00 ZF Man GT 43000 Series

Maintenance
and Operating
Manual for
Gearbox type
ZF W43000 Series
Mod. 03.2010
Date
General Index
The manual consists of 11 sections as follows:

Section 1:
TECHNICAL DATA
Page
Section 2:
MAINTENANCE AND OPERATION MANUAL
Page
11
Section 3:
AFTER RECEIPT OF EQUIPMENT
Page
15
Section 4:
OPERATING NOTES
Page
21
Section 5:
WORKING PRINCIPLES
Page
25
Section 6:
INSTALLATION DESCRIPTION
Page
39
Section 7:
STARTING OPERATION
Page
51
Section 8:
EMERGENCY OPERATION
Page
65
Section 9:
MAINTENANCE
Page
71
Section 10:
TROUBLESHOOTING REMEDIES
Page
83
Section 11:
SERVICE CENTERS
Page
89
Section 12:
APPENDIX
Page
95
Appendix 1:
Recommended Oils
Appendix 2:
Clutch discs
Appendix 3:
Filters
Appendix 4:
Pumps
Appendix 5:
Cooler
Appendix 6:
Valves
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Date
Remarks
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ZF Padova S.p.A.
Section 1
Date
Technical data
Section 1
1.1 IDENTIFICATION
The identification plate is fixed on the marine gearbox. The guarantee ceases to be valid if
this plate is tampered with or removed. Every time an assistance centre is contacted the
details on the plate must be reported.
TYPE
PART LIST No
SERIAL No
RATIO
CUSTOMER No
DRY MASS (kg)
Pleasure
OIL TYPE
Light
OIL
CAPACITY (z)
Medium
Continuous
CLUTCH OIL
PRESSURE (bar)
OIL CHANGE: after first 250 hours of operation and every

2000 hours or 12 months thereafter, whichever occurs first.
CHECK OIL LEVEL WEEKLY
Fig. 1.1
ZF Padova S.p.A.
Date
Technical data
Section 1
Oil quantity
280 dm3
Working clutch oil pressure at monitoring

(only for nr version)
versions
{ NR
NC with clutchable PTO version
~ 5 bar Nominal { NC Without clutchable PTO versions
25 bar Nominal
Permitted working oil temperature range
5 - 75 C
Functional working oil temperature
50 70 C
Water temperature at oil cooler inlet
38 C max
Engine room temperature range
from 5 to 50 C
Water pressure in heat exchanger

Water flow range in heat exchanger
Basic weight of gearbox without oil
10 bar MAX
7 11,9 m3/h
12 30 m3/h
{ KS 12 Cooler version
{ KS 20 Cooler version
5400 Kg NC version / 6400 Kg NR version
Size of filtration element in heat

exchanger aspiration
2,5 mm
Roller Bearings
Temperature thrust bearing
Slide Bearings
{
{
65C Nominal
85C Rising Alarm
45C Nominal
68C Rising Alarm
3 bar Nominal
< 0,4 bar Alarm
< 0,21 bar Engine Stop
Luboil pressure
{ NR versions
Stop 26 bar Rising { NC with clutchable PTO versions
Start 0,8 bar Falling NC without clutchable PTO versions
Stop 3,5 bar Rising {
Start 20 bar Falling

Stand By-Pump
(versions with Roller Bearings)
Start 19 bar Falling

Start 0,8 bar (Lube) Falling
Stand By-Pump
(versions with Plain Bearings)
Stop 26 bar Rising

Stop 3,5 bar (Lube) Rising
Start 0,8 bar Falling
Stop 3,5 bar Rising
Filter contaminations
NR versions
NC with clutchable PTO versions
{ NC without clutchable PTO versions
max difference inlet outlet:

1,2 bar (Roller Bearings)
3,5 bar (Slide Bearings)
ZF Padova S.p.A.
Date
Technical data
Section 1
DESCRIPTION
POS.
DESCRIPTION
POS.
PTO (optional)
14
Control box
Oil pump
15
Input shaft
Output shaft
16
PTO shaft (and PTI shaft)
Monitoring
17
Check valve
Drain plugs
18
SAE 2 1/2 flange

(connection for standby pump)
Lower half casing
19
Double oil filter
Central section
20
Drip tray
Oil dipstick
21
Upper section
Breather
22
Control valve
10
Heat exchanger
11
Connection for O.D. box
12 A-B
13
Inspection covers
Thermometer
ZF Padova S.p.A.
Technical data
Date
Section 1
Remarks
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10
ZF Padova S.p.A.
Section 2
Maintenance and
Operation Manual
Date
Section 2
Maintenance and Operation Manual
Purpose of this manual:

The following manual contains the information required for installers and users of ZF Marine Propulsion Systems equipment. Users may include ships staff, shipping company
superintendents, land based support staff, shipbuilders and dry-dock supervisory staff.
This manual is intended to provide the information necessary for the safe installation,
onboard operation and routine ships maintenance. The manual also contains spare parts
ordering information.
It is appreciated by ZF Marine Propulsion Systems that regional laws, insurance provisions, shipping company standards and shipyard regulations as well as ships design specific considerations, etc, may result in the necessity to modify, or change the technology,
practices and procedures described herein. Please be advised, however, that any modification, or change of technology, practices and/or procedures may invalidate the manufacturer warranty, unless prior written agreement has been received, from ZF Marine.
Instructions within this manual include specific symbols to be carefully observed:

: danger to life and limb
: danger to product and/or overall plant
: danger to other aspects
: attention to notes
ZF Padova S.p.A.
13
Maintenance and
Operation Manual
Date
Section 2
Limitations of liability: end user, customer and

manufacturer responsibility:
Installation and Operation of the equipment, including unauthorized modifications, outside the parameters described in this manual, may result in irreparable damage to, and/or
malfunction of the equipment. Such actions may result in invalidation and rejection of
existing warranty and any warranty claims, solely at the manufacturers discretion.
Installation, maintenance and/or modification work shall only be performed by certified
ZF Marine service engineers or ZF Marine qualified service facilities. Please refer to the
ZF Marine service organizations listed inside this manual or visit the Support Section of
our web site at www.ZF-Marine.com
NOTE RELATING TO REPAIR WORK:
Due to continuing development of our products, manufacturing technology and procedures future repair work may require the application of work practices, test or adjustment
data that are not covered by this manual at the time of issue. We therefore recommend
that repair work carried out on your ZF product is performed only by skilled technicians
who have undergone practical and theoretical skills training. ZF training includes refresher and assessment courses, and are conducted at approved ZF training centers.
The ZF group has installed a network of fully staffed Sales and Service Organization Centers, (SSOs), at strategic locations throughout the world so that our customers receive
field support close to their geographical location. Repair work carried out at ZF SSOs will
be guaranteed in accordance with the prevailing contractual conditions.
NOTE RELATING TO DAMAGE:
Damages resulting from work performed by non-ZF personnel and which is deemed
by ZF to have been conducted in an improper manner are, in their entirety, excluded
from the ZF contractual guarantee. This includes all follow-up remedial work, the
costs thereof, consequential damages such as loss of vessel operational time and any
other associated loss of revenue including any and all third party liabilities.
ZF Padova S.p.A.
Via Penghe, 48
I-35030 Caselle di Selvazzano (PD)
ITALY
Tel. +39-049 8299-311
Fax +39-049 8299-550
www.ZF-Marine.com
14
ZF Padova S.p.A.
Section 3
After Receipt of Equipment
Date
Section 3
After Receipt of Equipment:

Handling and Storage.
3.1 GENERAL:
The material has been shipped in good condition, protected against mechanical damage
and corrosion by appropriate packaging. The consignee/shipyard shall inspect the material upon delivery and make sure that all items have been delivered as shown on the transport documents no item has suffered any damage during transportation and handling all
parts are free of corrosion.
ZF Padova S.p.A.
17
Date
Section 3
3.2 UPON RECEIPT OF THE GOODS:
NOTE:
Before ZF marine gears are supplied to our customers, they are tested on test rigs/benches. During this test, every function, oil pressures, temperature and noise level are checked
thoroughly and recorded. After the test run, the inside of the transmission is flushed with
oil to preserve it. The transmission can then be stored in a dry place for up to 12 months
without the need for further special measures.
Any necessary preservation of the outside of the transmission depends on storage conditions and should be undertaken by the customer. Preservation measures for long storage
periods must be specified when ordering.
All shipping crates and packages must immediately undergo an inspection for external
damage. If any damage is noticed, the damaged locations must be photographed and
together with a notification letter sent to the ZF Marine contract administration department.
Please note that failure to do so promptly may invalidate or delay any insurance claims
filed on behalf of either shipyard and/or ZF Marine and shall absolve ZF Marine of any
responsibility for damages that might be found during the installation process.
After unpacking of the equipment, the scope of supply shall be carefully checked against
the packing list and the technical specification of the system. Please contact the ZF
Marine contract administration department in the event that any part(s) are missing for a
speedy replacement.
Once the consignee/shipyard has accepted the delivery of the goods, the consignee/
shipyard is responsible for ensuring that the goods are stored in a covered storage site to
prevent mechanical damage to and/or corrosion of the goods. No dirt, dust, humidity or
any other matter shall be allowed to penetrate into the mechanical devices and/or electric
or electronic components.
18
ZF Padova S.p.A.
Date
Section 3
3.3 NOTES ON HANDLING AND STORAGE:

When handling the equipment make sure the carrying capacity of the crane is
adequate.
Use exclusively approved handling equipment.
Attach the handling equipment carefully to the suspension devices indicated in the installation drawing.
Lift the gearbox carefully and without jolts.

Move the gearbox in its mounting position only and avoid jolts and shocks.
Put the gearbox down carefully and without jolts.
When lifting the gearbox make sure that the handling elements do not cause damage
to attachment parts.
Store the gearboxes in dry and moderately heated rooms only.
Store the gearboxes only in their intended mounting position.
Make sure that the gearboxes are only set down in the area of the alignment bolts as
indicated in the installation drawing.
Make sure that gearboxes put on the ground rest immovably and are not exposed to
external forces.
Remove blank flanges and plugs closing off oil and cooling water connections only after
gearbox mounting has been completed.
Make sure that dirt, foreign substances and water cannot enter the gearbox
interior.
Note: ZF will dispose of any packing material supplied with the gearboxes when this is
returned to the factory free of charge.
ZF Padova S.p.A.
19
Date
Section 3
3.4 CORROSION PREVENTION:

Gearboxes supplied by ZF are not filled with oil. The interior of the gearboxes has been
protected against corrosion by oil flushing.
The surfaces of external flanges, shaft ends and flange attachment faces are protected
against corrosion.
The gearboxes are protected against corrosion for a period of 12 months provided the
instructions given under point 3.2 are carefully observed.
If the gearboxes are turned prior to commissioning and only taken into service at a much
later date, suitable corrosion preventive measures must in any case be taken. For further
details in this connection, please contact the ZF Service Department.
FOLLOWING INSTRUCTIONS MUST BE ADHERED TO!

CUSTOMER IS RESPONSIBLE FOR STORAGE/ PROTECTION.
CORROSION PROTECTION MUST IMMEDIATELY BE RENEWED.

CORROSION PROTECTION MUST BE RENEWED AT MONTHLY INTERVALS.
MINOR CORROSION SPOTS MUST BE POLISHED AND NEW PROTECTION APPLIED.
20
ZF Padova S.p.A.
Section 4
Operating notes
Date
Section 4
4.1 SAFETY NOTES

The gear unit is constructed in accordance with the state of the art and is reliable in the
condition as shipped. Unauthorized modifications which impair its reliability are NOT
permissible. This also applies to guards which are fitted as protection against accidental
contact.
The gear unit may only be used and operated within the scope of the conditions specified in the contract of performance and supply.
The customer has to ensure that the persons entrusted with installation, operation and
maintenance have read and understood the Operating Instructions and observe them
in all respects in order to:
Prevent hazard to life and limb of the user and third parties
Ensure the reliability of the gear unit
and
Prevent failure and evironmental pollution due to incorrect handling.
The relevant regulations concerning industrial safery and pollution control should be
observed during handling, installation, operation, and care and maintenance.
The gear unit may only be operated, serviced and repaired by authorized, trained and
properly instructed personnel.
Cleaning with a high-pressure cleaning device is not permissible.
All work should be carried out with care with the safety aspect in mind.
All work on the gear unit may only be carried out when it is stationary.
The drive unit must be secured to prevent accidental startup (e.g. by locking the key
switch or by removing the fuses in the power supply). A notice should be displayed at
the switch-on point stating that work is in progress on the gear unit.
ZF Padova S.p.A.
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Operating notes
Date
Section 4
On the occasion of oil changes, the old oil should be collected in a suitable receptacle.
Any pools of oil which have occurred should be removed at once with an oil binding
agent.
Very dirty and oil-soaked cleaning rags should be kept in suitable containers.
The oil, the oil binding agnt and the cleaning rags should be disposed of in accordance
with the relevant pollution control requirements.
The drive unit should be shut off at once if changes in the gear unit are detected during
operation, such as for example increased operating temperature or a change in gear
unit noises.
Rotating parts, such as couplings, gear wheels or belt drives must be protected by
means of suitable guards to prevent accidental contact.
During installation of the gear unit in units or systems, the manufacturer of the units or
systems is obliged to incorporate the requirements notes and descriptions contained in
these Operating Instructions in his own Operating Instructions.
Notes affixed to gear units, such as for example rating plate, direction of rotation arrows, etc., must be observed. They must be kept free from paint and dirt. Missing plates
must be replaced.
Working with naked flames and performing welding work in the vicinity of the
gearbox and pipe openings are prohibited.
Make sure work is only performed when the equipment has been disconnected
from the electrical supply system.
24
ZF Padova S.p.A.
Section 5
Working principles
Date
Section 5
Working principles
5.1 WORKING PRINCIPLES

The main functions of the marine gear box are the following: to couple the engine with
the propeller axle and reduce the number of propeller revolutions, to stop propeller axle
motion (neutral).
ZF Padova S.p.A.
27
Working principles
Date
Section 5
The gearbox models are available with or without engaging clutches (types NR and
NC) and also with a wide range of Power Take Off (PTO) and Power Take IN (PTI)
secondary drives.
The multiple disk clutches incorporated in the gearbox are hydraulically operated via
directional control valves activated by the clutch control.
Types of Gearboxes
NC
NR
Single reduction
gearbox without clutch
Single reduction
gearbox with clutch
The gearbox permits the following kinds of function.

Neutral
With the output shaft [B] connected to the propeller shaft and transmitting no rotation.
The clutch is disengaged.
In gear
With the output shaft [B] connected to the propeller shaft with opposite direction of rotation from the input shaft [A]. The clutch [C] is engaged.
The transmission of motion takes place with the ratio as indicated on the identification plate.
The kinds of functioning are controlled by the, mechanical or electrical, control unit.
28
ZF Padova S.p.A.
Working principles
Date
Section 5
Non-Reversing Reduction without clutch for CPP
Non-Reversing Reduction with clutch for CPP
ZF Padova S.p.A.
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Working principles
Date
Section 5
Non-Reversing Reduction with clutch for CPP with PTO
30
ZF Padova S.p.A.
Working principles
Date
Section 5
Non-Reversing Reduction without clutch for CPP with PTO
with clutchable PTO 4
ZF Padova S.p.A.
with live PTO 5
31
Date
Working principles
Section 5
Layout of a BI - PTO
D2
C
A
D1
B
A - INPUT SHAFT
B - OUTPUT SHAFT
C - CLUTCH
D1/D2 - P.T.O. SHAFTS
Layout of a TRI - PTO

C2
D2
D1
C
A
D3
C3
B
A - INPUT SHAFT
B - OUTPUT SHAFT
C - INPUT SHAFTS CLUTCHS
D1/D2/D3-P.T.O. SHAFTS
32
ZF Padova S.p.A.
Working principles
Date
Section 5
The housing sections are made by rigid cast design or in welded sheet steel construction.
Optimum vibration characteristics with excellent smooth running have been additionally
achieved by means of pronounced ribbing.
The bottom of the housing is used as an oil tanks, this configuration eliminates a very large
extent the problems resulting from thermal expansion when aligning the gear box in the vessel.
On this level of the lower parting line the output shaft with the propeller trust bearing is located in the rear area. The propeller thrust is transmitted from this bearing via the housing
bottom part with its stopper faces directly to the stoppers of the ship foundation.
So, no forces caused by the propeller thrust are applied on the remaining housing structure.
The housing is exactly fixed to the foundation by closed fitting bolts.
The input shaft with the main pinion and the gears, are located on the same level with the
output shaft.
To ensure service of the gear box there are some covers permitting simple quick inspection
of gear system.
ZF Padova S.p.A.
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Working principles
Date
Section 5
On the gear systems the single helical involute tooth systems are case hardened and grinded.
Load-dependent tooth flank correction, combined with high tooth system quality, ensure quiet, reliable running.
The tooth pitch has been chosen to ensure balanced tooth system loading.
A tooth contact pattern check has been carried out in the workshop during assembly.
This check ensures that the gear box has optimum internal alignment, this being essential for
a long service life.
34
ZF Padova S.p.A.
Working principles
Date
Section 5
5.2 BEARINGS
The output shaft is supported by roller or slide bearings. They are designed to take maximum
propeller thrust astern and ahead.
The output shaft is axially secured by thrust bearing self aligning which also absorbs the propeller thrust and transmits it to the ships foundation.
The input shaft is also supported by roller bearings: the axial forces resulting from the gear
theeth are absorbed by axial part of the roller bearings.
The roller and slide bearings are supplied with oil by housing bores.
ZF Padova S.p.A.
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Working principles
Date
Section 5
The gear system is oiling with an oil pump, that is use for engagement of the clutch.
The oil pump receives the motion of the shaft entrance and the speed of rotation depends on
the revolutions of the engine.
The oil pressure is maintained constant by means of the distributor.
The oil is cooled by an heat exchanger made by cooling tubes which are resistant to salty sea
water.
The volume of heat generated in the gearbox is removed partly by radiating from the surface of the
housing and partly through the oil cooler the oil cooler included in the basic version of the gearbox
is mounted on the housing.
All the necessary oil lines are securely attached and ready for operation.
For permissible water flow rate and pressure loss between cooling water inlet and outlet the specified water pressure and temperature at the cooling water inlet must not be exceeded.
The correct gearbox temperature is achieved by adjustment of the cooling water flow rate.
A replaceable orifice, valve or similar device must be included in the ciruit for this purpose.
For this reason, the gearbox water circuit should be arranged in a by-pass from the engine cooling
water circuit. The maximum temperature increase of the cooling water in the gearbox oil cooler is
3 C and is of no significance to the engine oil circuit.
The stated maximum cooling water flow through the gearbox oil cooler must not be exceeded
since this may lead to cavitation in the cooler.
Similarly, the minimum flow rate must always be maintained or else sludge may form in the cooler
after only a relatively short period of operation.
Before being cooled, the oil passes through a double oil filter with a contamination indicator.
Simplified hydraulics diagram
Fig. 2.1
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ZF Padova S.p.A.
Working principles
Date
Section 5
Seals
The split - type seals, because of the labyrinth inside prevent any leakage of lube oil at the
input and output shafts.
They are designed for an easy maintenance.
Clutch
The multiple disk clutches incorporated in the gearbox are hydraulically operated via directional control valves activated by the clutch control.
A smooth and reliable hydraulic shifting electrically activated is obtained by a pressure
modulation.
Stand-by oil pump

The electrical driven stand-by pump supplies the gear box with oil prior to startup. If necessary, this pump will also perform the function of the oil pump fitted to the gear box.
During the installation of the stand by pump verify that the suction pressure is
not lower than - 0,6 bar.
ZF Padova S.p.A.
37
Working principles
Date
Section 5
5.3 MONITORING
The marine gearbox has been designed for the connection of the instruments (monitoring)
in order to record the oil pressure, temperature and level according with the Classification
Society requirements.
38
ZF Padova S.p.A.
Section 6
Installation Description
Date
Section 6
6.1 INTRODUCTION
This section describes the installation of the gearbox and appropriate products. The drawings
to which the descriptions refer are included in the Appendix. The preceding safety notes must
be carefully observed.
Put the gearbox on the foundation top plate and, before removing the hoisting elements,
secure it in this position to prevent dislocation.
Make sure the gearbox is set down on the alignment bolts only.
Make sure the gearbox housing is not subjected to distortion and properly connected to the
ships foundation.
Make sure the pipes for the lubrication and cooling system are connected to the gearbox in
a flexible manner.
The pipes and fittings for supplying the seawater cooler and for the auxiliary pump are to be
supplied by the shipyard.
The connection must be free from stress caused by vibration.
Make sure pipes and connections are cleaned before installation; they must be free from
scales and welding beads.
Absolutely avoid heavy blows and shocks.
Make sure the gearbox housing, input and output shafts are not subjected to high axial
forces.
ZF Padova S.p.A.
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Date
Section 6
Protect the gearbox against damage, humidity and dirt.

