Operating Instructions

Transcription

1 Operating Instructions Transmission oil cooler for ZF marine transmission ZF 2000 ZF 2500 ZF 3000 ZF 4600 with pipe bundle cooler ZF 7500/7600 with pipe bundle cooler ZF 9000

2 2 These operating instructions are protected by copyright. Any reproduction and dissemination in whatever form also in adapted, paraphrased or extracted form in particular as a reprint, pho-tomechanical or electronic reproduction or as a storage in data-processing equipment or data net-works without approval by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law. Technical subject to alterations in design. Edition: 2009/02 Index of revisions: Document No.: Printed in Germany ZF Friedrichshafen AG, 2009 ZF MARINE GMBH Friedrichshafen Deutschland Telephone Telefax info.zfmarine@zf.com ZF Edition: february 2009 /

3 3 TABLE OF CONTENTS 1 Assembly Cooling systems Open sea water cycle cooling system Closed cycle cooling system Transmission oil cooler Cooler design Requirements cooling-water circuit Arrangement of the transmission oil cooler in the cooling-water circuit Temperatures Flow rates Water pressure Filtering Earthing Free-standing transmission Flanged transmission Cooler drainage Draining the water in case of longer standstill Pipework Installation Screw-in socket Flow velocity Materials of the cooling-water pipe Earthing cooling-water pipe General notes Clearance for maintenance works Tool-kit Tools for cleaning transmission oil cooler Maintenance system job sheets Troubleshooting Table of faults (ZF 2000 und ZF 7500) Table of faults (ZF 2500) Table of faults (ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF 9000) Fault clearance Closing leaking pipes Leaking o-rings Maintenance Assembly of transmission oil cooler (ZF 3000, ZF 4600, ZF 4660, ZF 7600, ZF 9000) Pipe bundle Housing Receivers Gaskets Installation position of transmisson oil cooler Assembly of transmission oil cooler (ZF 2000, ZF 7500) Pipe bundle Housing Receivers Cover Gaskets Installation position of transmisson oil cooler Maintenance time schedule Regular maintenance jobs Additional one-off maintenance jobs on new or overhauled transmission Maintenance work before shut-down / stop Closed cycle cooling system Open cycle cooling system Maintenance job schedule Maintenance level / maintenance jobs / Edition: february 2009 ZF

4 4 ZF Edition: february 2009 /

5 Assembly 5 1 ASSEMBLY 1.1 Cooling systems Open sea water cycle cooling system 1.2 Transmission oil cooler Cooler design water inlet water outlet oil outlet oil inlet Fig. 3: Schematic assembly of the cooler Requirements cooling-water circuit Fig. 1: Open sea water cycle system In the case of the open sea water circuit, sea water runs through the transmission oil cooler as cooling agent. The ductwork has to be designed so that in case of standstill of the plant either the feed line or the return line of the transmission oil cooler can drain. This line must be connected to the lower con-nection of the transmission oil cooler Closed cycle cooling system Fig. 2: Closed cycle cooling system In the case of this arrangement, the cooling-water circuit for the motor and the transmission is separa-ted from the sea water circuit. The heat transmission of the motor/transmission oil circuit to the sea water happens via a separate heat exchanger or via sur-face attemperators in the outer skin of the ship. Nor-mally, the heat transfer medium in the motor cooling circuit is a mixture of water and an anticorrosive agent. Thus, corrosion in the cooling system is lar-gely reduced. Given the cleanliness of the medium, the transmission oil cooler is hardly exposed to silta-tion or pitting corrosion. The amount of heat generated in the transmission is dissipated through the oil cooler. The oil cooler, which is part of the basic model of the transmission, is mounted to, installed in or fixed onto the transmission housing. For the admissible water flow rate and the pressure loss between cooling-water inlet and outlet, see technical specifications in the transmission installation drawing. The indicated water pressure at the cooling-water inlet must not be exceeded. The cooler is so designed that the heat dissipation is sufficient at a transmission ambient temperature of 60 C and a water inlet temperature according to the transmission installation drawing - also at full transmission load and maximum speed Arrangement of the transmission oil cooler in the cooling-water circuit The correct transmission temperature is set by adjusting the cooling-water flow rate. For doing this, an exchangeable gland, a valve or the like has to be provided in the ductwork. Therefore, the water circuit of the transmission oil cooler should be arranged in the bleed off of the motor cooling-water circuit (see section Cooling systems on page 5). The closed cooling circuit should be the preferred one since the cooling water is cleaner in this case Temperatures Max. cooling-water inlet temperature: see transmission installation drawing Flow rates Max. admiss. cooling-water flow rate: see transmission installation drawing Min. admiss. cooling-water flow rate: see transmission installation drawing / Edition: february 2009 ZF

