Kuehler Betriebsanleitung 01 - ÖZMAR · PDF fileOperating Instructions Transmission oil cooler for ZF marine transmission ZF 2000 ZF 2500 ZF 3000 ZF 4600 with pipe bundle cooler ZF

Operating InstructionsTransmission oil cooler for ZF marine transmission

ZF 2000

ZF 2500

ZF 3000

ZF 4600 with pipe bundle cooler

ZF 7500/7600 with pipe bundle cooler

ZF 9000

© ZF Edition: february 2009 / 3000.758.102

2

These operating instructions are protected by copy-right. Any reproduction and dissemination in whatever form – also in adapted, paraphrased or extracted form – in particular as a reprint, pho-tomechanical or elect-ronic reproduction or as a storage in data-processing equipment or data net-works without approval by the holder of the copyright is prohibited and will be prose-cuted under civil and criminal law.

Technical subject to alterations in design.

Printed in Germany

© ZF Friedrichshafen AG, 2009

ZF MARINE GMBH

88038 FriedrichshafenDeutschlandTelephone +49 7541 77-2207Telefax +49 7541 [email protected]

Edition: 2009/02

Index of revisions:

Document No.: 3000.758.102

3

TABLE OF CONTENTS

1 Assembly ............................................................ 51.1 Cooling systems ........................................... 5

1.1.1 Open sea water cycle cooling system .. 51.1.2 Closed cycle cooling system ................ 5

1.2 Transmission oil cooler ................................. 51.2.1 Cooler design ...................................... 51.2.2 Requirements cooling-water circuit ..... 5

1.2.2.1 Arrangement of the transmission oil cooler in the cooling-water circuit ................................... 5

1.2.2.2 Temperatures ....................... 51.2.2.3 Flow rates ............................ 51.2.2.4 Water pressure ..................... 61.2.2.5 Filtering ................................ 6

1.2.3 Earthing ............................................... 61.2.3.1 Free-standing transmission ... 61.2.3.2 Flanged transmission ............ 6

1.2.4 Cooler drainage ................................... 61.2.4.1 Draining the water in case of

longer standstill .................... 61.3 Pipework ...................................................... 7

1.3.1 Installation ........................................... 71.3.2 Screw-in socket ................................... 71.3.3 Flow velocity ....................................... 71.3.4 Materials of the cooling-water pipe ..... 71.3.5 Earthing cooling-water pipe ................. 7

1.4 General notes ............................................... 81.4.1 Clearance for maintenance works ........ 8

2 Maintenance ...................................................... 92.1 Assembly of transmission oil cooler (ZF 3000,

ZF 4600, ZF 4660, ZF 7600, ZF 9000) .......... 92.1.1 Pipe bundle ......................................... 92.1.2 Housing ............................................... 92.1.3 Receivers ............................................. 92.1.4 Gaskets ............................................... 9

2.2 Installation position of transmisson oil cooler .................................. 10

2.3 Assembly of transmission oil cooler (ZF 2000, ZF 7500) ..................................... 112.3.1 Pipe bundle ....................................... 112.3.2 Housing ............................................. 112.3.3 Receivers ........................................... 112.3.4 Cover ................................................. 112.3.5 Gaskets ............................................. 11

2.4 Installation position of transmisson oil cooler .................................. 12

2.5 Maintenance time schedule ........................ 132.5.1 Regular maintenance jobs . . . . . . . . 132.5.2 Additional one-off maintenance jobs

on new or overhauled transmission . 132.5.3 Maintenance work before

shut-down / stop . . . . . . . . . . . . . . . 132.5.3.1 Closed cycle cooling system 132.5.3.2 Open cycle cooling system . 13

2.6 Maintenance job schedule .......................... 142.6.1 Maintenance level / maintenance jobs 14

2.7 Tool-kit ........................................................142.7.1 Tools for cleaning

transmission oil cooler ........................142.8 Maintenance system job sheets ..................15

3 Troubleshooting ............................................... 373.1 Table of faults (ZF 2000 und ZF 7500) ........373.2 Table of faults (ZF 2500) .............................393.3 Table of faults (ZF 3000, ZF 4600, ZF 4660,

ZF 7600 und ZF 9000) .................................403.4 Fault clearance ............................................42

3.4.1 Closing leaking pipes .........................423.4.2 Leaking o-rings ..................................42

3000.758.102 / Edition: february 2009 © ZF

4


Assembly 5

1 ASSEMBLY

1.1 Cooling systems

1.1.1 Open sea water cycle cooling system

Fig. 1: Open sea water cycle system

In the case of the open sea water circuit, sea water runs through the transmission oil cooler as cooling agent. The ductwork has to be designed so that in case of standstill of the plant either the feed line or the return line of the transmission oil cooler can drain. This line must be connected to the lower con-nection of the transmission oil cooler.

1.1.2 Closed cycle cooling system

Fig. 2: Closed cycle cooling system

In the case of this arrangement, the cooling-water cir-cuit for the motor and the transmission is separa-ted from the sea water circuit. The heat transmission of the motor/transmission oil circuit to the sea water happens via a separate heat exchanger or via sur-face attemperators in the outer skin of the ship. Nor-mally, the heat transfer medium in the motor cooling circuit is a mixture of water and an anticorrosive agent. Thus, corrosion in the cooling system is lar-gely reduced. Gi-ven the cleanliness of the medium, the transmission oil cooler is hardly exposed to silta-tion or pitting cor-rosion.

1.2 Transmission oil cooler

1.2.1 Cooler design

Fig. 3: Schematic assembly of the cooler

1.2.2 Requirements cooling-water circuit

The amount of heat generated in the transmission is dissipated through the oil cooler. The oil cooler, which is part of the basic model of the transmission, is mounted to, installed in or fixed onto the transmission housing.

For the admissible water flow rate and the pressure loss between cooling-water inlet and outlet, see tech-nical specifications in the transmission installation dra-wing. The indicated water pressure at the cooling-water inlet must not be exceeded. The cooler is so designed that the heat dissipation is sufficient at a transmission ambient temperature of 60°C and a water inlet temperature according to the transmission installation drawing - also at full transmission load and maximum speed.

1.2.2.1 Arrangement of the transmission oil cooler in the cooling-water circuit

The correct transmission temperature is set by adju-sting the cooling-water flow rate. For doing this, an exchangeable gland, a valve or the like has to be pro-vided in the ductwork. Therefore, the water circuit of the transmission oil cooler should be arranged in the bleed off of the motor cooling-water circuit (see sec-tion “Cooling systems” on page 5). The closed cooling circuit should be the preferred one since the cooling water is cleaner in this case.

