Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
and Operating
Manual for
Gearbox type
ZF W43000 Series
Mod. 03.2010
Date
General Index
TECHNICAL DATA
Page
Section 2:
Page
11
Section 3:
Page
15
Section 4:
OPERATING NOTES
Page
21
Section 5:
WORKING PRINCIPLES
Page
25
Section 6:
INSTALLATION DESCRIPTION
Page
39
Section 7:
STARTING OPERATION
Page
51
Section 8:
EMERGENCY OPERATION
Page
65
Section 9:
MAINTENANCE
Page
71
Section 10:
TROUBLESHOOTING REMEDIES
Page
83
Section 11:
SERVICE CENTERS
Page
89
Section 12:
APPENDIX
Page
95
Appendix 1:
Recommended Oils
Appendix 2:
Clutch discs
Appendix 3:
Filters
Appendix 4:
Pumps
Appendix 5:
Cooler
Appendix 6:
Valves
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Date
Remarks
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
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
Section 1
Date
Technical data
Section 1
1.1 IDENTIFICATION
The identification plate is fixed on the marine gearbox. The guarantee ceases to be valid if
this plate is tampered with or removed. Every time an assistance centre is contacted the
details on the plate must be reported.
TYPE
PART LIST No
SERIAL No
RATIO
CUSTOMER No
Pleasure
OIL TYPE
Light
OIL
CAPACITY (z)
Medium
Continuous
CLUTCH OIL
PRESSURE (bar)
Fig. 1.1
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Date
Technical data
Section 1
Oil quantity
280 dm3
versions
{ NR
NC with clutchable PTO version
~ 5 bar Nominal { NC Without clutchable PTO versions
25 bar Nominal
5 - 75 C
50 70 C
38 C max
from 5 to 50 C
10 bar MAX
7 11,9 m3/h
12 30 m3/h
{ KS 12 Cooler version
{ KS 20 Cooler version
2,5 mm
Roller Bearings
Slide Bearings
{
{
65C Nominal
85C Rising Alarm
45C Nominal
68C Rising Alarm
3 bar Nominal
< 0,4 bar Alarm
< 0,21 bar Engine Stop
Luboil pressure
{ NR versions
Stop 26 bar Rising { NC with clutchable PTO versions
Start 0,8 bar Falling NC without clutchable PTO versions
Stop 3,5 bar Rising {
Filter contaminations
NR versions
NC with clutchable PTO versions
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Date
Technical data
Section 1
DESCRIPTION
POS.
DESCRIPTION
POS.
PTO (optional)
14
Control box
Oil pump
15
Input shaft
Output shaft
16
Monitoring
17
Check valve
Drain plugs
18
19
Central section
20
Drip tray
Oil dipstick
21
Upper section
Breather
22
Control valve
10
Heat exchanger
11
12 A-B
13
Inspection covers
Thermometer
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
Technical data
Date
Section 1
Remarks
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
10
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
Section 2
Maintenance and
Operation Manual
Date
Section 2
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
13
Maintenance and
Operation Manual
Date
Section 2
Due to continuing development of our products, manufacturing technology and procedures future repair work may require the application of work practices, test or adjustment
data that are not covered by this manual at the time of issue. We therefore recommend
that repair work carried out on your ZF product is performed only by skilled technicians
who have undergone practical and theoretical skills training. ZF training includes refresher and assessment courses, and are conducted at approved ZF training centers.
The ZF group has installed a network of fully staffed Sales and Service Organization Centers, (SSOs), at strategic locations throughout the world so that our customers receive
field support close to their geographical location. Repair work carried out at ZF SSOs will
be guaranteed in accordance with the prevailing contractual conditions.
NOTE RELATING TO DAMAGE:
Damages resulting from work performed by non-ZF personnel and which is deemed
by ZF to have been conducted in an improper manner are, in their entirety, excluded
from the ZF contractual guarantee. This includes all follow-up remedial work, the
costs thereof, consequential damages such as loss of vessel operational time and any
other associated loss of revenue including any and all third party liabilities.
ZF Padova S.p.A.
Via Penghe, 48
I-35030 Caselle di Selvazzano (PD)
ITALY
Tel. +39-049 8299-311
Fax +39-049 8299-550
www.ZF-Marine.com
14
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Section 3
Date
Section 3
3.1 GENERAL:
The material has been shipped in good condition, protected against mechanical damage
and corrosion by appropriate packaging. The consignee/shipyard shall inspect the material upon delivery and make sure that all items have been delivered as shown on the transport documents no item has suffered any damage during transportation and handling all
parts are free of corrosion.
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
17
Date
Section 3
NOTE:
Before ZF marine gears are supplied to our customers, they are tested on test rigs/benches. During this test, every function, oil pressures, temperature and noise level are checked
thoroughly and recorded. After the test run, the inside of the transmission is flushed with
oil to preserve it. The transmission can then be stored in a dry place for up to 12 months
without the need for further special measures.
Any necessary preservation of the outside of the transmission depends on storage conditions and should be undertaken by the customer. Preservation measures for long storage
periods must be specified when ordering.
All shipping crates and packages must immediately undergo an inspection for external
damage. If any damage is noticed, the damaged locations must be photographed and
together with a notification letter sent to the ZF Marine contract administration department.
Please note that failure to do so promptly may invalidate or delay any insurance claims
filed on behalf of either shipyard and/or ZF Marine and shall absolve ZF Marine of any
responsibility for damages that might be found during the installation process.
After unpacking of the equipment, the scope of supply shall be carefully checked against
the packing list and the technical specification of the system. Please contact the ZF
Marine contract administration department in the event that any part(s) are missing for a
speedy replacement.
Once the consignee/shipyard has accepted the delivery of the goods, the consignee/
shipyard is responsible for ensuring that the goods are stored in a covered storage site to
prevent mechanical damage to and/or corrosion of the goods. No dirt, dust, humidity or
any other matter shall be allowed to penetrate into the mechanical devices and/or electric
or electronic components.
18
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Date
Section 3
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.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
19
Date
Section 3
20
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
Section 4
Operating notes
Date
Section 4
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
23
Operating notes
Date
Section 4
On the occasion of oil changes, the old oil should be collected in a suitable receptacle.
Any pools of oil which have occurred should be removed at once with an oil binding
agent.
Very dirty and oil-soaked cleaning rags should be kept in suitable containers.
The oil, the oil binding agnt and the cleaning rags should be disposed of in accordance
with the relevant pollution control requirements.
The drive unit should be shut off at once if changes in the gear unit are detected during
operation, such as for example increased operating temperature or a change in gear
unit noises.
Rotating parts, such as couplings, gear wheels or belt drives must be protected by
means of suitable guards to prevent accidental contact.
During installation of the gear unit in units or systems, the manufacturer of the units or
systems is obliged to incorporate the requirements notes and descriptions contained in
these Operating Instructions in his own Operating Instructions.
Notes affixed to gear units, such as for example rating plate, direction of rotation arrows, etc., must be observed. They must be kept free from paint and dirt. Missing plates
must be replaced.
Working with naked flames and performing welding work in the vicinity of the
gearbox and pipe openings are prohibited.
Make sure work is only performed when the equipment has been disconnected
from the electrical supply system.
24
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Section 5
Working principles
Date
Section 5
Working principles
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
27
Working principles
Date
Section 5
The gearbox models are available with or without engaging clutches (types NR and
NC) and also with a wide range of Power Take Off (PTO) and Power Take IN (PTI)
secondary drives.
The multiple disk clutches incorporated in the gearbox are hydraulically operated via
directional control valves activated by the clutch control.
Types of Gearboxes
NC
NR
Single reduction
gearbox without clutch
Single reduction
gearbox with clutch
28
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
Working principles
Date
Section 5
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
29
Working principles
Date
Section 5
30
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
Working principles
Date
Section 5
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
31
Date
Working principles
Section 5
Layout of a BI - PTO
D2
C
A
D1
B
A - INPUT SHAFT
B - OUTPUT SHAFT
C - CLUTCH
D1/D2 - P.T.O. SHAFTS
D1
C
A
D3
C3
B
A - INPUT SHAFT
B - OUTPUT SHAFT
C - INPUT SHAFTS CLUTCHS
D1/D2/D3-P.T.O. SHAFTS
32
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Working principles
Date
Section 5
The housing sections are made by rigid cast design or in welded sheet steel construction.
Optimum vibration characteristics with excellent smooth running have been additionally
achieved by means of pronounced ribbing.
The bottom of the housing is used as an oil tanks, this configuration eliminates a very large
extent the problems resulting from thermal expansion when aligning the gear box in the vessel.
On this level of the lower parting line the output shaft with the propeller trust bearing is located in the rear area. The propeller thrust is transmitted from this bearing via the housing
bottom part with its stopper faces directly to the stoppers of the ship foundation.
So, no forces caused by the propeller thrust are applied on the remaining housing structure.
The housing is exactly fixed to the foundation by closed fitting bolts.
The input shaft with the main pinion and the gears, are located on the same level with the
output shaft.
To ensure service of the gear box there are some covers permitting simple quick inspection
of gear system.
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
33
Working principles
Date
Section 5
On the gear systems the single helical involute tooth systems are case hardened and grinded.
Load-dependent tooth flank correction, combined with high tooth system quality, ensure quiet, reliable running.
The tooth pitch has been chosen to ensure balanced tooth system loading.
A tooth contact pattern check has been carried out in the workshop during assembly.
This check ensures that the gear box has optimum internal alignment, this being essential for
a long service life.
34
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Working principles
Date
Section 5
5.2 BEARINGS
The output shaft is supported by roller or slide bearings. They are designed to take maximum
propeller thrust astern and ahead.
The output shaft is axially secured by thrust bearing self aligning which also absorbs the propeller thrust and transmits it to the ships foundation.
The input shaft is also supported by roller bearings: the axial forces resulting from the gear
theeth are absorbed by axial part of the roller bearings.
The roller and slide bearings are supplied with oil by housing bores.
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
35
Working principles
Date
Section 5
The gear system is oiling with an oil pump, that is use for engagement of the clutch.
The oil pump receives the motion of the shaft entrance and the speed of rotation depends on
the revolutions of the engine.
The oil pressure is maintained constant by means of the distributor.
The oil is cooled by an heat exchanger made by cooling tubes which are resistant to salty sea
water.
The volume of heat generated in the gearbox is removed partly by radiating from the surface of the
housing and partly through the oil cooler the oil cooler included in the basic version of the gearbox
is mounted on the housing.
All the necessary oil lines are securely attached and ready for operation.
For permissible water flow rate and pressure loss between cooling water inlet and outlet the specified water pressure and temperature at the cooling water inlet must not be exceeded.
The correct gearbox temperature is achieved by adjustment of the cooling water flow rate.
A replaceable orifice, valve or similar device must be included in the ciruit for this purpose.
For this reason, the gearbox water circuit should be arranged in a by-pass from the engine cooling
water circuit. The maximum temperature increase of the cooling water in the gearbox oil cooler is
3 C and is of no significance to the engine oil circuit.
The stated maximum cooling water flow through the gearbox oil cooler must not be exceeded
since this may lead to cavitation in the cooler.
Similarly, the minimum flow rate must always be maintained or else sludge may form in the cooler
after only a relatively short period of operation.
Before being cooled, the oil passes through a double oil filter with a contamination indicator.
Simplified hydraulics diagram
Fig. 2.1
36
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
Working principles
Date
Section 5
Seals
The split - type seals, because of the labyrinth inside prevent any leakage of lube oil at the
input and output shafts.
They are designed for an easy maintenance.
Clutch
The multiple disk clutches incorporated in the gearbox are hydraulically operated via directional control valves activated by the clutch control.
A smooth and reliable hydraulic shifting electrically activated is obtained by a pressure
modulation.
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.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
37
Working principles
Date
Section 5
5.3 MONITORING
The marine gearbox has been designed for the connection of the instruments (monitoring)
in order to record the oil pressure, temperature and level according with the Classification
Society requirements.
38
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Section 6
Installation Description
Date
Section 6
Installation Description
6.1 INTRODUCTION
This section describes the installation of the gearbox and appropriate products. The drawings
to which the descriptions refer are included in the Appendix. The preceding safety notes must
be carefully observed.
Put the gearbox on the foundation top plate and, before removing the hoisting elements,
secure it in this position to prevent dislocation.
Make sure the gearbox is set down on the alignment bolts only.
Make sure the gearbox housing is not subjected to distortion and properly connected to the
ships foundation.
Make sure the pipes for the lubrication and cooling system are connected to the gearbox in
a flexible manner.
The pipes and fittings for supplying the seawater cooler and for the auxiliary pump are to be
supplied by the shipyard.
The connection must be free from stress caused by vibration.
Make sure pipes and connections are cleaned before installation; they must be free from
scales and welding beads.
Absolutely avoid heavy blows and shocks.
Make sure the gearbox housing, input and output shafts are not subjected to high axial
forces.
