ZF KH1200

Project:
GALATA - KH 1200
Gearbox Model ZF W93300 NC + PTO 4
Shipyard SELAH
NB 51
KH Size KH 1200
Order Number AL06041
Maintenance
and Operating
Manual for
Gearbox type ZF W
Date
After Receipt of Equipment
Section 1
Thank you for choosing
A product by Marine Propulsion Systems
PROJECT NAME: Galata
SHIPYARD: Selah
NB: 51
CLASSIFICATION: BV
COSTUMER ORDER NUMBER: AL06041
GEARBOX MODEL: ZF W93300 NC + PTO 4
RATIO: 5,000
SERIAL NUMBER:
PART NUMBER: 3104004009
CPP MODEL: CPP00154
ZF Padova S.p.A.
Via Penghe, 48 – I-35030 Caselle di Selvazzano (PD) – ITALY 3
Tel. +39-049 8299-311 – Fax +39-049 8299-550 – www.ZF-Marine.com
Date
ZF Padova S.p.A.
4 Via Penghe, 48 – I-35030 Caselle di Selvazzano (PD) – ITALY
Date
General Index
The manual consists of 11 sections as follows:
Section 1: TECHNICAL DATA Page 7
Section 2: MAINTENANCE AND OPERATION MANUAL Page 13
Section 3: AFTER RECEIPT OF EQUIPMENT Page 17
Section 4: OPERATING NOTES Page 23
Section 5: WORKING PRINCIPLES Page 27
Section 6: INSTALLATION DESCRIPTION Page 41
Section 7: STARTING OPERATION Page 53
Section 8: EMERGENCY OPERATION Page 73
Section 9: MAINTENANCE Page 79
Section 10: TROUBLESHOOTING REMEDIES Page 91
Section 11: SERVICE CENTERS Page 97
Section 12: APPENDIX Page 103

Appendix 1: Recommended Oils
Appendix 2: Bearing Calculation
Appendix 3: Thermal growth
Appendix 4: Spare parts list
Appendix 5: Torsional Vibration Calculation
Appendix 6: Ortlinghaus discs
Appendix 7: Mahle filters
Appendix 8: Kracht pumps
Appendix 9: Hs cooler
Appendix 10: Gestra valves
Appendix 11: Drawings
ZF Padova S.p.A.
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Remarks
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ZF Padova S.p.A.
Section 1
Date
Technical data
Section 1
Type of Vessel Chemical Tanker
Classification BV
Ice Class 1A
Voltage / Frequency 450 V / 60 Hz
Engine Manufacturer MAK
Engine Type 9M32C
Engine Power 4500 Kw @ 600 r.p.m.
Input Torque 71625,00 N.m.
Engine Rotation CCW
Gearbox Model ZF W93300 NC + PTO 4
Gearbox Part Number 3104004009
Gearbox Ratio 5,000
Offset 980 mm
Bearings PLAIN
Propeller Type KH 1200
Output speed 120 r.p.m.
Secondary PTO-RATING 1100 KW
Secondary PTO-SPEED 1780,42
PTO Ratio 0,337
ZF Padova S.p.A.
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
SERIAL No RATIO
PART LIST No CUSTOMER No DRY MASS (kg)
Pleasure Light Medium Continuous
OIL CLUTCH OIL

OIL TYPE CAPACITY (z) 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 600 dm3
Working clutch oil pressure at monitoring

25 bar Nominal { NR versions
NC with clutchable PTO version
~ 5 bar Nominal { NC Without clutchable PTO versions
(only for nr version)
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 10 bar MAX
Water flow range in heat exchanger

7 ÷ 11,9 m3/h { KS 12 Cooler version
12 ÷ 30 m3/h { KS 20 Cooler version
Basic weight of gearbox without oil 15800 Kg NC version
Size of filtration element in heat
1,5 mm
exchanger aspiration
Roller Bearings { 65°C Nominal

85°C Rising Alarm
Temperature thrust bearing
Slide Bearings { 45°C Nominal
68°C Rising Alarm
3 bar Nominal
Luboil pressure < 0,4 bar Alarm
< 0,21 bar Engine Stop
Start 20 bar Falling { NR versions

Stand By-Pump Stop 26 bar Rising { NC with clutchable PTO versions
(versions with Roller Bearings)
Stop 3,5 bar Rising { NC without clutchable PTO versions
Start 0,8 bar Falling
{
Start 19 bar Falling
Start 0,8 bar (Lube) Falling NR versions
Stand By-Pump Stop 26 bar Rising NC with clutchable PTO versions

(versions with Plain Bearings) Stop 3,5 bar (Lube) Rising
Start 0,8 bar Falling

Stop 3,5 bar Rising { NC without clutchable PTO versions
max difference inlet outlet:
Filter contaminations 1,2 bar (Roller Bearings)
3,5 bar (Slide Bearings)
ZF Padova S.p.A.
Date
Technical data
Section 1
10 9
9
23 12C 12C
13
1 12B
14 22
16
17 9
4
19 21
17 15
20
2
7 12A 11
3
7
8
6
18 6
5 5
POS. DESCRIPTION POS. DESCRIPTION
1 PTO 13 Control unit (for PTI)
2 Oil pump 14 Control box
3 Output shaft 15 Input shaft
4 Monitoring unit 16 PTO shaft (and PTI shaft)
5 Drain plugs 17 Check valve