1.2.2.2 Temperatures

Max. cooling-water inlet temperature: see transmission installation drawing

1.2.2.3 Flow rates

Max. admiss. cooling-water flow rate: see transmission installation drawing

Min. admiss. cooling-water flow rate: see transmission installation drawing

oil inletoil outlet

water inlet

water outlet


6 Assembly

1.2.2.4 Water pressure

Max. admiss. cooling water pressure at inlet: see transmission installation drawing

1.2.2.5 Filtering

Suction filter on the water side required with mesh size: see transmission installation drawing

This is necessary in order to prevent contaminations such as solid matters or shells from ingressing into the cooler and the conduits since they would obstruct the cooler. An obstructed cooler or individually obstructed cooler pipes lead to a reduced cooling thermal perfor-mance.

Fig. 4: Contamination (wood shavings) caused by a filter screen with a too big mesh size (Exa-mple)

Note: In case of obstructed cooler pipes, the required flow velocity is not reached. This can lead to deposits or to foul and consequently to pitting corrosion.

1.2.3 Earthing

In order to avoid galvanic corrosion, it is important that there is no electric potential difference at the sea water containing components. Therefore, the transmission and therefore also the cooler have to be connected with the earthbus so that they are antistatic - as all other sea water containing components.

Material: copper

Min. cross section: 16 mm2

It must be made sure that the junctions of the earth strap are free of colour or of other electrically insula-ting materials.

1.2.3.1 Free-standing transmission

Fig. 5: Earthing with free-standing transmission

1.2.3.2 Flanged transmission

Fig. 6: Earthing with flanged transmission

1.2.4 Cooler drainage

Ideally, the cooling-water circuit has to be designed so that the transmission oil cooler is automatically drai-ned if the cooling-water pump is in standstill.

Note: The bacteria in the standing water form degradation products which deposit in the cooler. In case of a sur-face which has not been passivated yet, this can lead to pitting corrosion. The passivation of the surfaces is only built-up after some time of operation in oxy-gen-rich water.

1.2.4.1 Draining the water in case of longer stand-still

If the plant is switched off for a longer period of time(standstill time see section “Maintenance work before shut-down / stop” on page 13) the water has to be drained if the sea water circuit is open.

Note: This is only necessary, if the cooler is not automatically drained when the cooling-water pump is in standstill.

In order to be able to drain the cooling circuit, a drain plug or drain valve has to be provided. The connection must lie deeper than the cooler so that the cooler can drain completely.


Assembly 7

1.3 Pipework

1.3.1 Installation

All required oil pipes are connected fixed and ready for operation. The connections for the cooling-water inlet and outlet are closed by means of blind flanges upon delivery. These flanges can be used as welding flanges during the installation of the cooling-water pipe. For uncoupling, an elastic adapter (compensa-tor, hose piece) must be put between these flanges and the cooling-water pipes on the side of the ship. The exact position of the connections can be taken from the corresponding transmission installation dra-wing. The flow direction of the water must be adhered to, i.e. water inlet and water outlet must not be ex-changed.

The temperature increase of the cooling water in the transmission oil cooler is maximally 5°C. The mixing temperature for the motor cooling circuit increases by approx. 0.5°C and is therefore irrelevant. The indica-ted maximum rate of cooling-water flowing through the transmission oil cooler must not be exceeded; otherwise there is the risk of cavitation in the cooler. The minimum flow rate must not lie below since the flow velocity would be too low and there would be the risk that the cooler silts up early or is impaired by salt excretion of the water flow.

1.3.2 Screw-in socket

The maximum admissible thread depth in the connec-tion threads for the cooling water amounts to 20 mm in order to avoid an obstruction of the flow in the area in front of the pipe plates.

Fig. 7: Thread depth in the connection threads for the cooling water (example)

Note: The maximum screw-in length of 20 mm is only appli-cable for the transmission oil coolers for ZF 3000, ZF 4600, ZF 4660 and ZF 7600 transmissions.

Note: For transmission oil coolers for the ZF 9000 transmis-sion the maximum screw-in length is 27 mm.

1.3.3 Flow velocity

Minimum flow velocity: 1.5 m/sMaximum flow velocity: 3.0 m/s

The cross sections of the conduits are to be designed so that at nominal speed the minimum flow velocity is reached and the maximum flow velocity is not excee-ded.

Fig. 8: Fouling: Organic sediments on the pipe bun-dle caused by low flow velocity and long down time (example)

1.3.4 Materials of the cooling-water pipe

When choosing the materials for the water pipes, it must be taken into account that different materials cannot be combined at random. If a more precious metal is combined with a less precious metal, the less precious metal will corrode.

Material of the pipes and the stop valves in the sea water circuit: Copper alloy, e.g. CuNi10Fe1Mn

Galvanised steel pipes must not be used since there is the risk that the zinc coating is partially eaten away by galvanic processes and that iron corrosion parts depo-sit at the discs or the flange pipes of the cooler. Within a short period of time, pitting corrosion would damage the cooler.

1.3.5 Earthing cooling-water pipe

In order to avoid galvanic corrosion, it is important that there is no electric potential difference at the sea wa-ter-containing components.

Therefore, all cooling-water pipes must be connected with the earth bus of the ship in an antistatic manner. If there is an insulating separation line in the pipe (hose or compensator), this must be bridged by an earth strap in an antistatic manner (see section “Eart-hing” on page 6).


8 Assembly

1.4 General notes

1.4.1 Clearance for maintenance works

The cooler has to be maintained in regular intervals according to the maintenance instruction. Therefore, a corresponding clearance has to be provided for the di-sassembly of the pipe bundle.

Fig. 9: Required clearance for the disassembly of the pipe bundle (example)


Maintenance 9

2 MAINTENANCE

2.1 Assembly of transmission oil cooler (ZF 3000, ZF 4600, ZF 4660, ZF 7600, ZF 9000)

Fig. 10: Schematic assembly of transmission oil cooler (example)

Note: The actual assembly of the transmission oil cooler can differ in details.

2.1.1 Pipe bundle

The pipe bundle consists of two identical pipe plates (7) facing each other with three splines each. The cooling pipes (10) are expanded into the pipe plates. Between the pipe plates on the outside of the pipes there is a surface enlargement mounted in the form of fins (11) and positively connected with the pipes. Along the whole length of the fin package there are slits which serve for housing sealing strips (12). A dif-ferent number of baffle plates (13) can have been mounted in the fin package. After assembly, each of the inner O-ring splines of the pipe plates seals in the housing. The outer splines serve as gaskets in the re-ceivers. This prevents media from mixing in case of a failure of the gaskets and makes leak detection easier. In the middle spline, fixing plates (4) engage with a pipe plate, which fix this pipe plate after assembly and which allow a thermal expansion of the facing pipe plate.

2.1.2 Housing

The housing (1) serves for housing the pipe bundle and constitutes the outer pressure chamber. It is a standardised cast housing made of an aluminium alloy or of grey cast iron.