Remove blank flanges and plugs closing off oil and cooling water connections only after
gearbox mounting has been completed.
Change the setting of the pressure control valves and monitoring devices only in cooperation
with ZF
Note: Modifications on the setting of the (Clutch Control Unit) are only allowed by authorized
ZF personnel.
Only use the accessories supplied by ZF. The risks associated with the use of third-party
products lies solely with the client.
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ZF Padova S.p.A.
Date
Section 6
6.2 MOUNTING WORK TO BE PERFORMED

6.2.1 Gearbox
Clean gearbox supporting surfaces, input shaft output flange and pipe connections faces to
remove the anti-corrosive agents.
Make sure there are no oil or grease on the cleaned surfaces.

Align the gearbox properly in relation to the propeller line shafting calculation.
Make a prealignment in dry dock.
Expertly mount the gearbox and tighten the holding down bolts as instructed.
Connect the flange of the gearbox output shaft to the flange of the propeller line shafting
using close fitting bolts.
Remove any blank flanges and plugs closing off openings where piping connects.
Make sure that the transmission has been installed while leaving the space necessary
for future maintenance. The transmission must be anchored to the foundation of
the gearbox with adequate fastenings in order to prevent any compensations to the
housing of the transmission.
6.2.2 Electric motor for stand by pump
Take care that there is no restriction of the cooling air passage to and away from the electric
motors.
Take suitable measures to prevent the hot waste air from being in again.
The electrical connection of the electric motors is to be done as outlined below. Be sure to
observe respective safety notes. Disconnect (de-energize) the equipment from the power
supply.
Make sure all mounting and installation work is only performed when the equipment
has been disconnected from the electrical supply system.
ZF Padova S.p.A.
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Date
Section 6
Make sure that only skilled expert personnel is entrusted with the required work and that these
persons undertake to strictly adhere to the applicable rules and supplied documentation.
Before making the respective connections check the data given on the rating plate.
Take care that these data coincide with the conditions prevailing aboard (voltage
and frequency).
Make sure that the size of the connecting cables suits the nominal current of the electric
motors.
Make sure that the electric pump start and stop functions are connected according to the
Classification Society.
Be sure that cabling connections are made as instructed on the circuit diagram provided in
the terminal box of the electric motors.
Note: The type of connection depends on the starting method used, i.e. direct-on-line or
star-delta, and will be prescribed by the shipyard.
Note that connection of electric motors must suit the prescribed rotational direction.
Take care that the protective conductor is connected with the appropriately marked
terminal.
Make sure that the rotational directions indicated by arrows on electric motors and oil pumps
coincide as required.
Attach the connecting cables to the terminal plate of the electric motors.
During the installation of the stand by pump verify that the suction pressure is not
lower than 0,6 bar.
In case the stand-by pump is not already fitted on the gearbox a flexible fireproof connection is recommended between the pump and the piping. Working
pressure: 30 bar.
If the connection will be rigid, respect the concentricity between the flanges in
order to avoid residual stress on the piping.
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ZF Padova S.p.A.
Date
Section 6
6.2.3 Oil cooler

Attach the cooling water pipes to the inlet and outlet nozzles provided on the front end of the oil
cooler.
Note: Make sure that only pipework and elbows are used that have the nominal diameters specified
by ZF, refer to respective drawings in the Appendix.
Attention need be paid to the direction of flow when connecting the water carrying piping.
6.2.4 Monitoring system

The electrical installation shall be effected as outlined below. The preceding safety notes must be
carefully followed.
Make sure all mounting and installation work is only performed after the equipment
has been disconnected from the electrical supply system.
Make sure that only skilled expert personnel is entrusted with the necessary work. These persons
must undertake to strictly adhere to the applicable rules and supplied documentation.
Make sure cabling is laid in suitable cable raceways or trays so that they are effectively
protected.
Connect the cables leading on to the engine control room via the terminal block arranged in the
switch cabinet following the enclosed wiring diagram (see appendix).
Note: Make sure that the size of the connecting cables suits the requirements.
Make sure that the monitoring is connected according to the classification society.
ZF Padova S.p.A.
45
Date
Section 6
6.3. ALIGNMENT WORK TO BE PERFORMED

Measures to be taken for gearbox alignment are described below.
Note: The alignment must be verified while the craft is in the water.
Make sure that the hull does not come in contact with the sea floor.
Before launch secure the transmission against movement.
Secure the shaft propeller against turning.
Be sure to mount the gearbox with associated coupling removed so that the gearbox housing is
free from distortions when being attached to the ships foundation.
Prerequisite for a trouble-free operation of the gearbox is that the output and input ends are
carefully aligned.
Displacement that may arise during operation must be duly taken into account when aligning the
unit. Such displacements result from a thermal expansion of the gearbox housing and operating
position of the output and input shafts.
Note: As required by the respective alignment temperatures and the shafts rotational direction
observe the necessary compensation values and their measuring points as per the Diagram
Reported in the appendix (see Appendix).
Generic behaviour of thermal growth
Operating Temperature
This diagram show the characteristic compensation curve caused by the operational temperature
on the input output shaft of the transmission and permits an high precision in cold alignment.
46
ZF Padova S.p.A.
Date
Section 6
6.3.1 Radial and axial run-out

A prerequisite for the correct alignment of the gear box with respect to the propeller shaft is to
avoid allowing the shaft to lower or bend due to the weight of the shaft itself and the propeller
shaft flange.
Align the gearbox standing on the alignment bolts in relation to the propeller line shafting. For
horizontal alignment suitable set screws must be arranged laterally on the four corners of the
gearbox baseplate.
Note: The location of the alignment bolts can be seen from the installation drawing included in the
Appendix.
Note: For alignment purposes check the elastic line calculations established for the propeller line
shafting and take from it the respective values regarding deflection and gap between the
two shafts.
Also you have to check the radial and axial run-out of the propeller shaft flange.
For this verification, the output flange of the transmission must not be in contact to the propeller shaft.
Take care to not damage the shaft seal with uncareful movement.
Position a comparator (A) so that the feeler is radially in contact with the propeller shaft flange and
a second comparator (B) must be positioned perpendicular to the face of the flange, as shown
in the illustration. (Fig. 6.3) The comparator (A) detects the radial run-out and the comparator (B)
detects the axial run-out.
6.3.2 Radial and angular misalignment

For this check go ahead like shown in (fig. 7.3)
Put the comparator (A) and (B) like discribed and fix them to the output flange of the gearbox.
The comparator (A) detects the absolute radial error and (B) the angular error referenced to a
flange with diameter of 500 mm.
At operation temperature and under full load the allowable deviations are:
Radial and axial run-out max: 0.04 mm
Radial and angular misalignment max: 0.05 mm (on 500 mm)
To avoid measuring errors when determining the amount of angular displacement during
alignment turn the gearbox shafts in one direction only. Changing the direction of rotation will
cause shaft displacement in the gearbox housing due to roller bearing play.
ZF Padova S.p.A.
47
Date
Section 6
During shaft alignment make sure to turn the two shafts simultaneously and take measurements
always on the same spot on the flanges. Measuring result ascertained in this way will not be
affected by concentric or plane runout which may exist.
Check the alignment in relation to the propeller line shafting after the gearbox has finally been
provided with shims and bolted to the ships foundation.
Align the motor in relation to the gearbox input shaft.
Subsequently, mount the coupling between motor and gearbox.
For motor alignment observe the manufacturers instructions issued and pay also attention to
guidance notes applicable to the coupling.
Please note that it is not the responsibility of ZF Padova to carry out the above described
measures to properly align gearbox, motor and coupling.
An accurate alignment is indispensable for maintaining the flexible coupling as long as possible,
as every misalignment has a negative effect on all the rotating elements. Use only flexible, highly
elastic couplings.
Make sure that the flexible coupling for input shaft is able to absorb the vibrations caused by away
from the area between idling and rated speed of the engine. Selection normally will be done by
the engine manifacturer.
Therefore ZF PADOVA is not responsible for vibration problems resulting from the installation.
48
ZF Padova S.p.A.
Date
Section 6
6.4 FASTENING WORK TO BE PERFORMED

Bedding of the gearbox on cast-iron/steel adapters or resinoid adapters and subsequent fastening
to the ships foundation are effected as described below.
Stoppers or fitted bolts must transfer the propeller thrust in the gear foundation.
Gearbox foundation
Note: Make sure that the bores for the foundation bolts have been provided in the ships foundation
in line with the shipyards job scheduling.
The arrangement of the bores in the gearbox foundation plate is shown in the installation drawing
included in the Appendix.
Before foundation work is carried out the respective drawings and calculation data must have
been prepared by the Contractor performing the work and submitted to the classification society
for approval.
Note: Please note that all foundation work is subject to the respective rules and regulations issued
by the classification society.
ZF Padova S.p.A.
49
Date
Section 6
Make sure that all loads affecting the sizing of the required shims are duly taken into account:
torque, propeller thrust and deadweight of the gearbox.
The supports must be adequately sized and tightly anchored to the gearbox foundation.
You can use either the foundation screws with the supports or the transmission screws.
Only rectangular set chock type support are permitted and the material must be agreed with the
Certifying Authorities. The support surface of the ZF mounting bracket has been designed for
direct mounting on a rigid surface.
Once the casting resin has hardened, the gearbox should only be supported by the
casting resin and not by the alignment screws or any other alignment aids. When
aligning the gearbox, the way in which the casting resin reacted to shrink fitting during
hardening should be taken into consideration.
We recommend that plans for the design of any mountings made of casting resin are made
in conjunction with the casting resin supplier and/or a certified specialist company. A specialist
company is able to provide advice at an early stage and is able to create the calculations and
drawings required for approval from a classification society and to submti these for approval.
The anchoring screws must be at least class 8.8 ISO 898 steel and they must comply with
requirements in consideration of the vessel specifications. Tightening torque values depend on the
vessel specifications. Make sure the transmission does not shift longitudinally due to the effect of
the axial thrust exerted by the propeller.
Use longitudinal foundation shirms in steel. Make a final check of alignment and, if satisfactory,
secure the screws with double nuts. Mark the nut threads with paint to facilitate periodic bolt
tightness visual inspections.
50
ZF Padova S.p.A.
Section 7
Starting Operation
Date
Section 7
Starting Operation
7.1 INTRODUCTION
This section describes the preparatory measures and course of action to be followed when taking
the gearbox into and out of service. The respective notes on safety shall be duly observed.
The safety and maintenance are prerequisites for trouble-free operation, maximum performance
and along service life.
Do not touch any rotating parts.

Periodic supervision and registration of measured parameters provides a duty profile for the marine
gearbox.
Provide for the arrangement of adequate touch guards for all rotating parts located on
the input and output side of the gearbox.
Check the correct operating position of the stop valves and gate valves mounted in the piping system.
Note: Make sure the stop valves arranged in the oil discharge lines between gearbox and contaminated oil tank are closed.
When carrying out the following activities make sure that no lubricants are discharged
into the environment.
ZF Padova S.p.A.
53
Starting Operation
Date
Section 7
7.2 PREPARATORY MEASURES

Note: Please note that ZF has adjusted the pressure relief valves of the motor-driven oil pump units
to the prescribed pressures as well as the switching points of the monitoring devices.
Fill clean oil into the gearbox system as prescribed by the lubricating oil specification and follow the
procedures and instruction given below:
When filling the system take care that no dirt, foreign matter or water are allowed to
enter the gearbox interior.
Note: A list of approved oil brands forms is reported in the Appendix.
Note down the volume of oil filled in when carrying out oil changes within the scope of maintenance work.
Other oil brands must only be used if ZF approval has been obtained. The risk of damage in
case a non-approved product is product is employed lies solely with the Owner.
Before first start be sure that the cartridges are present in the twin-type filter.
Fill the operating oil volume into the gearbox, when gear unit stands still: the correct oil level is
between the two marks on the oil dipstick.
Check and, if necessary, correct the oil level, when stand-by pump is switch on.
Using the transmission with an insufficient quantity of oil air may be taken in by the
pump.
On the other hand, on high quantity of oil could result in leakage through the gaskets and vents,
and could cause the operational temperature to increase significantly, including low clutch pressure.
Top both oil pump up with oil through the connection located upstream of each of the intake nozzles to avoid the pumps running dry when first taken into service.
54
ZF Padova S.p.A.
Starting Operation
Date
Section 7
Check if the non return valves are assembled correctly.

Gearbox and dil pipes have to be flushed using the stand-by pump for at least two hours.
Inspect the filter and eventually clean it.
Make up the cooling water supply connection to the oil cooler and make sure that the cooling
water pressure is lower than the oil pressure. This will largely safeguard the in the lubricating oil
circuit against the ingress of water in the event of a cooler leakage.
Note: Be sure that the rated current level indicated on the electric motor rating plate is not exceeded.
Check the fittings for possible oil learage.
Check the oil supply and monitoring system for leakage and proper functioning.
Check the negative pressure at the intake connection of the oil pump.
Note: Take care that the determined negative pressure does not exceed 0,6 bar.
Check the oil pressure on the discharge connection of the oil pump via the attached pressure
gauge.
Take care that the determined negative oil pressure does not exceed 0,6 bar.
Should oil pressure corrections be necessary they are effected via the pressure relief valve attached to the oil pump.
Check and, if necessary, correct the oil level once more. Observe the markings on the oil dipstick.
Check all rotating parts for ease of movement by rotating the propulsion system.
ZF Padova S.p.A.
55
Starting Operation
Date
Section 7
7.3 COMMISSIONING ACTIVITIES

Initial commissioning
Switch on motorized oil pump unit. The motorized oil pump unit
- prelubricates the gearbox.
Start the propulsion system and slowly increase the speed to approx. 50% of rated speed. Operate
the gearbox under partial load at abt. 25% of rated torque until the oil temperature at the gearbox
input is approx. 45C at an oil pressure of 2 0.5 bar. Gradually increase the load to 40% of rated
torque and maintain this load for a period of approx. 3 hours.
Slowly increase speed and power. Maintain a load corresponding to 70% of rated torque for a
period of abt. 3 hours before operating the system under full load.
Check the contact patterns of the tooth flanks of all pinions and gears after approx. 10 hours
full-load operation.
For correction clutch functioning, the gear engaging must take place in a reasonably short time.
The maximum speed allowed for the gear engaging should be about 60% of the maximum engine rotation.
Reduce speed and power if the bearing temperatures are found to be inadmissibly high.
Bearing temperature, lubricating oil pressure limits and the oil supply are specified in the technical
data.
To be able to detect any malfunctions in good time and thus to implement preventive measures,
monitoring during operation is indispensable.
It is advisable to note the operating pressures, oil temperature and bearing temperatures regularly.
If irregularities are detected during operation (noise, vibration) or if the operating data change, the
system should be shut off immediately and the cause established.
Therefore, check after approx.. 10 hours full-load operation:
- all bolted connections and pipe couplings / union for tightness as well as
- the complete gearbox installation for leakage.
Tighten all loose bolted connections and pipe couplings at the prescribed torque
rate.
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ZF Padova S.p.A.
Starting Operation
Date
Section 7
Replace damage gaskets/seals when the unit is stationary and the engine is in cold state.
Observe the noise and vibration characteristics of the gearbox system during all operating states.
Note: In the event of irregularities please notify the service department of ZF immediately.
Check the operating chamber of the twin-type filter for fouling.
Note: The contact-type differential pressure gauge attached to the twin-type filter indicates even
minor states of filter fouling.
Check the settings of the pressure monitoring equipment.
Note: The nominal switch points are listed in the oil supply and monitoring diagram included in
the Appendix.
Check the oil level of the gearbox. If the oil level is found to be incorrect the oil volume must be
topped up as required.
When initial commissioning has been completed prepare the respective protocol and submit one
copy of it to ZF service department.
Note: This document will be added to the production data compiled by ZF and shall serve as a
basis in the event warranty claims are raised.
7.3.1 Towing
During if the navigation in tow, it will be necessary to lubricate the rotating parts for at least five
minutes.
Lubrication can be done by the stand by pump.
If lubrication is not possible, the propeller shaft must be blocked in order to prevent its rotation as
a result of the dragging effect, otherwise you can damage the gearbox.
Continuous trailing operation is possible with a stand by pump running.
ZF Padova S.p.A.
57
Starting Operation
Date
Section 7
7.3.2 PTH Power Take Home mode condition