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
41
Installation Description
Date
Section 6
42
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
Installation Description
Date
Section 6
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.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
43
Installation Description
Date
Section 6
Make sure that only skilled expert personnel is entrusted with the required work and that these
persons undertake to strictly adhere to the applicable rules and supplied documentation.
Before making the respective connections check the data given on the rating plate.
Take care that these data coincide with the conditions prevailing aboard (voltage
and frequency).
Make sure that the size of the connecting cables suits the nominal current of the electric
motors.
Make sure that the electric pump start and stop functions are connected according to the
Classification Society.
Be sure that cabling connections are made as instructed on the circuit diagram provided in
the terminal box of the electric motors.
Note: The type of connection depends on the starting method used, i.e. direct-on-line or
star-delta, and will be prescribed by the shipyard.
Note that connection of electric motors must suit the prescribed rotational direction.
Take care that the protective conductor is connected with the appropriately marked
terminal.
Make sure that the rotational directions indicated by arrows on electric motors and oil pumps
coincide as required.
Attach the connecting cables to the terminal plate of the electric motors.
During the installation of the stand by pump verify that the suction pressure is not
lower than 0,6 bar.
In case the stand-by pump is not already fitted on the gearbox a flexible fireproof connection is recommended between the pump and the piping. Working
pressure: 30 bar.
If the connection will be rigid, respect the concentricity between the flanges in
order to avoid residual stress on the piping.
44
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
Installation Description
Date
Section 6
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
45
Installation Description
Date
Section 6
Operating Temperature
This diagram show the characteristic compensation curve caused by the operational temperature
on the input output shaft of the transmission and permits an high precision in cold alignment.
46
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Installation Description
Date
Section 6
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
47
Installation Description
Date
Section 6
During shaft alignment make sure to turn the two shafts simultaneously and take measurements
always on the same spot on the flanges. Measuring result ascertained in this way will not be
affected by concentric or plane runout which may exist.
Check the alignment in relation to the propeller line shafting after the gearbox has finally been
provided with shims and bolted to the ships foundation.
Align the motor in relation to the gearbox input shaft.
Subsequently, mount the coupling between motor and gearbox.
For motor alignment observe the manufacturers instructions issued and pay also attention to
guidance notes applicable to the coupling.
Please note that it is not the responsibility of ZF Padova to carry out the above described
measures to properly align gearbox, motor and coupling.
An accurate alignment is indispensable for maintaining the flexible coupling as long as possible,
as every misalignment has a negative effect on all the rotating elements. Use only flexible, highly
elastic couplings.
Make sure that the flexible coupling for input shaft is able to absorb the vibrations caused by away
from the area between idling and rated speed of the engine. Selection normally will be done by
the engine manifacturer.
Therefore ZF PADOVA is not responsible for vibration problems resulting from the installation.
48
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Installation Description
Date
Section 6
Gearbox foundation
Note: Make sure that the bores for the foundation bolts have been provided in the ships foundation
in line with the shipyards job scheduling.
The arrangement of the bores in the gearbox foundation plate is shown in the installation drawing
included in the Appendix.
Before foundation work is carried out the respective drawings and calculation data must have
been prepared by the Contractor performing the work and submitted to the classification society
for approval.
Note: Please note that all foundation work is subject to the respective rules and regulations issued
by the classification society.
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
49
Installation Description
Date
Section 6
Make sure that all loads affecting the sizing of the required shims are duly taken into account:
torque, propeller thrust and deadweight of the gearbox.
The supports must be adequately sized and tightly anchored to the gearbox foundation.
You can use either the foundation screws with the supports or the transmission screws.
Only rectangular set chock type support are permitted and the material must be agreed with the
Certifying Authorities. The support surface of the ZF mounting bracket has been designed for
direct mounting on a rigid surface.
Once the casting resin has hardened, the gearbox should only be supported by the
casting resin and not by the alignment screws or any other alignment aids. When
aligning the gearbox, the way in which the casting resin reacted to shrink fitting during
hardening should be taken into consideration.
We recommend that plans for the design of any mountings made of casting resin are made
in conjunction with the casting resin supplier and/or a certified specialist company. A specialist
company is able to provide advice at an early stage and is able to create the calculations and
drawings required for approval from a classification society and to submti these for approval.
The anchoring screws must be at least class 8.8 ISO 898 steel and they must comply with
requirements in consideration of the vessel specifications. Tightening torque values depend on the
vessel specifications. Make sure the transmission does not shift longitudinally due to the effect of
the axial thrust exerted by the propeller.
Use longitudinal foundation shirms in steel. Make a final check of alignment and, if satisfactory,
secure the screws with double nuts. Mark the nut threads with paint to facilitate periodic bolt
tightness visual inspections.
50
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Section 7
Starting Operation
Date
Section 7
Starting Operation
7.1 INTRODUCTION
This section describes the preparatory measures and course of action to be followed when taking
the gearbox into and out of service. The respective notes on safety shall be duly observed.
The safety and maintenance are prerequisites for trouble-free operation, maximum performance
and along service life.
Provide for the arrangement of adequate touch guards for all rotating parts located on
the input and output side of the gearbox.
Check the correct operating position of the stop valves and gate valves mounted in the piping system.
Note: Make sure the stop valves arranged in the oil discharge lines between gearbox and contaminated oil tank are closed.
When carrying out the following activities make sure that no lubricants are discharged
into the environment.
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
53
Starting Operation
Date
Section 7
When filling the system take care that no dirt, foreign matter or water are allowed to
enter the gearbox interior.
Note: A list of approved oil brands forms is reported in the Appendix.
Note down the volume of oil filled in when carrying out oil changes within the scope of maintenance work.
Other oil brands must only be used if ZF approval has been obtained. The risk of damage in
case a non-approved product is product is employed lies solely with the Owner.
Before first start be sure that the cartridges are present in the twin-type filter.
Fill the operating oil volume into the gearbox, when gear unit stands still: the correct oil level is
between the two marks on the oil dipstick.
Check and, if necessary, correct the oil level, when stand-by pump is switch on.
Using the transmission with an insufficient quantity of oil air may be taken in by the
pump.
On the other hand, on high quantity of oil could result in leakage through the gaskets and vents,
and could cause the operational temperature to increase significantly, including low clutch pressure.
Top both oil pump up with oil through the connection located upstream of each of the intake nozzles to avoid the pumps running dry when first taken into service.
54
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Starting Operation
Date
Section 7
Take care that the determined negative oil pressure does not exceed 0,6 bar.
Should oil pressure corrections be necessary they are effected via the pressure relief valve attached to the oil pump.
Check and, if necessary, correct the oil level once more. Observe the markings on the oil dipstick.
Check all rotating parts for ease of movement by rotating the propulsion system.
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
55
Starting Operation
Date
Section 7
Tighten all loose bolted connections and pipe couplings at the prescribed torque
rate.
56
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
Starting Operation
Date
Section 7
Replace damage gaskets/seals when the unit is stationary and the engine is in cold state.
Observe the noise and vibration characteristics of the gearbox system during all operating states.
Note: In the event of irregularities please notify the service department of ZF immediately.
Check the operating chamber of the twin-type filter for fouling.
Note: The contact-type differential pressure gauge attached to the twin-type filter indicates even
minor states of filter fouling.
Check the settings of the pressure monitoring equipment.
Note: The nominal switch points are listed in the oil supply and monitoring diagram included in
the Appendix.
Check the oil level of the gearbox. If the oil level is found to be incorrect the oil volume must be
topped up as required.
When initial commissioning has been completed prepare the respective protocol and submit one
copy of it to ZF service department.
Note: This document will be added to the production data compiled by ZF and shall serve as a
basis in the event warranty claims are raised.
7.3.1 Towing
During if the navigation in tow, it will be necessary to lubricate the rotating parts for at least five
minutes.
Lubrication can be done by the stand by pump.
If lubrication is not possible, the propeller shaft must be blocked in order to prevent its rotation as
a result of the dragging effect, otherwise you can damage the gearbox.
Continuous trailing operation is possible with a stand by pump running.
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
57
Starting Operation
Date
Section 7
After stop gearbox turning the stand by pumps has to work at leat 10 min. in order to
gradually cool the transmission.
Switch off the respective motor-driven oil pump when turning has been completed.
Stop the cooling water flow to the oil cooler and drain the cooler via the respective drain plugs
provided.
Check the gearbox system for damage, leakage, corrosion and untight components.
Water in the lubricating oil is especially dangerous. A bearing can run for a short time
with a limited quantity of water in the oil, but thus may NEVER be allowed to happen
with a gear wheel as wate, even in the smallest quantities, causes immediate pitting.
To prevent condensed moisture forming in the casing during operation and above all
during stationary periods the gear unit is vented. The air heats up in the gear unit and
is thus able to absorb the moisture. After the system has been shut off, ensure that no
engine room fans are directed at the casing. This applies particularly in tropical zones,
where considerable temperature gradients must be expected, especially at night.
58
ZF Padova S.p.A.
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 Commissioning Report
Date
Section 7
.......................................................................
Shipyard:
.......................................................................
.......................................................................
Commissioning Engineer(s):
1) ...................................................................
2) ...................................................................
3) ...................................................................
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
59
ZF Commissioning Report
Date
Section 7
OK
OK
OK
2.0 INSTALLATION
2.1 Thermal Alignment Engine Gearbox after Chockfast Recomendation:
Mesured:
Temperature in Engine Room ______________ [C]
(yard)
O.K.
O.K.
O.K.
O.K.
(yard)
O.K.
O.K.
Chockfast
Resilient
60
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 Commissioning Report
Date
Section 7
OK (yard)
4.2 Height from suction flange bottom of gearbox to pump suction flange: _________________ [cm]
_________________________________________ (yard)
_________________________________________ (yard)
_________________________________________ (yard)
OK
OK
__________________________________________ [bars]
__________________________________________ [bars]
OK
Leakage?
__________________________________________ [C]
__________________________________________ [C]
________________________________________ [bars]
________________________________________ [bars]
OK
5.3 After turning off the engine open inspection cover internal condition of the gearbox:
Good:
Corroded:
Defects:
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
61
Date
ZF Commissioning Report
Section 7
ROOT
.........................................
side
.........................................
side
1. Contact pattern after approx.: ........................... hours ...........................% load .......................... rpm
TOOTH TIP
ROOT
.........................................
side
.........................................
side
2. Contact pattern after approx.: ........................... hours ...........................% load .......................... rpm
TOOTH TIP
ROOT
.........................................
62
side
.........................................
side
ZF Padova S.p.A.
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 Commissioning Report
Date
Section 7
COMMENTS:
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
Acceptance Statement
For Shipyard:
For Avk:
Name Surname:
..................................................................................................
Position:
..................................................................................................
Signature:
..................................................................................................
Date:
..................................................................................................
Name Surname:
..................................................................................................
Position:
..................................................................................................
Signature:
..................................................................................................
Date:
..................................................................................................
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
63
ZF Commissioning Report
Date
Section 7
Remarks
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
..............................................................................................................................................................................................
64
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
Section 8
Emergency Operation
Date
Section 8
Emergency Operation
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
67
Emergency Operation
Date
Section 8
Make sure the engine and propeller are at a stand still before carrying out kind of operation
on the gear box.
68
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
Emergency Operation
Date
Section 8
DANGER - If the electrical supply is cut off, the running position will be maintained.
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
69
Emergency Operation
Date
Section 8
70
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
Section 9
Maintenance
Date
Section 9
Maintenance Schedule
Z1
A1A
A1B
A2
A4
A3
A5
MAINTENANCE OPERATIONS
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
73
Maintenance
Date
Section 9
Regular maintenance
Maintenance level
Operating hours
Max. value
A1A
A1B
400
6 months
A2
1000
1 years
A3
2000
2 years
A4
20000
5 years
A5
40000
10 years
Additional maintenance jobs on new or overehauled gear boxes, necessary only once
Maintenance Level
Operating hours
Max. value
Z1
100250
12 months
Necessary measures for protection against corrosion afther a long period out of use
Maintenance Level
Procedure
K1
at end of operating
period
12 months
K2
at end of operating
period
36 months
The operating hours given in the maintenance schedule as well as the tests and maintenance jobs
given in the maintenance work plan are the results of average operating data. Therefore the date
can only be guide values. Under special service conditions it may be necessary to change the time
schedule and maintenance work plan.
74
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
Maintenance
Date
Section 9
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
75
Maintenance
Date
Section 9
11
5
POS.
1
2
3
4
5
6
7
8
9
10
11
12 A-B
13
DESCRIPTION
PTO (optional)
Oil pump
Output shaft
Monitoring
DRAIN PLUGS
Lower half casing
Central section
OIL DIPSTICK
Breather
Heat exchanger
CONNECTION FOR O.D. BOX
Inspection covers
Thermometer
76
POS.