6 6 Assembly Water pressure Max. admiss. cooling water pressure at inlet: see transmission installation drawing Free-standing transmission Filtering Suction filter on the water side required with mesh size: see transmission installation drawing This is necessary in order to prevent contaminations such as solid matters or shells from ingressing into the cooler and the conduits since they would obstruct the cooler. An obstructed cooler or individually obstructed cooler pipes lead to a reduced cooling thermal performance. Fig. 5: Earthing with free-standing transmission Flanged transmission Fig. 6: Earthing with flanged transmission Cooler drainage Fig. 4: Contamination (wood shavings) caused by a filter screen with a too big mesh size (Example) In case of obstructed cooler pipes, the required flow velocity is not reached. This can lead to deposits or to foul and consequently to pitting corrosion Earthing In order to avoid galvanic corrosion, it is important that there is no electric potential difference at the sea water containing components. Therefore, the transmission and therefore also the cooler have to be connected with the earthbus so that they are antistatic - as all other sea water containing components. Material: copper Min. cross section: 16 mm 2 It must be made sure that the junctions of the earth strap are free of colour or of other electrically insulating materials. Ideally, the cooling-water circuit has to be designed so that the transmission oil cooler is automatically drained if the cooling-water pump is in standstill. The bacteria in the standing water form degradation products which deposit in the cooler. In case of a surface which has not been passivated yet, this can lead to pitting corrosion. The passivation of the surfaces is only built-up after some time of operation in oxygen-rich water Draining the water in case of longer standstill If the plant is switched off for a longer period of time(standstill time see section Maintenance work before shut-down / stop on page 13) the water has to be drained if the sea water circuit is open. This is only necessary, if the cooler is not automatically drained when the cooling-water pump is in standstill. In order to be able to drain the cooling circuit, a drain plug or drain valve has to be provided. The connection must lie deeper than the cooler so that the cooler can drain completely. ZF Edition: february 2009 /

7 Assembly Pipework Installation All required oil pipes are connected fixed and ready for operation. The connections for the cooling-water inlet and outlet are closed by means of blind flanges upon delivery. These flanges can be used as welding flanges during the installation of the cooling-water pipe. For uncoupling, an elastic adapter (compensator, hose piece) must be put between these flanges and the cooling-water pipes on the side of the ship. The exact position of the connections can be taken from the corresponding transmission installation drawing. The flow direction of the water must be adhered to, i.e. water inlet and water outlet must not be exchanged. The temperature increase of the cooling water in the transmission oil cooler is maximally 5 C. The mixing temperature for the motor cooling circuit increases by approx. 0.5 C and is therefore irrelevant. The indicated maximum rate of cooling-water flowing through the transmission oil cooler must not be exceeded; otherwise there is the risk of cavitation in the cooler. The minimum flow rate must not lie below since the flow velocity would be too low and there would be the risk that the cooler silts up early or is impaired by salt excretion of the water flow Screw-in socket The maximum admissible thread depth in the connection threads for the cooling water amounts to 20 mm in order to avoid an obstruction of the flow in the area in front of the pipe plates Flow velocity Minimum flow velocity: 1.5 m/s Maximum flow velocity: 3.0 m/s The cross sections of the conduits are to be designed so that at nominal speed the minimum flow velocity is reached and the maximum flow velocity is not exceeded. Fig. 8: Fouling: Organic sediments on the pipe bundle caused by low flow velocity and long down time (example) Materials of the cooling-water pipe When choosing the materials for the water pipes, it must be taken into account that different materials cannot be combined at random. If a more precious metal is combined with a less precious metal, the less precious metal will corrode. Material of the pipes and the stop valves in the sea water circuit: Copper alloy, e.g. CuNi10Fe1Mn Galvanised steel pipes must not be used since there is the risk that the zinc coating is partially eaten away by galvanic processes and that iron corrosion parts deposit at the discs or the flange pipes of the cooler. Within a short period of time, pitting corrosion would damage the cooler Earthing cooling-water pipe Fig. 7: Thread depth in the connection threads for the cooling water (example) The maximum screw-in length of 20 mm is only applicable for the transmission oil coolers for ZF 3000, ZF 4600, ZF 4660 and ZF 7600 transmissions. For transmission oil coolers for the ZF 9000 transmission the maximum screw-in length is 27 mm. In order to avoid galvanic corrosion, it is important that there is no electric potential difference at the sea water-containing components. Therefore, all cooling-water pipes must be connected with the earth bus of the ship in an antistatic manner. If there is an insulating separation line in the pipe (hose or compensator), this must be bridged by an earth strap in an antistatic manner (see section Earthing on page 6) / Edition: february 2009 ZF

8 8 Assembly 1.4 General notes Clearance for maintenance works The cooler has to be maintained in regular intervals according to the maintenance instruction. Therefore, a corresponding clearance has to be provided for the disassembly of the pipe bundle. Fig. 9: Required clearance for the disassembly of the pipe bundle (example) ZF Edition: february 2009 /

9 Maintenance 9 2 MAINTENANCE 2.1 Assembly of transmission oil cooler (ZF 3000, ZF 4600, ZF 4660, ZF 7600, ZF 9000) Fig. 10: Schematic assembly of transmission oil cooler (example) 1 housing 5 cylindrical bolt 9 divider 13 baffle plate 2 reciever 6 washer 10 pipe 14 fin ring 3 cover 7 pipe plate 11 fin 4 fixing plate 8 o-ring 12 sealing strip The actual assembly of the transmission oil cooler can differ in details Pipe bundle The pipe bundle consists of two identical pipe plates (7) facing each other with three splines each. The cooling pipes (10) are expanded into the pipe plates. Between the pipe plates on the outside of the pipes there is a surface enlargement mounted in the form of fins (11) and positively connected with the pipes. Along the whole length of the fin package there are slits which serve for housing sealing strips (12). A different number of baffle plates (13) can have been mounted in the fin package. After assembly, each of the inner O-ring splines of the pipe plates seals in the housing. The outer splines serve as gaskets in the receivers. This prevents media from mixing in case of a failure of the gaskets and makes leak detection easier. In the middle spline, fixing plates (4) engage with a pipe plate, which fix this pipe plate after assembly and which allow a thermal expansion of the facing pipe plate Housing The housing (1) serves for housing the pipe bundle and constitutes the outer pressure chamber. It is a standardised cast housing made of an aluminium alloy or of grey cast iron Receivers The receivers are the both covers made of bronze and cast iron, which are situated at both ends. Together with the pipe bundle, the receivers form the pressure chamber of the cooling medium. The receivers are fixed to the housing by means of screws. On the side of the cooler, there are metal sheets inserted between the receiver and the housing. These metal sheets fix the pipe plate. On the side of the water connection of the cooler, a receiver (2) with two connections is installed and on the other side, there is a return cover (3) installed. For sealing the two chambers in the receiver, there is a plastic or aluminium divider (9) inserted into the pipe plate on the connection side. When assembled, this divider seals between pipe plate and receiver and thus divides the current of the medium flowing through the cooler along the pipe Gaskets The gaskets of the pipe plates consist of O-rings. The pipe threads at the connection are sealed by means of a copper or aluminium ring. The pipe bundle is sealed lengthwise on the side with a sealing strip (12) towards the housing. The sealing strip is made of the same material as the O-rings. The O-rings are available from the customer service of ZF Marine GmbH by indicating the item number / Edition: february 2009 ZF