SAE 2 1/2 flange
6 Lower half casing 18
(connection for standby pump)
7 Central section 19 Double oil filter
8 Oil dipstick 20 Drip tray (optional)
9 Breather 21 Upper section
10 Oil cooler 22 Control valve
11 Connection for O.D. box 23 Thermometer
12 A-B-C Inspection covers
ZF Padova S.p.A.
Section 2
Maintenance and Date
Operation Manual
Section 2
Maintenance and Operation Manual
Purpose of this manual:
The following manual contains the information required for installers and users of ZF Ma-
rine Propulsion System’s equipment. Users may include ship’s 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 ship’s maintenance. The manual also contains spare parts
ordering information.
It is appreciated by ZF Marine Propulsion Systems that regional laws, insurance provi-
sions, shipping company standards and shipyard regulations as well as ship’s design spe-
cific considerations, etc, may result in the necessity to modify, or change the technology,
practices and procedures described herein. Please be advised, however, that any modi-
fication, or change of technology, practices and/or procedures may invalidate the manu-
facturer 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.
Maintenance and Date
Operation Manual
Section 2
Limitations of liability: end user, customer and

manufacturer responsibility:
Installation and Operation of the equipment, including unauthorized modifications, out-

side 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 proce-

dures 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 re-
fresher 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 Cen-
ters, (SSO’s), at strategic locations throughout the world so that our customers receive
field support close to their geographical location. Repair work carried out at ZF SSO’s 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
ZF Padova S.p.A.
Section 3
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 mate-
rial upon delivery and make sure that all items have been delivered as shown on the trans-
port documents no item has suffered any damage during transportation and handling all
parts are free of corrosion.
ZF Padova S.p.A.
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/bench-
es. 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 condi-
tions 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 depart-
ment.
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.
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 in-
stallation 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.
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.
ZF Padova S.p.A.
Section 4
Date
Operating notes
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 speci-
fied 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.
Date
Operating notes
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 ar-
rows, 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.
ZF Padova S.p.A.
Section 5
Date
Working principles
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.
Date
Working principles
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 Single reduction

gearbox without clutch 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 rota-
tion 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.
ZF Padova S.p.A.
Date
Working principles
Section 5
Non-Reversing Reduction without clutch for CPP
Non-Reversing Reduction with clutch for CPP
ZF Padova S.p.A.
Date
Working principles
Section 5
Non-Reversing Reduction with clutch for CPP with PTO
ZF Padova S.p.A.
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Working principles
Section 5
Non-Reversing Reduction without clutch for CPP with PTO
with clutchable PTO 4 with live PTO 5
ZF Padova S.p.A.
Date
Working principles
Section 5
Layout of a BI - PTO
D2
D1
A - INPUT SHAFT
B - OUTPUT SHAFT
C - CLUTCH
D1/D2 - P.T.O. SHAFTS
Layout of a TRI - PTO
C2
D2
D1
A
D3
C3
B
A - INPUT SHAFT
B - OUTPUT SHAFT
C - INPUT SHAFTS CLUTCHS
D1/D2/D3-P.T.O. SHAFTS
ZF Padova S.p.A.
Date
Working principles
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 ves-
sel.
On this level of the lower parting line the output shaft with the propeller trust bearing is lo-
cated 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.
Date
Working principles
Section 5
On the gear systems the single helical involute tooth systems are case hardened and grind-
ed.
Load-dependent tooth flank correction, combined with high tooth system quality, ensure qui-
et, 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.
ZF Padova S.p.A.
Date
Working principles
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 pro-
peller thrust and transmits it to the ship’s 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.
Date
Working principles
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 speci-
fied 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
ZF Padova S.p.A.
Date
Working principles
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 direc-
tional 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 neces-
sary, 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.
Date
Working principles
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.
ZF Padova S.p.A.
Section 6
Date
Installation Description
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
ship’s 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.
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.
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.
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 fire-
proof 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.
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.
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 ship’s 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 shaft’s 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.
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.
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 ship’s foundation.
Align the motor in relation to the gearbox input shaft.
Subsequently, mount the coupling between motor and gearbox.
For motor alignment observe the manufacturer’s 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.
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 ship’s 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 ship’s foundation
in line with the shipyard’s 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.
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.
ZF Padova S.p.A.
Section 7
Date
Starting Operation
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 contami-
nated 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.
Date
Starting Operation
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 mainte-
nance 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 pres-
sure.
Top both oil pump up with oil through the connection located upstream of each of the intake noz-
zles to avoid the pumps running dry when first taken into service.
ZF Padova S.p.A.
Date
Starting Operation
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 at-
tached 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.
Date
Starting Operation
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. 45°C 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 en-
gine 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.
ZF Padova S.p.A.
Date
Starting Operation
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.
Date
Starting Operation
Section 7
7.4 SHUTDOWN ACTIVITIES
When the transmission system is shut down for a maximum period of one week no special meas-
ures 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.
ZF Padova S.p.A.
Date
ZF Commissioning Report
Section 7
ZF Commissioning Report Gearbox
1. GENERAL DATA
Gear Type
Model: ____________________________________________
Serial/n°: ____________________________________________
Reduction Ratio: ____________________________________________
Sense of Rotation Output: ____________________________________________
Sense of Rotation PTO: ____________________________________________
Part List No.( on name plate): ____________________________________________
Engine Manufacturer
Engine Type: ____________________________________________
Vessel Type: ____________________________________________
Vessel Name: ____________________________________________
IMO Number: ____________________________________________
Shipyard and NB No: ____________________________________________
Comissioning Date: ____________________________________________
ZF Padova S.p.A.
Date
Section 7
2. VISUAL INSPECTION
Are there any visible damages 䡺 YES 䡺 NO