14
15
16
17
18
19
20
21
22
DESCRIPTION
Control box
Input shaft
PTO shaft (and PTI shaft)
Check valve
SAE 2 1/2 flange (connection for standby pump)
Double oil filter
Drip tray
Upper section
Control valve
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Maintenance
Date
Section 9
Note: The contamination indicator monitors the filter side during operation, as shown by the position of the selector lever lock. The flow transfer valve must be switched before carrying out
filter maintenance. At this point the contamination indicator signal is reset so the red button
can be released again.
1. Activate the pressure equalisation lever and hold it in position; the lever is located in the selector
lever Swivel commutation lever. Engage the lock on the right-hand side nearest to the filter.
Place the drip tray underneath to collect oil that flows out.
2. Loosen bleeder screw [1] of the unused filter side by 2-3 turns; fully out for backward motion up
against the safety stop.
3. Unscrew the filter grit trap anti-clockwise and clean thoroughly.
4. Remove the filter element with a sideways movement.
5. Check the O-ring on the filters grit trap for possible signs of damage and renew if necessary.
6. Ensure the part number of the spare corresponds with the number on the filter label. Open the plastic bag and push the element onto the part inside the filter head. Now remove the plastic bag.
7. When installation is complete, tighten the grit trap by turning it clockwise as far as it will go.
Unscrew the grit trap by between a 14 and 12 turn.
8. To fill the filter chamber, activate the pressure equalisation lever until the oil flows out from the
bleed hole without bubbles.
9. Tighten the bleed screw. Check that the filters are not leaking by activating the pressure equalisation lever again.
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
77
Maintenance
Date
Section 9
78
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
Maintenance
Date
Section 9
There are 4 fixing plates or washers between hood and cover; these must be returned to the same
position at the time of reassembly. For this purpose check the mark on the flange of the main
body.
If disassembly is carried out without removing the tube core, first disassemble the hood/cover
without fixing plates to ensure that the tube core is not dislodged. Now remove the fixing plates.
This operation can be performed with the aid of a second set of fixing plates, or with other similar
means.
Disassembly without removing the tube core:
Remove the O-rings from the external grooves of the tube plates and fix the tube core to the
main body with four screws and the four fixing plates in the middle groove of the tube plates.
Using this method the tube side can be inspected and cleaned mechanically. The casing side
remains pressurised.
Disassembly of the tube with removal of the tube core:
Remove the O-rings from the external grooves of the tube plates. The fixed position in relation
to the main body is marked on one of the tube plates. A mark X indicating the mid point is
present on the front side of the tube plate and on the adjacent flange of the main body. Check
the position of this symbol. Push the tube (using specific tools if necessary) sideways until the
O-ring of the internal groove is visible. Remove the O-ring from the internal groove. Extract the
tube core in the opposite direction. Carefully remove the tube core from the main body taking
care not to damage the fins. As far as possible keep the tube core suspended by means of wide
lifting webbing. Take care not to damage the O-ring seating grooves.
When removing devices fixed in a vertical direction, always make sure that the tube core does
not slip downwards once the fixing plates have been removed. It is good practice to have an
extra set of fixing plates and start the disassembly operation from the part on which there are no
fixing plates. In this case first of all fix the roll. After having removed the second hood, you can
remove the roll (proceed with caution). At the time of reassembly you can use just one set of
fixing plates (the set on the symbols side).
Assembly
To assembly the unit perform the disassembly steps in reverse sequence. Take account also of the
following considerations:
It is normal practice to use new O-rings and clean the grooves before fitting them.
Take note of the symbol to ensure the tube core is assembled correctly (X).
Take not of the symbol to assemble the fixing plates correctly (F).
The closing strips are located on the tube core side. Remove the strips only if damaged. When
inserting the tube core ensure that the closing strips have not been moved or twisted. Before
assembling the tube core, grease the closing strips. The operating product can be used. The
closing strips must ensure an efficient seal around the entire length of the tube core.
Lubricate the O-rings with a suitable grease.
While inserting the tube plate in the closing location, ensure the O-rings are not severed.
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
79
Maintenance
Date
Section 9
The hoods/covers must be fitted in parallel on the tube plate and pushed uniformly onto the
O-ring: ensure the O-ring is not severed during this operation.
With two-stroke devices arrange the plastic separation strip on the side of the hood with the two
connections. This done, install also the fixing plates from the same side.
When assembling the two-stroke hood ensure that the separation plate is fitted correctly.
Continue as described in Operation.
Cleaning
In the presence of a small quantity of scaling, the tube can be cleaned mechanically. Disassemble
the device as described in the disassembly chapter, without removing the tube core, and use a
suitable nylon bristle brush to clean the tubes inside (do not use metal wire brushes). Now flush
the unit with water. Never use force to prise out trapped deposits or large size debris.
In the presence of trapped deposits, use a chemical system to clean the tube core. The procedure can be performed by flushing the tube when the device is assembled or by submerging it in
chemical solution when disassembled.
This cleaning operation should be carried out exclusively by a specialised technician. Use exclusively suitable solvents. Construct the attached list to find the most suitable product. Analyse the
material of the plastic separation strip and the O-rings when the device is assembled. The Contacts section of this manual contains a list of companies that handle products that are suitable in
relation to the parts, or that offer complete cleaning services. If the eleventh letter of the type code
is C (e.g: KS12-BCN-821C L1000), this indicates that the tube core is coated. To prevent the
corrosion damage of the tube core, it is internally coated in the tube and in the tube header plate.
During disassembly of the roll and during cleaning procedures, tale care to ensure the coating is
not damaged. Use exclusively nylon bristle cleaning brushes and cleaning products in compliance
with the applicable regulations. If in doubt concerning a specific product, consult our maintenance
department.
Troubleshooting
Efficiency is too low! / oil outlet temperature is too high!
Check that all temperatures and materials comply with the project specifications.
Check that there is no foreign matter in the pipe or in the device, such as to create an obstruction.
Check that the tube core is correctly assembled; check the symbols.
Check that the plastic strips and fixing plates are correctly assembled in the two-stroke hood.
Check that air has been bled completely from all the compression chambers.
Check that the tube side or the casing side are not excessively fouled (with excessively dense
product deposits).
Check that no more than 10% of the tubes are clogged.
Leakages from the tubes
If you think there are leaks from the tubes, proceed as illustrated in the section concerning disassembly without removing the tube core. The casing part can remain pressurised. After having
cleaned the tube plates you will be able to identify the leaking tube by the condition of the liquid
80
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Maintenance
Date
Section 9
that comes out. Close both ends of the tube with conical plugs made of copper or hardwood. You
can plug a maximum of 10% of the tubes without any significant loss of efficiency. It is possible to
remove the defective tube.
Leaks from the rolled joints
If you notice a leak from a rolled joint while checking for leaks from a tube, you can roll the part
again by means of a special tool. Note however that this procedure should always be performed
by specialised personnel. Since these defects are relatively uncommon, we recommend having
the entire tube core checked at our works.
Leaks from the O-rings
If you notice a leak between the hood/cover and the main body, this indicates that one of the Orings of the tube plate is defective. The type of substance emerging identifies the groove of the
tube plate in which the defect has occurred. If the defect is on the tube side, proceed as illustrated
in the section concerning disassembly without removing the tube core. If the defect is from the
side of the casing, proceed as described in the part relative to disassembly with removal of the
tube core. In this case there is no need to remove the tube core completely from the main body.
Assemble the O-ring as illustrated in the part relative to Assembly.
3. Standstill periods:
When the installation is at a standstill for a period of:
Less than two days
Water flow within range that on average complies with operation of the pump (see table)
More than two days
Water flow for minimum period of one hour
More than two weeks
The water circuit must be drained and flushed with fresh water.
Technical data: see installation drawings and oil cooler manual and the technical data given in this
manual
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
81
Maintenance
Date
Section 9
Remarks
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
82
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
Section 10
Date
Troubleshooting Remedies
Section 10
Troubleshooting Remedies
MALFUNCTIONS
Overheating
CAUSES
REMEDY
Gearbox is overloaded
Bearings damaged
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
85
Date
Troubleshooting Remedies
Section 10
MALFUNCTIONS
Lack of oil pressure
Oil leakage
86
CAUSES
REMEDY
Filter obstructed
Clean filter
Pump wear
a) Renew seals
b) Install sealing cover in such
a manner that the passage is free from the
outer bearing side
c) Clean seals
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Date
Troubleshooting Remedies
Section 10
MALFUNCTIONS
Gearbox noise
CAUSES
REMEDY
Filter choked
(Excessive pump pressure)
Clean filter
Propeller damaged
Re-align installation
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
87
Date
Troubleshooting Remedies
Section 10
MALFUNCTIONS
The propeller does
not stop turning in
Neutral
CAUSES
REMEDY
Renew seals
Oil to cold
88
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
Section 11
Service Centres
Date
Section 11
Service Centres
ARGENTINA
CYPRUS
AUSTRALIA
CHILE
ECUADOR
ESTONIA
FINLAND
ATOY OY
Lauttasaarentie 54
00200 Helsinki
FINLAND
Tel. +358 9 682 71
Fax +358 9 682 73 05
E-mail: zf@atoy.fi
FRANC
ZF FRANCE S.a.r.l.
3-11 Rue Henri Poincar
92 167 Antony Cedex
FRANCE
Tel. +33 1 4096 4265
Fax +33 1 4096 4285
E-mail: raymond.gouge@zf.com
CROATIA
ZF PADOVA SHANGHAI
REPRESENTATIVE OFFICE
COPRIMARSA
KM 12.5 Va a Daule Urb.
Colina del Sol Mz. 2021 V. 5
ECUADOR
Tel. +59 3 9 961 3032
Fax +59 3 9 702 0468
E-mail: coprimarsa@yahoo.com
see also U.S.A.
ZF DANMARK ApS
Taastrupgaardsvej 8-10
2630 Taastrup
DENMARK
Tel. +45 7022 6243
Fax +45 7022 2643
E-mail: zfdk@zf.com
CHINA
DENMARK
ZF DO BRASIL Ltda *
Avenida Conde Zeppelin, 1935
CEP 18103-905 Sorocaba-SP
BRASIL
Tel. +55 15 4009 2389
Fax +55 15 4009 2233
E-mail: marine.info@zf-group.com.br
BELGIUM
BENELUX
LUXEMBURG
NETHERLANDS
BRAZIL
CHAR. (INDUSTRIAL)
PILAKOUTAS Ltd.**
GERMANY
ITEC d.o.o.
Ul. Kneza Domagoja 10
47000 Karlovac
CROATIA
Tel. +385 47 631 755
Fax +385 47 631 756
E-mail: nautica@itec.hr
ZF Padova S.p.A.
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 MARINE GmbH *
Ehlersstr. 50
88046 Friedrichshafen
GERMANY
Tel. +49 7541 77 2207
Fax +49 7541 77 4222
E-mail: info.zfmarine@zf.com
ZF MARINE GmbH
Representative Office
Zamdorferstrasse 90
81677 Mnchen
GERMANY
Tel. +49 89 930 094 63/64
Fax +49 89 930 094 21
E-mail: guenther.koeppel@zf.com
91
Service Centres
Date
Section 11
PIENING PROPELLER
Via S. Andrea, 16
38062 Arco (TN)
ITALY
Tel. +39 0464 580 555
Fax +39 0464 580 544
E-mail: info.zfhurth@zf.com
ZF ITALIA S.r.l.
SCHIFFSDIESELTECHNIK KIEL
Via Donizetti, 11
20090 Assago (MI)
ITALY
Tel. +39 02 4888 31
Fax +39 02 4884 3807
E-mail: marine@zf-group.it
Grasweg 26 b
24118 Kiel
GERMANY
Tel. +49 431 544 420
Fax +49 431 544 4220
E-mail: info@sdt-kiel.de
JAPAN
GREECE
TEKMAR Ltd.
15 Ethn. Makariou Str.
18 547 Neofaliro. Piraeus
GREECE
Tel. +30 210 4820 814
Fax +30 210 4811 803
E-mail: tekmar@hol.gr
KOREA (South)
ARIEXPO S.A.
68, Alimou Avenue, Alimos
17 455 Athens
GREECE
Tel. +30 210 984 3863
Fax +30 210 983 1346
E-mail: ariexpo@tee.gr
INDIA
MALAYSIA
LOURENCO MARINE
G-20 Lina Residency, Fatorda
Margao - Goa 403 602
INDIA
Tel. +91 832 2743 468
Fax +91 832 2743 450
E-mail:lourencomarine@sancharnet.in
INDONESIA
ISRAEL
MALTA
NORWAY
ZF PADOVA S.p.A. *
(ZF MARINE HEADQUARTERS)
Via Penghe, 48
35030 Caselle di Selvazzano (PD)
ITALY
Tel. +39 049 8299 311
Fax +39 049 8299 550
E-mail: info.zfpadova@zf.com
92
OCEANS
9, Main Street
Zurrieq ZRQ 03
MALTA
Tel. +356 21 640 703
Fax +356 21 641 223
E-mail: mylake@maltanet.net
ITALY
KGK NORGE AS
Caspar Storms vei 19
0664 Oslo
NORWAY
Tel. +47 22 88 4680
Fax +47 22 72 0902
E-mail: toma.wulff@zf-group.no
PERU
ZF Padova S.p.A.
