantle traiiing pump. 4. Take o-ring. 5. Rebound locking ring. 6. Remove drive pinion.
7. Take parallel key (6). 8. Remove fixing screw on Cover (10) and dismantle housing (7). 9. Dismantle piston non-return valve (8).
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Edition: 2009104 / 3103.758.101
Maintenance Cleaning and testing of trailing operation pump 1. Thoroughly clean parts using a lint-free cloth. 2. Check inner (2) and outer rotor (3) for wear. 3. Check reverse housing (1) for wear. 4. Check bearing bushings (9) for wear, 5. Check piston non-return valve (8) for wear. 6. Apply thin layer of oil to movable parts. Assembly of trailing operation oil pump 1. lnsert three pressure springs (5) in cover (10) and fill with grease to ensure that the three steel balls (5) stay in position. 2. lnsert reverse housing (1) in the cover (10). 3. lnsert inner rotor (2) in cover (1 0). 4. lnsert outer rotor (3) in reverse housing (1) 5. Place housing (7) on cover (I 0). 6. Mount cover (10) by tightening the fixing screws (torque = 46Nm). 7. lnstall piston return valve (8) in housing (7) 8. Mount parallel key (6) to pump shaft. 9. Heat drive pinion to approx. 85'C and mount to pump shaft.
10. Rebound locking ring in ring groove of pump shaft. 11. lnsert o-ring 12. Mount trailing pump to the cover of the output shaft by tightening the fixing screws (torque = 46 Nm).
125
I
126
Maintenance
rransmission type: JZF9000 Series
naintenance
~ork
jafety measure
Lock motor starting device.
Tool kit W1
Seal kit
-est equipment
See opposite page
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Maintenance
127
Fig. 100:Control unit ZF 9000 series without NR2, NRZB, NR2H (exarnple) 1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 17 18 19
Cylinder screw Cylinder screw Cover Seal Control housing Cylinder screw Cylinder screw Cylinder screw Gland Bushing Screen Locking screw Gland Cylinder screw Seal nut Cover Seal Set screw Piston
20 Pressure spring 21 Screw plug 22 Seal 23 Screw plug Cover 24 Screw plug 25 Ball 26 Screw plug 27 Screen 28 Bushing 29 Star knob 30 Disc 31 Pressure spring 32 Control piston 33 Retaining ring 34 Screw plug 35 Screw plug 36 Piston 37 Control piston 38 Disc
Checking of control unit: If possibie, instead of disrnantling control unit rather replace cornpletely.
3103.758.101 i Edition: 2009104
39 Pressure spring 40 V ring 41 Screw plug
Note: if dismantling is required for purpose of cleaning or replacement of individual pressure springs readjustment of the control unit is not required. However, a pressure test at the transrnission must be performed.
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Maintenance
128
Abb. lOI:Contro/ unit Nß2, NR26, NR2H (exomple)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Cylinder screw Cylinder screw Cylinder screw Cover Seal Control housing Slotted screw plug Ball Gland Cylinder screw Screw plug Cover Seal Hexagon screw Cover Seal Piston Spacer bushing Spacer bushing
Checking of control unit:
If possible, instead of dismantling control unit rather replace completely.
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20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Disc Pressure spring Bushing Pressure spring Screw plug Seal Screen Spacer bushing Gland Pressure spring Control piston Retaining ring Screw plug Screw plug Sprengring Control piston Control piston Bushing Screw plug
Note: If dismantling is required for purpose of cleaning or replacement of individual pressure springs readjustment of the control unit is not required. However, a pressure test at the transmission must be ~erformed.
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Maintenance
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129
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Maintenance
130
Transmission type:
jafety measure
ZF 9000 Series
.ock motor starting device.
-001 kit
W1
'art kits T1 and T2
Zleaning agents
rest equipment
. ... .. . . .. .. . ... . ... . .... ... .
e e opposite Page
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Maintenance
131
Fig. 702:Electricol control (ZF 9000 series without NR2, NRZB, NRZH, exomple)
Fig. 703: Electricol control (NRZB, NRZB, NRZH, exomple) Testing electrical operating controls: Note: The electrical controi is supplied as complete part and cannot be dismantled. In case of a defective controi unit the complete part must be replaced. 1. Measure electrical resistance (18 to 25ohm).
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1
Maintenance
132
rransmission type:
Z F 9000 Series
I
Maintenance job no
Maintenance level
-1
1
.
if poasibie, t c performed in conjunction with maintenance job no.