External condition of the gearbox: 䡺 Good 䡺 Defects ________________
Are there any parts missing or exchanged by
non genuine spare parts 䡺 YES 䡺 NO
2.1 Remarks
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
ZF Padova S.p.A.
Date
Section 7
3. INSTALLATION
3.1 Alingment Engine Gearbox
Recomendation:
Measured:
3.2 Alingment Gearbox- Shaft Alternator
Recomendation:
Measured:
3.3 Aligment Gearbox- Second PTO
Recomendation:
Measured:
3.4 Installation of the Gearbox
Chock fast: ____________________________________________

Resilient: ____________________________________________
Front Stoppers?: 䡺 YES 䡺 NO

Side Stoppers?: 䡺 YES 䡺 NO
Fitting bolts?: 䡺 YES 䡺 NO
3.5 Installation of the engine:
Chockfast: ____________________________________________
Resilient: ____________________________________________
ZF Padova S.p.A.
Date
Section 7
4. COOLING WATER SYSTEM
Heat exchanger attached to the gearbox?: 䡺 YES 䡺 NO

In case heat exchanger not supplied by ZF
Manufacturer: ___________________________________________
Type: ___________________________________________
Cooling water pipes connected with compensators?: 䡺 YES 䡺 NO
4.1 Remarks:
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
ZF Padova S.p.A.
Date
Section 7
5. LUBRICATON SYSTEM
5.1 Standby Pump

Are the pipes of the stand-by pump connected by
compensators
䡺 YES 䡺 NO
Height from suction flange bottom of gearbox to
pump suction Flange: ___________________________________________
___________________________________________
5.2 Oil Filling:

Lube oil
manufacturer:
______________________________________________________________________
Type / S.A.E.:
______________________________________________________________________
Filling litres:
______________________________________________________________________
______________________________________________________________________
5.3
Were the pipes acidified and cleaned: 䡺 YES 䡺 NO
Was the hydraulic system flushed with the standby 䡺 YES 䡺 NO
pump at least one hour?
5.4 Operation with standby pump

Clutch oil pressure:
Lub oil pressure:
Leakage?: 䡺 YES 䡺 NO
5.5 Remarks
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
ZF Padova S.p.A.
Date
Section 7
6. CONTROL / MONITORING
6.1 Electrical, supply voltage ________________
6.2 Monitoring:
Function checked according to monitoring schema / List of measuring points
Alarm “ Oil pressure too low” ________________ bars

䡺 O.K. 䡺 Not applicable
Automatic start of stand-by pump ____________ bars
“Emergency stop of main engine” ____________ bars
Alarm “Oil temperature too high” ____________ °C
Prelubricating / stand-by pump switched off automati-
cally when minimum speed of engine is exceeded?
Alarm suppressed during engagement of clutch to
t=10,0 sec.
Oil level monitoring, function, time delay? (15/30sec.)
Main clutch oil pressure ahead ______________ bars
Main clutch oil pressure astern ______________ bars
(only reversable gearboxes) 䡺 O.K. 䡺 Not applicable
6.3 Remarks
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
ZF Padova S.p.A.
Date
Section 7
7. RUN AT SEA TRIALS
7.1 Oil Temperature ____________ °C
Thrust Bearing Temperature ____________ °C
Clutch oil pressure ____________ bars.
Lube oil pressure ____________ bars.
7.2 Oil leakage?
䡺 YES 䡺 NO
7.3 After turning off the engine open inspection cover:
Internal condition of the gearbox:

Good:
Corroded:
Defects:
7.4 Remarks
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
Sign:
__________________________ __________________________ __________________________

Shypyard representative Owner representative ZF Engineer
ZF Padova S.p.A.
Date
Section 7
Electronic System
2.1 HARBOUR ACCEPTANCE TEST(HAT)PROCEDURE
Ser. Test devices,

No. Activity Description of step
auxiliaries, remarks
1.
Check of locations - Visual inspection for completeness Documentation
1.1 Mechanical and

electrical test
Visual - mechanical structure
devices
inspection of the - electrical connection work
Automatic
installation - Cut-off / interrupt all fuse links.
circuit breakers,
fuses etc.
1.2 - Check the correctness of structure of the plant components.
Checking the plant Serial Nos.,
- Check the correctness of arrangement(topology,block diagram).
components order Nos.
- Check the plant components for any damage.
2 Preparation of
Documentation
feeding
2.1 Disconnecting the
- Disconnect all bus connections (unplugthebus).
bus connections,di
- Disconnect the I/O plug of external interfaces(on the bus
sconnecting
modules).
theinterfaces (data)
2.2 Disconnecting the
- Disconnect the power supply(power supply for lighting, supply
power feed of the
voltage).
busstations
2.3
Checking the - Check all feed systems(power supply for lighting, supply
power supply voltage).
2.3.1 - Disconnect the main feed + emergency feed.

Checking the - Switch ON for a short moment.
power supply for - Check the voltage/polarity of the main feed. Multimeter
the central unit - Check the voltage/polarity of the emergency feed.
- Connectthe wires.
2.3.2 - Disconnect the feedings (lighting, supply).
Checking the
- Switch ON for a short moment.
power supply for Multimeter
- Check the voltage/polarity.
each bus station
- Connect the wires.
2.3.3 Checking the bus
Take into account
connections and
- Measure the voltage on all terminals. also any alternating
interfaces (data) for
voltages.
external feed
3 Starting in the
Power supply for central unit and
all bus stations following the
topology.
3.1 - Switch ON the main and emergency feed.
- Switch ON the automatic circuit breaker. Keep an eye on the
Power supply /
start of the stored-programcontrol system (SPS).
Central station
- Connect again the bus to the central unit, fit on the data inter-
faces.
ZF Padova S.p.A.
Date
Section 7
Ser. Test devices,