Via Penghe, 48 I-35030 Caselle di Selvazzano (PD) ITALY
Tel. +39-049 8299-311 Fax +39-049 8299-550 www.ZF-Marine.com
Date
Service Centres
Section 11
POLAND
TURKEY
Prostokatna 5A Str.
81-601 Gydnia
POLAND
Tel. +48 58 627 3380
Fax +48 58 627 3390
E-mail: mirek.czurak@volvopenta.pl
E-mail: miroslaw.czurak@volvo.com
RUSSIA
ZF MARINE RUSSIA
Suite 404 - Obvodny Kanal Emb., 118
190005 St. Petersburg
RUSSIA
Tel. +7 812 441 37 94
Fax +7 812 441 37 94
E-mail: alexander.lyshkov@zf.sp.ru
SINGAPORE
SOUTH AFRICA
SPAIN
UNITED
KINGDOM
UNITED
ARAB
EMIRATES
U.S.A.
MEXICO
ZF MARINE, LLC
ZF ESPAA, S.A.
Avenida Fuentemar, 11
28820 Coslada (Madrid)
SPAIN
Tel. +34 91 485 2698
Fax +34 91 485 0036
E-mail: marine.zfesp@zf.com
SWEDEN
KG KNUTSSON AB
TRANSMISSIONSDIVIONEN
Nottingham NG7 2SX
UNITED KINGDOM
Tel. +44 115 986 9211
Fax +44 870 460 1479
E-mail: zfmarine@zf-group.co.uk
VENEZUELA
KG KNUTSSON AB
TRANSMISSIONSDIVISIONEN
SISTEMAS DE PROPULSION
Avda 67 A, entre 149B y 150
Municipio San Francisco, Maracaibo, Estado Zu
VENEZUELA
Tel. +58 261 736 0747
Fax +58 261 736 0746
E-mail: m.graticola@sistemasdepropulsion.com
Hammarbacken 8
19181 Sollentuna
SWEDEN
Tel. +46 8 923 000
Fax +46 8 929 599
E-mail: karl-henry.pragsten@kgk.se
THAILAND
*
**
MANUFACTURING LOCATIONS
ZF HURTH MARINE REPRESENTATIVE ONLY
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
93
Service Centres
Date
Section 11
94
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
Section 12
Recommended Oils
%
%
!" !" !"
!"#
#
$ $%&'(
" #
#
$ ) )' * ')
')
'.
#
$')
'.
*
0 ;= "2:
!"# $%
+
+
%
%
, - , - ,
#
, - ,
,/
#
#
#
,
56 3
1
%2
: ;1%1 :2 < =>
#
=: ; % :=;=; 3 % 87 1
1
:#<
: < = 33 ; 53 1
?0?4' 11>
)(.) "@484A 11 1
"@
B,'4&6>
+
% 2 C
1
3
:
=;1<
2
% ;:>
<2 % 2 C < 11; <2 % 2 :3 =3 % :
= % =1
>
=
$%,
* 3 3 50 -/-4,--74,-4,-4,-"-"7-"-"9-"8 / 13 - -/6
1 2 3F "/ ' "/ ,
1 =
=:; :;= #
< G.H#
#
-
.
(> : 4< ; =1
1
%2
< ;1%1 :2 < => !
<
; =1 3>
> :
1
1% 11 3 %= %
1 , :2 < =>
%
%= 11 3 1 , , :2 < =>
#
#
#
03 % (
=
$%/
* 3 3
1 2 3F "/ ' "/ ,
1 =
=:; :;= #
< G.H#
#
$%/
8"@8 '
8"@8 ,
/@!/A@ 7/!-
/@!/A@ 7/!-
" "0/ 8 ,
*@ 8 /8 (
' "/ '
*@ 8 /8 (
, "/ ,
!@ 0/A* ,
M. *@! 0 "/ ,
@*/7
,' "/ ,
0@4!/ 7* 77/-
"/88 7 ,
$!/"88 /?@ ,
"!!@8 /"/8$L ,
03 ' % (
=
!@!8 "@8 *! ,
!@!8 0 ,
!@!8 " ,
03 , % (
=
$%0
*=3 3 #
1 2 3F "/ )$4, - ($4, - ()$4, #
#
$%0
*@ 8 /8 ( "
*@ 8 /8 *A ()$4,
"0/*8!7@ ()$,
03 ) % (
=
$%1
= :1 !: = 5!6#
#
$%1
0 8/A-/
@8 !
@8 ! /
*"@8 "0/@-"
*"@8
"L!/! !
/ !@*!
8 /A !4 *
! 7*
0 ! A
0 ! A
0 ! 8!
0 ! * A
"!@8 !"*A
"!@8 !"L
/0" ! B
!/A*! ,&(
!/A*! B,)/
!/A*!
/@!/A@ 7/!-
!/A*! ,((
/@!/A@ 7/!-
!/A*! ,&(
/@!/A@ 7/!-
!/A*! B,)/
/@!/A@ 7/!-
!/A*! &
/@!/A@ 7/!-
!/A*! "
/@!/A@ 7/!-
!/A! 0"*
/@!/A@ "L/L-"
8!/A !4*
/@!/A@ "L/L-"
/@!/A@ "L/L-"
"*! */@
! !L0/
70 !
! /
/A@
03
% (
=
/""@ !
*@ 8 !
*@ 8 ! '
*@ 8 ! "
*@ 8 *8!4/8/ !
8 "8 @!7/*-
* L@/A '
!!/8 7-
7 !
L@?
.
L@? ..
8@!@" !
!@ "!*!
L4!@M/ 5!6
! ,
! ,'
"/@ !"/A
?8@ ! ?
M. !@ (,
M. !@ (, "L!/!
M. !@ ()
M. !@ () /
M. !@
!
*@8 !
8M*!
*@!8 /A@
/"!/ !4"
! "L!
@ *!
!!/8 7-
*8 ! A
@? //8 "!0@"!-8
@? //8 "!0@"!-8
@* !4"
!
03 B % (
=
0?/8@ A@ /
780 !"*!
0@ !
0@ !4
0"! !
0@8 !
0@8 ! /
/@8 /A@ /
@ !
*! !
*! "!/!@
">>/>8> *-/
78 !
">>/>8> *-/
">>/>8> *-/
"/88 @A !
"/88 @A !A
"/88 @A !
*! !@*!
*! !@*! /
$!/"88 !
"!!@8 !"$L A
"L!@*!
!"$L " A
"*! (,&
"*! ()'
! 08"
/8*! 7 "L
/8*! 7'
*! 0
*!
*! "
B
!@!8 8/ ! ,
!@!8 8/
03 . % (
=
*!
4/@8 08"
8/78)
03 & % (
=
$%"
* 3 3 50 -/-4,--74,-4,-4,-"-"7-"-"9-"8 / 13 - -/6
1 2 3F "/ )
+
-
.
: 4< ; =1
1
%2
< ;1%1 :2 < => !
<
; =1 3>
03 ( % (
Clutch discs
Numering System
Filters
Duplex Filter
Pi 370
Operating pressure 200 (250) bar, Nominal size up to 450
1. Features
Efficient filters for modern
hydraulic systems
Modular design
Minimal pressure loss
Compact design
Visual / electrical / electronical differential pressure
indication
Threaded or SAE 4 bolt flange ports
Switching valve on upstream side
Ergonomic switch-over handle with safety lock and pressure
compensation
User-optimized one-hand-operation
World-wide sales
MAHLE Filtersysteme GmbH Bereich Industriefilter Postfach 13 09 74603 hringen Telefon (0 79 41 ) 67-0 Telefax (0 79 41 ) 67-429
33 mm/s (4,5 E)
10
20
30
40
50
60
Pi 3705 Sm-x
20
40
60
80
100
Pi 3708 Sm-x
10
20
30
40
50
60
Pi 3705 Sm-xvst
20
40
60
80
100
Pi 3708 Sm-xvst
20
40
60
80
100
120
140
160
Pi 3715 Sm-x
50
100
150
200
250
300
350
Pi 3730 Sm-x
20
40
Pi 3715 Sm-xvst
60
80
100
120
140
160
200
300
400
500
100
120
100
Pi 3745 Sm-x
80
60
40
20
120
Pi 3711 Sm-xvst
100
80
60
40
20
Pi 3711 Sm-x
50
100
Pi 3730 Sm-xvst
150
200
250
300
350
100
Pi 3745 Sm-xvst
200
300
400
500
3. Separation characteristics
5000
Beta-ratio
1000
99,5
98,6
98,0
95,0
10
Sm-x elements
with p 20 bar
99,98
99,9
100
75
Sm-x 3
Sm-x 6
Sm-x 10
Sm-x 25
6
10
25
3
Sm-xvst elements
with p 210 bar
Sm-xvst 3
Sm-xvst 6
Sm-xvst 10
Sm-xvst 25
75
75
75
75
6
10
25
3
75
75
75
75
90,0
75,0
2
1
50,0
10
15
20
25
30
0,0
35
Order-no. 781.036.9
Order-no. 768.020.0
Type
number
781 0294
Pi 3705 -01 2
781 031 0
Pi 3705 -014
781 0302
781 0328
Pi 3705 -01 3
Pi 3705 -01 5
781 0336
Pi 3708-01 2
781 0351
Pi 3708-014
781 0344
781 0369
Pi 3708-01 3
Pi 3708-01 5
781 0377
Pi 37 1 1 -01 2
781 0393
Pi 37 1 1 -014
781 0385
781 0401
Pi 37 1 1 -01 3
Pi 37 1 1 -01 5
781 041 9
Pi 37 1 5 -01 2
781 0435
Pi 37 1 5 -014
781 0427
781 0443
Pi 37 1 5 -01 3
Pi 37 1 5 -01 5
781 0450
Pi 3730-01 2
781 0476
Pi 3730-014
781 0468
781 0484
Pi 3730-01 3
Pi 3730-01 5
781 0492
Pi 3745 -01 2
781 441 1
Pi 3745 -014
781 4403
781 4429
Pi 3745 -01 3
Pi 3745 -01 5
Nominal
size
(NG)
50
80
110
150
300
450
When filter with non bypass configuration is selected, collapse pressure of element may not be exceeded.