2.1.3 Receivers

The receivers are the both covers made of bronze and cast iron, which are situated at both ends. Together with the pipe bundle, the receivers form the pressure chamber of the cooling medium. The receivers are fixed to the housing by means of screws. On the side of the cooler, there are metal sheets inserted between the receiver and the housing. These metal sheets fix the pipe plate. On the side of the water connection of the cooler, a receiver (2) with two connections is in-stalled and on the other side, there is a return cover (3) installed. For sealing the two chambers in the re-ceiver, there is a plastic or aluminium divider (9) in-serted into the pipe plate on the connection side. When assembled, this divider seals between pipe plate and receiver and thus divides the current of the medium flowing through the cooler along the pipe.

2.1.4 Gaskets

The gaskets of the pipe plates consist of O-rings. The pipe threads at the connection are sealed by means of a copper or aluminium ring. The pipe bundle is sealed lengthwise on the side with a sealing strip (12) to-wards the housing. The sealing strip is made of the same material as the O-rings.

Note: The O-rings are available from the customer service of ZF Marine GmbH by indicating the item number.

1 housing 5 cylindrical bolt 9 divider 13 baffle plate2 reciever 6 washer 10 pipe 14 fin ring3 cover 7 pipe plate 11 fin4 fixing plate 8 o-ring 12 sealing strip

3 5 6 10 11 12 13 14 1 7 8 4 9 2


10 Maintenance

2.2 Installation position of transmisson oil cooler

Fig. 11: ZF 3000

Fig. 12: ZF 4600

Fig. 13: ZF 4660

Fig. 14: ZF 7600

Fig. 15: ZF 9000


Maintenance 11

2.3 Assembly of transmission oil cooler (ZF 2000, ZF 7500)

Fig. 16: Schematic assembly of transmission oil cooler (example)

Note: The actual assembly of the transmission oil cooler can differ in details.

2.3.1 Pipe bundle

The pipe bundle (4) consist of two identical pipe plates (7), positioned opposite of each other, and of the cooling pipes (9). The cooling pipes are expanded into the pipe plates. In total, five baffle plates (10) are mounted on the cooling pipes of the pipe bundle. The plates directionally lead the oil flow through the cas-ing. The two o-rings (8) – one on the side of the clo-sure the other on the side of the receiver – seal the pipe bundle in the casing on the oil side. The outer o-rings (8) serve for sealing the water side at the cover (3) and at the receiver (2). This prevents media from mixing in case of a failure of the gaskets.

2.3.2 Housing

The housing (1) serves for housing the pipe bundle and constitutes the outer pressure chamber. It is a standardised cast housing made of an aluminium alloy or of grey cast iron.

2.3.3 Receivers

A receiver (2) is installed on the water connection side of the cooler. The receiver is made of cast bronze. The receiver is attached to the housing (1) by means of three bolts (5) Between the receiver and the housing, the pipe bundle (4) is fixed by means of the sheet con-nected to the pipe plate.

2.3.4 Cover

On the other side, a reverser cover (3) is installed. The cover is also made of cast bronze. The cover is at-tached to the housing (1) by means of three bolts (5). A spacer plate (6) is arranged between the cover and the housing. The spacer plate serves for fixation of the o-rings (8).

2.3.5 Gaskets

The connection flanges on the water side are sealed by means of flat gaskets. The pipe plates are sealed with a total of four identical o-rings (8). For versions with the transmission oil cooler directly flanged to the transmission housing, the oil connections are sealed by means of o-rings inserted into the splines. For versi-ons with the transmission oil cooler mounted exter-nally, the pipe connection threads are sealed by means of a copper ring.

Note: The O-rings are available from the customer service of ZF Marine GmbH by indicating the item number.

1 housing 5 cylindrical bolt 9 pipe2 reciever 6 washer 10 baffle plates3 cover 7 pipe plate4 pipe bundle compl. 8 o-ring

3

5 6

10 178

4

9 2

5

587


12 Maintenance

2.4 Installation position of transmisson oil cooler

Fig. 17: ZF 2000

Fig. 18: ZF 7500


Maintenance 13

2.5 Maintenance time schedule

The maintenance system for marine transmissions is based on a preventive maintenance concept. The pre-ventive maintenance enables an advance planning and ensures a high availability.

Note:

NOTEThe time intervals according to which the main-tenance work is to be executed, as well as the scope of the described control and maintenance work are the average result of operating experience and thus only to be seen as approximate values.

Special operating conditions as well as technical de-mands can require additional maintenance work and/or changes of maintenance intervals.

The maintenance work number stated in the mainte-nance system operating sheet indicates the respective maintenance position. It serves as reference for the re-quired tools and amount of parts.

2.5.1 Regular maintenance jobs

Tab. 1: Regular maintenance job for transmission oil cooler

2.5.2 Additional one-off maintenance jobs on new or overhauled transmission

Tab. 2: Additional one-off maintenance jobs on new or overhauled transmission

2.5.3 Maintenance work before shut-down / stop

2.5.3.1 Closed cycle cooling system

With a closed cycle cooling system the cooler can be kept filled.

2.5.3.2 Open cycle cooling system

For a temporary stop of the facility (< 2 weeks) the cooler can be kept filled.

For a longer stop of the facility (> 2 weeks) the cooler is to be emptied on the water side.

Note: This is only required, if the cooler is not emptied auto-matically with the cooling water pump being stopped.

Tab. 3: Standstill times / draining cooling water

Maintenance level Application groups Interval (operating hours)

At least every

A1 All Every day of operation 3 monthsA2 All 500 h 6 monthsA3.1 All ---------------- 1 year

A4C and M ---------------- 5 yearsL and P ---------------- 8 years

A5All Each time the engine undergoes a

basic overhaulTransmission operating condition

Maintenance level Operating hours At least everyZ1 50 to 100 12 monthsZ2 ---------------- 2 months

Cooling system Down time Measures

Open system / sea

water

> 2 weeks Empty transmission oil cooler on water side.

Rinse additionally with clean water

If possible, dry pipe bundle from the inside with

compressed air.


14 Maintenance

2.6 Maintenance job schedule

2.6.1 Maintenance level / maintenance jobs

Tab. 4: Maintenance level / maintenance jobs

2.7 Tool-kit

2.7.1 Tools for cleaning transmission oil cooler

Nylon brush for ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF 9000:(ZF part no. 1X56.190.838)

Nylon brush for ZF 2000 und ZF 7500:(ZF part no. 1X56.190.840)

Maintenance level Maintenance jobsRegular One-offA5 A4 A3.1 A2 A1 Z1 Z2

103 Carry out visual check 122 Retighten all screw/bolt connections169 Realise visual examination and clean

transmission oil cooler200 Basic transmission overhaul


Maintenance 15

2.8 Maintenance system job sheets

Index job sheets

Maintenance operation Page

103 Carry out visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

122 Retighten all accessible screw/bolt connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

169 Realise visual examination and clean oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Edition: february 2009 / 3000.758.102 © ZF

16 Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission oil cooler

Maintenance job no.