3.2 a) Switch ON the power for the bus station,evaluate the correct Follow the
Power supply /
system start. topology. Observe
Bus stations
b) Establish again the bus connections,fit on the data interfaces. the functions.
3.3 Power supply for
other plant - Switch ON the supply voltage. Functional check.
components
3.4 - Check the communication of the bus modules. On-line analysis of
Checking the - Check the status notices of the bus modules.Perform a visual software.Pay
system start inspection of the function of all other plant components used attention to
(signal lamps, transmitters, indicators, ...). thealarm notices.
4 So far as
checks can be
Functional test
done without any
Part 1
diverse signal
adaptation.
4.1 - Test the lamps for all operating desks.
Checking the - Check the dimmer.
If any.
lighting system. - Check the energization of external signalling devices.
- Identify the current operating status.
5 Checking the input
signals
5.1 - Check the harmonization / Control lever.
Checking /
- Check other analogue inputs (e.g. speed potentiometers, limit
harmonization of Refer to parameter
potentiometers, ...)
the ANALOGUE listing.
- Check the harmonization of the pitch.
inputs
Section 8
- Check the harmonization of the analogue inputs of main engine
5.2 So far as it is
Checking the purposeful, use
Push buttons, switches,operating lever etc.(all operating desks).
DIGITAL inputs here the
touchscreen.
6
Checking the
output signals
6.1 Checking /
harmonization of
- Check the signal output to the propeller / engine.
the ANALOGUE
outputs
6.2
Checking the
-Signal lamps, indicators etc.
DIGITAL outputs
7
Functional test
Part 2
7.1 - Choose the operating desks concerned. Refer to the

Change-
- Change over between these operating desks. functional
overbetween the
- Check the take-over conditions. description for the
operating desks
- Check the correctness of energization of the control and signal lamps. project.
7.2 Checking the Refer to the
- Check the change-over operation.
operating functional de-
- Check the blocking systems.
modes;combinator scription for the
- Check the analogue signal output to the engine, propeller,main
mode,constant- project;indication
switch board
speedmode by signal lamps
ZF Padova S.p.A.
Date
Section 7
Ser. Test devices,

7.3 - Change over between the programs offered (e.g. free running,
Checking the
manoeuvre, emergency). Refer to the
change-
- Check the take-over conditions. functional
overbetween the
- Check the correctness of energization of the control and signal description for the
acceleration
lamps. project.
programs
- Check the ANALOGUE signal output.
7.4 Checking the
function „Load - Check the SLOW DOWN and SHUT DOWN functions.
controller“
7.5 Refer to the
Checking the
- Adapt the pitch controller to the proportionaldirectional control functional
function
valve (control edge adjustment,amplification, dead zone) description for the
“Pitchcontroller”
project.
7.6 - Check the start blocking systems. Refer to the
Checking the
- Check the start process. functional
function”Automatic
- Check the stopping process. description for
Start/Stop”
- Check the deceleration times. the project.
7.7 Refer to the
Checking the
functional
function - Check the proper function.
description forthe
“Chief-Limitation”
project.
7.8 Change-over to - Check the proper function.
Allcontrol desks.
theback-upsystem - Reset to automatic mode.
8 - Check for individual errors.
- (SPS Back-up battery,local extensions,decentralized
Error analysis via
extensions,I/Oconfigurations, short
Checking the display,analysis
- Circuit analysis(digital output modules),speed set
erroridentification via LED or signal
value,pitchset value
lamps
- Check the cumulative error indication
- (Identificationvia signalling devices,outputof cumulative errors)
9
Demonstrationand
- Demonstration for classification societies
handing-over
ZF Padova S.p.A.
Date
Section 7
2.2 SEA ACCEPTANCE TEST (SAT) PROCEDURE
Ser. Test devices,

1. Functional check
of the lighting
system
1.1 - Perform a lamp test on all operating desks.
Checkingthe - Check the dimmer.
If any.
lighting system - Check the energization of external signalling devices. Identify
the current operating status.
2 Functional check
of the operation
2.1 -Choose the operating desks concerned.
Refer to the
Change- -Change over between these operating desks.
functional
overbetween the -Check the take-over conditions.
description for the
operating desks -Check the correctness of energization of the control and signal
project.
lamps.
2.2 Checking the Refer to the
operating modes; - Check the change-over operation. functional
combinator mode, - Check the blocking systems. description forthe
constant-speed- - Check the ANALOGUE signal output. project; indication
mode by signal lamps.
2.2.1 Refer to the
Checking the listshowing the
combinator/ relationship
- Check the tables for the relationship between pitch and speed
constant-speed- between control
mode lever position /
speed / pitch
2.3 Checking the load To be done in
- Check all control times of the accelerationprograms (conformity
and unload times / consultation with
with the engine manufacturer’s specification)
acceleration the engine
- If necessary, change these parameters.
programs manufacturer.
2.4 Checking the To be done also
- Check the SLOW DOWN and SHUT DOWNfunctions.
function under full-load
- Check the filling limits of load control.
„Load controller” conditions.
2.5 Refer to the
Checking the
- Check the proper operation of the pitch controller (control edge functional
function „Pitch
adjustment,amplification,dead zone) description for the
controller“
project.
2.6 Checking the - Check the start blocking systems. Refer to the
function - Check the start process. functional
„Automatic Start/ - Check the stopping process. description for the
Stop” - Check the deceleration times. project; if any.
2.7 Refer to the
Checking the
functional
function - Check the function and maximum value of limitation.
description for the
“Chieflimitation”
project.
2.8 Error analysis via
Change-over to - Check the proper operation. display,analysis
back-up system - Reset to automatic mode. via LED or signal
lamps.
3
Demonstrationand - Demonstration and handing-over to classification societies and
handing-over owners.
ZF Padova S.p.A.
Date
Section 7
Remarks
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
ZF Padova S.p.A.
Section 8
Date
Emergency Operation
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 me-
chanical system.
The operation must be carried out with the engine stopped.
ZF Padova S.p.A.
Date
Emergency Operation
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.
ZF Padova S.p.A.
Date
Emergency Operation
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 us-
ing 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 posi-
tions.
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.
Date
Emergency Operation
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 op-
erating 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 fric-
tion, 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 PTO’swith own clutch
can be caused to turn unexpectedly, e.g. by running machines on board (vibrations).
ZF Padova S.p.A.
Section 9
Date
Maintenance
Section 9
Maintenance Schedule
MAINTENANCE OPERATIONS
A1A
A1B
A5
A4
A3
A2
Z1
✓ ✓ ✓ 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.
Date
Maintenance
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 100÷250 12 months
Necessary measures for protection against corrosion afther a long period out of use
Maintenance Level Procedure Period out of use

