ZF 4-1 M, Operating Manual

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Operating Manual ZF 4-1 M / ZF 30 M
LEVER TRAVEL:
Mod: ZF 5 M - 6 M - 10 M-- 10 M- 12 M
- 15 M - 15 MA - 15 MIV - 25 M - 25
MA - 30 M.
Minimum travel of gear shift lever (N-
A=N-B) must be 35 mm (1.3/8”) for
outer pivot point and 30 mm (1.3/16”)
for inner pivot point.
Fig. 8:
1) Clamping screw torque
22 ± 1 Nm (17 lbf ft)
2) Minimum lever travel for control
cable
3) Do not open cover
4) Oil drain plug
Driving torque: Ma=22 Nm (16 lb-
ft).
LEVER TRAVEL :
Mod: ZF 4-1 M
Travel of gear shift lever (N-A=N-B)
must be 38,5±1,5 mm (1.52 in ± 0.06
in) for outer pivot point and 33,5±1,5
mm, (1.32 in ± 0.06 in) for inner pivot
point, from neutral position.
When the lever pass over the angle of
10°-12°, it starts to move outside per-
pendiculary and stops when the travel
is completed (angle of 40°).
Fig. 9:
1) Clamping screw torque
22 ± 1 Nm (17 lbf ft)
2) Do not unscrew the nut
3)
Do not open cover
LEVER POSITION: In neutral position
perpendicular to control rod or cable.
Gear shift lever can be
fi xed in any
position by means of clamping screw.
Minimum distance between gear shift
lever and cover 0.5 mm (0.02”). Open-
ing or loosening of cover requires
renewed adjustment (by specialized
personnel only).
Fig. 10:
1) Oil dipstick and filler screw, 17
mm
Driving torque: Ma = 20 Nm (15
lb-ft).
2) Control lever clearance min 0.5
mm
INSPECTIONS : Frequently check the
position of the lever to make sure that
everything operates correctly.
6.1 Maintenance
6.1.1 FLUID LEVEL CHECK
WARNING
Do not work on the transmission
when being towed, or anchoring in
a river because the propeller may
rotate.
DESCRIPTION OF THE DIPSTICK
(Fig. 11):
1) Housing surface
2) Dipstick
3) ATF level
4) ATF
5) Retention washer
Transmission fluid level may be
checked in cold or hot condition.
NOTE : Always check the oil level be-
fore operating the reverser. Proceed
as described below.
- Loosen
fl uid dipstick ( fi gure 11) by
turning the grip counterclockwise.
- Wipe dipstick with a clean and dust-
free cloth.
- Insert dipstick do not screw in (3-
4 fi gure 11). Remove dipstick and
check fl uid level: Fluid level has to
be between minimum and maximum
marks.
- Insert the dipstick and lock it by turn-
ing the grip clockwise.
CAUTION
According to the type and arrange-
ment of the cooler and pipelines
a certain amount of oil will collect
after stopping the engine and will
flow back into the transmission
after a longer rest period. This may
cause the oil level in the transmis-
sion to exceed the max. mark. Do
not remove off the surplus oil but
proceed according to steps.
- Let engine run at idle speed with
shifting lever in neutral position until
fl uid cooler and all pipelines are fi lled
with fl uid.
- Switch off engine and check fl uid
level within a short time. If neces-
sary, top
fl uid level off to the dipstick
mark.
The fl uid level on the dipstick ( fi gure
11) should be between the min. and
max. marks.The
fl uid level must be
checked again after a short driving
period.
6.1.2 FLUID CHANGE
CAUTION
The fi rst change must be performed
after 25 hours of operation. All sub-
sequent
fl uid changes to be made
after every 300 hours of operation
or once in a year (according to the
term which is reached earlier).
CAUTION
Used lubricant must be treated
as special waste that pollutes the
environment: it must therefore de
disposed of in accordance with its
particular structure.
6.1.3 DRAINING
TRANSMISSION FLUID
Remove the plug (1 Fig. 12) and allow
the oil to drain through the hole in the
lower part of the housing.
6.1.4 FILLING UP WITH
TRANSMISSION FLUID
Fill with ATF oil for automatic gear-
boxes according to the indicated
quantities. Add the quantity considered
necessary for
fi lling the heat exchanger
and relative connection pipes.
ZF 4-1 M: ... 0,42 liters (0,45 US-qts)
ZF 5 M: ....... 0,42 liters (0,45 US-qts)
ZF 6 M: ....... 0,42 liters (0,45 US-qts)
ZF 10 M: ..... 0,42 liters (0,45 US-qts)
ZF 12 M: ..... 0,60 liters (0,64 US-qts)
ZF 15 M: ..... 0,60 liters (0,64 US-qts)
ZF 15 MA: ... 0,56 liters (0,60 US-qts)
ZF 15 MIV: .. 1,00 liters (1,06 US-qts)
ZF 25 M: ..... 0,75 liters (0,80 US-qts)
ZF 25 MA: ... 0,75 liters (0,80 US-qts)
ZF 30 M: min. 0,90 liters (0,95 US-qts)
max. 1,10 liters (1,17 US-qts)
• Valid for shafts tilting less than 20
degrees (15° for ZF MIV).