10 10 Maintenance 2.2 Installation position of transmisson oil cooler Fig. 11: ZF 3000 Fig. 14: ZF 7600 Fig. 12: ZF 4600 Fig. 15: ZF 9000 Fig. 13: ZF 4660 ZF Edition: february 2009 /

11 Maintenance Assembly of transmission oil cooler (ZF 2000, ZF 7500) Fig. 16: Schematic assembly of transmission oil cooler (example) 1 housing 5 cylindrical bolt 9 pipe 2 reciever 6 washer 10 baffle plates 3 cover 7 pipe plate 4 pipe bundle compl. 8 o-ring The actual assembly of the transmission oil cooler can differ in details Pipe bundle The pipe bundle (4) consist of two identical pipe plates (7), positioned opposite of each other, and of the cooling pipes (9). The cooling pipes are expanded into the pipe plates. In total, five baffle plates (10) are mounted on the cooling pipes of the pipe bundle. The plates directionally lead the oil flow through the casing. The two o-rings (8) one on the side of the closure the other on the side of the receiver seal the pipe bundle in the casing on the oil side. The outer o-rings (8) serve for sealing the water side at the cover (3) and at the receiver (2). This prevents media from mixing in case of a failure of the gaskets Housing The housing (1) serves for housing the pipe bundle and constitutes the outer pressure chamber. It is a standardised cast housing made of an aluminium alloy or of grey cast iron Receivers A receiver (2) is installed on the water connection side of the cooler. The receiver is made of cast bronze. The receiver is attached to the housing (1) by means of three bolts (5) Between the receiver and the housing, the pipe bundle (4) is fixed by means of the sheet connected to the pipe plate Cover On the other side, a reverser cover (3) is installed. The cover is also made of cast bronze. The cover is attached to the housing (1) by means of three bolts (5). A spacer plate (6) is arranged between the cover and the housing. The spacer plate serves for fixation of the o-rings (8) Gaskets The connection flanges on the water side are sealed by means of flat gaskets. The pipe plates are sealed with a total of four identical o-rings (8). For versions with the transmission oil cooler directly flanged to the transmission housing, the oil connections are sealed by means of o-rings inserted into the splines. For versions with the transmission oil cooler mounted externally, the pipe connection threads are sealed by means of a copper ring. The O-rings are available from the customer service of ZF Marine GmbH by indicating the item number / Edition: february 2009 ZF

12 12 Maintenance 2.4 Installation position of transmisson oil cooler Fig. 17: ZF 2000 Fig. 18: ZF 7500 ZF Edition: february 2009 /

13 Maintenance Maintenance time schedule The maintenance system for marine transmissions is based on a preventive maintenance concept. The preventive maintenance enables an advance planning and ensures a high availability. NOTEThe time intervals according to which the maintenance work is to be executed, as well as the scope of the described control and maintenance work are the average result of operating experience and thus only to be seen as approximate values. Special operating conditions as well as technical demands can require additional maintenance work and/ or changes of maintenance intervals. The maintenance work number stated in the maintenance system operating sheet indicates the respective maintenance position. It serves as reference for the required tools and amount of parts Regular maintenance jobs Maintenance level Application groups Interval At least every (operating hours) A1 All Every day of operation 3 months A2 All 500 h 6 months A3.1 All year A4 C and M years L and P years A5 All Each time the engine undergoes a basic overhaul Transmission operating condition Tab. 1: Regular maintenance job for transmission oil cooler Additional one-off maintenance jobs on new or overhauled transmission Maintenance level Operating hours At least every Z1 50 to months Z months Tab. 2: Additional one-off maintenance jobs on new or overhauled transmission Maintenance work before shut-down / stop Closed cycle cooling system With a closed cycle cooling system the cooler can be kept filled Open cycle cooling system For a temporary stop of the facility (< 2 weeks) the cooler can be kept filled. For a longer stop of the facility (> 2 weeks) the cooler is to be emptied on the water side. This is only required, if the cooler is not emptied automatically with the cooling water pump being stopped. Cooling system Down time Measures Open system / sea water > 2 weeks Empty transmission oil cooler on water side. Rinse additionally with clean water If possible, dry pipe bundle from the inside with compressed air. Tab. 3: Standstill times / draining cooling water / Edition: february 2009 ZF