at end of operating
K1 12 months
period
at end of operating
K2 36 months
period
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.
ZF Padova S.p.A.
Date
Maintenance
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 gear-
box 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 speci-
fied type.
ZF Padova S.p.A.
Date
Maintenance
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. 24 below) and extract the oil level dipstick (pos. 8 below).
Drain the lubrication oil by removing the filler 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).
10 9
9
23 12C 12C
13
1 12B
14 22
16
17 9
4
19 21
17 15
20
2
7 12A 11
3
7
8
6
18 24 6
5 5
POS. DESCRIPTION POS. DESCRIPTION

1 PTO 13 Control unit (for PTI)
2 Oil pump 14 Control box
3 Output shaft 15 Input shaft
4 Monitoring unit 16 PTO shaft (and PTI shaft)
5 DRAIN PLUGS 17 Check valve
6 Lower half casing 18 SAE 2 1/2 flange (connection for standby pump)
7 Central section 19 Double oil filter
8 OIL DIPSTICK 20 Drip tray (optional)
9 Breather 21 Upper section
10 Oil cooler 22 Control valve
11 Connection for O.D. box 23 Thermometer
12 A-B-C Inspection covers 24 Filler Plug
ZF Padova S.p.A.
Date
Maintenance
Section 9
9.4 CHANGING THE OIL FILTER
Note: The contamination indicator monitors the filter side during operation, as shown by the posi-
tion 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 filter’s 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 plas-
tic 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 1⁄4 and 1⁄2 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 equali-
sation lever again.
ZF Padova S.p.A.
Date
Maintenance
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 exces-
sive 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 contami-
nated 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 iden-
tify 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.
ZF Padova S.p.A.
Date
Maintenance
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.
Date
Maintenance
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 proce-
dure 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 exclu-
sively 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 “Con-
tacts” 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 à “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 obstruc-
tion.
• 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 “disas-
sembly 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
ZF Padova S.p.A.
Date
Maintenance
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 O-
rings 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.
Date
Maintenance
Section 9
Remarks
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
ZF Padova S.p.A.
Section 10
Date
Troubleshooting Remedies
Section 10
10.1 Possible faults
MALFUNCTIONS CAUSES REMEDY
Overheating Oil level is too high Correct oil level
Lubricating oil pressure too low Re-set operating oil pressure to the lowest
(insufficiently cooled oil) permitted value
Gearbox is overloaded Reduce input power
Operating oil pressure is too low Regulate operating pressure

(clutch is slipping) (see 2-stage valve)
Excessive pump pressure Clean the filter
Oil does not flow back from the outer Install end covers or seal covers in such a way
bearing sides 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.
Date
Section 10
Lack of oil pressure 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
Oil leakage 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 Seal with new compound and tighten all bolts
sealed
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
Gearbox noise Idle speed is within a critical range Increase idling speed
Gearbox runs within the critical speed Avoid running the gearbox continuously in the
range. critical range
(The noise is not to be observed
throughout the whole speed range)
Input flange loose Tighten the flange or replace when damaged
The oil level is too low Correct oil level

(Suction noise of the pump)
Suction pipe not tight. Tighten all fittings on the suction line
(Pump sucks in air)
Filter choked Clean filter

(Excessive pump pressure)
Pump drive not in order. Repair damaged parts, or replace

Gearwheel damaged or loose
Extreme misalignment between Re-align the whole installation

engine and gearbox
Gearbox bearings damaged Renew damaged bearings
Gear teeth damaged by foreign Grind damaged areas.

matters If necessary, replace the gear wheels
The gear rims loosened by Re-tighten the rims

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

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

side of the gearbox
ZF Padova S.p.A.
Date
Section 10
The propeller does The vessel is still moving Wait until it is at a complete standstill
not stop turning in
“Neutral” The propeller is being driven by a Wait until it is at a complete standstill
current
Gearbox controller is not properly in Adjust the remote control

the “stop” position
Defective gearbox controller Replace gearbox controller

(Uncontrolled oil to one clutch)
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 The idling speed is too low Increase the idling speed
during reversing
The operating pressure is too high, Reduce the operating pressure to normal
When switching therefore, engagement is too quick value
over, the engine
threatens to stall, The gearbox controller is defective
at this manoeuvre (uncontrolled oil flow to one clutch) Replace gearbox controller
the engine must
be “caught” by fuel Clutch plates are damaged Replace damaged clutch plates
admission so that the
power taken from The splines of the clutch are Re-work the splines or renew the parts (check
the propeller will not damaged for critical speed range)
be larger than the
engine power at this The release springs do not work Clean the clutch.
moment. Replace the springs if necessary
Piston of the clutch is jammed, Renew damaged seals

seals are damaged
ZF Padova S.p.A.
Section 11
Date
Service Centres
Section 11
Service Centres
AUSTRALIA ZF AUSTRALIA PACIFIC PTY LTD FINNPARTS OY

14 Lidco St., Arndell Park, NSW 2148 Lehtisaarentie 1
AUSTRALIA FIN-00340 Helsinki
Tel. +61 (0)2 9679 5555 FINLAND
Fax +61 (0)2 9679 5500 Tel. +358 (0)9 480 822
E-mail: mailbox@zf.com.au Fax +358 (0)9 481 474
www.zf.com.au E-mail: fparts@saunalahti.fi
BRAZIL ZF DO BRASIL S.A. ** FRANCE ZF FRANCE S.a.r.l.