Maintenance level If possible, to be performed in conjunction with maintenance

job no.

Time required inminutes

103 A1 -------- 5

Description of maintenance work 103 Carry out visual check

Safety measuresCarry out visual examination of rotating parts with sufficient distance in order to avoid the risk of being pulled in by the rotating part.

Tools ------------------------------

Parts ------------------------------

Material ------------------------------

Test equipment ------------------------------

ProcedureCheck the leak tightness of the oil cooler and the oil level (water leakage in oil or oil leakage in water when engine has been stopped).

Location: Date: Page: 1 of: 1


Maintenance 17


18 Maintenance



Maintenance job no.


job no.


122 Z1 -------- 5

Description of maintenance work 122 Retighten all accessible screw/bolt connections

Safety measures Retighten bolted connections only with transmission stopped.

Tools ------------------------------

Parts ------------------------------

Material ------------------------------

Test equipment ------------------------------

Procedure Re-tighten the screwed connections from and to the transmission oil cooler



Maintenance 19


20 Maintenance



Maintenance job no.


job no.


169 Z2 -------- 180

Description of maintenance work 169 Realise visual examination and clean oil cooler

Safety measures ------------------------------

Tools Tool kit WI (see corresponding instructions manual)

Parts ------------------------------

Material ------------------------------

Test equipment ------------------------------

Procedure See opposite page



Maintenance 21

ZF 2000 und ZF 7500

Fig. 19: Schmatic design of the transmission oil cooler (ZF 2000, ZF 7500, example)

The numbers in the brackets refer to figure 19.

Note: The O-rings that have to be demounted must be ex-changed on each maintenance.

Disassembly of the transmission oil cooler (without extraction the pipe bundle)

1. Clearly mark the position of the bolted flanges to each other.

2. Block all tubing.

3. Empty the transmission oil cooler on the water side.

4. Remove the tubing on the water side.

5. Wait for 30 min after the facility has been stop-ped, until the oil pressure has decreased.

6. Empty the transmission oil cooler on the oil side; for this purpose drain the oil from the oil filter and the transmission (see maintenance system opera-ting sheets 141 and 142).

7. Remove the fastening screws on the transmission oil cooler and detach the transmission oil cooler.

Note: Step 5-7 is only necessary in case of transmissions where the cover (3) cannot be dismantled for lack of space.

8. Remove the reciever (2) and the cover (3) by loos-ening the screws on the reciever/cover-hous-ing-connection.

9. Remove the o-rings on both sides of the pipe bun-dle.

Fig. 20: Disassembly of the o-rings (ZF 2000, exa-mple)

10. The pipe bundle must be secured against the housing (1) by means of a screw and an appropri-ate number of washers.

Fig. 21: Pipe bundle secured with a bolt (ZF 2000, example)

Note: Now, the water side may be inspected and mechani-cally cleaned.

3

5 6

10 178

4

9 2

5

587

1 housing2 reciever3 cover4 pipe bundle compl.5 cylindrical bolt6 distance plate7 pipe plate8 o-rings9 pipe10 baffle plates


22 Maintenance

Water-side cleaning

The transmission oil cooler has to be cleaned on the water side at least 1x a year. Avoid excessive dirt on the pipes.

Note: The time intervals for maintenance have to be reduced in case of a long ship operation at harbours or in other dirty waters and according to the experiences of the operator.

In case of little dirt the water side can be cleaned me-chanically:

1. Disassemble the transmission oil cooler as described “Disassembly of the transmission oil cooler (without extraction the pipe bundle)” on page 21 .

2. Clean each pipe of the pipe bundle on the inside by means of a nylon brush (see section “Tool-kit” on page 14).

Fig. 22: Cleaning of pipes with a nylon brush (ZF 2000, example)

Note: Do not use metal brushes for the cleaning of the pipes.

Note: Firmly bonded deposits may not be removed with tools. In such a case the pipe bundle has to be cleaned chemically. This can be done with the pipe bundle still installed by coating the pipes with a chem-ical solution. In doing so you have to take into account that the plastic partition and the O-rings will not be af-fected by the chemical solution. A chemical cleaning should only be done by specialised staff.

Note: Suppliers of cleaning agents are, for example, Ashland Chemicals (www.ashchem.com), Henkel Ober-flächentechnik (www.henkel.com) and Ondeo Nalco (www.nalco.com). Suppliers of complete cleanings are, for example, Vecom (www.vecom.nl) and Ondeo Nalco (www.nalco.com).

Disassembly of the transmission oil cooler (with extraction the pipe bundle)



3. Empty the transmission oil cooler on the water side..



6. Empty the transmission oil cooler on the oil side, for this purpose drain the oil from the oil filter and the transmission (see maintenance system opera-ting sheets 141 and 142).

7. Remove the fastening screws on the transmission oil cooler and detach the transmission oil cooler.

8. Remove the reciever (2) and the cover (3) by loo-sening the screws of the reciever/cover housing connection.

9. Remove the o-rings on both sides of the pipe bun-dle.

Fig. 23: Disassembly of the o-rings (ZF 2000, exa-mple)

10. Remove the spacer plate (6) on the side opposite the water side.

Fig. 24: Remove spacer plate (ZF 2000, example)


Maintenance 23

11. Push the pipe bundle to the water side that far (if required, use an auxiliary tool) until the o-ring on the opposite side is loosened.

12. Remove the o-ring.

Fig. 25: Disassembly of the o-ring on the side oppo-site to the water side (ZF 2000, example)

13. Draw out the pipe bundle towards the water side. In doing this, the pipe bundle must be removed from the housing very carefully, in order not to damage the diverter plates.

Fig. 26: Disassembly of the pipe bundle (ZF 2000, example)

14. Remove the o-ring on the water side of the pipe bundle by slipping it over the pipe bundle.

Fig. 27: Remove o-ring on the water side (ZF 2000, example)

Assembly of the transmission oil cooler (without extraction of the pipe bundle)

The assembly of the transmission oil cooler is carried out in reverse order as the disassembly of the cooler.

1. Remove the securing bolt, including the washers from the pipe bundle.

2. Lubricate the outer o-rings with a suitable type of grease and mount onto the pipe bundle.

Fig. 28: Assemble the outer o-ring (ZF 2000, example)

3. Parallelly mount the receiver (2) and the cover (3) on the two sides of the transmission oil cooler and evenly slip them onto the outer o-ring

Note: When slipping the receiver (2) and the cover (3) onto the o-rings it must be observed that the o-ring do not shear off.