14 14 Maintenance 2.6 Maintenance job schedule Maintenance level / maintenance jobs Maintenance level Maintenance jobs Regular One-off A5 A4 A3.1 A2 A1 Z1 Z2 103 Carry out visual check 122 Retighten all screw/bolt connections 169 Realise visual examination and clean transmission oil cooler 200 Basic transmission overhaul Tab. 4: Maintenance level / maintenance jobs 2.7 Tool-kit Tools for cleaning transmission oil cooler Nylon brush for ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF 9000: (ZF part no. 1X ) Nylon brush for ZF 2000 und ZF 7500: (ZF part no. 1X ) ZF Edition: february 2009 /

15 Maintenance Maintenance system job sheets Index job sheets Maintenance operation Page 103 Carry out visual check Retighten all accessible screw/bolt connections Realise visual examination and clean oil cooler Edition: february 2009 / ZF

16 16 Maintenance MAINTENANCE SYSTEM JOB SHEET Transmission oil cooler Maintenance job no. Maintenance level If possible, to be performed in conjunction with maintenance job no. Time required in minutes 103 A Description of maintenance work 103 Carry out visual check Safety measures Carry out visual examination of rotating parts with sufficient distance in order to avoid the risk of being pulled in by the rotating part. Tools Parts Material Test equipment Procedure Check the leak tightness of the oil cooler and the oil level (water leakage in oil or oil leakage in water when engine has been stopped). Location: Date: Page: 1 of: 1 ZF Edition: february 2009 /

17 Maintenance / Edition: february 2009 ZF

18 18 Maintenance MAINTENANCE SYSTEM JOB SHEET Transmission oil cooler Maintenance job no. Maintenance level If possible, to be performed in conjunction with maintenance job no. Time required in minutes 122 Z Description of maintenance work 122 Retighten all accessible screw/bolt connections Safety measures Retighten bolted connections only with transmission stopped. Tools Parts Material Test equipment Procedure Re-tighten the screwed connections from and to the transmission oil cooler Location: Date: Page: 1 of: 1 ZF Edition: february 2009 /

19 Maintenance / Edition: february 2009 ZF

20 20 Maintenance MAINTENANCE SYSTEM JOB SHEET Transmission oil cooler Maintenance job no. Maintenance level If possible, to be performed in conjunction with maintenance job no. Time required in minutes 169 Z Description of maintenance work 169 Realise visual examination and clean oil cooler Safety measures Tools Tool kit WI (see corresponding instructions manual) Parts Material Test equipment Procedure See opposite page Location: Date: Page: 1 of: 1 ZF Edition: february 2009 /

21 Maintenance 21 ZF 2000 und ZF housing 2 reciever 3 cover 4 pipe bundle compl. 5 cylindrical bolt 6 distance plate 7 pipe plate 8 o-rings 9 pipe 10 baffle plates Fig. 19: Schmatic design of the transmission oil cooler (ZF 2000, ZF 7500, example) The numbers in the brackets refer to figure 19. The O-rings that have to be demounted must be exchanged on each maintenance. 9. Remove the o-rings on both sides of the pipe bundle. Disassembly of the transmission oil cooler (without extraction the pipe bundle) 1. Clearly mark the position of the bolted flanges to each other. 2. Block all tubing. 3. Empty the transmission oil cooler on the water side. 4. Remove the tubing on the water side. 5. Wait for 30 min after the facility has been stopped, until the oil pressure has decreased. 6. Empty the transmission oil cooler on the oil side; for this purpose drain the oil from the oil filter and the transmission (see maintenance system operating sheets 141 and 142). Fig. 20: Disassembly of the o-rings (ZF 2000, example) 10. The pipe bundle must be secured against the housing (1) by means of a screw and an appropriate number of washers. 7. Remove the fastening screws on the transmission oil cooler and detach the transmission oil cooler. Step 5-7 is only necessary in case of transmissions where the cover (3) cannot be dismantled for lack of space. 8. Remove the reciever (2) and the cover (3) by loosening the screws on the reciever/cover-housing-connection. Fig. 21: Pipe bundle secured with a bolt (ZF 2000, example) Now, the water side may be inspected and mechanically cleaned / Edition: february 2009 ZF

22 22 Maintenance Water-side cleaning The transmission oil cooler has to be cleaned on the water side at least 1x a year. Avoid excessive dirt on the pipes. The time intervals for maintenance have to be reduced in case of a long ship operation at harbours or in other dirty waters and according to the experiences of the operator. In case of little dirt the water side can be cleaned mechanically: 1. Disassemble the transmission oil cooler as described Disassembly of the transmission oil cooler (without extraction the pipe bundle) on page Clean each pipe of the pipe bundle on the inside by means of a nylon brush (see section Tool-kit on page 14). Disassembly of the transmission oil cooler (with extraction the pipe bundle) 1. Clearly mark the position of the bolted flanges to each other. 2. Block all tubing. 3. Empty the transmission oil cooler on the water side.. 4. Remove the tubing on the water side. 5. Wait for 30 min after the facility has been stopped, until the oil pressure has decreased. 6. Empty the transmission oil cooler on the oil side, for this purpose drain the oil from the oil filter and the transmission (see maintenance system operating sheets 141 and 142). 7. Remove the fastening screws on the transmission oil cooler and detach the transmission oil cooler. 8. Remove the reciever (2) and the cover (3) by loosening the screws of the reciever/cover housing connection. 9. Remove the o-rings on both sides of the pipe bundle. Fig. 22: Cleaning of pipes with a nylon brush (ZF 2000, example) Do not use metal brushes for the cleaning of the pipes. Firmly bonded deposits may not be removed with tools. In such a case the pipe bundle has to be cleaned chemically. This can be done with the pipe bundle still installed by coating the pipes with a chemical solution. In doing so you have to take into account that the plastic partition and the O-rings will not be affected by the chemical solution. A chemical cleaning should only be done by specialised staff. Suppliers of cleaning agents are, for example, Ashland Chemicals ( Henkel Oberflächentechnik ( and Ondeo Nalco ( Suppliers of complete cleanings are, for example, Vecom ( and Ondeo Nalco ( Fig. 23: Disassembly of the o-rings (ZF 2000, example) 10. Remove the spacer plate (6) on the side opposite the water side. Fig. 24: Remove spacer plate (ZF 2000, example) ZF Edition: february 2009 /