I
Time required in minutes
I
iafety measures
n-board tools
................................
................................
'est equipment
....
ee opposite page
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Edition: 2009104 13103.758.101
Maintenance Check indicator devices for oil pressures and oil ternperatures for correctness of indicated values. Option 1: Connect calibrated indicator devices in parallel and cornpare indicated values. lndicating errors rnust not exceed 10% in the individual operating ranges. Option 2: Disrnantle indicator devices and arrange for recalibration andlor use reolacernent indicator devices.
133
I
134
Maintenance
Transmission type:
ZF 9000 Series Maintenance level
If possible, to be performed in conjunction with maintenance job no.
Time required in minutes
Safety measures
Tools
Tool kit W1
Parts
Seal kit
Test equipment
See opposite Page
Location:
@ZF
Edition: 2009104 13103.758.101
Maintenance
135
Fig. 104:Tronsmission oil cooler (ZF 9000 series without NR2, NR26, NRZH, exomple)
Fig. 106: Transmission oil cooler on transmission ZF 9060 NR2B (exomple)
Fig. 105: Transmission oil cooler design (ZF9000 series without NR2, NR26, NRZH, exomple)
Fig. 107: Transmission oil cooler design (NR2, NR26, NR2H. exomple)
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136
Maintenance
Fig. 108:Schematic design of transmission oil cooler (example) 1 2 3 4
Housing Receiver Cover Fixation plate
5 6 7 8
Cylinder screw Disc Pipe plate 0 ring
9 10 11 12
Note: The numbers in brackets referto figure 108. Note: The actuai design of the transmission oil cooler may vary in details. Pipe bundle The pipe bundle consists of two identical pipe plates (7). positioned opposite of each other, with three grooves each. The cooling pipes (1 0) are expanded into the pipe plates. Between the pipe plates on the outside of the pipes there is a surface enlargement rnounted in the form of discs (1 1) which is positively connected with the pipes. Along the entire length of the disc Sets there are siits which accommodate seal strips (12). A varying nurnber of baffle plates (13) may have been instailed in the disc set. After assembly, the housing is sealed by the inner o-ring groove of the pipe plates. This prevents rnedia from mixing in case of a faiiure of the seals and facilitates leak detections. In the centre groove, fixation plates (4) engage with a pipe plate which fix this pipe after assembly and which allow thermal expansion of the opposite pipe plate. Housing The housing (1) serves for accommodation of the pipe bundle and constitutes the outer pressure chamber. It is a standardised Cast housing rnade of an aluminiurn alloy or of grey Cast iron.
0ZF
Separating strip Pipe Disc Seal strip
13 Baffle plate 14 Disc ring
Receivers The two Cast bronze Covers at both ends serve as receivers. Together with the pipe bundle, the receivers form the pressure chamber of the cooling medium. The receivers are rnounted to the housing by screws. On one side of the cooler metal sheets are inserted between the housing and the receiver; these metal sheets fix the pipe plate. On the water connection side of the cooler a receiver(2) with two connections is installed and a return Cover (3) is installed on the other side. For sealing the two charnbers in the receiver a separating strip of piastic or aluminium (9) is inserted into the pipe plate on the connection side. When assembled, this separating strip serves as a seal between the pipe plate and the receiver dividing the flow of the pipe-side medium through cooler. Seals The pipe plate seals consist of o-rings. The pipe threads at the connection are sealed by means of a copper or aluminium ring. The pipe bundle is sealed towards the housing on the side by rneans of a lengthwise seal strip (12). The seal strips are made of the sarne material as the o-rings. Note: The o-rings are available from the customer Service of ZF Marine GmbH; the item nurnber must be indicated. With every maintenance, the o-rings which must be dismantled, have to be replaced.
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Maintenanca
137
Disassembly of the transmission oii cooler (without extraction of the pipe bundle) 1. The position of the screwed flanges to each other must be rnarked in order to be identified at assembly. 2. lsolata all pipelines.
3. Drain the transmission oil cooler on the water side. 4. Rernove the pipe linas on the water side
5. After shut down of the plant wait for minimum 30 minutes until the oil pressura has decreased. 6 . Drain the transmission oii cooler on the oil side; for this purpose drain the oil from the oil filter and the transmission (see Maintenance System Work Sheets 141 and 142 in the present operating instructions). 7. Remove the fixing screws on the transmission oil cooler and remove the transmission oil cooler. Note: The steps 5 to 7 are only required for transmissions from which the cover (3) cannot be removed for reasons of space.