Avenida Conde Zeppelin, 1935
Z.I.
CEP 18103-000 Sorocaba-SP
BRAZIL 3-11 Rue Henri Poincaré
Tel. +55 (0)15 235 2389 F-92 167 Antony Cédex
Fax +55 (0)15 235 2233 FRANCE
Tel. +33 (0)1 4096 4265
Fax +33 (0)1 4096 4285
CHILE ZF DELEGACION E-mail: raymond.gouge@zf.com
ARGENTINA/CHILE
Rafael Correa, 1268. Vitacura ZF Masson S.A **
Santiago de Chile
5, Rue Henri Cavallier
CHILE
Tel. +56-2-2128481 F - 89100 Saint Denis les Sens
Fax +56-2-2128481 FRANCE
E-mail: g.rogers@terra.cl Tel. +33 (0)386 95 6262
Fax +33 (0)386 95 1378
CHINA ZF MARINE SHANGHAI

Room 2504, Jiangnan Building GERMANY ZF MARINE GmbH **
No 600 Luban Road ZF Hurth Marine Rep.
Shanghai 200023 Zamdorferstrasse 90
P.R. CHINA D-81677 München
Tel. +86 (0)21 6301 4338 GERMANY
Fax +86 (0)21 6301 6449 Tel. +49 (0)89 930094 63/64
E-mail: zftang@shanghai.cngb.com Fax +49 (0)89 930094 21
E-mail: guenther.koeppel@zf.com
FOILBORN ENTERPRISE Ltd.
Unit A8-9, 13/F PIENING PROPELLER
Veristrong Ind. Ctr Otto Piening GmbH
34 - 36 Au Pui Wan. St. Am Altendeich 83
Fo-tan, Shatin D-25348 Glückstadt
N.T. Hong Kong GERMANY
Tel. +852 (0)2 687 2988 Tel. +49 4124 9168 12
Fax +852 (0)2 687 1996 Fax +49 4124 3716
E-mail: foilborn@netvigator.com E-mail: pein@piening-propeller.de
CYPRUS CHAR. PILAKOUTAS Ltd. ** ZF MARINE GmbH ***

P.O. Box 1168, 7 Larnaca Road Ehlersstr. 50
D-88046 Friedrichshafen
1503 Nicosia
GERMANY
CYPRUS
Tel. +49 7541 77-2207
Tel. +357 (0)2 349572
Fax +49 7541 77-4222
Fax +357 (0)2 349952
E-mail: industrial@charpilakoutas.com.cy
SCHIFFSDIESELTECHNIK KIEL
DENMARK ZF DANMARK ApS Grasweg 26 b
D-24118 Kiel
Hesselager 21 - P.O. Box 97
GERMANY
DK-2600 Broenby
Tel. +49 (0)431 542029
DENMARK
Fax +49 (0)431 542382
Tel. +45 (0)43 436243
E-mail: info@sdt-kiel.de
Fax +45 (0)43 432643
E-mail: zfdk@zf-group.dk
GREECE TEKMAR Ltd
ESTONIA BALTIC MARINE Group AS 15 Ethn. Makarion Str.
GR-185 47 Piraeus
Maleva 1 GREECE
11711 Tallinn - ESTONIA Tel. +30 (0)1 4820814
Tel. +372 (0)68 33300 Fax +30 (0)1 4811803
Fax +372 (0)68 33301 E-mail: tekmar@hol.gr
E-mail: bm@bm.ee
EURODIESEL K. &
FINLAND ATOY OY E. MALERDOS CO.
9 Papazoglou Str.
Maleva 1 GR-185 40 Piraeus
PO Box 137, Lauttasaarentie 54
GREECE
FIN-00200 Helsinki
Tel. +30 (0)210 4179693
FINLAND
Tel. +358 (0)9 6827 1 Fax +30 (0)210 4175441
Fax +358 (0)9 6827 305 E-mail: malerdos@otenet.gr
E-mail: zf@atoy.fi
ZF Padova S.p.A.
Date
Service Centres
Section 11
GREECE ARIEXPO Engineering S. A. MALAYSIA AJENSI TULEN SDN. Bhd.