23 Maintenance Push the pipe bundle to the water side that far (if required, use an auxiliary tool) until the o-ring on the opposite side is loosened. 12. Remove the o-ring. Assembly of the transmission oil cooler (without extraction of the pipe bundle) The assembly of the transmission oil cooler is carried out in reverse order as the disassembly of the cooler. 1. Remove the securing bolt, including the washers from the pipe bundle. 2. Lubricate the outer o-rings with a suitable type of grease and mount onto the pipe bundle. Fig. 25: Disassembly of the o-ring on the side opposite to the water side (ZF 2000, example) 13. Draw out the pipe bundle towards the water side. In doing this, the pipe bundle must be removed from the housing very carefully, in order not to damage the diverter plates. Fig. 26: Disassembly of the pipe bundle (ZF 2000, example) 14. Remove the o-ring on the water side of the pipe bundle by slipping it over the pipe bundle. Fig. 27: Remove o-ring on the water side (ZF 2000, example) Fig. 28: Assemble the outer o-ring (ZF 2000, example) 3. Parallelly mount the receiver (2) and the cover (3) on the two sides of the transmission oil cooler and evenly slip them onto the outer o-ring When slipping the receiver (2) and the cover (3) onto the o-rings it must be observed that the o-ring do not shear off. 4. Assemble the receiver (2) and the cover (3) by means of three bolts, tightening the conjugate bolts alternating from receiver to cover, applying the correct tightening torque (see table 5 Tightening torques on page 23). Transmission type Tab. 5: Screw / strength ZF 2000 M8 / Nm ZF 7500 M10 / Nm Tightening torques 5. In transmissions where the transmission oil cooler has been removed from the transmission housing, the cooler must be positioned onto the transmission housing and fixed to the housing by means of four fastening bolts. 6. Mount the flanged sockets with new gaskets to the receiver (2). 7. Connect the pipelines on the water side. 8. Open and re-fill all pipelines. Tightening torque / Edition: february 2009 ZF

24 24 Maintenance 9. Bleed the transmission oil cooler on the water side. 10. Fill the transmission with oil. Step 10 is only required, if the transmission oil cooler has been removed for cleaning the transmission housing. 4. Lubricate the o-ring for the side of the pipe bundle opposite the water side with a suitable type of grease and assemble the o-ring on the side opposite the water side. Assembly of the transmission oil cooler (after extraction of the pipe bundle) 1. Grease the o-ring for the water side of the pipe bundle. 2. Carefully slip the o-ring over the pipe bundle to the stop on the water side. Fig. 31: Assembly of the o-ring on the side opposite to the water side (ZF 2000, example) During assembly of the o-ring it must be observed that the ring does not shear off. 5. Mount the spacer plate (6) on the side opposite the water side. Fig. 29: Assemble o-ring on the water side. (ZF 2000, example) During assembly of the o-ring it must be observed that the ring does not shear off. 3. Carefully insert the pipe bundle into the housing (1). Fig. 32: Mount the spacer plate (ZF 2000, example) 6. Lubricate the outer o-rings with a suitable type of grease and mount onto the pipe bundle. Fig. 30: Assembly of the pipe bundle (ZF 2000, example) ZF Edition: february 2009 /

25 Maintenance 25 Fig. 33: Assemble the outer o-ring (ZF 2000, example) 7. Parallelly mount the receiver (2) and the cover (3) on the two sides of the transmission oil cooler and evenly slip them onto the outer o-ring. When slipping the receiver (2) and the cover (3) onto the o-rings it must be observed that the o-ring do not shear off. 8. Assemble the receiver (2) and the cover (3) by means of three bolts, applying the correct tightening torque (see table 6 Tightening torques on page 25). Replacement of the pipe bundle If more than 10% of the pipes in the bundle are leaking/not tight, the entire pipe bundle must be replaced. 1. Assemble the transmission oil cooler as described in the section Disassembly of the transmission oil cooler (with extraction the pipe bundle) on page Remove the defective pipe bundle. 3. Insert the new pipe bundle. 4. Assemble the transmission oil cooler as described in the section Assembly of the transmission oil cooler (after extraction of the pipe bundle) on page 24. Revision After assembly, both the oil side and the water side must be revised. During this operation it must be observed that the pressure (oil side and water side) does not exceed the value stated in the transmission installation drawing and/or on the type plate. Transmission type Tab. 6: Screw / strength ZF 2000 M8 / Nm ZF 7500 M10 / Nm Tightening torques Tightening torque 9. Position the cooler onto the transmission housing and fix it to the housing by means of four fastening bolts. 10. Mount the flanged sockets with new gaskets to the receiver (2). 11. Connect the pipelines on the water side. 12. Open and re-fill all pipelines. 13. Bleed the transmission oil cooler on the water side. 14. Fill the transmission with oil / Edition: february 2009 ZF