Fig. I7O:Pipe bundle secured with fkotion plates (ZF 9000 series without NR2, NRZB, NRZH, example) Note: Now, the water side may be inspected and mechanicaliy cleaned. In the case of transmissions where the transmission oil cooler has not been removed, the oil side may remain pressurised. 10. Remove separating strip (9)
8. Remove the receiver (2) and the cover (3) by loosening the bolts from the receiver-housing and cover-housing connections.
9. Rernove the o-rings frorn the outer groove of the pipe platas and secure tha pipe bundle against the housing (1) in the centre groove of the pipe plates using four bolts and the four fixation plates (4).
Fig. I 7 7: Removing the separating strip (NR2, NRZB, NR2H. example)
Fig. 109:Pipe bundle secured with fixation plates (NR2, NRZB, NRZH, example)
Fig. 172:Removing the separating strip (ZF 9000 series without NR2, NRZB, NRZH, example)
138 Water side cleaning The transmission oil cooler requires water-side cleaning at least once per year. Excessive contamination of the pipes must be avoided. Note: The time intervals for rnaintenance must be reduced for lang-term operation of the ship in ports and other soiied waters, and according to the operator's experience. In case of slight contamination the water side may be cleaned mechanically: 11. Dismantle the transmission oil cooler as described in the section Dismantling the transmission oil cooler (without extraction of the pipe bundle). 12. Clean every pipe of the pipe bundle on the inside using a nylon brush (see chapter Tool set).
Maintenance Note: Do not use tools to remove firmly adhering deposits. In such a case the pipe bundle must be chemically cleaned. This operation may be carried out in assembled condition by spraying the chemical cleaning solutiori onto the pipes. It must be ensured that the condition of the o-rings is not affected by the chemical solution. Chemical cleaning should only be carried out by qualified personnel. Note: Suppliers of suitable cleaning agents are e.g. Ashland Chemicals (www.ashchem.com), Honkcl Oberflächentechnik (www.henkel.com) and Ondeo Nalco (www.nalco.com). Suppliers of cornplete cleaning services are e.g. Vecom (www.vecom.nl) and Ondeo Nalco (www.nalco.com). Disassembly of the transmission oii cooler 1. Mark position of the screwed flanges to each other.
2. M a t e all pipelines. 3. Drain the transmission oil cooler on the water side. 4. Remove the pipelines on the water side.
5. After shut down of the system wait for 30 minutes until the oil pressure has decreased. 6 . Drain the transmission oil cooler on the oil side; for
this purpose drain the oil from the oil filter and the transmission (see Maintenance System Work Sheets 141 and 142 in the present Operating instructions). Fig. 113:Cleaning the pipes b y rneans o f a nylon brush (NR2, NR26, NR2H, exarnple)
7. Unscrew the fixing screws at the transmission oil cooler and remove the cooler. 8 . Remove the receiver (2) and the Cover (3) by loo-
sening the Crews from the receiver-housing and cover-housing connections. Note: Four fixing plats (4) are located between the receiver (2) and the casing (1). These plates must be instalied an the same side when assembling the unit. For this purpose observe the identification mark F on the housing flange.
Fig. 114:Cleaning the pipes b y rneans o f a nylon brush (ZF 9000 series wlthout NR2, NR2B, NRZH, exarnple) Note: Do not use metal brushes for cleaning the pipes.
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Maintenance
139
Note: On one pipe plate an identification mark for the installation position is provided opposite the casing. The edge of the pipe piate and the adjacent casing flange each contain one half of an X . This mark must be obsewed.
Fig. 115:ldentification mark F for fixation plates (example)
9. Remove the o-rings from the outer groove of the pipe plates.
Fig. 118:ldentification mark X forinstallation of the pipe bundle (NR2, NR2B. NRZH, example)
Fig. 116:Dismantling the outer o-ring (NR2, NRZB, NRZH, example)
Fig. 1 19:ldentification mark X for installation of the pipe bundle (ZF 9000 series without NR2, NR2B. NRZH, example) 1 0 . Push the pipe bundle towards the water side that far (if required, use an auxiliary tool) until the o-ring on the inner groove is visible).