with
visual
indicator
with
electrical
indicator
5. Test regulations
MAHLE filter elements are manufactured respectively, tested in accordance with the following international standards:
Norm
Designation
ISO 2942
Hydraulic-fluid power-Filter elements-Verification of fabrication integrity and determination of the first bubble point
ISO 3723
ISO 2941
ISO 2943
ISO 3724
ISO 3968
ISO 16 889
ISO 10 771.1
6. Symbols
T
Sm-x 3
p 20 bar
Sm-x 6
p 20 bar
Sm-x 10
p 20 bar
Sm-x 25
p 20 bar
76801 35
7943509
7680325
7680440
( 590 cm)
76801 35
[Pi 2105]
( 590 cm)
7943509
[Pi 5105]
( 590 cm)
7680325
[Pi 3105]
( 590 cm)
7680440
( 900 cm)
( 900 cm)
7680457
7680457
( 1 31 5 cm)
( 1 31 5 cm)
( 1 31 5 cm)
( 1 31 5 cm)
7943525
7680333
7680465
7680465
( 2010 cm)
( 2010 cm)
( 2010 cm)
( 2010 cm)
7955099
7680358
7680473
[Pi 31 1 5]
7680473
( 3800 cm)
( 3800 cm)
( 3800 cm)
( 3800 cm)
7955107
7680366
7680481
[Pi 31 30]
7680481
( 5600 cm)
( 5600 cm)
( 5600 cm)
( 5600 cm)
79551 1 5
7680374
7680499
[Pi 3145]
[Pi 4230]
7680549
76801 84
[Pi 5145]
[Pi 3230]
7680531
768041 6
( 6540 cm)
[Pi 2145]
[Pi 5230]
7680408
79551 31
( 6540 cm)
7680374
[Pi 2230]
79551 23
7680234
( 6540 cm)
79551 1 5
7680226
[Pi 41 30]
( 6540 cm)
76801 84
[Pi 421 5]
7680531
76801 76
[Pi 51 30]
[Pi 321 5]
7680523
7680408
( 4420 cm)
[Pi 21 30]
[Pi 521 5]
7680390
79551 23
( 4420 cm)
7680366
[Pi 221 5]
7943558
7680226
( 4420 cm)
7955107
768021 8
[Pi 41 1 5]
( 4420 cm)
76801 76
[Pi 421 1 ]
7680523
76801 68
[Pi 51 1 5]
[Pi 321 1 ]
768051 5
7680390
( 2350 cm)
[Pi 21 1 5]
[Pi 521 1 ]
7681 1 90
7943558
( 2350 cm)
7680358
[Pi 221 1 ]
7943541
768021 8
( 2350 cm)
7955099
7680200
[Pi 41 1 1 ]
( 2350 cm)
76801 68
[Pi 4208]
768051 5
76801 50
[Pi 31 1 1 ]
[Pi 3208]
7680507
7681 1 90
( 1 700 cm)
[Pi 51 1 1 ]
[Pi 5208]
7680382
7943541
( 1 700 cm)
[Pi 21 1 1 ]
[Pi 2208]
7943533
7680200
( 1 700 cm)
7680333
76801 92
[Pi 4108]
( 1 700 cm)
7943525
[Pi 4205]
( 900 cm)
7680341
76801 50
[Pi 3205]
( 470 cm)
( 900 cm)
794351 7
[Pi 3108]
[Pi 5205]
( 470 cm)
Sm-xvst 25
p 210 bar
7680507
7680143
[Pi 5108]
[Pi 2205]
( 470 cm)
Sm-xvst 10
p 210 bar
7680382
( 1 1 50 cm)
[Pi 2108]
( 470 cm)
Sm-xvst 6
p 210 bar
7943533
( 1 1 50 cm)
7680341
Sm-xvst 3
p 210 bar
76801 92
( 1 1 50 cm)
794351 7
[ ] = type number
[Pi 4105]
( 1 1 50 cm)
7680143
7680499
[Pi 4145]
7680234
[Pi 2245]
7680242
7680242
79551 31
[Pi 5245]
7955149
7955149
768041 6
[Pi 3245]
7680424
7680424
7680549
[Pi 4245]
7680556
7680556
8. Specifications
Design:
Operating pressure:
200 bar*
Test pressure:
260 bar*
Temperature range:
(other temperature ranges on request)
-10C to +120C
p 7 bar 10 %
GGG
St
Material of seals:
NBR / PTFE / CU
p 5 bar 10 %
230 V~/=
2,5 A
Pi 3730Pi 3745
60 VA/ 40 W
G DIN 910
70 VA
Type of protection:
Contact:
bistable
Cable connection:
PG 11 6-10
9. Dimensions
Weight
[kg]
100 86
70
58
11,0
45
100 86
70
58
13,0
90
45
100 86
70
58
15,0
62
140
45
210 136
94
82
31,5
280 M 12 x 18
62
140
45
210 136
94
82
37,0
280 M 12 x 18
62
140
45
210 136
94
82
41,5
G
SW
80
27
65
144
45
182
M 8 x 15
55
90
45
G 1*
294 346 80
27
65
144
45
182
M 8 x 15
55
90
G 1*
370 422
80
27
65
144
45
182
M 8 x 15
55
50
30
110 175
70
280 M 12 x 18
78
50
30
110 175
70
78
50
30
110 175
70
Pi 3705
78
38
G 1*
219 271
Pi 3708
78
38
Pi 3711
78
38
Pi 3715
78
Pi 3730
Pi 3745
Type
Y
vent screw
W
U
2. Please always ensure that you have original MAHLE-replacement elements in stock: disposable elements (Sm-x) cannot be
cleaned.
10.4 Element replacement
Type-Number/ Housing
Pi 3705Pi 371 1
Seal kit
NBR
FPM
EPDM
8305062
8305054
8305047
Contamination indicator
visual
electrical
766991 4
Pis 3093/5 bar
Seal kit
NBR
FPM
EPDM
7669864
Pis 3092/5 bar
NBR
FPM
EPDM
7760275
7760283
7760291
9375056
9375064
9375072
electrical upper
section only
7536550
5. Check O-ring and back-up ring on the filter bowl and spigot
for damage. Replace, if necessary.
Pos.
Modular design
Minimal pressure loss
Compact design
Visual / electrical / electronical differential pressure
indication
World-wide sales
MAHLE Filtersysteme GmbH Bereich Industriefilter Postfach 13 09 74603 hringen Telefon (0 79 41 ) 67-0 Telefax (0 79 41 ) 67-429
20,0
10,0
20,0
10,0
5,0
20,0
10,0
5,0
2,0
20,0
Pi 3408 Sm-xvst
Pi 3408 Sm-x
Pi 3405 Sm-xvst
Pi 3405 Sm-x
33 mm/s (4,5 E)
10,0
5,0
2,0
5,0
2,0
2,0
1,0
1,0
1,0
1,0
0,5
0,5
0,5
0,5
10
20
50
100
0,1
10
20
50
100
20,0
10,0
10
20
50
100
2,0
1,0
1,0
1,0
0,5
0,5
0,5
0,5
200
500 1000
0,1
50
100
200
500 1000
50
100
200
500 1000
2,0
1,0
1,0
1,0
0,5
0,5
0,5
0,5
100
200
500 1000
Flow rate [l/min]
0,1
20
50
100
200
500 1000
Flow rate [l/min]
0,1
200
500 1000
5,0
2,0
50
100
10,0
5,0
1,0
20
50
20,0
2,0
0,1
20
Pi 3445 Sm-xvst
10,0
5,0
0,1
20,0
10,0
5,0
20
20,0
10,0
100
2,0
Pi 3445 Sm-x
20,0
0,1
Pi 3430 Sm-xvst
Pi 3430 Sm-x
20
50
100
20
5,0
2,0
50
10
10,0
5,0
1,0
20
20,0
2,0
0,1
Pi 3415 Sm-xvst
10,0
5,0
0,1
20,0
10,0
5,0
Pi 3415 Sm-x
20,0
0,1
Pi 3411 Sm-xvst
Pi 3411 Sm-x
0,1
2,0
20
50
100
200
500 1000
Flow rate [l/min]
0,1
20
50
100
200
500 1000
Flow rate [l/min]
3. Separation characteristics
determined by multi-pass-tests (ISO 4572)
Beta-ratio
1000
99,5
98,6
98,0
95,0
10
Sm-x elements
with p 20 bar
99,98
99,9
100
75
Sm-x 3
Sm-x 6
Sm-x 10
Sm-x 25
6
10
25
3
Sm-xvst Elements
with p 210 bar
Sm-xvst 3
Sm-xvst 6
Sm-xvst 10
Sm-xvst 25
75
75
75
75
6
10
25
3
75
75
75
75
90,0
75,0
2
1
5000
50,0
10
15
20
25
30
0,0
35
Bestell-Nr. 787.441.5
Bestell-Nr. 768.020.0
7. Order numbers
7.1 Housing design
Order
number
Type
number
7874324
Pi 3405 1 2
7874340
Pi 3405 14
7874332
7874357
Pi 3405 1 3
Pi 3405 1 5
7874381
Pi 3408 1 2
7874407
Pi 3408 14
7874399
787441 5
Pi 3408 1 3
Pi 3408 1 5
7874499
Pi 341 1 1 2
7874464
Pi 341 1 14
7874456
7874472
Pi 341 1 1 3
Pi 341 1 1 5
7921 91 9
Pi 341 5 1 2
7921 935
Pi 341 5 14
7921 927
7921 943
Pi 341 5 1 3
Pi 341 5 1 5
7921 968
Pi 3430 1 2
7921 984
Pi 3430 14
7921 976
7921 992
Pi 3430 1 3
Pi 3430 1 5
7922008
Pi 3445 1 2
7922024
Pi 3445 14
792201 6
7922032
Pi 3445 1 3
Pi 3445 1 5
Nominal
size
(NG)
With bypass
valve and visual
indicator
With bypass
valve and electrical
indicator
With
visual
indicator
50
80
110
150
300
450
When filter with non bypass configuration is selected the collapse pressure of the element may not be exceeded
With
electrical
indicator
5. Test regulations
MAHLE filter elements are manufactured respectively, tested in accordance with the following international standards:
No .
Designation
ISO 2941
ISO 2942
ISO 2943
ISO 3723
ISO 3724
ISO 3968 . 2
Hydraulic -filters:
ISO 4572
6. Symbols
Sm-x 3
p 20 bar
Sm-x 6
p 20 bar
Sm-x 10
p 20 bar
Sm-x 25
p 20 bar
76801 35
7943509
7680325
7680440
( 590 cm)
76801 35
[Pi 2105]
( 590 cm)
7943509
[Pi 5105]
( 590 cm)
7680325
[Pi 3105]
( 590 cm)
7680440
( 900 cm)
( 900 cm)
7680457
7680457
( 1 31 5 cm)
( 1 31 5 cm)
( 1 31 5 cm)
( 1 31 5 cm)
7943525
7680333
7680465
7680465
( 2010 cm)
( 2010 cm)
( 2010 cm)
( 2010 cm)
7955099
7680358
7680473
[Pi 31 1 5]
7680473
( 3800 cm)
( 3800 cm)
( 3800 cm)
( 3800 cm)
7955107
7680366
7680481
[Pi 31 30]
7680481
( 5600 cm)
( 5600 cm)
( 5600 cm)
( 5600 cm)
79551 1 5
7680374
7680499
[Pi 3145]
[Pi 4230]
7680549
76801 84
[Pi 5145]
[Pi 3230]
7680531
768041 6
( 6540 cm)
[Pi 2145]
[Pi 5230]
7680408
79551 31
( 6540 cm)
7680374
[Pi 2230]
79551 23
7680234
( 6540 cm)
79551 1 5
7680226
[Pi 41 30]
( 6540 cm)
76801 84
[Pi 421 5]
7680531
76801 76
[Pi 51 30]
[Pi 321 5]
7680523
7680408
( 4420 cm)
[Pi 21 30]
[Pi 521 5]
7680390
79551 23
( 4420 cm)
7680366
[Pi 221 5]
7943558
7680226
( 4420 cm)
7955107
768021 8
[Pi 41 1 5]
( 4420 cm)
76801 76
[Pi 421 1 ]
7680523
76801 68
[Pi 51 1 5]
[Pi 321 1 ]
768051 5
7680390
( 2350 cm)
[Pi 21 1 5]
[Pi 521 1 ]
7681 1 90
7943558
( 2350 cm)
7680358
[Pi 221 1]
7943541
768021 8
( 2350 cm)
7955099
7680200
[Pi 41 1 1 ]
( 2350 cm)
76801 68
[Pi 4208]
768051 5
76801 50
[Pi 31 1 1 ]
[Pi 3208]
7680507
7681 1 90
( 1 700 cm)
[Pi 51 1 1 ]
[Pi 5208]
7680382
7943541
( 1 700 cm)
[Pi 21 1 1 ]
[Pi 2208]
7943533
7680200
( 1 700 cm)
7680333
76801 92
[Pi 4108]
( 1 700 cm)
7943525
[Pi 4205]
( 900 cm)
7680341
76801 50
[Pi 3205]
( 470 cm)
( 900 cm)
794351 7
[Pi 3108]
[Pi 5205]
( 470 cm)
Sm-xvst 25
p 210 bar
7680507
7680143
[Pi 5108]
[Pi 2205]
( 470 cm)
Sm-xvst 10
p 210 bar
7680382
( 1 1 50 cm)
[Pi 2108]
( 470 cm)
Sm-xvst 6
p 210 bar
7943533
( 1 1 50 cm)
7680341
Sm-xvst 3
p 210 bar
76801 92
( 1 1 50 cm)
794351 7
[ ] = type number
[Pi 4105]
( 1 1 50 cm)
7680143
7680499
[Pi 4145]
7680234
[Pi 2245]
7680242
7680242
76851 31
[Pi 5245]
7955149
7955149
768041 6
[Pi 3245]
7680424
7680424
7680549
[Pi 4245]
7680556
7680556
8. Specifications
Design:
Flange filter
Operating pressure:
Screws for
attachement
250 bar*
325 bar
Temperature range:
-10 C to +120 C
(other temperature ranges
on request)
Pi 34153445 G 1
is possible
p 7 bar 10 %
the deliveries.
GGG
St
Material of seals:
NBR / PTFE / Cu
p 5 bar 10 %
Electrical data of
contamination indicator:
Maximum voltage:
Seal
41,5 x 3
Seal
"Outlet"
230 V~/=
18,72 x 2,62
2,5 A
"Outlet"
60 VA/ 40 W
Inrush current:
70 VA
Type of protection:
IP 65 when inserted
and secured
Contact:
"Inlet"
bistable
Cable connection:
"Inlet"
PG 11 610
9. Dimensions
G
SW
Weight
kg
Pi 3405
78
29
181
241
110
27
66
90
101
13
11
83
45
58
26
3,5
Pi 3408
78
29
259
319
110
27
66
90
101
13
11
83
45
58
26
4,5
Pi 3411
78
29
335
395
110
27
66
90
101
13
11
83
45
58
26
5,5
Pi 3415
78
60
308
368
110
30
109
140
150
30
22
135
45
95
52
58
14,8
Pi 3430
78
60
G
433
493
110
30
109
140
150
30
22
135
45
95
52
58
17,3
Pi 3445
78
60
G
550
610
110
30
109
140
150
30
22
135
45
95
52
58
19,6
Type
3. Please always ensure that you have original MAHLE-replacement elements in stock: disposable elements (Sm-x) cannot be
cleaned.