68, Alimou Avenue 35 A Jalan Anggerek 36
GR-17455 Alimos (Athens) Taman Johor Jaya
GREECE 81100 Johor Bahru
Tel. +30 (0)10 9843863 Johor, MALAYSIA
Fax +30 (0)10 9811237 Tel. +60 (0)7 354 7755
E-mail: ariexpo@tee.gr Fax +60 (0)7 354 7757
E-mail: atulen@po.jaring.my
MARITES LIMITED
17, Solomou Str MALTA OCEANS
GR-166 74 Glyfada 9, Main Street
GREECE ZRQ 03 Zurrieq
Tel. +30 (0)210 8948132 MALTA
Fax +30 (0)210 8982934 Tel. +356 (0)21 682244
E-mail: marites@ath.forthnet.gr Fax +356 (0)21 641223
E-mail: mylake@maltanet.net
INDIA LOURENCO MARINE
G-20, LIma Residency Fatorda, MEXICO ZF DELEGACION MEXICO
Margao, GOA- 403 602
Real del Castillo, 48. Fraccion Chapultepec
INDIA
22870 Ensenada, Baja California
Tel. +91 832 2743468
MEXICO
Fax +91 832 2743450
Tel. +52-61-07 37 38
E-mail: vcturbo@goatelecom.com
Fax +52-61-78 12 28
E-mail: boisson@telnor.net
IRAN ZF Iran S.S.K.
ZF Iran S.S.K. NETHERLANDS ADS van STIGT
P.O. Box 15875-4166
Avelingen - West 30
Km14 Karaj special Rd.
NL - 4202 MS Gorinchem
Iran Khodro Blvd
THE NETHERLANDS
20 Metri Zamyad ST.
Tel. +31 (0)183 650000
Tehran 13861
Fax +31 (0)183 650001
IRAN
E-mail: info@vanstigt.nl
Tel. +98 (0) 2657 62790
Fax +98 (0) 2657 62791
E-mail: karl-heinz.breil@zf-iran.com NORWAY ZF NORGE AS
Casper Storms Vei 19
ISRAEL NIMDA N-0664 Oslo
NORWAY
Lev Pesach Street - North Ind. Zone
Tel. +47 (0)22 720 575
71293 Lod
Fax +47 (0)22 720 902
ISRAEL
E-mail: karl.baumgart@zf-group.no
Tel. + 972 (0)8 978 1111
Fax + 972 (0)8 978 1137
PERU ZF DELEGACION PERU
ITALY ZF PADOVA S.p.A. * Las Lilas, 120. La Molina
12 Lima
ZF MARINE
PERU
Via Penghe, 48
Tel. +51 1 3495050
I-35030 Caselle di Selvazzano (PD)
E-mail: pgorbegoso@perusat.net.pe
ITALY
Tel. +39 049 8299 311
Fax +39 049 8299 550 POLAND MARCO MOTORS
ul. Lady 2
ZF HURTH MARINE S.p.A. ** PL-71-605 Szczecin, Warsaw
POLAND
Via S. Andrea, 16
Tel. +48 (0)91 4500552
I-38062 Arco (TN)
Fax +48 (0)91 223942
ITALY
Tel. +39 0464 580555
Fax +39 0464 580544 RUSSIA ZF MARINE RUSSIA
Suite 313, 71 ulitsa Marata
ZF ITALIA S.r.l. St. Petersburg 191119
RUSSIA
Via Donizetti, 11
Tel. +7 (0)812 324 54 72
I-20090 Assago (MI)
Fax +7 (0)812 140 18 15
ITALY
E-mail: alexander.lyshkov@zf.sp.ru
Tel. +39 02 4884 2778
Fax +39 02 4884 3260
SINGAPORE ZF SOUTH EAST ASIA Pte.
ZF TRIMAX S.r.l. 11 Tuas Drive 1
Singapore 638678
Via Provinciale, 73
Rep. of SINGAPORE
I-23841 Annone Brianza (LC)
Tel. +65 (0)8 610177
ITALY
Fax +65 (0)8 619173
Tel. +39 0341 575306
E-mail: zf_sea@zf-group.com.sg
Fax +39 0341 260105
JAPAN ZF MARINE JAPAN Co. Ltd. SOUTH AFRICA ZF of SOUTH AFRICA Pty. Ltd.
P.O. BOX 2098,
Fujikoshi Building. 1 - 10 - 11
Kempton Park 1620
Iriya Taito-ku
Rep. of SOUTH AFRICA
Tokyo 110-0013
Tel. +27 (0)11 457 0000
JAPAN
Fax +27 (0)11 453 7506
Tel. +81 (0)3 5808 4521
E-mail: pierre@zfsa.co.za
Fax +81 (0)3 5808 4531
E-mail: y_ikeda@zf-marine.co.jp
SPAIN ZF ESPAÑA, S.A.
KOREA ZF KOREA CO. Ltd. Avenida Fuentemar, 11
E-28820 Coslada, Madrid
422-2 Chongchon-dong
SPAIN
Bupyong-Gu, Inchon, Seoul 403-032
Tel. +34 (0)91 485 2698
Rep. of KOREA
Fax +34 (0)91 485 0036
Tel. +82 (0)32 505 1530
E-mail: Oliver.Baumgarten@zf.com
Fax +82 (0)32 505 1514
E-mail: chun.bs@zf-group.co.kr
ZF Padova S.p.A.
Date
Service Centres
Section 11
SWEDEN KG KNUTSSON AB ZF INDUSTRIES INC.

Box 48 054, Ruskvädersgatan 10 ZF MARINE GULF COAST FACILITY
SE-41822 Göteborg 161, James Drive West, Suite 120
SWEDEN St. Rose, LA 70087
Tel. +46 (0)31 648800 U.S.A.
Fax +46 (0)31 537928 Tel. +1 504 443 0501
E-mail: bo.hansson@kgk.se Fax +1 504 443 0504
Email: Info.ZFMarineNewOrleans@zf.com
TAIWAN ZF-FASTER PROPULSION
SYSTEM Co.Ltd.(2) ZF INDUSTRIES INC:
17, Ta Yu 1st Ta Fa Industrial District ZF MARINE WEST COAST BRANCH
Ta Liao Hsiang - Kaohsiung Hsien 1095 Andover Park East,
TAIWAN R.O.C. Seattle, WA 98188
Tel. +886 7 787 1831 U.S.A.
Fax. +886 7 787 1833 Tel. +1 206 574 0375
Fax +1 206 574 0868
Info.ZFMarineWashington@zf.com
THAILAND ZF THAILAND CO. LTD
159/33 Soi Vipavadee 64
Vipavadee-Rangsit Road, Laksi
ZFI Marine Great Lakes Branch
Bangkok 10210, Thailand 1452 Mid-Valley Drive (HWY 41)
Tel. +66 2 521 6520 2 De Pere, Wisconsin 54115, USA
Fax +66 2 521 6523 Tel. +1 920 336-9522
E-mail: reungpoj@zf-thai.co.th Fax +1 920 336-5573
Email: Info.ZFMarineGreenbay@zf.com
TURKEY NIVEKO Makina Ticaret Limited ZF Mathers LLC(1)