1 1 . Remove the o-ring of the inner groove
Fig. 117:Dismontling the outer o-ring (ZF 9000 series without NR2, NR2B, NRZH, example)
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140
Maintenance
Fig. 120:Disrnantling of the inner o-ring (NR2, NRZB, NRZH, exomple)
Fig. 123: Removol of the pipe bundle (ZF 9000 series without NR2, NRZB, NRZH, exomple) Note: The grooves for accornrnodation of the o-rings must not be darnaged. When rernoving the pipe bundle, the baffle piate (13) may fall out. Assembly of the transmission oil cooler (without extraction of the pipe bundle)) The assernbly of the transrnission oil cooler is carried out in reverse order of dismantling the cooler. 1. Rernove the four bolts and the four fixing plates (4).
Fig. 12 I: Dismontling of the innero-ring (ZF9000 series
2. Lubricate the outer o-rings with a suitable type of grease and insert into the corresponding outer groove of the pipe plates (7).
without NR2, NRZB, NRZH, exomple) 12. Rernove the pipe bundle in opposite direction. In doing this, the pipe bundle rnust be rernoved frorn the casing very carefully, in order not to darnage the disc set. If possible, the pipe bundle should be suspended by large-surface transport slings.
Fig. 124: Obsetve outer o-ring during instollotion (NR2, NRZB, NRZH, exomple)
NRZH, exarnple)
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Edition: 2009104 13103.758.101
Maintenance
141 Note: With two-way transmission oil coolers a separating strip (9) must be inserted into the pipe plate on the wa. ter side (receiver (2) with two connections). 4. insert the four fixing plates (4) into the middle groove of the pipe plate (7) on the water side (receiver (2) with two connections) observing the identification mark F. 5. Place the receiver (2) and the cover (3) in parallel position on the corresponding pipe plate (7) and evenly slide them onto the outer o-ring.
Fig. 125:Observe outer o-ring during installation (ZF 9000 series without NR2, NRZB, NR2H, exomple) 3. Check for correct installation position of the separating strip (9) on the water side.
Note: When sliding the receiver (2) and the cover (3) onto the o-rings it must be observed that the o-rings do not shear off. 6. Assemble the receiver (2) and the cover (3) by means of four screws, tightening the conjugate bolts crosswise with the torque (see table 17, Tightening torques). Model
series (without NR2,
I
Screwl strength
1
M16183
1
iightening torque
(
1 9 5 Nm
Tob. 17: Tightening torques
Fig. 126:Ensure correct installation of seporating strip (9) (NR2, NRZB, NRZH, example)
7. In the case of transmissions where the transmission oil cooler has been removed from the transmission housing, the cooler must be positioned onto the transmission housing and fixed to the housing by means of four fixing screws. 8. Mount the pipe connections to the receiver (2). 9. Connect the pipelines on the water side.
10. Open and re-fill all pipelines 11. Bleed the transmission oil cooler on the water side. 12. Fill the transmission with oil Note: Step 12 is only required, if the transmission oil cooler has been removed for cleaning the transmission housing.
Fig. 127: Ensure correct instollation o f seporating strip (9) (ZF 9000 series without NR2, NRZB, NRZH, exomple)
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@ ZF
142
Maintenance
Assembly of the transmission oil cooler (after extraction of the pipe bundle) The assernbly of the transmission oil cooler is carried out in reverse order of disrnantling the cooler. 1. Grease the sealing strips (12) of the pipe bundle. The sewice fiuid rnay be used for this purpose.
Note: Seaiing strips (12) rnust only be replaced if they are darnaged. The sealing strips rnust be effective over the entire length of the pipe bundle. 2. Carefully insert the pipe bundle into the casing (1).
Fig. 130:Observe the sealing strips (12) und the disc ring (14) during instollotion (NR2, NRZB, NRZH, example)
Fig. 128:lnstallation of the pipe bundle (NR2, NRZB, NRZH, exomple)
Fig. 131:Observe the sealing strips (12) und the disc ring (14) during instollotion (ZF 9000 series without NR2, NR2B. NRZH, example) Note: On one pipe plate an identification rnark for the installation position is provided opposite the housing. The edge of the pipe plate and the adjacent casing flange each contain one half of an X. This mark is to be verified.
Fig. 129:Installotion of thepipe bundle (ZF9000 series without NR2, NR2B, NRZH, example)
Note: When inserting the pipe bundle, it rnust be o b s e ~ e d that the sealing strips (12) are not shifted or crirnped.
Fig. 132:ldentification mark X for instollotion of the pipe bundle (NR2, NRZB, NRZH, exomple) Edition: 2009104 / 3103.758.101
Maintenance
143
Note: When inserting the pipe plates (7) into the sealing surfaces, it rnust be observed that the o-ring do not shear off. 5. Lubricate the outer o-rings with a suitable type of grease and insert into the corresponding outer groove of the pipe plates (7).