To run the gearbox in the PTH condition is necessary to disconnect the gearbox input shaft from
the main engine by a nechanical solution.
Before to activate the PTH clutch is necessary to remove the mechanical safety block situated on
the gearbox PTO control.
After this operation the clutch can be actuated electically from the ECR and manually from the
gearbox. When the PTH clutch is going to be closed is necessary to have the CPP at zero pitch.
The PTH mode is only for emergency condition.
7.4 SHUTDOWN ACTIVITIES
When the transmission system is shut down for a maximum period of one week no special measures need be taken. If the shutdown period exceeds one week the propulsion system must be
turned once a week to prevent corrosion and oil gumming.
Note: Make sure the turning operation takes place when the motorized oil pump unit is
switched on.
After stop gearbox turning the stand by pumps has to work at leat 10 min. in order to
gradually cool the transmission.
Switch off the respective motor-driven oil pump when turning has been completed.
Stop the cooling water flow to the oil cooler and drain the cooler via the respective drain plugs
provided.
Check the gearbox system for damage, leakage, corrosion and untight components.
Water in the lubricating oil is especially dangerous. A bearing can run for a short time
with a limited quantity of water in the oil, but thus may NEVER be allowed to happen
with a gear wheel as wate, even in the smallest quantities, causes immediate pitting.
To prevent condensed moisture forming in the casing during operation and above all
during stationary periods the gear unit is vented. The air heats up in the gear unit and
is thus able to absorb the moisture. After the system has been shut off, ensure that no
engine room fans are directed at the casing. This applies particularly in tropical zones,
where considerable temperature gradients must be expected, especially at night.
58
ZF Padova S.p.A.
ZF Commissioning Report
Date
Section 7
ZF Reduction Gearbox Commissioning Checklist

Gearbox Serial No.:
.......................................................................
Shipyard:
.......................................................................
New Building No.:
.......................................................................
Commissioning Engineer(s):
1) ...................................................................
2) ...................................................................
3) ...................................................................
ZF Padova S.p.A.
59
Date
Section 7
1.0 VISUAL INSPECTION
1.2 Check external condition of gearbox
OK
OK
1.3 Are there any parts missing or exchanged by non Genuine

Spare parts?
OK
1.1 Are there any visible damages?
2.0 INSTALLATION
2.1 Thermal Alignment Engine Gearbox after Chockfast Recomendation:
Mesured:
Temperature in Engine Room ______________ [C]
2.2 Thermal Alignment Gearbox-Shaft Alternator after Chockfast Recomendation:

Mesured:
Temperature in Engine Room ______________ [C]
2.3 INSTALLATION OF THE GEARBOX

Front Stopper
Side Stopper
Fitted bolts
Tightening Torque: ___________________[Nm]
2.4 INSTALLATION OF THE engine
(yard)
O.K.
O.K.
O.K.
O.K.
(yard)
O.K.
O.K.
Chockfast
Resilient
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ZF Padova S.p.A.
Date
Section 7
3.0 COOLING WATER SYSTEM

OK
OK
3.1 Heat exchanger attached to the gearbox

3.2 Cooling water pipes connected with compensators
4.0 LUBRIFICATION SYSTEM

4.1 Standby Pump
Are the pipes of the stand-by pump connected by compensators?
OK (yard)
4.2 Height from suction flange bottom of gearbox to pump suction flange: _________________ [cm]
4.3 Oil Filing

Lube oil manufacturer:
Type / S.A.E.:
Filing litres:
_________________________________________ (yard)
_________________________________________ (yard)
_________________________________________ (yard)
OK
4.4 Where the pipes acidified and cleaned?

Was the lub oil system flusched with standby pump at least hour?
OK
4.5 Operation with standby pump

Clutch oil pressure:
__________________________________________ [bars]
Lub oil pressure:
__________________________________________ [bars]
OK
Leakage?
5.0 RUN AT SEA TRIALS

5.1 At Endurance Test (Measure min. 3 hours after continuos operation)
Oil Temperature:
Thrust Bearing Temperature:
Clutch oil pressure:
Lube oil pressure:
__________________________________________ [C]
__________________________________________ [C]
________________________________________ [bars]
________________________________________ [bars]
5.2 Oil leakage?
OK
5.3 After turning off the engine open inspection cover internal condition of the gearbox:
Good:
Corroded:
Defects:
ZF Padova S.p.A.
61
Date
Section 7
Check contact pattern of teeth (engine turned off)

Sketch contact pattern of pinion, indicate engine and water jet side:
TOOTH TIP
ROOT
.........................................
side
.........................................
side
1. Contact pattern after approx.: ........................... hours ...........................% load .......................... rpm
TOOTH TIP
ROOT
.........................................
side
.........................................
side
2. Contact pattern after approx.: ........................... hours ...........................% load .......................... rpm
TOOTH TIP
ROOT
.........................................
62
side
.........................................
side
ZF Padova S.p.A.
Date
Section 7
COMMENTS:
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
Acceptance Statement
For Shipyard:
For Avk:
Name Surname:
..................................................................................................
Position:
..................................................................................................
Signature:
..................................................................................................
Date:
..................................................................................................
Name Surname:
..................................................................................................
Position:
..................................................................................................
Signature:
..................................................................................................
Date:
..................................................................................................
ZF Padova S.p.A.
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Date
Section 7
Remarks
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
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ZF Padova S.p.A.
Section 8
Emergency Operation
Date
Section 8
Emergency Operation
8.1 HYDRAULIC SYSTEM BREAKDOWN (only for NR version)

If a breakdown occurs in the hydraulic system, the clutch can be engaged manually with a mechanical system.
The operation must be carried out with the engine stopped.
ZF Padova S.p.A.
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Emergency Operation
Date
Section 8
8.2 EMERGENCY OPERATION

Stop the engine and ensure that it is not involuntarily started up (set the control unit to neutral).
Remove the relative inspection cover. Tighten screws SW19 (tightening torque 71 Nm) evenly in
a diametrically opposite sequence in two steps. The disk pack is compressed and the clutch is
engaged. Set the control unit to NEUTRAL. The propeller shaft will turn as soon as the engine is
started.
Note: The utmost caution must be exercised during emergency operation with the main clutch.
When emergency screws SW19 are tightened, maximum torque transmission is permitted.
Once the problem has been solved, loosen the screws completely. On arrival in port check
the clutch disks and unscrew the bolts SW19 up to the original position. If the transmission
is used repeatedly in emergency mode strip it down and check all bearings and gearing
components carefully.
Make sure the engine and propeller are at a stand still before carrying out kind of operation
on the gear box.
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ZF Padova S.p.A.
Emergency Operation
Date
Section 8
8.3 MECHANICAL ACTIVATION GUIDE

101 Electrical control unit
102 Neutral position
105 Gear lever for emergency mechanical operation
106 Plug/socket connection
In the event of an electrical actuator fault, the gearbox can be operated mechanically by means of
the emergency lever. For safety reasons the normal actuator device should be disabled before using the emergency lever. This is achieved by unplugging the electrical connector from its socket.
The electrical actuator connected to the control unit is designed in such a way that the selected
position is maintained in the event of an electrical power loss. The emergency lever can be moved
manually. During the movement the operator will be able to note the detented operating positions.
DANGER - If the electrical supply is cut off, the running position will be maintained.
The emergency lever will remain in the selected position.

Consult your nearest ZF Service Centre for the necessary repairs.
ZF Padova S.p.A.
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Emergency Operation
Date
Section 8
8.4 NOTES ON OPERATION UNDER SPECIAL CONDITIONS
Action required at low shaft speed

It must be ensured that the standby engine oil pump unit is switched on under the following operating conditions:
- Turning of the gearbox for inspection purposes by means of the turning engine
- Driven propeller by approach flow with Diesel engine uncoupled.
Dragging of the propeller shaft

It has to be taken into account that, with the clutch shut down and the motors running, a torque is
being transmitted onto the propeller shaft due to residual friction between the clutch disks. Under
special conditions it is, therefore, possible that the propeller shaft is driven. The probability of the
propeller shaft being dragged is aided by the following circumstances:
- The disks of the clutch are new.
- Cold lube oil in circulation.
- Two or more drives are acting on the same output.
- In the case of a short overall length of the output shaft between gearbox and propeller the friction, on the whole, is comparatively low.
- A corresponding flow at the propeller will aid its drive.
- Dragging of the PTO shaft (if it existing)
In this case, however, special attention should be paid to the fact that the PTOswith own clutch
can be caused to turn unexpectedly, e.g. by running machines on board (vibrations).
70
ZF Padova S.p.A.
Section 9
Maintenance
Date
Section 9
Maintenance Schedule
Z1
A1A
A1B
A2
A4
A3
A5
MAINTENANCE OPERATIONS
Check for oil leaks
Check oil level
Tighten all external threaded fasteners

Clean transmission externally
Lubricate external moving parts
Oil change
Check oil filter
Check input - output shaft seals
Inspect clutch discs
Inspect gear teeth

Check instruments and indicators
Replace zinc anodes

Clean oil cooler
Cleaning
Inspect bearings
Check oil pump
Check control valve
Check oil temperature and pressure

Change oil filter
ZF Padova S.p.A.
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Maintenance
Date
Section 9
Regular maintenance
Maintenance level
Operating hours
Max. value
A1A
every day of operation
3 moths see also K1
A1B
400
6 months
A2
1000
1 years
A3
2000
2 years
A4
20000
5 years
A5
40000
10 years
Additional maintenance jobs on new or overehauled gear boxes, necessary only once
Maintenance Level
Operating hours
Max. value
Z1
100250
12 months
Necessary measures for protection against corrosion afther a long period out of use
Maintenance Level
Procedure
Period out of use
K1
at end of operating
period
12 months
K2
at end of operating
period
36 months
The operating hours given in the maintenance schedule as well as the tests and maintenance jobs
given in the maintenance work plan are the results of average operating data. Therefore the date
can only be guide values. Under special service conditions it may be necessary to change the time
schedule and maintenance work plan.
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ZF Padova S.p.A.
Maintenance
Date
Section 9
9.1 PROTECTION AGAINST CORROSION

Preservation
K1 Preservation
After operation, drain the gearbox oil and top up with anti-corrosion oil to at least the low oil level
mark on the dipstick (see description of maintenance work).
Use anti-corrosion oil grades C 642 or 644 acc. to MIL-L-21-260.
Immediately afterwards allow gearbox to run in with the clutch engaged for around 5 - 10 minutes
at max 50% of the nominal engine speed.
Shut off the engine.
Protect exterior steel parts against corrosion.
Extension of preservation period for another 9 months
Allow engine to run for approximately 5 minutes. Now drain off the protective oil and fill the gearbox with the correct grade and amount of oil specified for operation.
Start the engine again and allow it to run for at least 15 minutes. During this period the gearbox
selector clutches must be activated several times. Now repeat the K1 preservation procedure.
Returning to operation after the K1 preservation procedure
Start the engine and allow it to run for approx. 5 minutes so that any condensation water that may
have collected in the gearbox mixes with the protective oil. Drain off protective oil and fill gearbox
with the specified oil grade.
K2 Long term preservation
Drain off the oil in the gearbox after operation and fill with anti-corrosion oil up the low oil level
mark on the dipstick (see description of maintenance work). Use anti-corrosion oil C 642 or C 644
acc. to MIL-L-21 260.
Immediately afterwards allow gearbox to run with the clutch engaged for around 5 - 10 minutes
at max 50% of the nominal engine speed.
Shut off the engine end fill completely the gearbox with the same anti-corrosion oil.
Protect exterior steel parts against corrosion.
Returning to operation after the K2 long-term preservation procedure
Drain off anti-corrosion oil down to the usual oil level and allow the engine to run for approx. 5
minutes. Now drain off the anti-corrosion oil completely and fill the gearbox with oil of the specified type.
ZF Padova S.p.A.
75
Maintenance
Date
Section 9
9.2 MANUAL OIL LEVEL CHECK

The oil check is made in stop conditions.
The correct oil level is between the upper and lower
limits on the stick (fig.1.6)
9.3 OIL CHANGE

Remove the filler cap (pos. 11 below) and extract the oil level dipstick (pos. 8 below).
Drain the lubrication oil by removing the drain plugs (pos. 5 below).
Recover the spent oil, observing the statutory special waste disposal laws.
Refit the drain plug (pos. 3 fig. 2.3) proceed to fill the unit with new oil (pos. 1 fig. 2.6).
11
5
POS.
1
2
3
4
5
6
7
8
9
10
11
12 A-B
13
DESCRIPTION
PTO (optional)
Oil pump
Output shaft
Monitoring
DRAIN PLUGS
Lower half casing
Central section
OIL DIPSTICK
Breather
Heat exchanger
CONNECTION FOR O.D. BOX
Inspection covers
Thermometer
76
POS.
14
15
16
17
18
19
20
21
22
DESCRIPTION
Control box
Input shaft
PTO shaft (and PTI shaft)
Check valve
SAE 2 1/2 flange (connection for standby pump)
Double oil filter
Drip tray
Upper section
Control valve
ZF Padova S.p.A.
Maintenance
Date
Section 9
9.4 CHANGING THE OIL FILTER
Note: The contamination indicator monitors the filter side during operation, as shown by the position of the selector lever lock. The flow transfer valve must be switched before carrying out
filter maintenance. At this point the contamination indicator signal is reset so the red button
can be released again.
1. Activate the pressure equalisation lever and hold it in position; the lever is located in the selector
lever Swivel commutation lever. Engage the lock on the right-hand side nearest to the filter.
Place the drip tray underneath to collect oil that flows out.
2. Loosen bleeder screw [1] of the unused filter side by 2-3 turns; fully out for backward motion up
against the safety stop.
3. Unscrew the filter grit trap anti-clockwise and clean thoroughly.
4. Remove the filter element with a sideways movement.
5. Check the O-ring on the filters grit trap for possible signs of damage and renew if necessary.
6. Ensure the part number of the spare corresponds with the number on the filter label. Open the plastic bag and push the element onto the part inside the filter head. Now remove the plastic bag.
7. When installation is complete, tighten the grit trap by turning it clockwise as far as it will go.
Unscrew the grit trap by between a 14 and 12 turn.
8. To fill the filter chamber, activate the pressure equalisation lever until the oil flows out from the
bleed hole without bubbles.
9. Tighten the bleed screw. Check that the filters are not leaking by activating the pressure equalisation lever again.
ZF Padova S.p.A.
77
Maintenance
Date
Section 9
9.5 OIL COOLER CHECK

The most common types of problem caused by leakage of coolant from the tubes are corrosion
and erosion.
The cooling tubes are coated with copper-nickel 90/10; this type of treatment is seawater resistant
although not in all working conditions.
We therefore strongly recommend observing the following instructions to avoid the risk of erosion
/ corrosion of the oil cooler.
1. Start-up:
Make sure the anode is not corroded. The anode must be renewed when more than 60% is
corroded.
(See the maintenance program).
2. Maintenance
Periodic checks
Periodic checks of the device are required to guarantee its safe and reliable operation through
time. As a general rule greater attention must be directed towards the water-side of the circuit; the
oil side is less susceptible to contamination so checks can be carried out as recommended by the
experience of the operator.
The following checks should be carried out:
When working with seawater the sacrificial anodes installed in the hoods/covers should be
checked at 3-monthly intervals in the initial phase. If they are excessively eroded they must be
renewed. If the anodes deteriorate too rapidly, check the water quality.
The water side of the device must be cleaned at least once a year; it is essential to avoid excessive contamination of the tubes. The hoods can be removed without depressurisation of the
casing side. Increase the frequency of checks if operations in ports or other places with contaminated seawater are protracted, in accordance with the requirements of the operator.
The device must be subjected to an exterior visual inspection at more frequent intervals to identify possible leaks or similar problems in good time. By means of the double loop closure leaks
can be pinpointed and the relative magnitude can be estimated.
Disassembly
Adhere to this procedure for disassembly of the device:
Close all pipelines
Empty the device from the tube side. If you need to remove the tube core empty also the casing
side.
Remove the pipes from the tube side.
Remove hoods/covers. To perform this step loosen the 4 screws located at the joint between
dood/main body.
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ZF Padova S.p.A.
Maintenance
Date
Section 9
There are 4 fixing plates or washers between hood and cover; these must be returned to the same
position at the time of reassembly. For this purpose check the mark on the flange of the main
body.
If disassembly is carried out without removing the tube core, first disassemble the hood/cover
without fixing plates to ensure that the tube core is not dislodged. Now remove the fixing plates.
This operation can be performed with the aid of a second set of fixing plates, or with other similar
means.
Disassembly without removing the tube core:
Remove the O-rings from the external grooves of the tube plates and fix the tube core to the
main body with four screws and the four fixing plates in the middle groove of the tube plates.
Using this method the tube side can be inspected and cleaned mechanically. The casing side
remains pressurised.
Disassembly of the tube with removal of the tube core:
Remove the O-rings from the external grooves of the tube plates. The fixed position in relation
to the main body is marked on one of the tube plates. A mark X indicating the mid point is
present on the front side of the tube plate and on the adjacent flange of the main body. Check
the position of this symbol. Push the tube (using specific tools if necessary) sideways until the
O-ring of the internal groove is visible. Remove the O-ring from the internal groove. Extract the
tube core in the opposite direction. Carefully remove the tube core from the main body taking
care not to damage the fins. As far as possible keep the tube core suspended by means of wide
lifting webbing. Take care not to damage the O-ring seating grooves.
When removing devices fixed in a vertical direction, always make sure that the tube core does
not slip downwards once the fixing plates have been removed. It is good practice to have an
extra set of fixing plates and start the disassembly operation from the part on which there are no
fixing plates. In this case first of all fix the roll. After having removed the second hood, you can
remove the roll (proceed with caution). At the time of reassembly you can use just one set of
fixing plates (the set on the symbols side).
Assembly
To assembly the unit perform the disassembly steps in reverse sequence. Take account also of the
following considerations:
It is normal practice to use new O-rings and clean the grooves before fitting them.
Take note of the symbol to ensure the tube core is assembled correctly (X).
Take not of the symbol to assemble the fixing plates correctly (F).
The closing strips are located on the tube core side. Remove the strips only if damaged. When
inserting the tube core ensure that the closing strips have not been moved or twisted. Before
assembling the tube core, grease the closing strips. The operating product can be used. The
closing strips must ensure an efficient seal around the entire length of the tube core.
Lubricate the O-rings with a suitable grease.
While inserting the tube plate in the closing location, ensure the O-rings are not severed.
ZF Padova S.p.A.
79
Maintenance
Date
Section 9
The hoods/covers must be fitted in parallel on the tube plate and pushed uniformly onto the
O-ring: ensure the O-ring is not severed during this operation.
With two-stroke devices arrange the plastic separation strip on the side of the hood with the two
connections. This done, install also the fixing plates from the same side.
When assembling the two-stroke hood ensure that the separation plate is fitted correctly.
Continue as described in Operation.
Cleaning
In the presence of a small quantity of scaling, the tube can be cleaned mechanically. Disassemble
the device as described in the disassembly chapter, without removing the tube core, and use a
suitable nylon bristle brush to clean the tubes inside (do not use metal wire brushes). Now flush
the unit with water. Never use force to prise out trapped deposits or large size debris.
In the presence of trapped deposits, use a chemical system to clean the tube core. The procedure can be performed by flushing the tube when the device is assembled or by submerging it in
chemical solution when disassembled.
This cleaning operation should be carried out exclusively by a specialised technician. Use exclusively suitable solvents. Construct the attached list to find the most suitable product. Analyse the
material of the plastic separation strip and the O-rings when the device is assembled. The Contacts section of this manual contains a list of companies that handle products that are suitable in
relation to the parts, or that offer complete cleaning services. If the eleventh letter of the type code
is C (e.g: KS12-BCN-821C L1000), this indicates that the tube core is coated. To prevent the
corrosion damage of the tube core, it is internally coated in the tube and in the tube header plate.
During disassembly of the roll and during cleaning procedures, tale care to ensure the coating is
not damaged. Use exclusively nylon bristle cleaning brushes and cleaning products in compliance
with the applicable regulations. If in doubt concerning a specific product, consult our maintenance
department.
Troubleshooting
Efficiency is too low! / oil outlet temperature is too high!
Check that all temperatures and materials comply with the project specifications.
Check that there is no foreign matter in the pipe or in the device, such as to create an obstruction.
Check that the tube core is correctly assembled; check the symbols.
Check that the plastic strips and fixing plates are correctly assembled in the two-stroke hood.
Check that air has been bled completely from all the compression chambers.
Check that the tube side or the casing side are not excessively fouled (with excessively dense
product deposits).
Check that no more than 10% of the tubes are clogged.
Leakages from the tubes
If you think there are leaks from the tubes, proceed as illustrated in the section concerning disassembly without removing the tube core. The casing part can remain pressurised. After having
cleaned the tube plates you will be able to identify the leaking tube by the condition of the liquid
80
ZF Padova S.p.A.
Maintenance
Date
Section 9
that comes out. Close both ends of the tube with conical plugs made of copper or hardwood. You
can plug a maximum of 10% of the tubes without any significant loss of efficiency. It is possible to
remove the defective tube.
Leaks from the rolled joints
If you notice a leak from a rolled joint while checking for leaks from a tube, you can roll the part
again by means of a special tool. Note however that this procedure should always be performed
by specialised personnel. Since these defects are relatively uncommon, we recommend having
the entire tube core checked at our works.
Leaks from the O-rings
If you notice a leak between the hood/cover and the main body, this indicates that one of the Orings of the tube plate is defective. The type of substance emerging identifies the groove of the
tube plate in which the defect has occurred. If the defect is on the tube side, proceed as illustrated
in the section concerning disassembly without removing the tube core. If the defect is from the
side of the casing, proceed as described in the part relative to disassembly with removal of the
tube core. In this case there is no need to remove the tube core completely from the main body.
Assemble the O-ring as illustrated in the part relative to Assembly.
3. Standstill periods:
When the installation is at a standstill for a period of:
Less than two days
Water flow within range that on average complies with operation of the pump (see table)
More than two days
Water flow for minimum period of one hour
More than two weeks
The water circuit must be drained and flushed with fresh water.
Technical data: see installation drawings and oil cooler manual and the technical data given in this
manual
ZF Padova S.p.A.
81
Maintenance
Date
Section 9
Remarks
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
82
ZF Padova S.p.A.
Section 10
Date
Troubleshooting Remedies
Section 10
10.1 Possible faults
MALFUNCTIONS
Overheating
CAUSES
REMEDY
Oil level is too high
Correct oil level
Lubricating oil pressure too low