26 26 Maintenance ZF 2500 With every maintenance operation, the o-rings and the gasket that must be disassembled, have to be replaced. Cleaning process on the water side The water side of the transmission oil cooler must be cleaned at least once per year. Excessive contamination of the pipes must be avoided. The time intervals for maintenance must be adjusted (shortened) for long-term operation of the ship in harbours and other soiled waters, and/or according to the operator's experience. Tightly sticking deposits must not be removed by means of tools. In such a case the pipe bundle must be chemically cleaned. This operation may be carried out in assembled condition by spraying chemical cleaning solution onto the pipes. It must be ensured that the condition of the o-rings is not affected by the chemical solution. Chemical cleaning should only be carried out by expert personnel. Suppliers of suitable cleaning agents are e.g. Ashland Chemicals ( Henkel Oberflächentechnik ( and Ondeo Nalco ( Providers of complete cleaning services are e.g. Vecom ( und Ondeo Nalco ( Disassembly of the transmission oil cooler 1. The position of the screwed flanges to each other must be marked in order to be identified at assembly. 2. Close all pipelines. 3. Drain the transmission oil cooler on the water side. 4. Remove the pipelines on the water side. 5. After shut down of the system wait for minimum 30 minutes until the oil pressure has decreased. 6. Drain the transmission oil cooler on the oil side; for this the oil must be drained from the oil filter and the transmission (see Maintenance System - Operation Sheets 141 and 142 in the instructions manual of the respective transmission series). 7. Disassemble the cover by unscrewing the bolts at the cover-housing connection. 8. Extract the pipe bundle from the transmission housing. Fig. 34: Disassembly of the pipe bundle (ZF 2500, example) Assembly of the transmission oil cooler The assembly of the transmission oil cooler is carried out in reverse order as the disassembly of the cooler. 1. Carefully insert the pipe bundle into the transmission housing. Fig. 35: Assembly of the pipe bundle (ZF 2500, example) 2. Replace the gasket at the cover. Fig. 36: Replace gasket (ZF 2500, example) ZF Edition: february 2009 /

27 Maintenance Place the cover onto the pipe bundle and the transmission housing assembling it by means of eight bolts, tightening the conjugate bolts in an alternating fashion, applying the correct tightening torque (see table 7 Tightening torques on page 27). Transmission type Screw / strength ZF 2500 M10 / Nm Tightening torque Tab. 7: Tightening torques When assembling the cover, it must be observed that the gasket between pipe bundle and cover is positioned correctly. 4. Mount the flanged sockets with new gaskets to the cover. 5. Connect the pipelines on the water side. 6. Open and re-fill all pipelines. 7. Bleed the transmission oil cooler on the water side. 8. Fill the transmission with oil. Replacement of the pipe bundle If more than 10% of the pipes in the bundle are leaking/not tight, the entire transmission oil cooler must be replaced. 1. Disassemble the transmission oil cooler as described in the section Disassembly of the transmission oil cooler on page Remove the defective transmission oil cooler. 3. Insert the new transmission oil cooler. 4. Assemble the transmission oil cooler as described in the section Assembly of the transmission oil cooler on page 26. Revision After assembly, both the oil side and the water side must be revised. During this operation it must be observed that the pressure (oil side and water side) does not exceed the value stated in the transmission installation drawing and/or on the type plate / Edition: february 2009 ZF

28 28 Maintenance ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF housing 2 reciever 3 cover 4 fixing plate 5 cylindrical bolt 6 washer 7 pipe plate 8 o-ring 9 divider 10 pipe 11 fin 12 sealing strip 13 baffle plate 14 fin ring Fig. 37: Schematic Design of the transmission oil cooler ZF 3000, ZF 4600, ZF 4660, ZF 7600, ZF 9000, example) The numbers in the brackets refer to figure 37. The O-rings that have to be demounted must be exchanged on each maintenance. Disassembly of the Transmission oil cooler (without extraction of the pipe bundle) 1. Clearly mark the position of the bolted flanges to each other. 2. Block all tubing. 3. Empty the Transmission oil cooler on the water side. 4. Remove the tubing on the water side. 5. Wait for 30 min after the facility has been stopped, until the oil pressure has decreased. 6. Empty the Transmission oil cooler on the oil side; for this purpose drain the oil from the oil filter and the Transmission (see maintenance system operating sheets 141 and 142). 7. Remove the fastening screws on the Transmission oil cooler and detach the Transmission oil cooler. Step 5-7 is only necessary in case of Transmissions where the cover (3) cannot be dismantled for lack of space. 8. Remove the reciever (2) and the cover (3) by loosening the screws on the reciever/ cover-housing-connection. 9. Remove the o-rings from the outer spline of the pipe plates and secure the pipe bundle against the housing (19 in the middle spline of the pipe plates using four bolts and the four fixing plates (4). Fig. 38: Pipe bundle secured with fixing plates (ZF 3000, example) Fig. 39: Pipe bundle secured with fixing plates (ZF 9000, example) ZF Edition: february 2009 /