4. Assemble the receiver (2) and the cover (3) by means of three bolts, tightening the conjugate bolts alternating from receiver to cover, applying the correct tightening torque (see table 5 “Tighte-ning torques” on page 23).

Tab. 5: Tightening torques

5. In transmissions where the transmission oil cooler has been removed from the transmission housing, the cooler must be positioned onto the transmis-sion housing and fixed to the housing by means of four fastening bolts.

6. Mount the flanged sockets with new gaskets to the receiver (2).

7. Connect the pipelines on the water side.

8. Open and re-fill all pipelines.

Transmission type

Screw / strength

Tightening torque

ZF 2000 M8 / 8.8 23 Nm

ZF 7500 M10 / 8.8 46 Nm


24 Maintenance

9. Bleed the transmission oil cooler on the water side.

10. Fill the transmission with oil.

Note: Step 10 is only required, if the transmission oil cooler has been removed for cleaning the transmission housing.

Assembly of the transmission oil cooler(after extraction of the pipe bundle)

1. Grease the o-ring for the water side of the pipe bundle.

2. Carefully slip the o-ring over the pipe bundle to the stop on the water side.

Fig. 29: Assemble o-ring on the water side. (ZF 2000, example)

Note: During assembly of the o-ring it must be observed that the ring does not shear off.

3. Carefully insert the pipe bundle into the housing (1).

Fig. 30: Assembly of the pipe bundle (ZF 2000, example)

4. Lubricate the o-ring for the side of the pipe bun-dle opposite the water side with a suitable type of grease and assemble the o-ring on the side oppo-site the water side.

Fig. 31: Assembly of the o-ring on the side opposite to the water side (ZF 2000, example)

Note: During assembly of the o-ring it must be observed that the ring does not shear off.

5. Mount the spacer plate (6) on the side opposite the water side.

Fig. 32: Mount the spacer plate (ZF 2000, example)

6. Lubricate the outer o-rings with a suitable type of grease and mount onto the pipe bundle.


Maintenance 25

Fig. 33: Assemble the outer o-ring (ZF 2000, exa-mple)

7. Parallelly mount the receiver (2) and the cover (3) on the two sides of the transmission oil cooler and evenly slip them onto the outer o-ring.


8. Assemble the receiver (2) and the cover (3) by means of three bolts, applying the correct tight-ening torque (see table 6 “Tightening torques” on page 25).


9. Position the cooler onto the transmission housing and fix it to the housing by means of four faste-ning bolts.

10. Mount the flanged sockets with new gaskets to the receiver (2).





Replacement of the pipe bundle

If more than 10% of the pipes in the bundle are leaking/not tight, the entire pipe bundle must be re-placed.

1. Assemble the transmission oil cooler as described in the section “Disassembly of the transmission oil cooler (with extraction the pipe bundle)” on page 22.

2. Remove the defective pipe bundle.

3. Insert the new pipe bundle.

4. Assemble the transmission oil cooler as described in the section “Assembly of the transmission oil cooler (after extraction of the pipe bundle)” on page 24.

Revision

After assembly, both the oil side and the water side must be revised. During this operation it must be ob-served that the pressure (oil side and water side) does not exceed the value stated in the transmission instal-lation drawing and/or on the type plate.

Transmission type

Screw / strength

Tightening torque

ZF 2000 M8 / 8.8 23 Nm

ZF 7500 M10 / 8.8 46 Nm


26 Maintenance

ZF 2500

Note: With every maintenance operation, the o-rings and the gasket that must be disassembled, have to be re-placed.

Cleaning process on the water side

The water side of the transmission oil cooler must be cleaned at least once per year. Excessive contamina-tion of the pipes must be avoided.

Note: The time intervals for maintenance must be adjusted (shortened) for long-term operation of the ship in har-bours and other soiled waters, and/or according to the operator's experience.

Note: Tightly sticking deposits must not be removed by means of tools. In such a case the pipe bundle must be chemically cleaned. This operation may be carried out in assembled condition by spraying chemical cleaning solution onto the pipes. It must be ensured that the condition of the o-rings is not affected by the chemical solution. Chemical cleaning should only be carried out by expert personnel.

Note: Suppliers of suitable cleaning agents are e.g. Ashland Chemicals (www.ashchem.com), Henkel Ober-flächentechnik (www.henkel.com) and Ondeo Nalco (www.nalco.com). Providers of complete cleaning services are e.g. Vecom (www.vecom.nl) und Ondeo Nalco (www.nalco.com).

Disassembly of the transmission oil cooler

1. The position of the screwed flanges to each other must be marked in order to be identified at assembly.

2. Close all pipelines.

3. Drain the transmission oil cooler on the water side.

4. Remove the pipelines on the water side.

5. After shut down of the system wait for minimum 30 minutes until the oil pressure has decreased.

6. Drain the transmission oil cooler on the oil side; for this the oil must be drained from the oil filter and the transmission (see Maintenance System - Operation Sheets 141 and 142 in the instructions manual of the respective transmission series).

7. Disassemble the cover by unscrewing the bolts at the cover-housing connection.

8. Extract the pipe bundle from the transmission housing.


Assembly of the transmission oil cooler


1. Carefully insert the pipe bundle into the transmis-sion housing.

Fig. 35: Assembly of the pipe bundle (ZF 2500, exa-mple)

2. Replace the gasket at the cover.

Fig. 36: Replace gasket (ZF 2500, example)


Maintenance 27

3. Place the cover onto the pipe bundle and the transmission housing assembling it by means of eight bolts, tightening the conjugate bolts in an alternating fashion, applying the correct tighten-ing torque (see table 7 “Tightening torques” on page 27).


Note: When assembling the cover, it must be observed that the gasket between pipe bundle and cover is positio-ned correctly.

4. Mount the flanged sockets with new gaskets to the cover.






If more than 10% of the pipes in the bundle are leaking/not tight, the entire transmission oil cooler must be replaced.

1. Disassemble the transmission oil cooler as described in the section “Disassembly of the transmission oil cooler” on page 26.

2. Remove the defective transmission oil cooler.

3. Insert the new transmission oil cooler.

4. Assemble the transmission oil cooler as described in the section “Assembly of the transmission oil cooler” on page 26.

Revision


Transmission type

Screw / strength

Tightening torque

ZF 2500 M10 / 8.8 46 Nm


28 Maintenance

ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF 9000

Fig. 37: Schematic Design of the transmission oil cooler ZF 3000, ZF 4600, ZF 4660, ZF 7600, ZF 9000, example)

The numbers in the brackets refer to figure 37.

Note: The O-rings that have to be demounted must be exchanged on each maintenance.