(insufficiently cooled oil)
Re-set operating oil pressure to the lowest

permitted value
Gearbox is overloaded
Reduce input power
Operating oil pressure is too low

(clutch is slipping)
Regulate operating pressure

(see 2-stage valve)
Excessive pump pressure
Clean the filter
Oil does not flow back from the outer

bearing sides
Install end covers or seal covers in such a way

that the oil can flow back
Bearings damaged
Replace damaged bearings
Cooling water flow not enough
Check the water flow
ZF Padova S.p.A.
85
Date
Section 10
MALFUNCTIONS
Lack of oil pressure
Oil leakage
86
CAUSES
REMEDY
Wrong direction of rotation
Reverse engine rotation or reconstruct

gearbox for other direction of rotation
Filter obstructed
Clean filter
Oil level too low
Refill with oil and trace cause of oil loss
The viscosity of the oil is too low
Change to an oil conforming to the

recommended lubricants
Oil temperature too high
See Excessive gearbox temperature
Suction pipe obstructed
Clean suction pipe
Pump drive is defective
Renew the pump drive
Pump wear
Install new pump
Selector position is not correct
Adjust remote control operation
Wear of the oil supply
Renew oil supply
Drain plug is not tight
Replace the gasket and tighten drain plug
Dipstick connector not tight
Replace dipstick gasket and tighten
High-pressure system leaking
Tighten all fittings
Oil loss through the air vent
Check oil splash plate under the air vent
Mating faces of the housings are not

sealed
Seal with new compound and tighten all bolts
Leakage of the shaft seals
a) Renew seals
b) Install sealing cover in such
a manner that the passage is free from the
outer bearing side
c) Clean seals
Oil cooler is leaking
Replace the cooler insert
ZF Padova S.p.A.
Date
Section 10
MALFUNCTIONS
Gearbox noise
CAUSES
REMEDY
Idle speed is within a critical range
Increase idling speed
Gearbox runs within the critical speed

range.
(The noise is not to be observed
throughout the whole speed range)
Avoid running the gearbox continuously in the

critical range
Input flange loose
Tighten the flange or replace when damaged
The oil level is too low

(Suction noise of the pump)
Correct oil level
Suction pipe not tight.

(Pump sucks in air)
Tighten all fittings on the suction line
Filter choked
(Excessive pump pressure)
Clean filter
Pump drive not in order.

Gearwheel damaged or loose
Repair damaged parts, or replace
Extreme misalignment between

engine and gearbox
Re-align the whole installation
Gearbox bearings damaged
Renew damaged bearings
Gear teeth damaged by foreign

matters
Grind damaged areas.

If necessary, replace the gear wheels
The gear rims loosened by

overloading
Re-tighten the rims
Gear wheels are loose on the shaft

due to overloading
Re-tighten the wheels
Propeller damaged
Re-tighten the flange and replace if damaged
Extreme misalignment on the input

side of the gearbox
Re-align installation
ZF Padova S.p.A.
87
Date
Section 10
MALFUNCTIONS
The propeller does
not stop turning in
Neutral
CAUSES
REMEDY
The vessel is still moving
Wait until it is at a complete standstill
The propeller is being driven by a

current
Wait until it is at a complete standstill
Gearbox controller is not properly in

the stop position
Adjust the remote control
Defective gearbox controller

(Uncontrolled oil to one clutch)
Replace gearbox controller
Clutch plates broken
Renew clutch plates
Seal damaged, sticking piston
Renew seals
Splines of the clutch damaged
Re-work the teeth or renew the parts
Release springs not working
Clean the clutch.

Replace the springs if necessary
Oil to cold
Recommended given operating temperature

Lubricating 50 - 70
40 - 50
The engine stalls

during reversing
When switching
over, the engine
threatens to stall,
at this manoeuvre
the engine must
be caught by fuel
admission so that the
power taken from
the propeller will not
be larger than the
engine power at this
moment.
88
The idling speed is too low
Increase the idling speed
The operating pressure is too high,

therefore, engagement is too quick
Reduce the operating pressure to normal

value
The gearbox controller is defective

(uncontrolled oil flow to one clutch)
Replace gearbox controller
Clutch plates are damaged
Replace damaged clutch plates
The splines of the clutch are

damaged
Re-work the splines or renew the parts (check

for critical speed range)
The release springs do not work
Clean the clutch.

Replace the springs if necessary
Piston of the clutch is jammed,

seals are damaged
Renew damaged seals
ZF Padova S.p.A.
Section 11
Service Centres
Date
Section 11
Service Centres
ARGENTINA
TRANSMISIONES MARINAS S.A.
CYPRUS
Ing. Daniel Canoura

Hernandarias 3656 - B7603GNH Mar Del Plata
ARGENTINA
Tel. +54 223 4807174
Fax +54 223 4807174
E-mail: tm@tmgroup.com.ar
AUSTRALIA
CHILE
Avelingen West 30 - 4202 MS Gorinchem

NETHERLANDS
Tel. +31 183 650 000
Fax +31 183 650 001
E-mail: info@vanstigt.com
ECUADOR
ESTONIA
FINLAND
ATOY OY
Lauttasaarentie 54
00200 Helsinki
FINLAND
Tel. +358 9 682 71
Fax +358 9 682 73 05
E-mail: zf@atoy.fi
FRANC
ZF FRANCE S.a.r.l.
3-11 Rue Henri Poincar
92 167 Antony Cedex
FRANCE
Tel. +33 1 4096 4265
Fax +33 1 4096 4285
E-mail: raymond.gouge@zf.com
FOILBORNE ENGINEERING Ltd.
CROATIA
BALTIC MARINE GROUP AS

Paljassaare tee 14
10313 Tallinn
ESTONIA
Tel. +372 68 333 00
Fax +372 68 333 01
E-mail: bm@bm.ee
ZF PADOVA SHANGHAI
REPRESENTATIVE OFFICE
Unit A8-9, 13/F

Veristrong Ind. Ctr. - 34-36 Au Pui Wan St.
Fotan, Shatin
N.T. Hong Kong
Tel. +852 2 687 2988
Fax +852 2 687 1996
E-mail: foilborne@foilborne.biz.com.hk
COPRIMARSA
KM 12.5 Va a Daule Urb.
Colina del Sol Mz. 2021 V. 5
ECUADOR
Tel. +59 3 9 961 3032
Fax +59 3 9 702 0468
E-mail: coprimarsa@yahoo.com
see also U.S.A.
EQUIPAMIENTO MARINO LTDA.
Room 2206-08, Jiangnan Building

No. 600 Luban Road
Shanghai, 200023
P.R. CHINA
Tel. +86 21 6301 4338
Fax +86 21 6301 6449
E-mail: zhouqing.tang@zf.com
ZF DANMARK ApS
Taastrupgaardsvej 8-10
2630 Taastrup
DENMARK
Tel. +45 7022 6243
Fax +45 7022 2643
E-mail: zfdk@zf.com
ADS VAN STIGT
Rafael Correa 1268, Vitacura

Santiago de Chile
CHILE
P.R. CHINA
Tel./Fax +56 2 415 8737
Mob. +56 9 997 5059
E-mail: info@equipamientomarino.cl
CHINA
DENMARK
ZF DO BRASIL Ltda *
Avenida Conde Zeppelin, 1935
CEP 18103-905 Sorocaba-SP
BRASIL
Tel. +55 15 4009 2389
Fax +55 15 4009 2233
E-mail: marine.info@zf-group.com.br
BELGIUM
BENELUX
LUXEMBURG
NETHERLANDS
7, Larnaca Street - 1503 Nicosia

CYPRUS
Tel. +357 22 349 572
Fax +357 22 349 952
E-mail: pambos@charpilakoutas.com.cy
ZF AUSTRALIA PACIFIC Pty Ltd.

14 Lidco Street - Arndell Park NSW 2148
AUSTRALIA
Tel. +61 2 9679 5555
Fax +61 2 9679 5500
E-mail: mailbox@zf.com.au
BRAZIL
CHAR. (INDUSTRIAL)
PILAKOUTAS Ltd.**
GERMANY
ITEC d.o.o.
Ul. Kneza Domagoja 10
47000 Karlovac
CROATIA
Tel. +385 47 631 755
Fax +385 47 631 756
E-mail: nautica@itec.hr
ZF Padova S.p.A.
ZF MARINE GmbH *
Ehlersstr. 50
88046 Friedrichshafen
GERMANY
Tel. +49 7541 77 2207
Fax +49 7541 77 4222
E-mail: info.zfmarine@zf.com
ZF MARINE GmbH
Representative Office
Zamdorferstrasse 90
81677 Mnchen
GERMANY
Tel. +49 89 930 094 63/64
Fax +49 89 930 094 21
E-mail: guenther.koeppel@zf.com
91
Service Centres
Date
Section 11
PIENING PROPELLER
ZF MARINE ARCO S.p.A. *
Otto Piening GmbH

Am Altendeich 83
25348 Glckstadt
GERMANY
Tel. +49 4124 9168 0
Fax +49 4124 3716
E-mail: pein@piening-propeller.de
Via S. Andrea, 16
38062 Arco (TN)
ITALY
Tel. +39 0464 580 555
Fax +39 0464 580 544
E-mail: info.zfhurth@zf.com
ZF ITALIA S.r.l.
SCHIFFSDIESELTECHNIK KIEL
Via Donizetti, 11
20090 Assago (MI)
ITALY
Tel. +39 02 4888 31
Fax +39 02 4884 3807
E-mail: marine@zf-group.it
Grasweg 26 b
24118 Kiel
GERMANY
Tel. +49 431 544 420
Fax +49 431 544 4220
E-mail: info@sdt-kiel.de
JAPAN
GREECE
ZF JAPAN Co., Ltd.

Palazzo Astec 7, 8F
2-8-1, Higashi Shimbashi,
Minato-ku
Tokyo 105-0021
JAPAN
Tel. +81 3 4590-7700
Fax +81 3 4590-7770
E-mail: mikio.sato@zf.com
TEKMAR Ltd.
15 Ethn. Makariou Str.
18 547 Neofaliro. Piraeus
GREECE
Tel. +30 210 4820 814
Fax +30 210 4811 803
E-mail: tekmar@hol.gr
K. & E. MALERDOS Co.
KOREA (South)
20, Ymittou str

18 540 Piraeus
GREECE
Tel. +30 210 417 9693
Fax +30 210 417 5441
E-mail: malerdos@otenet.gr
ZF KOREA Co. Ltd.

422-2 Chongchon-dong
Bupyong-Gu
Incheon 403-032
Rep. of KOREA
Tel. +82 32 5051 508
Fax +82 32 5051 514
E-mail: chun.bs@zf-group.co.kr
ARIEXPO S.A.
68, Alimou Avenue, Alimos
17 455 Athens
GREECE
Tel. +30 210 984 3863
Fax +30 210 983 1346
E-mail: ariexpo@tee.gr
INDIA
MALAYSIA
No. 12, Jalan Teknologi 3/1

Seksyen 3 Kota Damansara
47810 Petaling Jaya
Selangor Darul Ehsan
MALAYSIA
Tel. +60 3 6157 8856
Fax +60 3 6157 9648
E-mail: malaysia@zf-seasia.com
LOURENCO MARINE
G-20 Lina Residency, Fatorda
Margao - Goa 403 602
INDIA
Tel. +91 832 2743 468
Fax +91 832 2743 450
E-mail:lourencomarine@sancharnet.in
INDONESIA
AJENSI TULEN Sdn. Bhd.

35A Jalan Anggerek 36
Johore Bahru, JH 81100
MALAYSIA
Tel. +60 7 3547 755
Fax +60 7 3547 757
E-mail: atulen@po.jaring.my
P.T. TESCO INDOMARITIM

Julan Tuiodong Bawah X No. 17
Jakarta Selatan 12190
INDONESIA
Tel. +62 21 5260 363 - 67
Fax +62 21 5260 369
E-mail: tesco@cbn.net.id
ISRAEL
MALTA
Lev Pesach Street

North Industrial Zone - Lod 71293
ISRAEL
Tel. +972 8 9781 111
Fax +972 8 9781 137
E-mail: davni@dslnim.co.il
NORWAY
ZF PADOVA S.p.A. *
(ZF MARINE HEADQUARTERS)
Via Penghe, 48
35030 Caselle di Selvazzano (PD)
ITALY
Tel. +39 049 8299 311
Fax +39 049 8299 550
E-mail: info.zfpadova@zf.com
92
OCEANS
9, Main Street
Zurrieq ZRQ 03
MALTA
Tel. +356 21 640 703
Fax +356 21 641 223
E-mail: mylake@maltanet.net
NIMDA Co. Ltd.
ITALY
ZF SALES & SERVICE

(MALAYSIA) Sdn. Bhd.
KGK NORGE AS
Caspar Storms vei 19
0664 Oslo
NORWAY
Tel. +47 22 88 4680
Fax +47 22 72 0902
E-mail: toma.wulff@zf-group.no
PERU
PGO INTERNATIONAL S.A.C.

Av. Arequipa 2450, Of. 1108
Lima 14
PERU
Tel. +51 1 421 6055
Fax +51 1 421 6664
E-mail: pgorbegoso@perusat.net.pe
ZF Padova S.p.A.
Date
Service Centres
Section 11
POLAND
VOLVO PENTA POLSKA sp.z o.o.
TURKEY
Prostokatna 5A Str.
81-601 Gydnia
POLAND
Tel. +48 58 627 3380
Fax +48 58 627 3390
E-mail: mirek.czurak@volvopenta.pl
E-mail: miroslaw.czurak@volvo.com
RUSSIA
ZF MARINE RUSSIA
Suite 404 - Obvodny Kanal Emb., 118
190005 St. Petersburg
RUSSIA
Tel. +7 812 441 37 94
Fax +7 812 441 37 94
E-mail: alexander.lyshkov@zf.sp.ru
SINGAPORE
ZF SOUTH EAST ASIA Pte. Ltd.

11 Tuas Drive 1
638678 Singapore
Rep. of SINGAPORE
Tel. +65 6424 8787
Fax +65 6424 8788
E-mail: singapore@zf-seasia.com
SOUTH AFRICA
ZF of SOUTH AFRICA (Pty.) Ltd.

Meadowdale Ext. 3
170 Herman Road
1401 Germiston Johannesburg
Rep. of SOUTH AFRICA
Tel. +27 11 457 0000
Fax +27 11 453 7506
E-mail: pierre@zfsa.co.za
SPAIN
80820 Arnavutky - Istanbul TURKEY

Tel. +90 212 2872780
Fax +90 212 2876571
E-mail: georg@niveko.com
UNITED
KINGDOM
ZF GREAT BRITAIN Ltd.
UNITED
ARAB
EMIRATES
ZF MARINE MIDDLE EAST LLC
U.S.A.
MEXICO
ZF MARINE, LLC
ZF ESPAA, S.A.
Abbeyfield Road, Lenton

Nottingham NG7 2SX
UNITED KINGDOM
Tel. +44 115 986 9211
Fax +44 870 460 1479
E-mail: zfmarine@zf-group.co.uk
502 & 503, Golden Tower

Buhaira Corniche
Sharjah
U.A.E.
Tel. +971 6 574 7074
Fax +971 6 574 7174
E-mail: narasimhan.manian@zf.com
(U.S. HEADQUARTERS Pleasure Craft, Propuls

Latin America, Caribbean, After Market)
3131 Southwest 42nd Street
Fort Lauderdale, FL 33312
U.S.A.
Tel. +1 954 581 4040
Latin America: +1 954 581 4063
Fax +1 954 581 4078-77
E-mail: Info.ZFMarineFtLauderdale@zf.com
ZF MARINE, LLC West Coast
Avenida Fuentemar, 11
28820 Coslada (Madrid)
SPAIN
Tel. +34 91 485 2698
Fax +34 91 485 0036
E-mail: marine.zfesp@zf.com
SWEDEN
NIVEKO MAKINA TICARET

Ltd. Takkeci Sokak No. 3
(Commercial and Fast Craft)

12125 Harbor Reach Drive, Ste. B
Mukilteo, WA 98275
U.S.A.
Tel. +1 425 583 1900
Fax +1 425 493 1579
Toll Free: 800 546 5455
E-mail: Info.ZFMarineWashington@zf.com
KG KNUTSSON AB
TRANSMISSIONSDIVIONEN
Nottingham NG7 2SX
UNITED KINGDOM
Tel. +44 115 986 9211
Fax +44 870 460 1479
E-mail: zfmarine@zf-group.co.uk
VENEZUELA
KG KNUTSSON AB
TRANSMISSIONSDIVISIONEN
SISTEMAS DE PROPULSION
Avda 67 A, entre 149B y 150
Municipio San Francisco, Maracaibo, Estado Zu
VENEZUELA
Tel. +58 261 736 0747
Fax +58 261 736 0746
E-mail: m.graticola@sistemasdepropulsion.com
Hammarbacken 8
19181 Sollentuna
SWEDEN
Tel. +46 8 923 000
Fax +46 8 929 599
E-mail: karl-henry.pragsten@kgk.se
THAILAND
SEA SYSTEMS Co., Ltd.