10.4 Element replacement
4. Check O-ring and back-up ring on the filter bowl and spigot for
damage. Replace, if necessary.
to
Pi 3405Pi 341 1
Seal kit
NBR
FPM
EPDM
7850381
7850399
7850407
Seal kit
NBR
FPM
EPDM
Contamination indicator
visual
electrical
5 bar
5 bar
766991 4
7669864
Pis 3093/5
Pis 3092/5
7936206
793621 4
7936222
electrical upper
part only
7536550
Pos.
Pumps
Cooler
INSTALLATION
AND
OPERATING MANUAL
: KS12-BCN-421 L718
:
:
: ZF Padova
:
Table of Contents
GENERAL
Operational Range
Service
Guarantee
Conservation
Transportation
STRUCTURAL BUILD-UP
Tube bundle
Shell
Bonnets
Seals
Accessories/spare parts
SERVICE
Installation
Screw fasteners
Type plate
Starting up
Operating instructions
MAINTENANCE
Periodic inspections
Dismounting
Assembly
Cleaning
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 2 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
TROUBLESHOOTING
Leaky tubes!
Leaky O-ring!
CONTACTS
Cleaning
Repair/spare parts
10
APPENDIX
Type plate
Data sheet
Drawings
Parts list
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 3 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
General
Operational Range
Heat exchanger of product line K were developed in particular for application in the field of the
industrial and maritime cooling. The present device is a high efficient heat exchanger on the principle
of shell and tube, in compact and lightweight design. The apparatus of this product line can be
adapted to different conditions of use by particular combination of material and components. The field
of application include all possible uses of cooling, in particular turbines, compressors, refrigeration
units, hydraulic plants, in the range of engines, gears etc. Service life of the devices is essentially
influenced by proper maintenance and operation. For this reason, observe strictly these instructions.
Service
For all service inquiries, please contact directly our factory, our sales force or your contracting party.
In the case of spare part orders, please indicate always the designation of the device and/or the spare
part. The necessary specifications can be taken from the enclosed drawings and from parts lists.
Guarantee
Warranty claims are to be taken from our general supply and payment terms, providing no other
individual agreements were made.
Repairs of defective parts at a later stage may only be carried out with our approval. If circumstances
should not permit asking our approval, you can ignore it. In this case you must inform us immediately
at the nearest occasion.
In principal any changed service conditions must be approved by us in writing.
Conservation
Under normal conditions are internal surfaces of the devices protected for a duration of 6 months. A
post-preserving is necessary after 6 months. The preserving liquid and the note on safety can be
provided by us. The used preservative is well compatible with all mineral lubricants. The removal of
these substances can be done by using any known solvent (check material compatibility!). The
devices should only be stored in closed rooms. Condensation through strong variation of temperature
must be avoided.
Transportation
A damage of the device must be by all means avoided. The transportation of the unpacked device
when using lifting systems has to be carried out with sufficient number of transportation straps set
around the casing. Please note the dead weight of the device indicated on the current data sheet or
the type plate.
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 4 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
Structural build-up
Tube bundle
The tube bundle consists of two opposite identical tube plates with three grooves. The tubes are rolled
into the tube plate wholes. Between the tube plates at the outer side of the tubes, the surface is
enlarged forming fins which are in connection with the tubes. The result is a compact finned bundle. At
the outer side of the finned bundle, there are grooves across the whole length which are used to take
up sealing straps. In the finned bundle, a different number of baffles can be installed. A groove is
milled in the top of the baffle which contains a spring and a sealing plate. The interior O-ring grooves
in the tube plates seal against the casing in assembled state. The external seals are used for sealing
the bonnet. In this way, a intermixing of the media is avoided if a seal becomes defective and a
leakage localization is simplified. In the central groove, sheets are positioned which fix the tube plate
in assembled state and allow a thermal expansion for the opposite tube plate. With two path devices,
the fixation must be at the side of the connections. In any case, the side of fixation is marked by an
imprinted 'F' at the flange of the casing in the area of the flanges M1 or M2. The fixation must be
positioned at this side when in working condition.
Shell
The shell is used for taking up the tube bundle and forms the shell side casing. It consists of end
pieces which are circular-welded with the shell
tube. The end pieces can be placed in such a way
that the connections are positioned at one
side or rotated by 180. The shell tube is a
precision tube with restricted allowances.
Changes must not be carried out on the casing.
!
At the starting area of the end pieces, the
interior groove of the tube plates seals by
means of an O-ring. This area must be treated carefully in order to guarantee a sealing effect.
The mounting brackets grip around the shell tube. These allow an optional assembly position of the
device.
Casings of model KK are cast casings in standardized, fixed version.
Bonnets
The bonnets consist of different materials (see part list), depending on version of the device. The
bonnet forms together with the tube bundle the chamber of the cooling medium and is fixed to the
casing by screws. At one side of the device, sheets are inserted between bonnet and casing which fix
the tube plate. At the other side, washers form a spacer.
The one path version has two identical bonnets positioned opposite each other. With the two path
version, one bonnet with two connections is mounted at one side of the device, at the other side there
is a reversing cover. To seperate the two chambers in the bonnet, a plastic or aluminium path partition
is inserted into the tube plate at the connection side. In assembled state, the path partition seals
bonnet and tube plate, i.e. it splits the flow of tubeside medium through the device.
Seawater resistant versions contains sacrificial anodes.
Seals
All tube plate seals consist of O-rings.
All pipe threads are sealed by copper or aluminum rings.
The tube bundle is sealed at the side along its length with a sealing strip against the casing. The
sealing strips consist of the same material as the O-rings. All seals are available from our factory with
indication of the drawing number.
Accessories/spare parts
Accessories and spare parts can be taken from the enclosed drawings and part lists. Drawing and
identification numbers of components which are necessary for ordering, are also listed there. Price
lists for the spare parts and not listed accessories can be requested via our marketing department or
directly from factory.
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 5 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
Service
Installation
The following items must be considered during the installation of the device:
Protective caps fitted to connections must be removed. If there is no protective cap on a
connection, check whether it has been pushed into the connection or foreign parts have
penetrated the device.
Foreign
bodies
must
not
penetrate the openings of the connections.
The connection of the pipes
must be tension-free to ensure that no inadmissibly high
thermal
or
mechanical
tensions affect the device in service.
!
All circuits must be designed
to avoid penetration of dirt and dust. We recommend the
assembly of dirt traps and suitable filters.
Tubes must be correctly installed so that air locks cannot built up.
The assembly can be horizontal or vertical.
Sufficient space should be available to ensure easy accessibility to all screw connections. Take
particular care for providing enough space for remove the tube bundle. You can take the
necessary space dimensions for remove the tube bundle from the sketch. It is possible to remove
the tube bundle from both sides of the device.
. The direction of flow is to be taken from the enclosed sketch and from the datatsheet
Before startup, the device must be completely bled.
Never weld or modify the cooler.
In case of using the device as oilcooler before startup, clean/flush the oil circuit but not the
lubricated points.
Orifice plates must only be installed at the outlet side of the device.
Screw fasteners
To ensure a safe operation and a long service of fastening elements, the screw fastenings should be
only torqued. The table below lists the torque figures for used screws. Through influence of various
factors, the specified values may show a deviation which in individual cases require lower or higher
values.
Connection shell/bonnet
Connection flanges
type
screw/
strength
torque [Nm]
screw/
strength
material
thread
K12
M12 5.6
38
M12 5.6
aluminium
30
M12 8.8
80
red bronze
30
M16 5.6
95
aluminium
75
M16 8.8
200
red bronze
75
M20 5.6
180
cast steel
100
M20 8.8
400
cast steel
300
K20
K25
M16 5.6
M24 5.6
of
torque [Nm]
Type plate
The type plate is at the side of the device and is permanently fixed. You can find a copy of the type
plate in the appendix.
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 6 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
Starting up
At first the apparatus must be filled up with the intended medium, then the entire system must be
checked for leakage. For watercooled
devices use only clean water at the tube side. Before
the actual starting up of the system,
make sure that the cooling medium is circulated.
!
Operating the device without flow of
cooling medium is not permissible.
Only for watercooled units:
If the flow adjustment is carried out by a control, we recommend a oil-sided control, especially when
operating with river or sea water.
Discuss the control of cooling water with our factory, because factors like material and quality of
cooling water are very important to avoid later problems.
The use of additives in the cooling water has to be confirmed through HS-Cooler GmbH.
Operating instructions
During the operation, make
sure by suitable means that pre-set parameters for which the
devices are designed are kept.
!
If reserve devices with switchover valves are present, switch these devices periodically on
(all 2-3 days) or load the reserve device daily for some time with the full water volume.
Maintenance
Periodic inspections
Devices of product line K are normally reliable and easy to maintain. However, some periodic
inspections of the device are necessary to provide a safe, continuous operation. Normally inspections
on the tubeside (waterside) predominate. The shellside is less inclined to pollution so that an
inspection can be carried out based on the experience of the operator.
The following inspections should be practiced:
When operating with sea water, sacrificial
anodes are installed in the bonnets/covers.
These should be checked in the initial
phase all 3 months. If the anodes are used
!
up, they must be replaced by new ones.
In the case of excessively fast consumption
of the anodes, water quality and the electrical potential of the system must be checked.
The device should be cleaned at the water side at least once a year. An excessive pollution of the
tubes must by all means be avoided. The bonnets can be removed without depressurerizing the
shell side. The intervals are to be shortened during long ship operation in harbors or in other
polluted waters and depending on the experience of the operator.
At shorter intervals the device must be subject to an externally visual inspection, in order to
identify leakage or other problems early. Through the double O-ring sealing, leakages can be
precisely located and the relevant expenditure can be estimated.
Dismounting
Proceed as follows when dismounting the apparatus:
Lock-up any pipelines
Empty the apparatus at the tube side, if a removal of the tube bundle is necessary, empty also the
shell side.
Remove the pipelines at the tube side.
Remove the bonnets/covers. For this purpose, the screws at the bonnet/casing connection must
be loosened. Between the bonnet/cover there are 4 fixing plates or washers. These must be
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 7 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
replaced at the same side again during re-assembly. The marking on the casing flange must be
here observed.
If you want to dismount without remove the
tube bundle, the bonnet/cover without fixing
plates must be disassembled first in order
to protect the tube bundle against
displacement, before you remove the
fixing plates. This can be done with another
!
set of fixing plates or with similar aids.
Dismounting without remove the tube bundle:
Remove the O-rings from the external groove of the tube plates and secure the tube bundle to the
casing with four screws and the four fixing plates in the middle groove of the tube plates. The tube
side can now be inspected and cleaned mechanically. The shell side can remain under pressure.
Dismounting with remove the tube bundle:
Remove the O-rings from the external groove of the tube plates. At one tube plate, a marking of
the fixed position in relation to the casing is attached. A half of a X is stamped at the front of the
tube plate and the adjacent casing flange. Check the position of the marking. Push the tube
bundle (where appropriate with auxiliary tools) so far sideways until the O-ring of the interior
groove becomes visible. Remove the O-ring from the interior groove. Pull out the tube bundle in
the opposite direction. Remove the tube bundle carefully from the casing without damaging the
fins. As far as possible suspend the
tube bundle with the help of large-surface
transportation straps. The grooves
taking the O-rings must not be damaged. During
dismounting of the tube bundle the
sealing plate and the spring can drop out of the
!
baffle groove. The spring and the
sealing plate have to be installed during assembly
of the bundle by pressing them into the groove whilst the baffle passes the inlet of the shell.
When dismounting vertically fixed devices, make sure in any case that the tube bundle does not
slips down after removal of the fixing plates. We
recommend to provide an additional
set of fixing plates and to start the removal at the side
where no fixing plates are mounted.
There the bundle must be secured first. After
dismounting the second bonnet,
!
the bundle can be removed carefully. While
assembling, only one set of fixing
plates is permittedat the side of the marking.
Assembly
The assembly is carried out in reversed order as dismounting. The following must also be considered:
Generally use new O-rings and clean O-ring grooves.
Note the marking for proper assembly of the tube bundle (X).
Note the marking for correct assembly of the fixing plates (F).
At the side of the tube
bundle there are sealing straps. These should only be replaced
when damaged. When
pushing-in the tube bundle take care that the sealing straps are
not displaced or twisted.
Before assembling the tube bundle, the sealing straps should
!
be greased. You can
use the operating medium. The sealing straps must be
effective along the entire length of the tube bundle.
Insert the sealing plate and the spring into the baffle groove and press down during insertion of the
tube bundle
Lubricate O-rings with suitable O-ring grease.
During insertion of the tube plate into the sealing faces, make sure that the O-rings do not shear.
The bonnets/covers must be set up in parallel onto the tube plate and must be pushed evenly onto
the O-ring; ensure also that the O-ring does not shear.