29 Maintenance 29 Now, the water side may be inspected and mechanically cleaned. In transmission where the transmission oil cooler has not been removed, the oil side may remain pressurised. 10. Remove the divider (9) 2. Clean every pipe of the pipe bundle on the inside using a nylon brush (see chapter Tool-kit on page 14). Fig. 42: Cleaning the pipes by means of a nylon brush (ZF 3000, example) Fig. 40: Disassembly of the pipe bundle (ZF 3000, example) Fig. 41: Disassembly of the pipe bundle (ZF 9000, example) Cleaning process on the water side The water side of the transmission oil cooler must be cleaned at least once per year. Excessive contamination of the pipes must be avoided. The time intervals for maintenance must be adjusted (shortened) for long-term operation of the ship in harbours and other soiled waters, and/or according to the operator's experience. In case of slight contamination the water side may merely be cleaned mechanically. 1. Disassemble the transmission oil cooler as described in the sectio Disassembly of the Transmission oil cooler (without extraction of the pipe bundle) on page 28. Fig. 43: Cleaning the pipes by means of a nylon brush (ZF 9000, example) Metal brushes must never be used for cleaning the pipes. Tightly sticking deposits must not be removed by means of tools. In such a case the pipe bundle must be chemically cleaned. This operation may be carried out in assembled condition by spraying chemical cleaning solution onto the pipes. It must be ensured that the condition of the o-rings and the plastic divider is not affected by the chemical solution. Chemical cleaning should only be carried out by expert personnel. Suppliers of suitable cleaning agents are e.g. Ashland Chemicals ( Henkel Oberflächentechnik ( and Ondeo Nalco ( Providers of complete cleaning services are e.g. Vecom ( und Ondeo Nalco ( / Edition: february 2009 ZF

30 30 Maintenance Disassembly of the transmission oil cooler (with extraction of the pipe bundle) 1. The position of the screwed flanges to each other must be marked in order to be identified at assembly. 2. Close all pipelines. 3. Drain the transmission oil cooler on the water side. 4. Remove the pipelines on the water side. 5. Nach dem Abstellen der Anlage 30 min warten, bis der Öldruck abgebaut ist. 6. Drain the transmission oil cooler on the oil side; for this the oil must be drained from the oil filter and the transmission (see Maintenance System - Operation Sheets 141 and 142 in the instructions manual of the respective transmission series). 7. Unscrew the attachment bolts from the transmission oil cooler and remove the cooler. 8. Remove the receiver (2) and the cover (3) by loosening the bolts from the receiver-housing and cover-housing connections. Four fixing plats (4) are located between the receiver (2) and the housing (1). These plates must be installed on the same side when assembling the unit. Observe the identification F on the housing flange, for this purpose. 9. Remove the o-rings from the outer spline of the pipe plates. Fig. 45: Disassembly of the outer o-ring (ZF 3000, example) Fig. 46: Disassembly of the outer o-ring (ZF 9000, example) On one pipe plate an identification mark for the installation position is provided opposite the housing. The edge of the pipe plate and the adjacent housing flange each contain one half of an X. This mark must be observed. Fig. 44: Identification mark F for the fixing plates (example) Fig. 47: Identification mark X for the installation of the pipe bundle (ZF 3000, example) ZF Edition: february 2009 /

31 Maintenance Draw out the pipe bundle towards the side it was inserted at. In doing this, the pipe bundle must be removed from the housing very carefully, in order not to damage the fin package. If possible, the pipe bundle should be supported by large-surface transport slings. Fig. 48: Identification mark X for the installation of the pipe bundle (ZF 9000, example) 10. Push the pipe bundle towards the water side that far (if required, use an auxiliary tool) until the o-ring on the inner spline is visible. 11. Remove the o-ring of the inner spline. Fig. 51: Disassembly of the pipe bundle (ZF 3000, example) Fig. 49: Disassembly of the inner o-ring (ZF 3000, example) Fig. 50: Disassembly of the inner o-ring (ZF 9000, example) Fig. 52: Disassembly of the pipe bundle (ZF 9000, example) The splines for the accommodation of the o-rings must not be damaged. When extracting the pipe bundle, the diverter plate (13) may fall out. When disassembling vertically installed coolers (applicable for transmission series ZF 4600) it must be ensured by appropriate means that the pipe bundle cannot slide downwards once the fixing plates have been removed. For this purpose, it is recommended to have an additional set of fixing plates (4) ready and to start the disassembly operation on the side on which no fixing plates are installed. The pipe bundle must be secured during this step. After disassembly of the second receiver (2) controlled extraction of the bundle is facilitated. For assembly, only one set of fixing plates (4) must be installed, on the side containing the identification mark F / Edition: february 2009 ZF

32 32 Maintenance Assembly of the transmission oil cooler (without extraction of the pipe bundle) The assembly of the transmission oil cooler is carried out in reverse order as the disassembly of the cooler. 1. Remove the four bolts and the four fixing plates (4). 2. Lubricate the outer o-rings with a suitable type of grease and insert into the corresponding outer spline of the pipe plates (7). Fig. 55: Correct installation of the divider (9) must be observed (ZF 3000, example) Fig. 53: During assembly the outer o-ring must be taken into consideration (ZF 3000, example) Fig. 54: During assembly the outer o-ring must be taken into consideration (ZF 9000, example) 3. Verify the correct installation position of the divider (9) on the water side. Fig. 56: Correct installation of the divider (9) must be observed (ZF 9000, example) With two-way transmission oil coolers a divider (9) must be inserted into the pipe plate on the water side (receiver (2) with two connections). 4. Insert the four fixing plates (4) into the middle spline of the pipe plate (7) on the water side (receiver (2) with two connections) observing the identification mark F. 5. Parallelly mount the receiver (2) and the cover (3) on the corresponding pipe plates (7) and evenly slip them onto the outer o-ring. When slipping the receiver (2) and the cover (3) onto the o-rings it must be observed that the o-ring do not shear off. ZF Edition: february 2009 /