477, Moo 2, Taiban Road
Tumbol Taiban, Ampur Muang
Samutprakan 10280
THAILAND
Tel. +66 2 703 3013-15
Fax +66 2 703 4044
E-mail: seacrest@csloxinfo.com
*
**
MANUFACTURING LOCATIONS
ZF HURTH MARINE REPRESENTATIVE ONLY
ZF Padova S.p.A.
93
Service Centres
Date
Section 11
94
ZF Padova S.p.A.
Section 12
Recommended Oils
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+
-
.
: 4< ; =1 1 %2 < ;1%1 :2 < => ! <
; =1 3>
03 ( % (
Clutch discs
Numering System
Filters
Duplex Filter
Pi 370
Operating pressure 200 (250) bar, Nominal size up to 450
1. Features
Efficient filters for modern
hydraulic systems
Modular design
Minimal pressure loss
Compact design
Visual / electrical / electronical differential pressure
indication
Threaded or SAE 4 bolt flange ports
Switching valve on upstream side
Ergonomic switch-over handle with safety lock and pressure
compensation
User-optimized one-hand-operation
Qualityfilters, easy to service
Highly efficient Sm-xfilter elements

-rated elements per ISO 4572
Large dirt holding capacity and high differential pressure
stability providing optimal element service life
World-wide sales
MAHLE Filtersysteme GmbH Bereich Industriefilter Postfach 13 09 74603 hringen Telefon (0 79 41 ) 67-0 Telefax (0 79 41 ) 67-429
190 mm/s (25 E)
2. Flow rate / pressure drop curve compl. filter
Differential pressure p [bar]
33 mm/s (4,5 E)
10
20
30
40
50
60
Flow rate [l/min]
Pi 3705 Sm-x
20
40
60
80
100
Flow rate [l/min]
Pi 3708 Sm-x
10
20
30
40
50
60
Flow rate [l/min]
Pi 3705 Sm-xvst
20
40
60
80
100
Flow rate [l/min]
Pi 3708 Sm-xvst
20
40
60
80
100
120
140
160
Flow rate [l/min]
Pi 3715 Sm-x
50
100
150
200
250
300
350
Flow rate [l/min]
Pi 3730 Sm-x
20
40
Pi 3715 Sm-xvst
60
80
100
120
140
160
Flow rate [l/min]
200
300
400
500
Flow rate [l/min]
100
120
100
Flow rate [l/min]
Pi 3745 Sm-x
80
60
40
20
120
Pi 3711 Sm-xvst
100
Flow rate [l/min]
80
60
40
20
Pi 3711 Sm-x
50
100
Pi 3730 Sm-xvst
150
200
250
300
350
Flow rate [l/min]
100
Pi 3745 Sm-xvst
200
300
400
500
Flow rate [l/min]
3. Separation characteristics
4. Filter performance data
5000
Beta-ratio
1000
99,5
98,6
98,0
95,0
10
Sm-x elements
with p 20 bar
99,98
99,9
100
75
Sm-x 3
Sm-x 6
Sm-x 10
Sm-x 25

6

10

25

3
Sm-xvst elements
with p 210 bar
Sm-xvst 3
Sm-xvst 6
Sm-xvst 10
Sm-xvst 25
75
75
75
75
at 7 bar differential pressure

6

10

25

3
75
75
75
75
at 1 6 bar differential pressure
90,0
75,0
2
1
tested according to ISO 4572 (multi-pass-test)
Degree of separation (%)
determined by multi-pass-tests (ISO 4572)
50,0
10
15
20
Particle size (m)
Example for ordering filters:
25
30
0,0
35
1. Housing design with = 80 l/min, electrical indicator

type-no. Pi 3708-015
Order-no. 781.036.9
+ 2. filter element Sm-xvst 3

type-no. Pi 2208
Order-no. 768.020.0
7. Order numbers for pressure side installation

7.1 Housing Design
Order
number
Type
number
781 0294
Pi 3705 -01 2
781 031 0
Pi 3705 -014
781 0302
781 0328
Pi 3705 -01 3
Pi 3705 -01 5
781 0336
Pi 3708-01 2
781 0351
Pi 3708-014
781 0344
781 0369
Pi 3708-01 3
Pi 3708-01 5
781 0377
Pi 37 1 1 -01 2
781 0393
Pi 37 1 1 -014
781 0385
781 0401
Pi 37 1 1 -01 3
Pi 37 1 1 -01 5
781 041 9
Pi 37 1 5 -01 2
781 0435
Pi 37 1 5 -014
781 0427
781 0443
Pi 37 1 5 -01 3
Pi 37 1 5 -01 5
781 0450
Pi 3730-01 2
781 0476
Pi 3730-014
781 0468
781 0484
Pi 3730-01 3
Pi 3730-01 5
781 0492
Pi 3745 -01 2
781 441 1
Pi 3745 -014
781 4403
781 4429
Pi 3745 -01 3
Pi 3745 -01 5
Nominal
size
(NG)
with bypass valve

and visual
indicator
with bypass valve

and electrical
indicator
50
80
110
150
300
450
When filter with non bypass configuration is selected, collapse pressure of element may not be exceeded.
with
visual
indicator
with
electrical
indicator
5. Test regulations
MAHLE filter elements are manufactured respectively, tested in accordance with the following international standards:
Norm
Designation
ISO 2942
Hydraulic-fluid power-Filter elements-Verification of fabrication integrity and determination of the first bubble point
ISO 3723
Hydraulic fluid power-Filter elements-Method for end load test
ISO 2941
Hydraulic-fluid power-Filter elements-Verification of collapse / burst resistance
ISO 2943
Hydraulic-fluid power-Filter elements-Verification of material compatibilitywith fluids
ISO 3724
Hydraulic fluid power-Filter elements-Verification of flowfatigue characteristics
ISO 3968
Hydraulic fluid power-Filters-Evaluation of pressure drop versus flow characteristics
ISO 16 889
Hydraulic Fluidpower filters-Multi-pass method for evaluation filtration performance of a filterelement
ISO 10 771.1
Fatigue pressure testing of metal containig envelopes in hydraulic fluid applications.
6. Symbols
T
7.2 Filter elements*
( ) = filter surface area
Sm-x 3
p 20 bar
Sm-x 6
p 20 bar
Sm-x 10
p 20 bar
Sm-x 25
p 20 bar
76801 35
7943509
7680325
7680440
( 590 cm)
76801 35
[Pi 2105]
( 590 cm)
7943509
[Pi 5105]
( 590 cm)
7680325
[Pi 3105]
( 590 cm)
7680440
( 900 cm)
( 900 cm)
7680457
7680457
( 1 31 5 cm)
( 1 31 5 cm)
( 1 31 5 cm)
( 1 31 5 cm)
7943525
7680333
7680465
7680465
( 2010 cm)
( 2010 cm)
( 2010 cm)
( 2010 cm)
7955099
7680358
7680473
[Pi 31 1 5]
7680473
( 3800 cm)
( 3800 cm)
( 3800 cm)
( 3800 cm)
7955107
7680366
7680481
[Pi 31 30]
7680481
( 5600 cm)
( 5600 cm)
( 5600 cm)
( 5600 cm)
79551 1 5
7680374
7680499
*further elements upon request.
[Pi 3145]
[Pi 4230]
7680549
76801 84
[Pi 5145]
[Pi 3230]
7680531
768041 6
( 6540 cm)
[Pi 2145]
[Pi 5230]
7680408
79551 31
( 6540 cm)
7680374
[Pi 2230]
79551 23
7680234
( 6540 cm)
79551 1 5
7680226
[Pi 41 30]
( 6540 cm)
76801 84
[Pi 421 5]
7680531
76801 76
[Pi 51 30]
[Pi 321 5]
7680523
7680408
( 4420 cm)
[Pi 21 30]
[Pi 521 5]
7680390
79551 23
( 4420 cm)
7680366
[Pi 221 5]
7943558
7680226
( 4420 cm)
7955107
768021 8
[Pi 41 1 5]
( 4420 cm)
76801 76
[Pi 421 1 ]
7680523
76801 68
[Pi 51 1 5]
[Pi 321 1 ]
768051 5
7680390
( 2350 cm)
[Pi 21 1 5]
[Pi 521 1 ]
7681 1 90
7943558
( 2350 cm)
7680358
[Pi 221 1 ]
7943541
768021 8
( 2350 cm)
7955099
7680200
[Pi 41 1 1 ]
( 2350 cm)
76801 68
[Pi 4208]
768051 5
76801 50
[Pi 31 1 1 ]
[Pi 3208]
7680507
7681 1 90
( 1 700 cm)
[Pi 51 1 1 ]
[Pi 5208]
7680382
7943541
( 1 700 cm)
[Pi 21 1 1 ]
[Pi 2208]
7943533
7680200
( 1 700 cm)
7680333
76801 92
[Pi 4108]
( 1 700 cm)
7943525
[Pi 4205]
( 900 cm)
7680341
76801 50
[Pi 3205]
( 470 cm)
( 900 cm)
794351 7
[Pi 3108]
[Pi 5205]
( 470 cm)
Sm-xvst 25
p 210 bar
7680507
7680143
[Pi 5108]
[Pi 2205]
( 470 cm)
Sm-xvst 10
p 210 bar
7680382
( 1 1 50 cm)
[Pi 2108]
( 470 cm)
Sm-xvst 6
p 210 bar
7943533
( 1 1 50 cm)
7680341
Sm-xvst 3
p 210 bar
76801 92
( 1 1 50 cm)
794351 7
[ ] = type number
[Pi 4105]
( 1 1 50 cm)
7680143
7680499
[Pi 4145]
7680234
[Pi 2245]
7680242
7680242
79551 31
[Pi 5245]
7955149
7955149
768041 6
[Pi 3245]
7680424
7680424
7680549
[Pi 4245]
7680556
7680556
8. Specifications
Design:
line mounting filter
Operating pressure:
200 bar*
Test pressure:
260 bar*
Temperature range:
(other temperature ranges on request)
-10C to +120C
Bypass opening pressure:
p 7 bar 10 %
Filter head material:
GGG
Filter bowl material:
St
Material of seals:
NBR / PTFE / CU
Activating pressure of visual / electrical

differential pressure indicator:
p 5 bar 10 %
Electrical data of contamination indicator:

Maximum voltage:
230 V~/=
Maximum current on contact:
2,5 A
Maximum contact load:

Inrush current:
Pi 3730Pi 3745
with drain plug
60 VA/ 40 W
G DIN 910
70 VA
Type of protection:
IP 65 when inserted and secured
Contact:
bistable
Cable connection:
PG 11 6-10
The electrical indicator function can be changed from the

Normally Open position to the Normally Closed position or visa
versa by inverting the electrical section.
With the inrush current of 70 VA the indicator can trigger small
contactors or contactor relays.
Inductivity in the direct current may require the use of a signal

eraser.
For further information and executions please see our leaflet:

Contamination indicators.
Filters compatible with standard mineral oils.
Please contact us in case of using other media.

* The housings Pi 3705, Pi 3708 and Pi 3711 are approved for
250 bar operating pressure (test pressure 325 bar).
9. Dimensions
All dimensions (except C) in mm.

Dimension
Weight
[kg]
100 86
70
58
11,0
45
100 86
70
58
13,0
90
45
100 86
70
58
15,0
62
140
45
210 136
94
82
31,5
280 M 12 x 18
62
140
45
210 136
94
82
37,0
280 M 12 x 18
62
140
45
210 136
94
82
41,5
G
SW
80
27
65
144
45
182
M 8 x 15
55
90
45
G 1*
294 346 80
27
65
144
45
182
M 8 x 15
55
90
G 1*
370 422
80
27
65
144
45
182
M 8 x 15
55
50
G 1* 302 354 110
30
110 175
70
280 M 12 x 18
78
50
G 1* 427 479 110
30
110 175
70
78
50
G 1* 543 595 110
30
110 175
70
Pi 3705
78
38
G 1*
219 271
Pi 3708
78
38
Pi 3711
78
38
Pi 3715
78
Pi 3730
Pi 3745
Type
*SAE flange connections (3000 PSI) on request.
10. Installation, operating and

maintenance instructions
10.1 Filter installation
Y
vent screw
10.2 Connecting the electrical contamination indicator
The electrical indicator is connected via a 2-pole appliance plug

according to DlN 43650 with poles marked 1 and 2.
The electrical section can be inverted to change from Normally
Open position to Normally Closed position or visa versa.
W
U
Install filter in accordance with the identified flow direction. The

filter head is provided with threaded holes for mounting the filter.
Ascertain that the required underclearance is provided so that
the filter element and the filter bowl can be removed.
Preferably the filter should be installed with the filter bowl
pointing downwards.
The contamination indicator must be well visible.
10.3 When must the filter element be replaced?
1. During cold starts, the indicator may give a warning signal.

Depress the red button of the visual indicator once again only
after operating temperature has been reached. lf the red
button immediately pops out again and/or the electrical signal
has not switched off after reaching operating temperature, the
filter element must be replaced after the end of the shift.
2. Please always ensure that you have original MAHLE-replacement elements in stock: disposable elements (Sm-x) cannot be
cleaned.
10.4 Element replacement
Note: The contamination indicator monitors the filter side in

operation, which is identified by the position of the
switching lever catch. The change-over valve must be
switched prior to filter servicing. Nowthe signal of the
contamination indicator is cancelled and the red button
can be depressed again.
1. Operate and hold pressure equalizing lever located behind the

switching lever. Pull catch knob and swivel switching lever.
Engage the catch on the clear filter side.
Place trough or drip pan underneath to collect leaking oil.
2. Loosen vent screw of the filter side not in use by 23 turns;

max. until contact is made with the safety stop.
Type-Number/ Housing
Pi 3705Pi 371 1
Seal kit
NBR
FPM
EPDM
Pi 371 5Pi 3745
8305062
8305054
8305047
Contamination indicator
visual
electrical
766991 4
Pis 3093/5 bar
Seal kit
NBR
FPM
EPDM
7669864
Pis 3092/5 bar
Seal kit for contamination indicator
NBR
FPM
EPDM
7760275
7760283
7760291
9375056
9375064
9375072
electrical upper
section only
7536550
4. Remove filter element with a side-to-side motion.
5. Check O-ring and back-up ring on the filter bowl and spigot
for damage. Replace, if necessary.
6. Make sure that the part number on the spare element

corresponds with the part number of the filter label. Open the
plastic bag and push element over the spigot in the filter head.
Now remove plastic bag.
7. Complete installation by screwing on the bowl, turning
clockwise until it comes to a full stop.
Back off the bowl
to turn.
8. To refill the filter chamber, operate only the pressure

equalizing lever (leave the switching lever arrested in its catch)
long enough for the medium to emerge bubble-free from the
vent bore.
9. Tighten vent screw. Checkfilter for leaks by operating the
pressure equalizing lever once again.
Subject to technical alteration.
MAHLE Filtersysteme GmbH
Bereich Industriefilter Schleifbachweg 45 D-74613 hringen Postfach 13 09 D-74603 hringen
Telefon (0 79 41 ) 67-0 Telefax (0 79 41 ) 67-429 Internet: http://www.mahle.com E-mail: ub2.industrie@mahle.com
07/03 Ba 2000 835.690.8
Pos.
3. Unscrewfilter bowl by rotating same counterclockwise and

clean with a suitable medium.
Printed in Germany/Imprim en Allemagne
11. Spare parts list
Medium Pressure Filter

Pi 340
Operating pressure 350 (250) bar, Nominal size up to 450
1. Features
Efficient filters for modern
hydraulic systems
Modular design
Minimal pressure loss
Compact design
Visual / electrical / electronical differential pressure
indication
Qualityfilters, easy to service
Highly efficient Sm-x filter elements

-rated elements per ISO 4572
Large dirt holding capacity and high differential pressure
stability providing optimal element service life
World-wide sales
MAHLE Filtersysteme GmbH Bereich Industriefilter Postfach 13 09 74603 hringen Telefon (0 79 41 ) 67-0 Telefax (0 79 41 ) 67-429
190 mm/s (25 E)
2. Flow rate / pressure drop curve compl. filter
20,0
10,0
20,0
10,0
5,0
20,0
10,0
5,0
2,0
Differential pressure & p [bar]
20,0
Pi 3408 Sm-xvst
Pi 3408 Sm-x
Pi 3405 Sm-xvst
Pi 3405 Sm-x
33 mm/s (4,5 E)
10,0
5,0
2,0
5,0
2,0
2,0
1,0
1,0
1,0
1,0
0,5
0,5
0,5
0,5
10
20
50
100
0,1
Flow rate [l/min]
10
20
50
100
20,0
10,0
10
20
50
100
2,0
1,0
1,0
1,0
0,5
0,5
0,5
0,5
200
500 1000
0,1
Flow rate [l/min]
50
100
200
500 1000
50
100
200
500 1000
2,0
1,0
1,0
1,0
0,5
0,5
0,5
0,5
100
200
500 1000
Flow rate [l/min]
0,1
20
50
100
200
500 1000
Flow rate [l/min]
0,1
200
500 1000
Flow rate [l/min]
5,0
2,0
50
100
10,0
5,0
1,0
20
50
20,0
2,0
0,1
20
Pi 3445 Sm-xvst
10,0
5,0
0,1
Flow rate [l/min]
20,0
10,0
5,0
20
20,0
10,0
100
2,0
Pi 3445 Sm-x
20,0
0,1
Flow rate [l/min]
Pi 3430 Sm-xvst
Pi 3430 Sm-x
20
50
100
20
Flow rate [l/min]
5,0
2,0
50
10
10,0
5,0
1,0
20
20,0
2,0
0,1
Pi 3415 Sm-xvst
10,0
5,0
0,1
Flow rate [l/min]
20,0
10,0
5,0
Pi 3415 Sm-x
20,0
0,1
Flow rate [l/min]
Pi 3411 Sm-xvst
Pi 3411 Sm-x
0,1
2,0
20
50
100
200
500 1000
Flow rate [l/min]
0,1
20
50
100
200
500 1000
Flow rate [l/min]
3. Separation characteristics
determined by multi-pass-tests (ISO 4572)
Beta-ratio
1000
99,5
98,6
98,0
95,0
10
Sm-x elements
with p 20 bar
99,98
99,9
100
75
Sm-x 3
Sm-x 6
Sm-x 10
Sm-x 25