Disassembly of the Transmission oil cooler (without extraction of the pipe bundle)



3. Empty the Transmission oil cooler on the water side.



6. Empty the Transmission oil cooler on the oil side; for this purpose drain the oil from the oil filter and the Transmission (see maintenance system opera-ting sheets 141 and 142).

7. Remove the fastening screws on the Transmission oil cooler and detach the Transmission oil cooler.

Step 5-7 is only necessary in case of Transmissions where the cover (3) cannot be dismantled for lack of space.

8. Remove the reciever (2) and the cover (3) by loo-sening the screws on the reciever/cover-housing-connection.

9. Remove the o-rings from the outer spline of the pipe plates and secure the pipe bundle against the housing (19 in the middle spline of the pipe plates using four bolts and the four fixing plates (4).

Fig. 38: Pipe bundle secured with fixing plates (ZF 3000, example)

Fig. 39: Pipe bundle secured with fixing plates (ZF 9000, example)

3 5 6 10 11 12 13 14 1 7 8 4 9 2

1 housing2 reciever3 cover4 fixing plate5 cylindrical bolt6 washer7 pipe plate8 o-ring9 divider10 pipe11 fin12 sealing strip13 baffle plate14 fin ring


Maintenance 29

Note: Now, the water side may be inspected and mechani-cally cleaned. In transmission where the transmission oil cooler has not been removed, the oil side may re-main pressurised.

10. Remove the divider (9)



Cleaning process on the water side

The water side of the transmission oil cooler must be cleaned at least once per year. Excessive contamina-tion of the pipes must be avoided.

Note: The time intervals for maintenance must be adjusted (shortened) for long-term operation of the ship in har-bours and other soiled waters, and/or according to the operator's experience.

In case of slight contamination the water side may merely be cleaned mechanically.

1. Disassemble the transmission oil cooler as described in the sectio “Disassembly of the Trans-mission oil cooler (without extraction of the pipe bundle)” on page 28.

2. Clean every pipe of the pipe bundle on the inside using a nylon brush (see chapter “Tool-kit” on page 14).

Fig. 42: Cleaning the pipes by means of a nylon brush (ZF 3000, example)

Fig. 43: Cleaning the pipes by means of a nylon brush (ZF 9000, example)

Note: Metal brushes must never be used for cleaning the pipes.

Note: Tightly sticking deposits must not be removed by means of tools. In such a case the pipe bundle must be chemically cleaned. This operation may be carried out in assembled condition by spraying chemical cleaning solution onto the pipes. It must be ensured that the condition of the o-rings and the plastic divider is not affected by the chemical solution. Chemical cleaning should only be carried out by expert person-nel.

Note: Suppliers of suitable cleaning agents are e.g. Ashland Chemicals (www.ashchem.com), Henkel Ober-flächentechnik (www.henkel.com) and Ondeo Nalco (www.nalco.com). Providers of complete cleaning services are e.g. Vecom (www.vecom.nl) und Ondeo Nalco (www.nalco.com).


30 Maintenance

Disassembly of the transmission oil cooler (with extraction of the pipe bundle)

1. The position of the screwed flanges to each other must be marked in order to be identified at assembly.

2. Close all pipelines.

3. Drain the transmission oil cooler on the water side.

4. Remove the pipelines on the water side.

5. Nach dem Abstellen der Anlage 30 min warten, bis der Öldruck abgebaut ist.

6. Drain the transmission oil cooler on the oil side; for this the oil must be drained from the oil filter and the transmission (see Maintenance System - Operation Sheets 141 and 142 in the instructions manual of the respective transmission series).

7. Unscrew the attachment bolts from the transmis-sion oil cooler and remove the cooler.

8. Remove the receiver (2) and the cover (3) by loos-ening the bolts from the receiver-housing and cover-housing connections.

Note: Four fixing plats (4) are located between the receiver (2) and the housing (1). These plates must be installed on the same side when assembling the unit. Observe the identification F on the housing flange, for this pur-pose.

Fig. 44: Identification mark F for the fixing plates (example)

9. Remove the o-rings from the outer spline of the pipe plates.

Fig. 45: Disassembly of the outer o-ring (ZF 3000, example)

Fig. 46: Disassembly of the outer o-ring (ZF 9000, example)

Note: On one pipe plate an identification mark for the instal-lation position is provided opposite the housing. The edge of the pipe plate and the adjacent housing flange each contain one half of an X. This mark must be observed.

Fig. 47: Identification mark X for the installation of the pipe bundle (ZF 3000, example)


Maintenance 31


10. Push the pipe bundle towards the water side that far (if required, use an auxiliary tool) until the o-ring on the inner spline is visible.

11. Remove the o-ring of the inner spline.

Fig. 49: Disassembly of the inner o-ring (ZF 3000, example)

Fig. 50: Disassembly of the inner o-ring (ZF 9000, example)

12. Draw out the pipe bundle towards the side it was inserted at. In doing this, the pipe bundle must be removed from the housing very carefully, in order not to damage the fin package. If possible, the pipe bundle should be supported by large-surface transport slings.



Note: The splines for the accommodation of the o-rings must not be damaged. When extracting the pipe bundle, the diverter plate (13) may fall out.

Note: When disassembling vertically installed coolers (appli-cable for transmission series ZF 4600) it must be en-sured by appropriate means that the pipe bundle cannot slide downwards once the fixing plates have been removed. For this purpose, it is recommended to have an additional set of fixing plates (4) ready and to start the disassembly operation on the side on which no fixing plates are installed. The pipe bundle must be secured during this step. After disassembly of the sec-ond receiver (2) controlled extraction of the bundle is facilitated.

Note: For assembly, only one set of fixing plates (4) must be installed, on the side containing the identification mark F.


32 Maintenance

Assembly of the transmission oil cooler (without extraction of the pipe bundle)


1. Remove the four bolts and the four fixing plates (4).

2. Lubricate the outer o-rings with a suitable type of grease and insert into the corresponding outer spline of the pipe plates (7).

Fig. 53: During assembly the outer o-ring must be taken into consideration (ZF 3000, example)


3. Verify the correct installation position of the divider (9) on the water side.

Fig. 55: Correct installation of the divider (9) must be observed (ZF 3000, example)


Note: With two-way transmission oil coolers a divider (9) must be inserted into the pipe plate on the water side (receiver (2) with two connections).

4. Insert the four fixing plates (4) into the middle spline of the pipe plate (7) on the water side (receiver (2) with two connections) observing the identification mark F.

5. Parallelly mount the receiver (2) and the cover (3) on the corresponding pipe plates (7) and evenly slip them onto the outer o-ring.