33 Maintenance Assemble the receiver (2) and the cover (3) by means of four bolts, tightening the conjugate bolts alternating from receiver to cover, applying the correct tightening torque (see table 8 Tightening torques on page 33). Transmission type ZF 3000 ZF 4600 ZF 4660 ZF 7600 Tab. 8: Screw / strength M10 / 8.8 Tightening torques Tightening torque 46 Nm ZF 9000 M16 / Nm 7. In cases where the transmission oil cooler has been removed from the transmission housing, the cooler must be positioned onto the transmission housing and fixed to the housing by means of four fastening bolts. 8. Mount the flanged sockets to the receiver (2). 9. Connect the pipelines on the water side. 10. Open and re-fill all pipelines. 11. Bleed the transmission oil cooler on the water side. 12. Fill the transmission with oil. Step 12 is only required, if the transmission oil cooler has been removed for cleaning the transmission housing / Edition: february 2009 ZF

34 34 Maintenance Assembly of the transmission oil cooler (after extraction of the pipe bundle) The assembly of the transmission oil cooler is carried out in reverse order as the disassembly of the cooler. 1. Grease the sealing strips (12) of the pipe bundle. The operational medium may be used for this purpose. Sealing strips (12) must only be replaced if they are damaged. The sealing strips must be effective over the entire length of the pipe bundle. 2. Carefully insert the pipe bundle into the housing (1). Fig. 59: During assembly the sealing strips (12) and the fin ring (14) must be taken into consideration (ZF 3000, example) Fig. 57: Assembly of the pipe bundle (ZF 3000, example) Fig. 60: During assembly the sealing strips (12) and the fin ring (14) must be taken into consideration (ZF 9000, example) On one pipe plate an identification mark for the installation position is provided opposite the housing. The edge of the pipe plate and the adjacent housing flange each contain one half of an X. This mark must be observed. Fig. 58: Assembly of the pipe bundle (ZF 9000, example) When inserting the pipe bundle, it must be observed that the sealing strips (12) are not shifted or crimped. Fig. 61: Identification mark X for the installation of the pipe bundle (ZF 3000, example) ZF Edition: february 2009 /

35 Maintenance 35 When inserting the pipe plates (7) into the sealin surfaces, it must be observed that the o-ring do not shear off. 5. Lubricate the outer o-rings with a suitable type of grease and insert into the corresponding outer spline of the pipe plates (7). Fig. 62: Identification mark X for the installation of the pipe bundle (ZF 9000, example) 3. Insert the fin ring (14) into the diverter plate (13) and press down during installation of the pipe bundle. 4. Lubricate the inner o-rings with a suitable type of grease and insert into the corresponding inner spline of the pipe plates (7). Fig. 65: During assembly the outer o-ring must be taken into consideration (ZF 3000, example) Fig. 63: During assembly the inner o-ring must be taken into consideration (ZF 3000, example) Fig. 66: During assembly the outer o-ring must be taken into consideration (ZF 9000, example) 6. Verify the correct installation position of the divider (9) on the water side. Fig. 64: During assembly the inner o-ring must be taken into consideration (ZF 9000, example) Fig. 67: Correct installation of the divider (9) must be observed (ZF 3000, example) / Edition: february 2009 ZF

36 36 Maintenance 14. Bleed the transmission oil cooler on the water side. 15. Fill the transmission with oil. Fig. 68: Correct installation of the divider (9) must be observed (ZF 9000, example) With two-way transmission oil coolers a divider (9) must be inserted into the pipe plate on the water side (receiver (2) with two connections). 7. Insert the four fixing plates (4) into the middle spline of the pipe plate (7) on the water side (receiver (2) with two connections) observing the identification mark F. 8. Parallelly mount the receiver (2) and the cover (3) on the corresponding pipe plates (7) and evenly slip them onto the outer o-ring. When slipping the receiver (2) and the cover (3) onto the o-rings it must be observed that the o-ring do not shear off. 9. Assemble the receiver (2) and the cover (3) by means of four bolts, tightening the conjugate bolts alternating from receiver to cover, applying the correct tightening torque (see table 9 Tightening torques on page 36). Replacement of the pipe bundle If more than 10% of the pipes in the bundle are leaking/not tight, the entire pipe bundle must be replaced. 1. Disassemble the transmission oil cooler as described in the section Disassembly of the transmission oil cooler (with extraction of the pipe bundle) on page Remove the defective pipe bundle. 3. Insert the new pipe bundle. 4. Assemble the transmission oil cooler as described in the section Assembly of the transmission oil cooler (after extraction of the pipe bundle) on page 34. Revision After assembly, both the oil side and the water side must be revised. During this operation it must be observed that the pressure (oil side and water side) does not exceed the value stated in the transmission installation drawing and/or on the type plate. Transmission type ZF 3000 ZF 4600 ZF 4660 ZF 7600 Tab. 9: Screw / strength M10 / 8.8 Tightening torques Tightening torque 46 Nm ZF 9000 M16 / Nm 10. Position the cooler onto the transmission housing and fix it to the housing by means of four fastening bolts. 11. Mount the flanged sockets to the receiver (2). 12. Connect the pipelines on the water side. 13. Open and re-fill all pipelines. ZF Edition: february 2009 /