6

10

25

3
Sm-xvst Elements
with p 210 bar
Sm-xvst 3
Sm-xvst 6
Sm-xvst 10
Sm-xvst 25
75
75
75
75
at 7 bar differential pressure

6

10

25

3
75
75
75
75
at 1 6 bar differential pressure
90,0
75,0
2
1
tested according to ISO 4572 (Multi-Pass-Test)
Degree of separation (%)
5000
4. Filter performance data
50,0
10
15
20
Particle size (m)
25
30
Example for ordering filters:
0,0
35
1. Housing design = 80 l/min, electrical Indication

Type-No. Pi 3408-69
Bestell-Nr. 787.441.5
+ 2. Filter element Sm-xvst 3

Type-No. Pi 2208
Bestell-Nr. 768.020.0
7. Order numbers
7.1 Housing design
Order
number
Type
number
7874324
Pi 3405 1 2
7874340
Pi 3405 14
7874332
7874357
Pi 3405 1 3
Pi 3405 1 5
7874381
Pi 3408 1 2
7874407
Pi 3408 14
7874399
787441 5
Pi 3408 1 3
Pi 3408 1 5
7874499
Pi 341 1 1 2
7874464
Pi 341 1 14
7874456
7874472
Pi 341 1 1 3
Pi 341 1 1 5
7921 91 9
Pi 341 5 1 2
7921 935
Pi 341 5 14
7921 927
7921 943
Pi 341 5 1 3
Pi 341 5 1 5
7921 968
Pi 3430 1 2
7921 984
Pi 3430 14
7921 976
7921 992
Pi 3430 1 3
Pi 3430 1 5
7922008
Pi 3445 1 2
7922024
Pi 3445 14
792201 6
7922032
Pi 3445 1 3
Pi 3445 1 5
Nominal
size
(NG)
With bypass
valve and visual
indicator
With bypass
valve and electrical
indicator
With
visual
indicator
50
80
110
150
300
450
When filter with non bypass configuration is selected the collapse pressure of the element may not be exceeded
With
electrical
indicator
5. Test regulations
MAHLE filter elements are manufactured respectively, tested in accordance with the following international standards:
No .
Designation
ISO 2941
Hydraulic -filter elements: Verification of burst resistance
ISO 2942
Hydraulic -filter elements: Determination of fabrication integrity
ISO 2943
Hydraulic -filter elements: Verification of material compatibilitywith hydraulic fluids
ISO 3723
Hydraulic -filter elements: Method for testing end -cap load
ISO 3724
Hydraulic -filter elements: Verification of flowfatigue characteristics
ISO 3968 . 2
Hydraulic -filters:
ISO 4572
Evaluation of pressure drop versus flow
Hydraulic -filter elements: Testing of filter performance (multi -pass -test)
6. Symbols
7.2 Filter elements*
( ) = filter surface area
Sm-x 3
p 20 bar
Sm-x 6
p 20 bar
Sm-x 10
p 20 bar
Sm-x 25
p 20 bar
76801 35
7943509
7680325
7680440
( 590 cm)
76801 35
[Pi 2105]
( 590 cm)
7943509
[Pi 5105]
( 590 cm)
7680325
[Pi 3105]
( 590 cm)
7680440
( 900 cm)
( 900 cm)
7680457
7680457
( 1 31 5 cm)
( 1 31 5 cm)
( 1 31 5 cm)
( 1 31 5 cm)
7943525
7680333
7680465
7680465
( 2010 cm)
( 2010 cm)
( 2010 cm)
( 2010 cm)
7955099
7680358
7680473
[Pi 31 1 5]
7680473
( 3800 cm)
( 3800 cm)
( 3800 cm)
( 3800 cm)
7955107
7680366
7680481
[Pi 31 30]
7680481
( 5600 cm)
( 5600 cm)
( 5600 cm)
( 5600 cm)
79551 1 5
7680374
7680499
[Pi 3145]
*Other element executions upon request
[Pi 4230]
7680549
76801 84
[Pi 5145]
[Pi 3230]
7680531
768041 6
( 6540 cm)
[Pi 2145]
[Pi 5230]
7680408
79551 31
( 6540 cm)
7680374
[Pi 2230]
79551 23
7680234
( 6540 cm)
79551 1 5
7680226
[Pi 41 30]
( 6540 cm)
76801 84
[Pi 421 5]
7680531
76801 76
[Pi 51 30]
[Pi 321 5]
7680523
7680408
( 4420 cm)
[Pi 21 30]
[Pi 521 5]
7680390
79551 23
( 4420 cm)
7680366
[Pi 221 5]
7943558
7680226
( 4420 cm)
7955107
768021 8
[Pi 41 1 5]
( 4420 cm)
76801 76
[Pi 421 1 ]
7680523
76801 68
[Pi 51 1 5]
[Pi 321 1 ]
768051 5
7680390
( 2350 cm)
[Pi 21 1 5]
[Pi 521 1 ]
7681 1 90
7943558
( 2350 cm)
7680358
[Pi 221 1]
7943541
768021 8
( 2350 cm)
7955099
7680200
[Pi 41 1 1 ]
( 2350 cm)
76801 68
[Pi 4208]
768051 5
76801 50
[Pi 31 1 1 ]
[Pi 3208]
7680507
7681 1 90
( 1 700 cm)
[Pi 51 1 1 ]
[Pi 5208]
7680382
7943541
( 1 700 cm)
[Pi 21 1 1 ]
[Pi 2208]
7943533
7680200
( 1 700 cm)
7680333
76801 92
[Pi 4108]
( 1 700 cm)
7943525
[Pi 4205]
( 900 cm)
7680341
76801 50
[Pi 3205]
( 470 cm)
( 900 cm)
794351 7
[Pi 3108]
[Pi 5205]
( 470 cm)
Sm-xvst 25
p 210 bar
7680507
7680143
[Pi 5108]
[Pi 2205]
( 470 cm)
Sm-xvst 10
p 210 bar
7680382
( 1 1 50 cm)
[Pi 2108]
( 470 cm)
Sm-xvst 6
p 210 bar
7943533
( 1 1 50 cm)
7680341
Sm-xvst 3
p 210 bar
76801 92
( 1 1 50 cm)
794351 7
[ ] = type number
[Pi 4105]
( 1 1 50 cm)
7680143
7680499
[Pi 4145]
7680234
[Pi 2245]
7680242
7680242
76851 31
[Pi 5245]
7955149
7955149
768041 6
[Pi 3245]
7680424
7680424
7680549
[Pi 4245]
7680556
7680556
8. Specifications
Design:
Flange filter
Operating pressure:
Screws for
attachement
250 bar*
Static test pressure:
(Property Class 12.9)
325 bar
Temperature range:
are not contained in
-10 C to +120 C
(other temperature ranges
on request)
Bypass opening pressure:
second inlet with
Pi 34153445 G 1
is possible
p 7 bar 10 %
Filter head material:
the deliveries.
GGG
Filter bowl material:
St
Material of seals:
NBR / PTFE / Cu
Activating pressure of visual / electrical

differential pressure indicator:
p 5 bar 10 %
Electrical data of
contamination indicator:
Maximum voltage:
Seal
41,5 x 3
Maximum current on contact:
Seal
"Outlet"
230 V~/=
18,72 x 2,62
2,5 A
Maximum contact load:
"Outlet"
60 VA/ 40 W
Inrush current:
70 VA
Type of protection:
IP 65 when inserted
and secured
Contact:
"Inlet"
bistable
Cable connection:
"Inlet"
PG 11 610
The electrical indicator function can be changed from the

Normally Open position to the Normally Closed position or visa
versa by inverting the electrical section.
With the inrush current of 70 VA the indicator can trigger small
contactors or contactor relays.
Inductivity in the direct current may require the use of a signal

eraser.
For further information and executions please see our leaflet

Contamination indicators.
Filters compatible with standard mineral oils.
Please contact us in case of using other media.
* Types Pi 3405... - 3411... have an operating pressure of 350 bar,

test pressure 455 bar.
Types Pi 3415... - 3445... without bypass have an operating
pressure of 315 bar, test pressure 410 bar.
9. Dimensions
All dimensions (except C) in mm

Dimension
G
SW
Weight
kg
Pi 3405
78
29
181
241
110
27
66
90
101
13
11
83
45
58
26
3,5
Pi 3408
78
29
259
319
110
27
66
90
101
13
11
83
45
58
26
4,5
Pi 3411
78
29
335
395
110
27
66
90
101
13
11
83
45
58
26
5,5
Pi 3415
78
60
308
368
110
30
109
140
150
30
22
135
45
95
52
58
14,8
Pi 3430
78
60
G
433
493
110
30
109
140
150
30
22
135
45
95
52
58
17,3
Pi 3445
78
60
G
550
610
110
30
109
140
150
30
22
135
45
95
52
58
19,6
Type
11. Installation, operating and

maintenance instructions
10.1 Filter installation
When installing the filter make sure that sufficient space is

available to remove filter element and filter bowl.
Preferable the filter should be installed with the filter bowl
pointing downwards.
The contamination indicator must be visible.
10.2 Connecting the electrical contamination indicator
The electrical indicator is connected via a 2-pole appliance plug

according DlN 43 650 with poles marked 1 and 2.
The electrical section can be inverted to change from Normally
Open position to Normally Closed position or visa versa.
10.3 When must the filter element be replaced?
1. Filters equipped with visual and electrical contamination

indicator:
During cold starts, the indicator may give a warning signal.
Depress the red button of the visual indicator once again only
after operating temperature has been reached. lf the red
button immediately pops out again and/or the electrical signal
has not switched off after reaching operating temperature, the
filter element must be replaced after the end of the shift.
2. Filters without contamination indicator:

The filter element should be replaced after the trial run or
flushing of the system. Afterwards follow instructions of the
manufacturer.
3. Please always ensure that you have original MAHLE-replacement elements in stock: disposable elements (Sm-x) cannot be
cleaned.
10.4 Element replacement
1. Stop system and relieve filter from pressure.
2. Unscrewthe filter bowl by turning counter-clockwise. Clean

the bowl using a suitable cleaning solvent.
3. Remove filter element with a side-to-side motion.
4. Check O-ring and back-up ring on the filter bowl and spigot for
damage. Replace, if necessary.
to
Type number/ housing
Pi 3405Pi 341 1
Seal kit
NBR
FPM
EPDM
7850381
7850399
7850407
Pi 341 5Pi 3445
Seal kit
NBR
FPM
EPDM
Contamination indicator
visual
electrical
5 bar
5 bar
766991 4
7669864
Pis 3093/5
Pis 3092/5
Seal kit for contamination indicator

NBR
7760275
FPM
7760283
EPDM
7760291
MAHLE Filtersysteme GmbH
7936206
793621 4
7936222
6. Complete installation by screwing on the bowl, turning

clockwise until it comes to a full stop.
Back off the bowl to
turn.
Subject to technical alteration without prior notice.
electrical upper
part only
7536550
Bereich Industriefilter Schleifbachweg 45 D-74613 hringen Postfach 13 09 D-74603 hringen
Telefon (0 79 41 ) 67-0 Telefax (0 79 41 ) 67-429 Internet: http://www.mahle.com E-mail: ub2.industrie@mahle.com
11/00 Ba 3000 835.675.0
Pos.
Printed in Germany/Imprim en Allemagne
12. Spare parts list
5. Make sure that the part number on the spare element

corresponds with the part number of the filter label. Open the
plastic bag and push element over the spigot in the filter head.
Now remove plastic bag.
Pumps
Cooler
INSTALLATION
AND
OPERATING MANUAL
Compact Heat Exchanger

Product Line K
Type
Order No.
Serial No.
Customer
Order No.
: KS12-BCN-421 L718
:
:
: ZF Padova
:
Table of Contents
GENERAL
Operational Range
Service
Guarantee
Conservation
Transportation
STRUCTURAL BUILD-UP
Tube bundle
Shell
Bonnets
Seals
Accessories/spare parts
SERVICE
Installation
Screw fasteners
Type plate
Starting up
Operating instructions
Switching off/standstill of the unit
MAINTENANCE
Periodic inspections
Dismounting
Assembly
Cleaning
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 2 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
TROUBLESHOOTING
To low performance!/outlet temperature to high!
Leaky tubes!
Leaky rolling connection!
Leaky O-ring!
CONTACTS
Cleaning
Repair/spare parts
10
APPENDIX
Type plate
Data sheet
Drawings
Parts list
Stand: 23.08.2004
INSTALLAT ION AND OPERAT ING M ANUAL

FOR COMPACT HEAT EXCHANGERS OF PRODUCT LINE K
General
Operational Range
Heat exchanger of product line K were developed in particular for application in the field of the
industrial and maritime cooling. The present device is a high efficient heat exchanger on the principle
of shell and tube, in compact and lightweight design. The apparatus of this product line can be
adapted to different conditions of use by particular combination of material and components. The field
of application include all possible uses of cooling, in particular turbines, compressors, refrigeration
units, hydraulic plants, in the range of engines, gears etc. Service life of the devices is essentially
influenced by proper maintenance and operation. For this reason, observe strictly these instructions.
Service
For all service inquiries, please contact directly our factory, our sales force or your contracting party.
In the case of spare part orders, please indicate always the designation of the device and/or the spare
part. The necessary specifications can be taken from the enclosed drawings and from parts lists.
Guarantee
Warranty claims are to be taken from our general supply and payment terms, providing no other
individual agreements were made.
Repairs of defective parts at a later stage may only be carried out with our approval. If circumstances
should not permit asking our approval, you can ignore it. In this case you must inform us immediately
at the nearest occasion.
In principal any changed service conditions must be approved by us in writing.
Conservation
Under normal conditions are internal surfaces of the devices protected for a duration of 6 months. A
post-preserving is necessary after 6 months. The preserving liquid and the note on safety can be
provided by us. The used preservative is well compatible with all mineral lubricants. The removal of
these substances can be done by using any known solvent (check material compatibility!). The
devices should only be stored in closed rooms. Condensation through strong variation of temperature
must be avoided.
Transportation
A damage of the device must be by all means avoided. The transportation of the unpacked device
when using lifting systems has to be carried out with sufficient number of transportation straps set
around the casing. Please note the dead weight of the device indicated on the current data sheet or
the type plate.
Stand: 23.08.2004
Structural build-up
Tube bundle
The tube bundle consists of two opposite identical tube plates with three grooves. The tubes are rolled
into the tube plate wholes. Between the tube plates at the outer side of the tubes, the surface is
enlarged forming fins which are in connection with the tubes. The result is a compact finned bundle. At
the outer side of the finned bundle, there are grooves across the whole length which are used to take
up sealing straps. In the finned bundle, a different number of baffles can be installed. A groove is
milled in the top of the baffle which contains a spring and a sealing plate. The interior O-ring grooves
in the tube plates seal against the casing in assembled state. The external seals are used for sealing
the bonnet. In this way, a intermixing of the media is avoided if a seal becomes defective and a
leakage localization is simplified. In the central groove, sheets are positioned which fix the tube plate
in assembled state and allow a thermal expansion for the opposite tube plate. With two path devices,
the fixation must be at the side of the connections. In any case, the side of fixation is marked by an
imprinted 'F' at the flange of the casing in the area of the flanges M1 or M2. The fixation must be
positioned at this side when in working condition.
Shell
The shell is used for taking up the tube bundle and forms the shell side casing. It consists of end
pieces which are circular-welded with the shell
tube. The end pieces can be placed in such a way
that the connections are positioned at one
side or rotated by 180. The shell tube is a
precision tube with restricted allowances.
Changes must not be carried out on the casing.
!
At the starting area of the end pieces, the
interior groove of the tube plates seals by
means of an O-ring. This area must be treated carefully in order to guarantee a sealing effect.
The mounting brackets grip around the shell tube. These allow an optional assembly position of the
device.
Casings of model KK are cast casings in standardized, fixed version.
Bonnets
The bonnets consist of different materials (see part list), depending on version of the device. The
bonnet forms together with the tube bundle the chamber of the cooling medium and is fixed to the
casing by screws. At one side of the device, sheets are inserted between bonnet and casing which fix
the tube plate. At the other side, washers form a spacer.
The one path version has two identical bonnets positioned opposite each other. With the two path
version, one bonnet with two connections is mounted at one side of the device, at the other side there
is a reversing cover. To seperate the two chambers in the bonnet, a plastic or aluminium path partition
is inserted into the tube plate at the connection side. In assembled state, the path partition seals
bonnet and tube plate, i.e. it splits the flow of tubeside medium through the device.
Seawater resistant versions contains sacrificial anodes.
Seals
All tube plate seals consist of O-rings.
All pipe threads are sealed by copper or aluminum rings.
The tube bundle is sealed at the side along its length with a sealing strip against the casing. The
sealing strips consist of the same material as the O-rings. All seals are available from our factory with
indication of the drawing number.
Accessories and spare parts can be taken from the enclosed drawings and part lists. Drawing and
identification numbers of components which are necessary for ordering, are also listed there. Price
lists for the spare parts and not listed accessories can be requested via our marketing department or
directly from factory.
Stand: 23.08.2004
Service
Installation
The following items must be considered during the installation of the device:
Protective caps fitted to connections must be removed. If there is no protective cap on a
connection, check whether it has been pushed into the connection or foreign parts have
penetrated the device.
Foreign
bodies
must
not
penetrate the openings of the connections.
The connection of the pipes
must be tension-free to ensure that no inadmissibly high
thermal
or
mechanical
tensions affect the device in service.
!
All circuits must be designed
to avoid penetration of dirt and dust. We recommend the
assembly of dirt traps and suitable filters.
Tubes must be correctly installed so that air locks cannot built up.
The assembly can be horizontal or vertical.
Sufficient space should be available to ensure easy accessibility to all screw connections. Take
particular care for providing enough space for remove the tube bundle. You can take the
necessary space dimensions for remove the tube bundle from the sketch. It is possible to remove
the tube bundle from both sides of the device.
. The direction of flow is to be taken from the enclosed sketch and from the datatsheet
Before startup, the device must be completely bled.
Never weld or modify the cooler.
In case of using the device as oilcooler before startup, clean/flush the oil circuit but not the
lubricated points.
Orifice plates must only be installed at the outlet side of the device.
Screw fasteners
To ensure a safe operation and a long service of fastening elements, the screw fastenings should be
only torqued. The table below lists the torque figures for used screws. Through influence of various
factors, the specified values may show a deviation which in individual cases require lower or higher
values.
Connection shell/bonnet
Connection flanges
type
screw/
strength
torque [Nm]
screw/
strength
material
thread
K12
M12 5.6
38
M12 5.6
aluminium
30
M12 8.8
80
red bronze
30
M16 5.6
95
aluminium
75
M16 8.8
200
red bronze
75
M20 5.6
180
cast steel
100
M20 8.8
400
cast steel
300
K20
K25
M16 5.6
M24 5.6
of
torque [Nm]
Type plate
The type plate is at the side of the device and is permanently fixed. You can find a copy of the type
plate in the appendix.
Stand: 23.08.2004
Starting up
At first the apparatus must be filled up with the intended medium, then the entire system must be
checked for leakage. For watercooled
devices use only clean water at the tube side. Before
the actual starting up of the system,
make sure that the cooling medium is circulated.
!
Operating the device without flow of
cooling medium is not permissible.
Only for watercooled units:
If the flow adjustment is carried out by a control, we recommend a oil-sided control, especially when
operating with river or sea water.
Discuss the control of cooling water with our factory, because factors like material and quality of
cooling water are very important to avoid later problems.
The use of additives in the cooling water has to be confirmed through HS-Cooler GmbH.
During the operation, make
sure by suitable means that pre-set parameters for which the
devices are designed are kept.
!
If reserve devices with switchover valves are present, switch these devices periodically on
(all 2-3 days) or load the reserve device daily for some time with the full water volume.
Switching off/standstill of the unit for watercooled units