With two path devices, a path partition must be fitted at the side of the bonnet with the two
connections. At this side, the fixing sheets must also be installed later.
When assembling the two path bonnet, make sure that the path partition is correctly placed.
Then continue as described under 'Operation'.
Cleaning
In the case of only small amount of fouling, the tube side can be mechanically cleaned. Disassemble
the device as described under
'dismounting without remove the tube bundle' and clean with
a suitable nylon brush (do not
use metal brushes) each tube inside, then clean with water.
Never remove stuck deposits or
coarse dirt by force.
!
In the case of stuck deposits,
the tube bundle must be cleaned chemically. This can be
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 8 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
carried out by rinsing the tube in the assembled state or submerging in disassembled state. Such a
cleaning must only be practiced by specialists. Only suitable solvents must be used. To select a
suitable agent, refer to the added part list. Take the materials of the plastic separator strip and O-rings
in the assembled state into consideration. Under 'Contacts' you find some companies offering
respective agents or carrying out a complete cleaning.
Provided that the type designation gets a C at the 11th position (example: KS12-BCN-821C L1000),
then it is a coated tube bundle. To prevent a damage caused by corrosion this bundle is coated on the
inside of the tubes and on the tubesheets. When dismounting the bundle and during cleaning make
sure that the coating will not be damaged or destroyed. Use only nylon cleaning brushes and
approved cleaning agents. If there are any doubts about suitability of an agent, please contact our
service department.
Troubleshooting
To low performance!/outlet temperature to high!
Check all temperatures and material flows in accordance with the design data?
Are foreign bodies in pipe or in device causing obstruction?
Is the tube bundle correctly assembled, check marking?
Are the path partition and the fixing plates correctly assembled in the two path bonnet?
Are all pressure rooms vented?
Are tube side or shell side too dirty (too thick deposits)?
Are more than 10% of the tubes plugged?
Leaky tubes!
If the presumption exists that tubes have become leaky, proceed as with 'dismounting without remove
the tube bundle'. The shell side can remain under pressure. After cleaning the tube plates, you can
identify the defective tube by the state of the emerging medium. Lock the leaky tube at both ends with
our Tubelock-Repairset. Alternative you can use a conical copper or aluminium plug or a conical hard
wood plug. The plug must not be pushed too strong since otherwise adjacent rolling connections can
be damaged. You can lock 10% of the tubes at the most without noticeable reduction in performance.
Dismounting the defective tube is not possible.
Leaky O-ring!
If a leakage is found between bonnet/cover and casing, an O-ring of the tube plate is defective. The
kind of the emerging medium defines at which groove of the tube plate the defect developed. In the
case of a defect on the tube side, proceed as described under 'dismounting without remove the tube
bundle'. In the case of a defect at the shell side, proceed as described under 'dismounting with
withdrawing the tube bundle'. In this case the tube bundle does not need to be removed completely
from the casing. Assemble the O-ring as described in 'Assembly'.
Contacts
Cleaning
Suppliers for cleaning agents:
Ashland Chemicals www.ashchem.com
Henkel Oberflchentechnik- www.henkel.com
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 9 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
Repair/spare parts
Repairs must only be carried out by specially trained personnel. However we recommend to carry out
any repair in our factory.
You can purchase spare parts directly from us with indicating the sketch and serial number. Please
contact our head offices or our sales office.
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 10 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
Pos.
Quantity
Unit
Description
pc.
Shell
pc.
Tube Bundle
pc.
KL12-B-002
pc.
Anode 3/8"
KL-1021
pc.
Cover
KL12-B-003
pc.
Anode 3/8"
KL-1021
pc.
Sealing Plug
Brass
pc.
Sealing Ring
Copper
pc.
Fixation Plate
KL12-0-108
Steel galv.
10
pc.
Clamp Bracket
KL12-0-109
Steel
11
pc.
Hex Bolt
Steel galv.
12
pc.
Hex Nut
Steel galv.
13
pc.
Washer
DIN 125 - A 13
Steel galv.
14
pc.
Hex Bolt
Steel galv.
AD-W7 (Stamped)
15
pc.
Hex Nut
Steel galv.
AD-W7 (Stamped)
16
12
pc.
Washer
DIN 125 - A 13
Steel galv.
17
pc.
Type Plate
DRAW
Part/Standard Number
Remark
GS12 - 1
RL12 - C N - 4 2 1
G-CuSn5PbZn
(3.1B)
G-CuSn5PbZn
(3.1B)
Aluminium
DATE
NAME
29.11.99
Garbe
Parts List
NORM
K S 1 2 - BCN - 4 2 1
SYM
REVISION
DATE
NAME
Sheet
1 of 1
Pos.
Quantity
Unit
Description
Part/Standard Number
KL12 - C - 052
Remark
CuZn38Sn1 F34
AD-W6/2 (3.1B)
CuAl10Fe5Ni5-C
DIN EN 1982 (3.1B)
pc.
Tubesheet
72
pc.
Tube LR = L + 28mm
7.5mm x 0.5mm
CuNi10Fe1Mn F29
AD-W6/2 (3.1B)
L/1.4
pc.
Fin 1.4
KL12-0-105
Aluminium
pc.
O-Ring
KL-1510
NBR
pc.
Sealing Strip
L x 13 x 3
NBR
pc.
Baffle
KL12-0-106
Aluminium
pc.
Water Partition
KL12-0-107
Polypropylen
DRAW
DATE
NAME
02.11.99
Garbe
PARTS LIST
NORM
R L 1 2 - CN - 4 2 1
SYM
REVISION
DATE
NAME
Sheet
1 of 1
INSTALLATION
AND
OPERATING MANUAL
: KS20-BCN-421- L600
:
:
: ZF Padova
:
Table of Contents
GENERAL
Operational Range
Service
Guarantee
Conservation
Transportation
STRUCTURAL BUILD-UP
Tube bundle
Shell
Bonnets
Seals
Accessories/spare parts
SERVICE
Installation
Screw fasteners
Type plate
Starting up
Operating instructions
MAINTENANCE
Periodic inspections
Dismounting
Assembly
Cleaning
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 2 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
TROUBLESHOOTING
Leaky tubes!
Leaky O-ring!
CONTACTS
Cleaning
Repair/spare parts
10
APPENDIX
Type plate
Data sheet
Drawings
Parts list
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 3 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
General
Operational Range
Heat exchanger of product line K were developed in particular for application in the field of the
industrial and maritime cooling. The present device is a high efficient heat exchanger on the principle
of shell and tube, in compact and lightweight design. The apparatus of this product line can be
adapted to different conditions of use by particular combination of material and components. The field
of application include all possible uses of cooling, in particular turbines, compressors, refrigeration
units, hydraulic plants, in the range of engines, gears etc. Service life of the devices is essentially
influenced by proper maintenance and operation. For this reason, observe strictly these instructions.
Service
For all service inquiries, please contact directly our factory, our sales force or your contracting party.
In the case of spare part orders, please indicate always the designation of the device and/or the spare
part. The necessary specifications can be taken from the enclosed drawings and from parts lists.
Guarantee
Warranty claims are to be taken from our general supply and payment terms, providing no other
individual agreements were made.
Repairs of defective parts at a later stage may only be carried out with our approval. If circumstances
should not permit asking our approval, you can ignore it. In this case you must inform us immediately
at the nearest occasion.
In principal any changed service conditions must be approved by us in writing.
Conservation
Under normal conditions are internal surfaces of the devices protected for a duration of 6 months. A
post-preserving is necessary after 6 months. The preserving liquid and the note on safety can be
provided by us. The used preservative is well compatible with all mineral lubricants. The removal of
these substances can be done by using any known solvent (check material compatibility!). The
devices should only be stored in closed rooms. Condensation through strong variation of temperature
must be avoided.
Transportation
A damage of the device must be by all means avoided. The transportation of the unpacked device
when using lifting systems has to be carried out with sufficient number of transportation straps set
around the casing. Please note the dead weight of the device indicated on the current data sheet or
the type plate.
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 4 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
Structural build-up
Tube bundle
The tube bundle consists of two opposite identical tube plates with three grooves. The tubes are rolled
into the tube plate wholes. Between the tube plates at the outer side of the tubes, the surface is
enlarged forming fins which are in connection with the tubes. The result is a compact finned bundle. At
the outer side of the finned bundle, there are grooves across the whole length which are used to take
up sealing straps. In the finned bundle, a different number of baffles can be installed. A groove is
milled in the top of the baffle which contains a spring and a sealing plate. The interior O-ring grooves
in the tube plates seal against the casing in assembled state. The external seals are used for sealing
the bonnet. In this way, a intermixing of the media is avoided if a seal becomes defective and a
leakage localization is simplified. In the central groove, sheets are positioned which fix the tube plate
in assembled state and allow a thermal expansion for the opposite tube plate. With two path devices,
the fixation must be at the side of the connections. In any case, the side of fixation is marked by an
imprinted 'F' at the flange of the casing in the area of the flanges M1 or M2. The fixation must be
positioned at this side when in working condition.
Shell
The shell is used for taking up the tube bundle and forms the shell side casing. It consists of end
pieces which are circular-welded with the shell
tube. The end pieces can be placed in such a way
that the connections are positioned at one
side or rotated by 180. The shell tube is a
precision tube with restricted allowances.
Changes must not be carried out on the casing.
!
At the starting area of the end pieces, the
interior groove of the tube plates seals by
means of an O-ring. This area must be treated carefully in order to guarantee a sealing effect.
The mounting brackets grip around the shell tube. These allow an optional assembly position of the
device.
Casings of model KK are cast casings in standardized, fixed version.
Bonnets
The bonnets consist of different materials (see part list), depending on version of the device. The
bonnet forms together with the tube bundle the chamber of the cooling medium and is fixed to the
casing by screws. At one side of the device, sheets are inserted between bonnet and casing which fix
the tube plate. At the other side, washers form a spacer.
The one path version has two identical bonnets positioned opposite each other. With the two path
version, one bonnet with two connections is mounted at one side of the device, at the other side there
is a reversing cover. To seperate the two chambers in the bonnet, a plastic or aluminium path partition
is inserted into the tube plate at the connection side. In assembled state, the path partition seals
bonnet and tube plate, i.e. it splits the flow of tubeside medium through the device.
Seawater resistant versions contains sacrificial anodes.
Seals
All tube plate seals consist of O-rings.
All pipe threads are sealed by copper or aluminum rings.
The tube bundle is sealed at the side along its length with a sealing strip against the casing. The
sealing strips consist of the same material as the O-rings. All seals are available from our factory with
indication of the drawing number.
Accessories/spare parts
Accessories and spare parts can be taken from the enclosed drawings and part lists. Drawing and
identification numbers of components which are necessary for ordering, are also listed there. Price
lists for the spare parts and not listed accessories can be requested via our marketing department or
directly from factory.
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 5 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
Service
Installation
The following items must be considered during the installation of the device:
Protective caps fitted to connections must be removed. If there is no protective cap on a
connection, check whether it has been pushed into the connection or foreign parts have
penetrated the device.
Foreign
bodies
must
not
penetrate the openings of the connections.
The connection of the pipes
must be tension-free to ensure that no inadmissibly high
thermal
or
mechanical
tensions affect the device in service.
!
All circuits must be designed
to avoid penetration of dirt and dust. We recommend the
assembly of dirt traps and suitable filters.
Tubes must be correctly installed so that air locks cannot built up.
The assembly can be horizontal or vertical.
Sufficient space should be available to ensure easy accessibility to all screw connections. Take
particular care for providing enough space for remove the tube bundle. You can take the
necessary space dimensions for remove the tube bundle from the sketch. It is possible to remove
the tube bundle from both sides of the device.
. The direction of flow is to be taken from the enclosed sketch and from the datatsheet
Before startup, the device must be completely bled.
Never weld or modify the cooler.
In case of using the device as oilcooler before startup, clean/flush the oil circuit but not the
lubricated points.
Orifice plates must only be installed at the outlet side of the device.
Screw fasteners
To ensure a safe operation and a long service of fastening elements, the screw fastenings should be
only torqued. The table below lists the torque figures for used screws. Through influence of various
factors, the specified values may show a deviation which in individual cases require lower or higher
values.
Connection shell/bonnet
Connection flanges
type
screw/
strength
torque [Nm]
screw/
strength
material
thread
K12
M12 5.6
38
M12 5.6
aluminium
30
M12 8.8
80
red bronze
30
M16 5.6
95
aluminium
75
M16 8.8
200
red bronze
75
M20 5.6
180
cast steel
100
M20 8.8
400
cast steel
300
K20
K25
M16 5.6
M24 5.6
of
torque [Nm]
Type plate
The type plate is at the side of the device and is permanently fixed. You can find a copy of the type
plate in the appendix.
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 6 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
Starting up
At first the apparatus must be filled up with the intended medium, then the entire system must be
checked for leakage. For watercooled
devices use only clean water at the tube side. Before
the actual starting up of the system,
make sure that the cooling medium is circulated.