Maintenance 33

6. Assemble the receiver (2) and the cover (3) by means of four bolts, tightening the conjugate bolts alternating from receiver to cover, applying the correct tightening torque (see table 8 “Tighte-ning torques” on page 33).


7. In cases where the transmission oil cooler has been removed from the transmission housing, the cooler must be positioned onto the transmission housing and fixed to the housing by means of four fastening bolts.

8. Mount the flanged sockets to the receiver (2).





Note: Step 12 is only required, if the transmission oil cooler has been removed for cleaning the transmission hous-ing.

Transmission type

Screw / strength

Tightening torque

ZF 3000ZF 4600’ZF 4660ZF 7600

M10 / 8.8 46 Nm

ZF 9000 M16 / 8.8 195 Nm


34 Maintenance

Assembly of the transmission oil cooler (after extraction of the pipe bundle)


1. Grease the sealing strips (12) of the pipe bundle. The operational medium may be used for this pur-pose.

Note: Sealing strips (12) must only be replaced if they are damaged. The sealing strips must be effective over the entire length of the pipe bundle.

2. Carefully insert the pipe bundle into the housing (1).



Note: When inserting the pipe bundle, it must be observed that the sealing strips (12) are not shifted or crimped.

Fig. 59: During assembly the sealing strips (12) and the fin ring (14) must be taken into consider-ation (ZF 3000, example)

Fig. 60: During assembly the sealing strips (12) and the fin ring (14) must be taken into consider-ation (ZF 9000, example)

Note: On one pipe plate an identification mark for the instal-lation position is provided opposite the housing. The edge of the pipe plate and the adjacent housing flange each contain one half of an X. This mark must be observed.



Maintenance 35


3. Insert the fin ring (14) into the diverter plate (13) and press down during installation of the pipe bundle.

4. Lubricate the inner o-rings with a suitable type of grease and insert into the corresponding inner spline of the pipe plates (7).

Fig. 63: During assembly the inner o-ring must be taken into consideration (ZF 3000, example)

Fig. 64: During assembly the inner o-ring must be taken into consideration (ZF 9000, example)

Note: When inserting the pipe plates (7) into the sealin sur-faces, it must be observed that the o-ring do not shear off.

5. Lubricate the outer o-rings with a suitable type of grease and insert into the corresponding outer spline of the pipe plates (7).



6. Verify the correct installation position of the divider (9) on the water side.



36 Maintenance


Note: With two-way transmission oil coolers a divider (9) must be inserted into the pipe plate on the water side (receiver (2) with two connections).

7. Insert the four fixing plates (4) into the middle spline of the pipe plate (7) on the water side (receiver (2) with two connections) observing the identification mark F.

8. Parallelly mount the receiver (2) and the cover (3) on the corresponding pipe plates (7) and evenly slip them onto the outer o-ring.


9. Assemble the receiver (2) and the cover (3) by means of four bolts, tightening the conjugate bolts alternating from receiver to cover, applying the correct tightening torque (see table 9 “Tighte-ning torques” on page 36).


10. Position the cooler onto the transmission housing and fix it to the housing by means of four fasten-ing bolts.

11. Mount the flanged sockets to the receiver (2).






If more than 10% of the pipes in the bundle are leak-ing/not tight, the entire pipe bundle must be replaced.

1. Disassemble the transmission oil cooler as described in the section “Disassembly of the transmission oil cooler (with extraction of the pipe bundle)” on page 30.

2. Remove the defective pipe bundle.

3. Insert the new pipe bundle.

4. Assemble the transmission oil cooler as described in the section “Assembly of the transmission oil cooler (after extraction of the pipe bundle)” on page 34.

Revision


Transmission type

Screw / strength

Tightening torque

ZF 3000ZF 4600’ZF 4660ZF 7600

M10 / 8.8 46 Nm

ZF 9000 M16 / 8.8 195 Nm


Troubleshooting 37

3 TROUBLESHOOTING

3.1 Table of faults (ZF 2000 und ZF 7500)

Failure Possible cause Inspection / remedy

Oil escapes into the water Oil level too lowPipes in the oil cooler are leaky

Drain and disassemble the cooler, disassemble receivers / covers, secure pipe bundle with fixing plates and bolt; give 5 bare compressed air onto the jacket; identify defective pipe on the pipe plates; close the defective pipe by means of a copper plug

Oil escapes from the cooler

Visible oil leakage at the cover

O-ring on pipe plate / housing is defective

Drain the cooler on the water and on the oil side and disassemble it; disassemble receivers / covers, extract pipe bundle; replace o-rings (all)

Visible oil leakage at the transmission

O-ring transmission flange connection defective

Drain cooler on the water and on the oil side and disassemble it; replace all o-rings

Water escapes from the cooler

Water leakage into the oil; oil level too high, milky

O-ring on pipe plate / water chamber is defective

Drain cooler on the water and on the oil side and disassemble it; disassemble receivers / covers, secure pipe bundle with fixing plate and bolt; replace all o-rings.

Visible water lea-kage at the cover

O-ring on pipe plate / cover is defective

Drain transmission oil cooler on the water side, disassemble receivers /covers, secure pipe bundle with fixing plate and bolt; replace all o-rings.

Visible water lea-kage at the flanged socket

Sealing pipe connec-tion defective

Replace gasket at the flanged socket.


38 Troubleshooting

Tab. 10: Table of faults

Transmission oil temperature too high

Cooling water out-flow temperature too high; tempera-ture measurement by means of click-on sensor, measuring whether water intake and water outflow have a tem-perature difference of about 2°C to 5°C

Cooling water intake temperature is too high

Water intake temperature is too high, consider nominal values in the transmission installation drawing.

Water flow rate is too low

Delivery rate of the cooling water pump too low; consider nominal values in the transmission installation drawing;increase delivery rate

Water flow in the cooler is hindered

Possibly foreign material in the pipe or in the cooler, which causes clog-ging; clean pipe / pipe bundle.

Water side is more contaminated than usual (e.g. through thick depo-sits); clean transmission oil cooler.

More than 10% of the pipes are leaky - replace entire transmission oil cooler.

Cooling water out-flow temperature not too high

Heat transfer from oil to water is hindered

Oil side is more contaminated than usual (e.g. through thick deposits); clean fins.

Pipe bundle installed correctly?

If this is not the case, the pipe bun-dle must be installed correctly.

Are all pressure chamber de-aer-ated? If this is not the case, de-aerate pres-sure chamber.



Troubleshooting 39

3.2 Table of faults (ZF 2500)



Oil escapes into the water Oil level too lowPipes in the cooler are leaky

Drain transmission oil cooler, disassemble receiver, remove cooler from the transmission housing, identify the defective pipe on the pipe plates, close the defective pipe by means of copper plugs or replace transmission oil cooler.