With a short-term standstill (<4 days) of the unit, the apparatus can remain filled.
When switching off the unit, the water must be removed. In the case of operating the device with sea
water or aggressive water, flush the unit additionally with clean water. The tube bundle should as far
as possible be dried inside with compressed air. Further, if a drainage is not possible, then a flow of
the correct amount of cooling water must be maintained.
Maintenance
Devices of product line K are normally reliable and easy to maintain. However, some periodic
inspections of the device are necessary to provide a safe, continuous operation. Normally inspections
on the tubeside (waterside) predominate. The shellside is less inclined to pollution so that an
inspection can be carried out based on the experience of the operator.
The following inspections should be practiced:
When operating with sea water, sacrificial
anodes are installed in the bonnets/covers.
These should be checked in the initial
phase all 3 months. If the anodes are used
!
up, they must be replaced by new ones.
In the case of excessively fast consumption
of the anodes, water quality and the electrical potential of the system must be checked.
The device should be cleaned at the water side at least once a year. An excessive pollution of the
tubes must by all means be avoided. The bonnets can be removed without depressurerizing the
shell side. The intervals are to be shortened during long ship operation in harbors or in other
polluted waters and depending on the experience of the operator.
At shorter intervals the device must be subject to an externally visual inspection, in order to
identify leakage or other problems early. Through the double O-ring sealing, leakages can be
precisely located and the relevant expenditure can be estimated.
Dismounting
Proceed as follows when dismounting the apparatus:
Lock-up any pipelines
Empty the apparatus at the tube side, if a removal of the tube bundle is necessary, empty also the
shell side.
Remove the pipelines at the tube side.
Remove the bonnets/covers. For this purpose, the screws at the bonnet/casing connection must
be loosened. Between the bonnet/cover there are 4 fixing plates or washers. These must be
Stand: 23.08.2004
replaced at the same side again during re-assembly. The marking on the casing flange must be
here observed.
If you want to dismount without remove the
tube bundle, the bonnet/cover without fixing
plates must be disassembled first in order
to protect the tube bundle against
displacement, before you remove the
fixing plates. This can be done with another
!
set of fixing plates or with similar aids.
Dismounting without remove the tube bundle:
Remove the O-rings from the external groove of the tube plates and secure the tube bundle to the
casing with four screws and the four fixing plates in the middle groove of the tube plates. The tube
side can now be inspected and cleaned mechanically. The shell side can remain under pressure.
Dismounting with remove the tube bundle:
Remove the O-rings from the external groove of the tube plates. At one tube plate, a marking of
the fixed position in relation to the casing is attached. A half of a X is stamped at the front of the
tube plate and the adjacent casing flange. Check the position of the marking. Push the tube
bundle (where appropriate with auxiliary tools) so far sideways until the O-ring of the interior
groove becomes visible. Remove the O-ring from the interior groove. Pull out the tube bundle in
the opposite direction. Remove the tube bundle carefully from the casing without damaging the
fins. As far as possible suspend the
tube bundle with the help of large-surface
transportation straps. The grooves
taking the O-rings must not be damaged. During
dismounting of the tube bundle the
sealing plate and the spring can drop out of the
!
baffle groove. The spring and the
sealing plate have to be installed during assembly
of the bundle by pressing them into the groove whilst the baffle passes the inlet of the shell.
When dismounting vertically fixed devices, make sure in any case that the tube bundle does not
slips down after removal of the fixing plates. We
recommend to provide an additional
set of fixing plates and to start the removal at the side
where no fixing plates are mounted.
There the bundle must be secured first. After
dismounting the second bonnet,
!
the bundle can be removed carefully. While
assembling, only one set of fixing
plates is permittedat the side of the marking.
Assembly
The assembly is carried out in reversed order as dismounting. The following must also be considered:
Generally use new O-rings and clean O-ring grooves.
Note the marking for proper assembly of the tube bundle (X).
Note the marking for correct assembly of the fixing plates (F).
At the side of the tube
bundle there are sealing straps. These should only be replaced
when damaged. When
pushing-in the tube bundle take care that the sealing straps are
not displaced or twisted.
Before assembling the tube bundle, the sealing straps should
!
be greased. You can
use the operating medium. The sealing straps must be
effective along the entire length of the tube bundle.
Insert the sealing plate and the spring into the baffle groove and press down during insertion of the
tube bundle
Lubricate O-rings with suitable O-ring grease.
During insertion of the tube plate into the sealing faces, make sure that the O-rings do not shear.
The bonnets/covers must be set up in parallel onto the tube plate and must be pushed evenly onto
the O-ring; ensure also that the O-ring does not shear.
With two path devices, a path partition must be fitted at the side of the bonnet with the two
connections. At this side, the fixing sheets must also be installed later.
When assembling the two path bonnet, make sure that the path partition is correctly placed.
Then continue as described under 'Operation'.
Cleaning
In the case of only small amount of fouling, the tube side can be mechanically cleaned. Disassemble
the device as described under
'dismounting without remove the tube bundle' and clean with
a suitable nylon brush (do not
use metal brushes) each tube inside, then clean with water.
Never remove stuck deposits or
coarse dirt by force.
!
In the case of stuck deposits,
the tube bundle must be cleaned chemically. This can be
Stand: 23.08.2004
carried out by rinsing the tube in the assembled state or submerging in disassembled state. Such a
cleaning must only be practiced by specialists. Only suitable solvents must be used. To select a
suitable agent, refer to the added part list. Take the materials of the plastic separator strip and O-rings
in the assembled state into consideration. Under 'Contacts' you find some companies offering
respective agents or carrying out a complete cleaning.
Provided that the type designation gets a C at the 11th position (example: KS12-BCN-821C L1000),
then it is a coated tube bundle. To prevent a damage caused by corrosion this bundle is coated on the
inside of the tubes and on the tubesheets. When dismounting the bundle and during cleaning make
sure that the coating will not be damaged or destroyed. Use only nylon cleaning brushes and
approved cleaning agents. If there are any doubts about suitability of an agent, please contact our
service department.
Troubleshooting
Check all temperatures and material flows in accordance with the design data?
Are foreign bodies in pipe or in device causing obstruction?
Is the tube bundle correctly assembled, check marking?
Are the path partition and the fixing plates correctly assembled in the two path bonnet?
Are all pressure rooms vented?
Are tube side or shell side too dirty (too thick deposits)?
Are more than 10% of the tubes plugged?
Leaky tubes!
If the presumption exists that tubes have become leaky, proceed as with 'dismounting without remove
the tube bundle'. The shell side can remain under pressure. After cleaning the tube plates, you can
identify the defective tube by the state of the emerging medium. Lock the leaky tube at both ends with
our Tubelock-Repairset. Alternative you can use a conical copper or aluminium plug or a conical hard
wood plug. The plug must not be pushed too strong since otherwise adjacent rolling connections can
be damaged. You can lock 10% of the tubes at the most without noticeable reduction in performance.
Dismounting the defective tube is not possible.

If it is found during the check for leaky tubes that a rolling connection is leaky, it can be rolled again
with a specific rolling tool. This work however is only to be carried out by specially trained personnel.
Since defects of this type are uncommon, a check of the complete bundle in our factory is
recommended.
Leaky O-ring!
If a leakage is found between bonnet/cover and casing, an O-ring of the tube plate is defective. The
kind of the emerging medium defines at which groove of the tube plate the defect developed. In the
case of a defect on the tube side, proceed as described under 'dismounting without remove the tube
bundle'. In the case of a defect at the shell side, proceed as described under 'dismounting with
withdrawing the tube bundle'. In this case the tube bundle does not need to be removed completely
from the casing. Assemble the O-ring as described in 'Assembly'.
Contacts
Cleaning
Suppliers for cleaning agents:
Ashland Chemicals www.ashchem.com
Henkel Oberflchentechnik- www.henkel.com
Stand: 23.08.2004
Ondeo Nalco www.ondeo-nalco.com
Contractors for complete cleaning

Vecom www.vecom.nl
- Ondeo Nalco www.ondeo-nalco.com
Repair/spare parts
Repairs must only be carried out by specially trained personnel. However we recommend to carry out
any repair in our factory.
You can purchase spare parts directly from us with indicating the sketch and serial number. Please
contact our head offices or our sales office.
Stand: 23.08.2004
Pos.
Quantity
Unit
Description
pc.
Shell
pc.
Tube Bundle
pc.
Waterbox 1 1/2" SAE
KL12-B-002
pc.
Anode 3/8"
KL-1021
pc.
Cover
KL12-B-003
pc.
Anode 3/8"
KL-1021
pc.
Sealing Plug
DIN 910 - G 1/8" A
Brass
pc.
Sealing Ring
DIN 7603 - A 10 x 13.5 x 1
Copper
pc.
Fixation Plate
KL12-0-108
Steel galv.
10
pc.
Clamp Bracket
KL12-0-109
Steel
11
pc.
Hex Bolt
ISO 4017 - M12 x 40 - 8.8
Steel galv.
12
pc.
Hex Nut
ISO 4032 - M12 - 8
Steel galv.
13
pc.
Washer
DIN 125 - A 13
Steel galv.
14
pc.
Hex Bolt
ISO 4014 - M12 x 60 - 5.6
Steel galv.
AD-W7 (Stamped)
15
pc.
Hex Nut
ISO 4032 - M12 - 5-2
Steel galv.
AD-W7 (Stamped)
16
12
pc.
Washer
DIN 125 - A 13
Steel galv.
17
pc.
Type Plate
DRAW
Part/Standard Number
Remark
GS12 - 1
RL12 - C N - 4 2 1
G-CuSn5PbZn
(3.1B)
G-CuSn5PbZn
(3.1B)
Aluminium
DATE
NAME
29.11.99
Garbe
CHECK 29.11.99 Graulich
Parts List
NORM
K S 1 2 - BCN - 4 2 1
SYM
REVISION
DATE
NAME
FILE: Parts List KS12.doc
Sheet
1 of 1
Pos.
Quantity
Unit
Description
KL12 - C - 052
Remark
CuZn38Sn1 F34
AD-W6/2 (3.1B)
CuAl10Fe5Ni5-C
DIN EN 1982 (3.1B)
pc.
Tubesheet
72
pc.
Tube LR = L + 28mm
7.5mm x 0.5mm
CuNi10Fe1Mn F29
AD-W6/2 (3.1B)
L/1.4
pc.
Fin 1.4
KL12-0-105
Aluminium
pc.
O-Ring
KL-1510
NBR
pc.
Sealing Strip
L x 13 x 3
NBR
pc.
Baffle
KL12-0-106
Aluminium
pc.
Water Partition
KL12-0-107
Polypropylen
DRAW
DATE
NAME
02.11.99
Garbe
PARTS LIST
NORM
R L 1 2 - CN - 4 2 1
SYM
REVISION
DATE
NAME
FILE: Parts List RL12.doc
Sheet
1 of 1
INSTALLATION
AND
OPERATING MANUAL
Compact Heat Exchanger

Product Line K
Type
Order No.
Serial No.
Customer
Order No.
: KS20-BCN-421- L600
:
:
: ZF Padova
:
Table of Contents
GENERAL
Operational Range
Service
Guarantee
Conservation
Transportation
STRUCTURAL BUILD-UP
Tube bundle
Shell
Bonnets
Seals
SERVICE
Installation
Screw fasteners
Type plate
Starting up
Switching off/standstill of the unit
MAINTENANCE
Dismounting
Assembly
Cleaning
Stand: 23.08.2004
TROUBLESHOOTING
Leaky tubes!
Leaky O-ring!
CONTACTS
Cleaning
Repair/spare parts
10
APPENDIX
Type plate
Data sheet
Drawings
Parts list
Stand: 23.08.2004
INSTALLAT ION AND OPERAT ING M ANUAL

FOR COMPACT HEAT EXCHANGERS OF PRODUCT LINE K
General
Operational Range
Heat exchanger of product line K were developed in particular for application in the field of the
industrial and maritime cooling. The present device is a high efficient heat exchanger on the principle
of shell and tube, in compact and lightweight design. The apparatus of this product line can be
adapted to different conditions of use by particular combination of material and components. The field
of application include all possible uses of cooling, in particular turbines, compressors, refrigeration
units, hydraulic plants, in the range of engines, gears etc. Service life of the devices is essentially
influenced by proper maintenance and operation. For this reason, observe strictly these instructions.
Service
For all service inquiries, please contact directly our factory, our sales force or your contracting party.
In the case of spare part orders, please indicate always the designation of the device and/or the spare
part. The necessary specifications can be taken from the enclosed drawings and from parts lists.
Guarantee
Warranty claims are to be taken from our general supply and payment terms, providing no other
individual agreements were made.
Repairs of defective parts at a later stage may only be carried out with our approval. If circumstances
should not permit asking our approval, you can ignore it. In this case you must inform us immediately
at the nearest occasion.
In principal any changed service conditions must be approved by us in writing.
Conservation
Under normal conditions are internal surfaces of the devices protected for a duration of 6 months. A
post-preserving is necessary after 6 months. The preserving liquid and the note on safety can be
provided by us. The used preservative is well compatible with all mineral lubricants. The removal of
these substances can be done by using any known solvent (check material compatibility!). The
devices should only be stored in closed rooms. Condensation through strong variation of temperature
must be avoided.
Transportation
A damage of the device must be by all means avoided. The transportation of the unpacked device
when using lifting systems has to be carried out with sufficient number of transportation straps set
around the casing. Please note the dead weight of the device indicated on the current data sheet or
the type plate.
Stand: 23.08.2004
Structural build-up
Tube bundle
The tube bundle consists of two opposite identical tube plates with three grooves. The tubes are rolled
into the tube plate wholes. Between the tube plates at the outer side of the tubes, the surface is
enlarged forming fins which are in connection with the tubes. The result is a compact finned bundle. At
the outer side of the finned bundle, there are grooves across the whole length which are used to take
up sealing straps. In the finned bundle, a different number of baffles can be installed. A groove is
milled in the top of the baffle which contains a spring and a sealing plate. The interior O-ring grooves
in the tube plates seal against the casing in assembled state. The external seals are used for sealing
the bonnet. In this way, a intermixing of the media is avoided if a seal becomes defective and a
leakage localization is simplified. In the central groove, sheets are positioned which fix the tube plate
in assembled state and allow a thermal expansion for the opposite tube plate. With two path devices,
the fixation must be at the side of the connections. In any case, the side of fixation is marked by an
imprinted 'F' at the flange of the casing in the area of the flanges M1 or M2. The fixation must be
positioned at this side when in working condition.
Shell
The shell is used for taking up the tube bundle and forms the shell side casing. It consists of end
pieces which are circular-welded with the shell
tube. The end pieces can be placed in such a way
that the connections are positioned at one
side or rotated by 180. The shell tube is a
precision tube with restricted allowances.
Changes must not be carried out on the casing.
!
At the starting area of the end pieces, the
interior groove of the tube plates seals by
means of an O-ring. This area must be treated carefully in order to guarantee a sealing effect.
The mounting brackets grip around the shell tube. These allow an optional assembly position of the
device.
Casings of model KK are cast casings in standardized, fixed version.
Bonnets
The bonnets consist of different materials (see part list), depending on version of the device. The
bonnet forms together with the tube bundle the chamber of the cooling medium and is fixed to the
casing by screws. At one side of the device, sheets are inserted between bonnet and casing which fix
the tube plate. At the other side, washers form a spacer.
The one path version has two identical bonnets positioned opposite each other. With the two path
version, one bonnet with two connections is mounted at one side of the device, at the other side there
is a reversing cover. To seperate the two chambers in the bonnet, a plastic or aluminium path partition
is inserted into the tube plate at the connection side. In assembled state, the path partition seals
bonnet and tube plate, i.e. it splits the flow of tubeside medium through the device.
Seawater resistant versions contains sacrificial anodes.
Seals
All tube plate seals consist of O-rings.
All pipe threads are sealed by copper or aluminum rings.
The tube bundle is sealed at the side along its length with a sealing strip against the casing. The
sealing strips consist of the same material as the O-rings. All seals are available from our factory with
indication of the drawing number.
Accessories and spare parts can be taken from the enclosed drawings and part lists. Drawing and
identification numbers of components which are necessary for ordering, are also listed there. Price
lists for the spare parts and not listed accessories can be requested via our marketing department or
directly from factory.
Stand: 23.08.2004
Service
Installation
The following items must be considered during the installation of the device:
Protective caps fitted to connections must be removed. If there is no protective cap on a
connection, check whether it has been pushed into the connection or foreign parts have
penetrated the device.
Foreign
bodies
must
not
penetrate the openings of the connections.
The connection of the pipes
must be tension-free to ensure that no inadmissibly high
thermal
or
mechanical
tensions affect the device in service.
!
All circuits must be designed
to avoid penetration of dirt and dust. We recommend the
assembly of dirt traps and suitable filters.
Tubes must be correctly installed so that air locks cannot built up.
The assembly can be horizontal or vertical.
Sufficient space should be available to ensure easy accessibility to all screw connections. Take
particular care for providing enough space for remove the tube bundle. You can take the
necessary space dimensions for remove the tube bundle from the sketch. It is possible to remove
the tube bundle from both sides of the device.
. The direction of flow is to be taken from the enclosed sketch and from the datatsheet
Before startup, the device must be completely bled.
Never weld or modify the cooler.
In case of using the device as oilcooler before startup, clean/flush the oil circuit but not the
lubricated points.
Orifice plates must only be installed at the outlet side of the device.
Screw fasteners
To ensure a safe operation and a long service of fastening elements, the screw fastenings should be
only torqued. The table below lists the torque figures for used screws. Through influence of various
factors, the specified values may show a deviation which in individual cases require lower or higher
values.
Connection shell/bonnet
Connection flanges
type
screw/
strength
torque [Nm]
screw/
strength
material
thread
K12
M12 5.6
38
M12 5.6
aluminium
30
M12 8.8
80
red bronze
30
M16 5.6
95
aluminium
75
M16 8.8
200
red bronze
75
M20 5.6
180
cast steel
100
M20 8.8
400
cast steel
300
K20
K25
M16 5.6
M24 5.6
of
torque [Nm]
Type plate
The type plate is at the side of the device and is permanently fixed. You can find a copy of the type
plate in the appendix.
Stand: 23.08.2004
Starting up
At first the apparatus must be filled up with the intended medium, then the entire system must be
checked for leakage. For watercooled
devices use only clean water at the tube side. Before
the actual starting up of the system,
make sure that the cooling medium is circulated.
!
Operating the device without flow of
cooling medium is not permissible.
Only for watercooled units:
If the flow adjustment is carried out by a control, we recommend a oil-sided control, especially when
operating with river or sea water.
Discuss the control of cooling water with our factory, because factors like material and quality of
cooling water are very important to avoid later problems.
The use of additives in the cooling water has to be confirmed through HS-Cooler GmbH.
During the operation, make
sure by suitable means that pre-set parameters for which the
devices are designed are kept.
!
If reserve devices with switchover valves are present, switch these devices periodically on
(all 2-3 days) or load the reserve device daily for some time with the full water volume.
Switching off/standstill of the unit for watercooled units

