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ZF Gearboxes Scheduled Maintenance Routines
Dynatron Services Pvt. Ltd. Is an eminent name in providing the repair of the various types of the Marine Gearboxes, overhauling and maintenance service for the ZF Gearboxes.
We also provide various scheduled maintenance routines such as A3.1 Routine, A3 Routine, A4 Routine and A5 Routine which is also called as Basic Overhaul as per OEM Manuals.
Recently we have done the A3 Routine on ICGS C-152, A4 Routines on ICGS Agrim, ICGS Abhiraj, INS Conkaraso, ICGS C-150, ICGS Abhinav etc. and A5 Routine on GBs of INS Battimalv.
DSPL has highly skilled and professional Engineers/Technicians who performs all the tasks with the atmost precisions and maintains the quality promise of our company.
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1.) A3.1 Routine (1000 Hourly/Annual)
In A3.1 Routine for ZF gearboxes, our company carries out the following tasks:
- Visual inspection of the gearbox externally
- Re-tighten all screw/bolt connections accessible from outside
- The chemical cleaning and pressure testing of oil cooler is done
- Safety Devise Checks.
2.) A3 Routine (2000 Hourly/2Yearly)
In A3 Routine for ZF Gearboxes, we basically execute the following tasks:
- Carry out visual inspection externally
- Re-tighten all the screw/bolt connections accessible from outside of the gearbox
- Check the control shift position settings and adjust if required
- Lubricate external moving parts
- Oil change
- Clean oil filter and filter housing
- Chemical Cleaning and Pressure testing of oil cooler and check output shaft seal.
3.) A4 Routine (6000 Hourly/ 5Yearly)
In A4 Routine for ZF Gearboxes, DSPL checkout list includes the following services:
- Checking out the oil level
- Carry out visual inspection
- Clean outside of transmission
- Re-tighten all screw/bolt connections accessible from outside
- Check shaft settings, and lubricate external moving parts
- Clean oil filter and filter housing
- Visually check flexible coupling between Gearbox and Engine
- Visually check flexible engine and transmission mounting
- Visually check clutch discs
- Visually check running gears
- Check control unit
- Check actuating unit
- Calibration of Gearbox Monitoring Devices and pressure testing oil cooler.
- Check spray line valves
- Check injection line valves
- Check input shaft seal
- Check output shaft seal
- Check input shaft seal
- Check output shaft seal
4.) A5 Routine (Basic Overhaul)
In A5 Routine, the Basic Overhauling of ZF Gearboxes, We provide the following services:
- Receipt of Gearbox in workshop
- On Receipt make the visual inspection and recorded it
- Dismantle the Gearbox completely
- Clean all the parts and inspect/calibrate all the parts as per the factory recommendation
- Make additional parts list if any required
- Clean Oil Filter and filter housing in case of long life filter or Change oil filter in case of cartridge filter
- Chemical cleaning and pressure testing of Oil coolers
- Assemble back the gearboxes with new/service parts.
- Setting of End play and other allowance
- Do the machining of shim as per the requirement
- Final setting of Endplay/ Clearance
- Calibration of Gearbox Monitoring Devices
- Spin Test as per factory test protocol
- Painting
Mandatory basic overhauling Spare Parts offered prior opening of the gearbox is as below. (Only Parts of wear and tear nature)
- Full set of seals, gaskets, O rings
- Full set of cup springs, small washers etc
- Full set of bearings
- Full set of clutch discs
- Complete Oil Pump
- Bushes, Compression Springs, slotted nuts, piston rings etc
- Oil Filter in case of cartridge filter
The above list does not cater for any damaged/ defective parts which would need replacement in addition to the standard wear and tear parts mentioned above, which could be identified only on complete striping and disassembly of the gearbox.