Oil escapes from the coolerVisible oil leakage at the cover

O-ring of gasket of the cover is defective

Drain transmission oil cooler on the water side and on the oil side; Disassemble cover,replace o-ring and gasket of the cover.

Water escapes from the cooler


Gasket of the receiver defective

Drain transmission oil cooler on the water side and on the oil side, disassemble receiver, replace gasket of the receiver.

Visible water leakage at the flanged socket




Cooling water out-flow temperature too high; temperature measurement by means of click-on sensor, measuring whether water intake and water outflow have a temperature difference of about 2°C to 5°C.


Water intake temperature is too high; consider nominal values in the transmission installation drawing.


Delivery rate of the cooling water pump too low; consider nominal values in the trans-mission installation drawing; increase delivery rate



Water side is more contaminated than usual (e.g. through thick depos-its); clean transmission oil cooler.

More than 10% of the pipes are leaky - replace entire transmission oil cooler.




Transmission oil cooler installed cor-rectly?

If this is not the case, the cooler must be installed correctly.

Are all pressure chamber de-aer-ated? If this is not the case, de-aer-ate pressure chamber.


40 Troubleshooting

3.3 Table of faults (ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF 9000)


Oil escapes into the water Oil level too lowPipes in the cooler are leaky

Drain and disassemble the cooler, disassemble receivers / covers, secure pipe bundle with fixing plates and bolt; give 5 bare compressed air onto the jacket; identify defective pipe on the pipe plates; close the defective pipe by means of a copper plug

Oil escapes from the cooler

Visible oil leakage at the cover

O-ring on pipe plate / housing is defective

Drain the cooler on the water and on the oil side and disassemble it; disas-semble receivers / covers, extract pipe bundle; replace o-rings (all)

Visible oil leakage at the transmission

O-ring transmission flange defective

Drain cooler on the water and on the oil side and disassemble it; replace all o-rings

Water escapes from the coo-ler


O-ring on pipe plate / water chamber is defective

Drain the cooler on the water and on the oil side and disassemble it; disas-semble receivers / covers, secure pipe bundle with fixing plate and bold; replace o-rings (all).

Visible water leakage at the cover

O-ring on pipe plate / cover is defective

Drain transmission oil cooler on the water side, disassemble receivers /covers, secure pipe bundle with fixing plate and bolt; replace all o-rings.

Visible water leakage at the flanged socket




Troubleshooting 41



Cooling water out-flow temperature too high; temperature measurement by means of click-on sensor, measuring whether water intake and water outflow have a temperature difference of about 2°C to 5°C.


Water intake temperature is too high, consider nominal values in the trans-mission installation drawing.


Delivery rate of the cooling water pump too low; consider nominal values in the trans-mission installation drawing; increase delivery rate

Gland for the bleed off too large; use smaller gland; choke the valve



Water side is more contaminated than usual (e.g. through thick depos-its); clean pipe bundle.

More than 10% of the pipes are leaky,replace entire pipe bundle.




Is divider correctly assembled on the two-way receiver and are the fixing plates mounted on this side; if this is not the case, assemble divider correctly.

Is the pipe bundle assembled cor-rectly? Inspect identification mark X;if this is not the case, assemble pipe bundle correctly.

Are all pressure chamber de-aer-ated? If this is not the case, de-aerate pres-sure chamber.



42 Troubleshooting

3.4 Fault clearance

3.4.1 Closing leaking pipes

If there is suspicion of the pipes having become leaky, proceed as under the sections “Disassembly of the transmission oil cooler (without extraction the pipe bundle)” on page 21 (ZF 2000 und ZF 7500), “Disas-sembly of the transmission oil cooler” on page 26 (ZF 2500) or “Disassembly of the Transmission oil coo-ler (without extraction of the pipe bundle)” on page 28 (ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF 9000). After cleaning the pipe plates, from the escaping me-dium it can be seen which pipe is leaking. The leaking pipe must be closed from both sides.

Note: For this purpose, ZF Marine GmbH offers special plugs. Thus, continued operation is possible without having to replace the entire cooler.

1. For disassembly of the transmission oil cooler, proceed as under the sections “Disassembly of the transmission oil cooler (without extraction the pipe bundle)” on page 21 (ZF 2000 und ZF 7500), “Disassembly of the transmission oil cooler” on page 26 (ZF 2500) or “Disassembly of the Transmission oil cooler (without extraction of the pipe bundle)” on page 28 (ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF 9000).

2. Thoroughly clean the defective pipe down to the offset of the plug.

Note: It must be ensured that this area on the inner side of the pipe is free from corrosion and pitting.

3. Press in the plug with a suitable device such that it is flush.

Note: The plug must not be hammered in too heavily since adjacent expanded portions could then be damaged. A maximum of 10% oft he pipes may be closed with-out a noticeable degradation in performance occur-ring. Disassembly of individual defective pipes is not possible. If more than 10% of the pipes are defective, this type of repair is not longer permissible as the ther-mal performance becomes too low.

3.4.2 Leaking o-rings

If a leaking point is detected between the receiver ort he cover and the housing, this is an indication for a defective o-ring at the pipe plate. The type of escaping medium allows for detection, at which point of the pipe plate (ZF 2000, ZF 7500) or at which spline of the pipe plate (ZF 3000, ZF 4600, ZF 4660, ZF 7600 and ZF 9000) the defect is present. In case of a defect on the water side, proceed as under the sections “Di-

sassembly of the transmission oil cooler (without ex-traction the pipe bundle)” on page 21 (ZF 2000 und ZF 7500) or “Disassembly of the Transmission oil coo-ler (without extraction of the pipe bundle)” on page 28 (ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF 9000). In case of a defect on the oil side, proceed as under the sections “Disassembly of the transmission oil coo-ler (with extraction the pipe bundle)” on page 22 (ZF 2000 und ZF 7500) or “Disassembly of the trans-mission oil cooler (with extraction of the pipe bundle)” on page 30 (ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF 9000).

Note: In such a case the pipe bundle must not be removed from the housing completely.

Note: Spare o-rings are available at customer service of ZF Marine GmbH. The o-ring must be mounted as de-scribed under the sections “Assembly of the transmis-sion oil cooler (after extraction of the pipe bundle)” on page 24 (ZF 2000 und ZF 7500) or “Assembly of the transmission oil cooler (after extraction of the pipe bundle)” on page 34 (ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF 9000).


Troubleshooting 43


ZF Marine GmbH88038 FriedrichshafenDeutschlandTelephone +49 7541 77-2207 Telefax +49 7541 [email protected]

Transmission and Chassis Engineering

Documents

Kuehler Betriebsanleitung 01 - ÖZMAR · PDF fileOperating Instructions Transmission oil cooler for ZF marine transmission ZF 2000 ZF 2500 ZF 3000 ZF 4600 with pipe bundle cooler ZF