!
Operating the device without flow of
cooling medium is not permissible.
Only for watercooled units:
If the flow adjustment is carried out by a control, we recommend a oil-sided control, especially when
operating with river or sea water.
Discuss the control of cooling water with our factory, because factors like material and quality of
cooling water are very important to avoid later problems.
The use of additives in the cooling water has to be confirmed through HS-Cooler GmbH.
Operating instructions
During the operation, make
sure by suitable means that pre-set parameters for which the
devices are designed are kept.
!
If reserve devices with switchover valves are present, switch these devices periodically on
(all 2-3 days) or load the reserve device daily for some time with the full water volume.
Maintenance
Periodic inspections
Devices of product line K are normally reliable and easy to maintain. However, some periodic
inspections of the device are necessary to provide a safe, continuous operation. Normally inspections
on the tubeside (waterside) predominate. The shellside is less inclined to pollution so that an
inspection can be carried out based on the experience of the operator.
The following inspections should be practiced:
When operating with sea water, sacrificial
anodes are installed in the bonnets/covers.
These should be checked in the initial
phase all 3 months. If the anodes are used
!
up, they must be replaced by new ones.
In the case of excessively fast consumption
of the anodes, water quality and the electrical potential of the system must be checked.
The device should be cleaned at the water side at least once a year. An excessive pollution of the
tubes must by all means be avoided. The bonnets can be removed without depressurerizing the
shell side. The intervals are to be shortened during long ship operation in harbors or in other
polluted waters and depending on the experience of the operator.
At shorter intervals the device must be subject to an externally visual inspection, in order to
identify leakage or other problems early. Through the double O-ring sealing, leakages can be
precisely located and the relevant expenditure can be estimated.
Dismounting
Proceed as follows when dismounting the apparatus:
Lock-up any pipelines
Empty the apparatus at the tube side, if a removal of the tube bundle is necessary, empty also the
shell side.
Remove the pipelines at the tube side.
Remove the bonnets/covers. For this purpose, the screws at the bonnet/casing connection must
be loosened. Between the bonnet/cover there are 4 fixing plates or washers. These must be
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 7 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
replaced at the same side again during re-assembly. The marking on the casing flange must be
here observed.
If you want to dismount without remove the
tube bundle, the bonnet/cover without fixing
plates must be disassembled first in order
to protect the tube bundle against
displacement, before you remove the
fixing plates. This can be done with another
!
set of fixing plates or with similar aids.
Dismounting without remove the tube bundle:
Remove the O-rings from the external groove of the tube plates and secure the tube bundle to the
casing with four screws and the four fixing plates in the middle groove of the tube plates. The tube
side can now be inspected and cleaned mechanically. The shell side can remain under pressure.
Dismounting with remove the tube bundle:
Remove the O-rings from the external groove of the tube plates. At one tube plate, a marking of
the fixed position in relation to the casing is attached. A half of a X is stamped at the front of the
tube plate and the adjacent casing flange. Check the position of the marking. Push the tube
bundle (where appropriate with auxiliary tools) so far sideways until the O-ring of the interior
groove becomes visible. Remove the O-ring from the interior groove. Pull out the tube bundle in
the opposite direction. Remove the tube bundle carefully from the casing without damaging the
fins. As far as possible suspend the
tube bundle with the help of large-surface
transportation straps. The grooves
taking the O-rings must not be damaged. During
dismounting of the tube bundle the
sealing plate and the spring can drop out of the
!
baffle groove. The spring and the
sealing plate have to be installed during assembly
of the bundle by pressing them into the groove whilst the baffle passes the inlet of the shell.
When dismounting vertically fixed devices, make sure in any case that the tube bundle does not
slips down after removal of the fixing plates. We
recommend to provide an additional
set of fixing plates and to start the removal at the side
where no fixing plates are mounted.
There the bundle must be secured first. After
dismounting the second bonnet,
!
the bundle can be removed carefully. While
assembling, only one set of fixing
plates is permittedat the side of the marking.
Assembly
The assembly is carried out in reversed order as dismounting. The following must also be considered:
Generally use new O-rings and clean O-ring grooves.
Note the marking for proper assembly of the tube bundle (X).
Note the marking for correct assembly of the fixing plates (F).
At the side of the tube
bundle there are sealing straps. These should only be replaced
when damaged. When
pushing-in the tube bundle take care that the sealing straps are
not displaced or twisted.
Before assembling the tube bundle, the sealing straps should
!
be greased. You can
use the operating medium. The sealing straps must be
effective along the entire length of the tube bundle.
Insert the sealing plate and the spring into the baffle groove and press down during insertion of the
tube bundle
Lubricate O-rings with suitable O-ring grease.
During insertion of the tube plate into the sealing faces, make sure that the O-rings do not shear.
The bonnets/covers must be set up in parallel onto the tube plate and must be pushed evenly onto
the O-ring; ensure also that the O-ring does not shear.
With two path devices, a path partition must be fitted at the side of the bonnet with the two
connections. At this side, the fixing sheets must also be installed later.
When assembling the two path bonnet, make sure that the path partition is correctly placed.
Then continue as described under 'Operation'.
Cleaning
In the case of only small amount of fouling, the tube side can be mechanically cleaned. Disassemble
the device as described under
'dismounting without remove the tube bundle' and clean with
a suitable nylon brush (do not
use metal brushes) each tube inside, then clean with water.
Never remove stuck deposits or
coarse dirt by force.
!
In the case of stuck deposits,
the tube bundle must be cleaned chemically. This can be
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 8 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
carried out by rinsing the tube in the assembled state or submerging in disassembled state. Such a
cleaning must only be practiced by specialists. Only suitable solvents must be used. To select a
suitable agent, refer to the added part list. Take the materials of the plastic separator strip and O-rings
in the assembled state into consideration. Under 'Contacts' you find some companies offering
respective agents or carrying out a complete cleaning.
Provided that the type designation gets a C at the 11th position (example: KS12-BCN-821C L1000),
then it is a coated tube bundle. To prevent a damage caused by corrosion this bundle is coated on the
inside of the tubes and on the tubesheets. When dismounting the bundle and during cleaning make
sure that the coating will not be damaged or destroyed. Use only nylon cleaning brushes and
approved cleaning agents. If there are any doubts about suitability of an agent, please contact our
service department.
Troubleshooting
To low performance!/outlet temperature to high!
Check all temperatures and material flows in accordance with the design data?
Are foreign bodies in pipe or in device causing obstruction?
Is the tube bundle correctly assembled, check marking?
Are the path partition and the fixing plates correctly assembled in the two path bonnet?
Are all pressure rooms vented?
Are tube side or shell side too dirty (too thick deposits)?
Are more than 10% of the tubes plugged?
Leaky tubes!
If the presumption exists that tubes have become leaky, proceed as with 'dismounting without remove
the tube bundle'. The shell side can remain under pressure. After cleaning the tube plates, you can
identify the defective tube by the state of the emerging medium. Lock the leaky tube at both ends with
our Tubelock-Repairset. Alternative you can use a conical copper or aluminium plug or a conical hard
wood plug. The plug must not be pushed too strong since otherwise adjacent rolling connections can
be damaged. You can lock 10% of the tubes at the most without noticeable reduction in performance.
Dismounting the defective tube is not possible.
Leaky O-ring!
If a leakage is found between bonnet/cover and casing, an O-ring of the tube plate is defective. The
kind of the emerging medium defines at which groove of the tube plate the defect developed. In the
case of a defect on the tube side, proceed as described under 'dismounting without remove the tube
bundle'. In the case of a defect at the shell side, proceed as described under 'dismounting with
withdrawing the tube bundle'. In this case the tube bundle does not need to be removed completely
from the casing. Assemble the O-ring as described in 'Assembly'.
Contacts
Cleaning
Suppliers for cleaning agents:
Ashland Chemicals www.ashchem.com
Henkel Oberflchentechnik- www.henkel.com
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 9 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
Repair/spare parts
Repairs must only be carried out by specially trained personnel. However we recommend to carry out
any repair in our factory.
You can purchase spare parts directly from us with indicating the sketch and serial number. Please
contact our head offices or our sales office.
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 10 of 10
Stand: 23.08.2004
Instruction Manual-English.doc
Pos.
Quantity
Unit
Description
pc.
Shell
pc.
Tube Bundle
pc.
KL20-B-002
pc.
Anode 3/8"
KL-1021
pc.
Sealing Screw
Brass
pc.
Sealing Ring
Copper
pc.
Cover
KL20-B-003
G-CuSn5PbZn
(3.1B)
pc.
Anode 3/8"
KL-1021
pc.
Sealing Screw
Brass
10
pc.
Sealing Ring
Copper
11
pc.
Fixation Plate
KL20-0-108
Steel galv.
12
pc.
Clamp Bracket
KL20-0-109
Steel
13
pc.
Hex Bolt
Steel galv.
14
pc.
Hex Nut
Steel galv.
15
pc.
Washer
DIN 125 - A 17
Steel galv.
16
pc.
Hex Bolt
Steel galv.
AD-W7 (stamped)
17
pc.
Hex Nut
Steel galv.
AD-W7 (stamped)
18
12
pc.
Washer
DIN 125 - A 17
Steel galv.
19
pc.
Type Plate
DRAW
Part/Standard Number
Remark
GS20 - 1
RL20 - C N - 4 2 1
G-CuSn5PbZn
(3.1B)
Aluminium
DATUM
NAME
02.12.99
Garbe
Parts List
NORM
K S 2 0 - BCN - 4 2 1
SYM
REVISION
DATUM
NAME
Sheet
1 of 1
Pos.
Quantity
Unit
Description
Part/Standard Number
KL20 - C - 052
Remark
CuZn38Sn1 F34
AD-W6/2 (3.1B)
CuAl10Fe5Ni5-C
DIN EN 1982 (3.1B)
pc.
Tubesheet
178
pc.
Tube LR = L + 41mm
7.5mm x 0.5mm
CuNi10Fe1Mn F29
AD-W6/2 (3.1B)
L/1.4
pc.
Fin 1.4
KL20-0-105
Aluminium
pc.
O-Ring
KL-1520
NBR
pc.
Sealing Strip
L x 13 x 3
NBR
pc.
Baffle
KL20-0-106
Aluminium
pc.
Water Partition
KL20-0-107
Polypropylen
DRAW
DATE
NAME
04.11.99
Garbe
PARTS LIST
NORM
R L 2 0 - CN - 4 2 1
SYM
REVISION
DATE
NAME
Sheet
1 of 1
Valves
RK 49 - RK 76 - RK 86
RK 86A - RK 16A
Installation Instructions 808532-01
Non-Return Valves RK
Proper Use
The non-return valves RK are automatic-stop check valves used in pipes
to prevent a backflow of fluid within the admissible pressure/
temperature ratings.
Contact the Factory for specific recommendations concerning the
chemical resistance and suitability of the valve material in a given
application.
Danger
Category
Nominal size DN
CE marking
Type
1)
gas
liquid
yes
yes
yes
yes
Exception pursuant
to article 3.3
II
III
III
32-100 mm
125-200 mm
100-200 mm
no
yes
yes
yes
all
all, RK 49
up to DN 80
RK 86, RK 86A
RK 49
15-25 mm
Description
Non-return valve RK with spiral centering ring (RK 76, RK 49) or selfcentering body. Installation in any position. Exception: Valves without
spring can only be installed in vertical lines with upward flow.
Installation
TOP
Technical Data
RK 49
DN 15-200
RK 76
DN 15-100
[C]
20 450
[F]
68 842
[barg] 160 114
[psig] 2321 1653
530
986
55
798
RK 86
[C]
[F]
[barg]
[psig]
300
572
31
450
RK 86
RK 16 A [C]
DN 15-100
[F]
[barg]
[psig]
20 100
68 212
49
42
711 609
20 100
550
68 212 1022
49
42
24
711 609
348
DN 15-100
DN 125-200
[C]
[F]
[barg]
[psig]
20 100
68 212
51
46
740 667
350
662
36
522
[C]
[F]
[barg]
[psig]
20 100
68 212
40
40
580 580
350
662
24
348
RK 86 A [C]
DN 15-100
[F]
[barg]
[psig]
RK 86 A [C]
For more information
see data sheets.
DN 125-200
[F]
[barg]
[psig]
20 100
550
68 212 1022
49
42
24
711 609
348
20 100
550
68 212 1022
40
33
22
580 479
319
Type: RK ...
DN: ...
PN: ...
..........
Type: RK ...
DN: ...
PN: ...
..........
Type: RK ...
DN: ...
PN: ...
..........
Type: RK ...
DN: ...
PN: ...
..........
ZF Padova S.p.A.
Via Penghe, 48
I-35030 Caselle di Selvazzano (PD)
ITALY
Tel. +39-049 8299-311
Fax +39-049 8299-550
www.ZF-Marine.com