Takkeci Sokak No. 3 12125 Harbour Reach Drive
TR-80820 Arnavutköy - Istanbul Building C, Suite 100
TURKEY Mukilteo, WA 98275
Tel. +90 (0)212 287 2780 USA
Fax +90 (0)212 287 6571 Tel. +1 360 757-6265
E-mail: service@niveko.com Fax +1 360 757-2500
UNITED KINGDOM ZF GREAT BRITAIN Ltd. VENEZUELA Sistemas de propulsion

Abbeyfield Road, Lenton Avda 67 A, entre 149 B y 150
Nottingham NG7 2SX 2da Etapa Zona Industrial
UNITED KINGDOM Maracaibo
Tel. +44 (0)115 935 5473 Maracaibo- Zulia
Fax +44 (0)870 460 1479 VENEZUELA
E-mail: zfmarine@zf-group.co.uk Tel. + 58-261-736 07 47
Fax + 58-261-736 07 47
Email: sistemadepropulsion@cantv.net
UNITED ARAB ZF MARINE MIDDLE EAST LLC

EMIRATES Office No. 502, Golden Tower Building
Opposite to Marbella Resort
Buhaira Corniche, P.O. BOX NO. 26093
Sharjah - U.A.E.
Tel. +971 6 5747 074
Fax +971 6 5747 174
E-mail: narasimhan.manian@zf.com
U.S.A. ZF INDUSTRIES INC

ZF MARINE U.S. HEADQUARTERS *
3131 Southwest 42nd Street
Fort Lauderdale, FL 33312
U.S.A.
Tel. +1 954 581 4056
Fax. +1 954 581 4078
Email: Info.ZFMarineLACA@zf.com
ZF INDUSTRIES INC
ZF MARINE U.S.
HEADQUARTERS
3131 Southwest 42nd Street
Fort Lauderdale, FL 33312
U.S.A.
Tel. +1 954 581 4040
Fax +1 954 581 4099
E-mail: Info.ZFMarineFtLauderdale@zf.com
* MANUFACTURING LOCATIONS
PLEASURE AND COMMERCIAL CRAFT
** FAST SPECIAL CRAFT
***
(1) ELECTRONICS CONTROLS
(2) PROPULSION
ZF Padova S.p.A.
Date
Service Centres
Section 11
ZF Padova S.p.A.
Section 12

ZF KH1200

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ZF KH1200

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A product by Marine Propulsion Systems

PROJECT NAME: Galata

COSTUMER ORDER NUMBER: AL06041

GEARBOX MODEL: ZF W93300 NC + PTO 4

PART NUMBER: 3104004009

CPP MODEL: CPP00154

The manual consists of 11 sections as follows:

Section 1: TECHNICAL DATA Page 7

Section 2: MAINTENANCE AND OPERATION MANUAL Page 13

Section 3: AFTER RECEIPT OF EQUIPMENT Page 17

Section 4: OPERATING NOTES Page 23

Section 5: WORKING PRINCIPLES Page 27

Section 6: INSTALLATION DESCRIPTION Page 41

Section 7: STARTING OPERATION Page 53

Section 8: EMERGENCY OPERATION Page 73

Section 9: MAINTENANCE Page 79

Section 10: TROUBLESHOOTING REMEDIES Page 91

Section 11: SERVICE CENTERS Page 97

Section 12: APPENDIX Page 103

Type of Vessel Chemical Tanker

Voltage / Frequency 450 V / 60 Hz

Engine Manufacturer MAK

Engine Type 9M32C

Engine Power 4500 Kw @ 600 r.p.m.

Input Torque 71625,00 N.m.

Engine Rotation CCW

Gearbox Model ZF W93300 NC + PTO 4

Gearbox Part Number 3104004009

Gearbox Ratio 5,000

Propeller Type KH 1200

Output speed 120 r.p.m.

Secondary PTO-RATING 1100 KW

Secondary PTO-SPEED 1780,42

PTO Ratio 0,337

PART LIST No CUSTOMER No DRY MASS (kg)

Pleasure Light Medium Continuous

OIL CLUTCH OIL

OIL CHANGE: after first 250 hours of operation and every

Oil quantity 600 dm3

Working clutch oil pressure at monitoring

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 10 bar MAX

Water flow range in heat exchanger

Roller Bearings { 65°C Nominal

Start 20 bar Falling { NR versions

Stand By-Pump Stop 26 bar Rising NC with clutchable PTO versions

Start 0,8 bar Falling

POS. DESCRIPTION POS. DESCRIPTION

1 PTO 13 Control unit (for PTI)

2 Oil pump 14 Control box

3 Output shaft 15 Input shaft

4 Monitoring unit 16 PTO shaft (and PTI shaft)

5 Drain plugs 17 Check valve

8 Oil dipstick 20 Drip tray (optional)

9 Breather 21 Upper section

10 Oil cooler 22 Control valve

11 Connection for O.D. box 23 Thermometer

12 A-B-C Inspection covers

Maintenance and Operation Manual