Fig. 133:ldentification mark X for installation of the pipe bundle (NR2, NRZB, NRZH, example) 3. Insert the disc ring (14) into the baffle plate (1 3) and press down during installation of the pipe bundle. 4. Lubricate the inner o-rings with a suitable type of grease and insert into the corresponding inner groove of the pipe plates (7).
Fig. 134:Observe the inner o-ring during instollation (NR2, NRZB, NRZH, example)
Fig. 736:Obsetve the inner o-ring during installation (NR2, NRZB, NR2H, example)
Fig. 137: Obsetve the inner o-ring during installation (ZF 9000 series without NR2, NRZB, NRZH, example) 6. Verify the correct installation position of the divider (9) on the water side.
Fig. 135:0bsen/e the inner o-ring during installation (ZF 9000 series without NR2, NRZB, NRZH, example)
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0 ZF
Maintenance
Model
1
Screwl strength
Tightening torque
series (without NR2, NRZB, NR2H) Tob. 18: fightening torques
Fig. 138: Observe correct instolloiion ofseporoting sirip (9) (NR2, NR2B, NRZH, exornple)
1. Position the cooler onto the transrnission housing and fix it to the housing using four fixing screw Mount the pipe connections to the receiver (2). 2. Connect the pipelines on the water side 3. Open and re-fill all pipelines. 4. Bleed the transrnission oil cooler on the water side. 5 . Fill tho transrnission with oil,
Replacement of pipe bundle If rnore than 10% of the pipes in the bundle are leakinglnot tight, the entire pif)e bundle rnust be replaced. 1. Disrnantle the transmission oil cooler as described in the section "Disrnantling the transrnission oil cooler (with extraction of the pipe bundle). f g 139: iitserve corrcci incrullut~on of seporoc~nqstr~p
(91 ( Z f 9000 series vv~rriourNR2, NRZß,
Note: With two-way transrnission oil coolers a separating strip (9) rnust be inserted into the pipe plate on the water side (receiver (2) with two connections). 7. Insert the four fixing plates (4) into the centre groove of the pipe plate (7) on the water side (receiver (2) with two connections) observing the identification rnark F. 8. Place the receiver (2) and the cover (3) in parallel position on the corresponding pipe plates (7) and
2. Rernove the defective pips bundle. 3. Insert the new pipe bundie. 4. Assernble the transrnission oil cooler as described in the section "Assernbiy of the transrnission oil cooler (after extraction of the pipe bundle).
Revision After assernbly, both the oil side and the water side rnust be revised. During this operation it rnust be obsewed that the pressure (oil side and water side) does not exceed the value stated in the transrnission installation drawing andlor on the type plate.
evenly slide them onto the outer 0-ring. Note: When sliding the receiver (2) and the cover (3) onto the o-rings it must be observed that the o-ring do not shear off. 9. Assernble the receiver (2) and the cover (3) by rneans of four screws, tightening over Cross with the correct tightening torque (see table 18 Tightening torques).
0 ZF
Edition: 2009104 I3103.758.101
Maintenance
3103.758.101 IEdition: 2009104
145
0 ZF
Maintenance
146
lransmission type:
I ZF 9000 Series
jafety measures
>arts
-est equipment
............................
?e opposite page
0 ZF
Edition: 2009104 / 3103.758.101
Maintenance
If possible, perform this operation in combination with maintenance work 121. 1 . Check input drive shaft for leaks (if required, collect escaping oil).
Note: If the input shaft seal ring is visibly damaged the input shaft seal ring must be replaced as soon as possible.
Fig. 140:lnput drive shoft (ZF 9000 series, exomple)
Fig. 141:lnput drive shoft (ZF 9000 V, example)
147
i
148
Maintenance
1
Transmission type: ZF 9000
Series
Parts
See opposite Page
0ZF
Edition: 2009104 / 3103.758.101
Maintenance
If possible, perform this operation in combination w i t h maintenance work 121. 1. Check output drive shaft for leaks (if required, collect escaping oil).
Note: If the output shaft seal ring is visibly damaged the input shaft seai ring rnust be replaced as soon as possible.
Fig. 142:Output drive shaft (ZF 9000 series NR2, NRZB, NRZH, example)
Fig. 143:Output drive shaft (ZF 9060 NRZB, exomple)
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0ZF
Maintenance
Edition: 2009104 I31 03.758.101