With a short-term standstill (<4 days) of the unit, the apparatus can remain filled.
When switching off the unit, the water must be removed. In the case of operating the device with sea
water or aggressive water, flush the unit additionally with clean water. The tube bundle should as far
as possible be dried inside with compressed air. Further, if a drainage is not possible, then a flow of
the correct amount of cooling water must be maintained.
Maintenance
Devices of product line K are normally reliable and easy to maintain. However, some periodic
inspections of the device are necessary to provide a safe, continuous operation. Normally inspections
on the tubeside (waterside) predominate. The shellside is less inclined to pollution so that an
inspection can be carried out based on the experience of the operator.
The following inspections should be practiced:
When operating with sea water, sacrificial
anodes are installed in the bonnets/covers.
These should be checked in the initial
phase all 3 months. If the anodes are used
!
up, they must be replaced by new ones.
In the case of excessively fast consumption
of the anodes, water quality and the electrical potential of the system must be checked.
The device should be cleaned at the water side at least once a year. An excessive pollution of the
tubes must by all means be avoided. The bonnets can be removed without depressurerizing the
shell side. The intervals are to be shortened during long ship operation in harbors or in other
polluted waters and depending on the experience of the operator.
At shorter intervals the device must be subject to an externally visual inspection, in order to
identify leakage or other problems early. Through the double O-ring sealing, leakages can be
precisely located and the relevant expenditure can be estimated.
Dismounting
Proceed as follows when dismounting the apparatus:
Lock-up any pipelines
Empty the apparatus at the tube side, if a removal of the tube bundle is necessary, empty also the
shell side.
Remove the pipelines at the tube side.
Remove the bonnets/covers. For this purpose, the screws at the bonnet/casing connection must
be loosened. Between the bonnet/cover there are 4 fixing plates or washers. These must be
Stand: 23.08.2004
replaced at the same side again during re-assembly. The marking on the casing flange must be
here observed.
If you want to dismount without remove the
tube bundle, the bonnet/cover without fixing
plates must be disassembled first in order
to protect the tube bundle against
displacement, before you remove the
fixing plates. This can be done with another
!
set of fixing plates or with similar aids.
Dismounting without remove the tube bundle:
Remove the O-rings from the external groove of the tube plates and secure the tube bundle to the
casing with four screws and the four fixing plates in the middle groove of the tube plates. The tube
side can now be inspected and cleaned mechanically. The shell side can remain under pressure.
Dismounting with remove the tube bundle:
Remove the O-rings from the external groove of the tube plates. At one tube plate, a marking of
the fixed position in relation to the casing is attached. A half of a X is stamped at the front of the
tube plate and the adjacent casing flange. Check the position of the marking. Push the tube
bundle (where appropriate with auxiliary tools) so far sideways until the O-ring of the interior
groove becomes visible. Remove the O-ring from the interior groove. Pull out the tube bundle in
the opposite direction. Remove the tube bundle carefully from the casing without damaging the
fins. As far as possible suspend the
tube bundle with the help of large-surface
transportation straps. The grooves
taking the O-rings must not be damaged. During
dismounting of the tube bundle the
sealing plate and the spring can drop out of the
!
baffle groove. The spring and the
sealing plate have to be installed during assembly
of the bundle by pressing them into the groove whilst the baffle passes the inlet of the shell.
When dismounting vertically fixed devices, make sure in any case that the tube bundle does not
slips down after removal of the fixing plates. We
recommend to provide an additional
set of fixing plates and to start the removal at the side
where no fixing plates are mounted.
There the bundle must be secured first. After
dismounting the second bonnet,
!
the bundle can be removed carefully. While
assembling, only one set of fixing
plates is permittedat the side of the marking.
Assembly
The assembly is carried out in reversed order as dismounting. The following must also be considered:
Generally use new O-rings and clean O-ring grooves.
Note the marking for proper assembly of the tube bundle (X).
Note the marking for correct assembly of the fixing plates (F).
At the side of the tube
bundle there are sealing straps. These should only be replaced
when damaged. When
pushing-in the tube bundle take care that the sealing straps are
not displaced or twisted.
Before assembling the tube bundle, the sealing straps should
!
be greased. You can
use the operating medium. The sealing straps must be
effective along the entire length of the tube bundle.
Insert the sealing plate and the spring into the baffle groove and press down during insertion of the
tube bundle
Lubricate O-rings with suitable O-ring grease.
During insertion of the tube plate into the sealing faces, make sure that the O-rings do not shear.
The bonnets/covers must be set up in parallel onto the tube plate and must be pushed evenly onto
the O-ring; ensure also that the O-ring does not shear.
With two path devices, a path partition must be fitted at the side of the bonnet with the two
connections. At this side, the fixing sheets must also be installed later.
When assembling the two path bonnet, make sure that the path partition is correctly placed.
Then continue as described under 'Operation'.
Cleaning
In the case of only small amount of fouling, the tube side can be mechanically cleaned. Disassemble
the device as described under
'dismounting without remove the tube bundle' and clean with
a suitable nylon brush (do not
use metal brushes) each tube inside, then clean with water.
Never remove stuck deposits or
coarse dirt by force.
!
In the case of stuck deposits,
the tube bundle must be cleaned chemically. This can be
Stand: 23.08.2004
carried out by rinsing the tube in the assembled state or submerging in disassembled state. Such a
cleaning must only be practiced by specialists. Only suitable solvents must be used. To select a
suitable agent, refer to the added part list. Take the materials of the plastic separator strip and O-rings
in the assembled state into consideration. Under 'Contacts' you find some companies offering
respective agents or carrying out a complete cleaning.
Provided that the type designation gets a C at the 11th position (example: KS12-BCN-821C L1000),
then it is a coated tube bundle. To prevent a damage caused by corrosion this bundle is coated on the
inside of the tubes and on the tubesheets. When dismounting the bundle and during cleaning make
sure that the coating will not be damaged or destroyed. Use only nylon cleaning brushes and
approved cleaning agents. If there are any doubts about suitability of an agent, please contact our
service department.
Troubleshooting
Check all temperatures and material flows in accordance with the design data?
Are foreign bodies in pipe or in device causing obstruction?
Is the tube bundle correctly assembled, check marking?
Are the path partition and the fixing plates correctly assembled in the two path bonnet?
Are all pressure rooms vented?
Are tube side or shell side too dirty (too thick deposits)?
Are more than 10% of the tubes plugged?
Leaky tubes!
If the presumption exists that tubes have become leaky, proceed as with 'dismounting without remove
the tube bundle'. The shell side can remain under pressure. After cleaning the tube plates, you can
identify the defective tube by the state of the emerging medium. Lock the leaky tube at both ends with
our Tubelock-Repairset. Alternative you can use a conical copper or aluminium plug or a conical hard
wood plug. The plug must not be pushed too strong since otherwise adjacent rolling connections can
be damaged. You can lock 10% of the tubes at the most without noticeable reduction in performance.
Dismounting the defective tube is not possible.

If it is found during the check for leaky tubes that a rolling connection is leaky, it can be rolled again
with a specific rolling tool. This work however is only to be carried out by specially trained personnel.
Since defects of this type are uncommon, a check of the complete bundle in our factory is
recommended.
Leaky O-ring!
If a leakage is found between bonnet/cover and casing, an O-ring of the tube plate is defective. The
kind of the emerging medium defines at which groove of the tube plate the defect developed. In the
case of a defect on the tube side, proceed as described under 'dismounting without remove the tube
bundle'. In the case of a defect at the shell side, proceed as described under 'dismounting with
withdrawing the tube bundle'. In this case the tube bundle does not need to be removed completely
from the casing. Assemble the O-ring as described in 'Assembly'.
Contacts
Cleaning
Suppliers for cleaning agents:
Ashland Chemicals www.ashchem.com
Henkel Oberflchentechnik- www.henkel.com
Stand: 23.08.2004
Ondeo Nalco www.ondeo-nalco.com
Contractors for complete cleaning

Vecom www.vecom.nl
- Ondeo Nalco www.ondeo-nalco.com
Repair/spare parts
Repairs must only be carried out by specially trained personnel. However we recommend to carry out
any repair in our factory.
You can purchase spare parts directly from us with indicating the sketch and serial number. Please
contact our head offices or our sales office.
Stand: 23.08.2004
Pos.
Quantity
Unit
Description
pc.
Shell
pc.
Tube Bundle
pc.
Waterbox 2 1/2" SAE
KL20-B-002
pc.
Anode 3/8"
KL-1021
pc.
Sealing Screw
DIN 910 - G 1/4" A
Brass
pc.
Sealing Ring
DIN 7603 - A 14 x 18 x 1.5
Copper
pc.
Cover
KL20-B-003
G-CuSn5PbZn
(3.1B)
pc.
Anode 3/8"
KL-1021
pc.
Sealing Screw
DIN 910 - G 1/4" A
Brass
10
pc.
Sealing Ring
DIN 7603 - A 14 x 18 x 1.5
Copper
11
pc.
Fixation Plate
KL20-0-108
Steel galv.
12
pc.
Clamp Bracket
KL20-0-109
Steel
13
pc.
Hex Bolt
ISO 4017 - M16 x 40 - 8.8
Steel galv.
14
pc.
Hex Nut
ISO 4032 - M16 - 8
Steel galv.
15
pc.
Washer
DIN 125 - A 17
Steel galv.
16
pc.
Hex Bolt
ISO 4014 - M16 x 75 - 5.6
Steel galv.
AD-W7 (stamped)
17
pc.
Hex Nut
ISO 4032 - M16 - 5-2
Steel galv.
AD-W7 (stamped)
18
12
pc.
Washer
DIN 125 - A 17
Steel galv.
19
pc.
Type Plate
DRAW
Remark
GS20 - 1
RL20 - C N - 4 2 1
G-CuSn5PbZn
(3.1B)
Aluminium
DATUM
NAME
02.12.99
Garbe
Parts List
NORM
K S 2 0 - BCN - 4 2 1
SYM
REVISION
DATUM
NAME
FILE: Parts List KS20.doc
Sheet
1 of 1
Pos.
Quantity
Unit
Description
KL20 - C - 052
Remark
CuZn38Sn1 F34
AD-W6/2 (3.1B)
CuAl10Fe5Ni5-C
DIN EN 1982 (3.1B)
pc.
Tubesheet
178
pc.
Tube LR = L + 41mm
7.5mm x 0.5mm
CuNi10Fe1Mn F29
AD-W6/2 (3.1B)
L/1.4
pc.
Fin 1.4
KL20-0-105
Aluminium
pc.
O-Ring
KL-1520
NBR
pc.
Sealing Strip
L x 13 x 3
NBR
pc.
Baffle
KL20-0-106
Aluminium
pc.
Water Partition
KL20-0-107
Polypropylen
DRAW
DATE
NAME
04.11.99
Garbe
PARTS LIST
NORM
R L 2 0 - CN - 4 2 1
SYM
REVISION
DATE
NAME
FILE: Parts List RL20.doc
Sheet
1 of 1
Valves
NON RETURN VALVES
RK 49 - RK 76 - RK 86
RK 86A - RK 16A
Installation Instructions 808532-01
Non-Return Valves RK
Important Safety Note
The valve must only be installed by qualified staff.

Qualified staff are those persons who through adequate training in
engineering, the use and application of safety equipment in accordance
with regulations concerning safety systems, and first aid & accident
prevention have achieved a recognised level of competence
appropriate to the installation and commissioning of this device.
Proper Use
The non-return valves RK are automatic-stop check valves used in pipes
to prevent a backflow of fluid within the admissible pressure/
temperature ratings.
Contact the Factory for specific recommendations concerning the
chemical resistance and suitability of the valve material in a given
application.
Danger
The valve is under pressure during operation.

When loosening flanged connections or sealing plugs, hot water,
steam, corrosive fluids or toxic gases may escape. This presents the
risk of severe burns and scalds to the whole body or severe cases of
poisoning.
Installation and maintenance work should only be carried out when the
system is depressurized.
The valve becomes hot or extremely cold during operation. This
presents the risk of severe burns to hands and arms. Installation and
maintenance work should only be carried out at room temperatures.
Sharp edges on internals present a danger of cuts to hands. Always
wear industrial gloves for installation and maintenance work.
Ratings pursuant to article 9 of the PED1)

Fluid
Fluid group
Use
Category
Nominal size DN
CE marking
Type
1)
gas
liquid
yes
yes
yes
yes
Exception pursuant
to article 3.3
II
III
III
32-100 mm
125-200 mm
100-200 mm
no
yes
yes
yes
all
all, RK 49
up to DN 80
RK 86, RK 86A
RK 49
15-25 mm
PED = Pressure Equipment Directive
Description
Non-return valve RK with spiral centering ring (RK 76, RK 49) or selfcentering body. Installation in any position. Exception: Valves without
spring can only be installed in vertical lines with upward flow.
Non-return valve with spiral centering ring
Non-return valve with body centering cams
Non-return valve with self-centering body
Position of guide ribs (horizontal installation)
Installation
TOP
Technical Data
RK 49
DN 15-200
RK 76
DN 15-100
[C]
20 450
[F]
68 842
[barg] 160 114
[psig] 2321 1653
530
986
55
798
RK 86
[C]
[F]
[barg]
[psig]
300
572
31
450
RK 86
RK 16 A [C]
DN 15-100
[F]
[barg]
[psig]
20 100
68 212
49
42
711 609
20 100
550
68 212 1022
49
42
24
711 609
348
DN 15-100
DN 125-200
[C]
[F]
[barg]
[psig]
20 100
68 212
51
46
740 667
350
662
36
522
[C]
[F]
[barg]
[psig]
20 100
68 212
40
40
580 580
350
662
24
348
RK 86 A [C]
DN 15-100
[F]
[barg]
[psig]
RK 86 A [C]
For more information
see data sheets.
DN 125-200
[F]
[barg]
[psig]
20 100
550
68 212 1022
49
42
24
711 609
348
20 100
550
68 212 1022
40
33
22
580 479
319
Name Plate / Marking
Type: RK ...
DN: ...
PN: ...
..........
Type: RK ...
DN: ...
PN: ...
..........
Type: RK ...
DN: ...
PN: ...
..........
Type: RK ...
DN: ...
PN: ...
..........
ZF Padova S.p.A.
Via Penghe, 48
I-35030 Caselle di Selvazzano (PD)
ITALY
Tel. +39-049 8299-311
Fax +39-049 8299-550
www.ZF-Marine.com

00 ZF Man GT 43000 Series

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Maintenance

The manual consists of 11 sections as follows:

MAINTENANCE AND OPERATION MANUAL

AFTER RECEIPT OF EQUIPMENT

DRY MASS (kg)

OIL CHANGE: after first 250 hours of operation and every

Working clutch oil pressure at monitoring

Permitted working oil temperature range

Functional working oil temperature

Water temperature at oil cooler inlet

Engine room temperature range

Water pressure in heat exchanger

5400 Kg NC version / 6400 Kg NR version

Size of filtration element in heat

Temperature thrust bearing

Start 20 bar Falling

Start 19 bar Falling

Stop 26 bar Rising

{ NC without clutchable PTO versions

max difference inlet outlet:

PTO shaft (and PTI shaft)

SAE 2 1/2 flange

Lower half casing

Double oil filter

Connection for O.D. box

Maintenance and Operation Manual

Purpose of this manual:

Instructions within this manual include specific symbols to be carefully observed:

Limitations of liability: end user, customer and

After Receipt of Equipment

After Receipt of Equipment:

After Receipt of Equipment

3.2 UPON RECEIPT OF THE GOODS:

After Receipt of Equipment

3.3 NOTES ON HANDLING AND STORAGE:

Lift the gearbox carefully and without jolts.

After Receipt of Equipment

3.4 CORROSION PREVENTION:

FOLLOWING INSTRUCTIONS MUST BE ADHERED TO!

CORROSION PROTECTION MUST IMMEDIATELY BE RENEWED.

4.1 SAFETY NOTES

5.1 WORKING PRINCIPLES

The gearbox permits the following kinds of function.

Non-Reversing Reduction without clutch for CPP

Non-Reversing Reduction with clutch for CPP

Non-Reversing Reduction with clutch for CPP with PTO

Non-Reversing Reduction without clutch for CPP with PTO

with clutchable PTO 4

with live PTO 5

Layout of a TRI - PTO

Stand-by oil pump

Protect the gearbox against damage, humidity and dirt.

6.2 MOUNTING WORK TO BE PERFORMED

Make sure there are no oil or grease on the cleaned surfaces.

6.2.3 Oil cooler

6.2.4 Monitoring system

6.3. ALIGNMENT WORK TO BE PERFORMED

6.3.1 Radial and axial run-out

6.3.2 Radial and angular misalignment

6.4 FASTENING WORK TO BE PERFORMED

Do not touch any rotating parts.

7.2 PREPARATORY MEASURES

Check if the non return valves are assembled correctly.

7.3 COMMISSIONING ACTIVITIES