Manual de Operacion
Manual de Operacion
Z F 2 0 0 0 S ERIES
Table of Contents
Foreword ............................................................................................................................................................. 7
1 Safety .................................................................................................................................................................. 9
1.1 Conventions for safety information in text .................................................................................................. 9
1.1.1 Safety information .......................................................................................................................... 9
1.2 General information ................................................................................................................................... 9
1.2.1 General .......................................................................................................................................... 9
1.2.2 Intended use .................................................................................................................................. 9
1.2.3 Changes or modifications ............................................................................................................... 9
1.2.4 Spare parts ..................................................................................................................................... 9
1.3 Personnel and organisational requirements .............................................................................................. 10
1.3.1 Demands on personnel ................................................................................................................. 10
1.3.2 Organisational measures .............................................................................................................. 10
1.3.3 Work clothing and protective equipment ...................................................................................... 10
1.4 Safety regulations for service and repair work .......................................................................................... 10
1.4.1 Safety regulations for commissioning ........................................................................................... 10
1.4.2 Safety regulations for operation .................................................................................................... 10
1.4.3 Operation of power plant .............................................................................................................. 10
1.4.4 Servicing and repair ...................................................................................................................... 11
1.4.5 Welding work ............................................................................................................................... 11
1.4.6 Pressing on and off ....................................................................................................................... 11
1.4.7 Working on electric/electronic subassemblies .............................................................................. 12
1.4.8 Operating electric devices ............................................................................................................ 12
1.5 Consumables and service fluids, fire and environmental protection .......................................................... 12
1.5.1 Fire prevention ............................................................................................................................. 12
1.5.2 Noise ............................................................................................................................................ 12
1.5.3 Environmental protection .............................................................................................................. 12
1.5.4 Service fluids and consumables .................................................................................................... 12
1.5.5 Used oil ........................................................................................................................................ 12
1.6 Transport ................................................................................................................................................. 13
1.6.1 Transmission without suspension bracket ..................................................................................... 13
1.6.2 Transmission with suspension brackets ........................................................................................ 13
1.6.3 Lowering the transmission after transport ..................................................................................... 13
5 Operation .......................................................................................................................................................... 65
5.1 Operating elements ................................................................................................................................. 65
5.1.1 Electrical transmission actuation with two solenoid valves (for ZF 2000 series without NR) .......... 66
5.1.1.1 Electrical transmission actuation elements ...................................................................... 66
5.1.1.2 Mechanical emergency actuation with two solenoid valves
(for ZF 2000 series without NR) ...................................................................................... 66
5.1.1.3 Operation using mechanical emergency actuation .......................................................... 68
5.1.2 Electrical transmission actuation (for ZF 2000 NR (CEW) series) ................................................... 69
5.1.2.1 Electrical transmission actuation elements ...................................................................... 69
5.1.2.2 Mechanical emergency actuation (for ZF 2000 NR (CEW) series) ................................... 70
5.1.2.3 Operation using mechanical emergency actuation .......................................................... 71
5.1.3 Electrical transmission actuation (for ZF 2000 NR (EW) series) ..................................................... 72
5.1.3.1 Electrical transmission actuation elements ...................................................................... 72
5.1.3.2 Mechanical emergency actuation (for ZF 2000 NR (EW) series) ..................................... 73
5.1.3.3 Operation using mechanical emergency actuation .......................................................... 74
5.1.4 Mechanical transmission actuation (for ZF 2000 series) ................................................................ 75
5.1.4.1 Mechanical transmission actuation elements .................................................................. 75
5.1.4.2 Mechanical emergency actuation (for ZF 2000 series) .................................................... 77
5.1.4.3 Operation using mechanical emergency actuation .......................................................... 77
5.2 Shift procedure ........................................................................................................................................ 78
5.2.1 Shifting Neutral > Ahead and Neutral > Astern ............................................................................. 78
5.2.2 Shifting Ahead > Astern and vice versa ......................................................................................... 79
5.2.3 Shifting in case of danger (crash stop) .......................................................................................... 79
5.3 Trailing operation ..................................................................................................................................... 79
5.3.1 Occasional trailing operation ........................................................................................................ 79
5.3.2 Regular trailing operation ............................................................................................................. 79
5.4 Operation using the emergency control ("Come home screws") ............................................................... 80
5.4.1 Activating emergency control ....................................................................................................... 80
5.4.2 Deactivating emergency control ................................................................................................... 81
5.5 Exchanging the filter cartridge during operation ...................................................................................... 82
8 Maintenance ..................................................................................................................................................... 93
8.1 Application area ...................................................................................................................................... 93
8.1.1 Application group P ...................................................................................................................... 93
8.1.2 Application group L ...................................................................................................................... 93
8.1.3 Application group M ..................................................................................................................... 93
8.1.4 Application group C ...................................................................................................................... 93
8.2 Maintenance schedule ............................................................................................................................. 94
8.2.1 Maintenance schedule concept .................................................................................................... 94
8.2.2 Maintenance work before taking out of operation/standstill .......................................................... 95
8.2.2.1 For closed cooling circuit ................................................................................................ 95
8.2.2.2 For open cooling circuit .................................................................................................. 95
8.3 Corrosion protection and conservation ..................................................................................................... 97
8.4 Maintenance work plan ........................................................................................................................... 99
8.5 Tool kit .................................................................................................................................................. 100
8.5.1 Tool kit W1 for maintenance ....................................................................................................... 100
8.6 Spare parts and spare parts orders ........................................................................................................ 101
8.7 Maintenance System Job Sheets ........................................................................................................... 102
Foreword
These Operating Instructions are a fundamental part of the transmission and must always be available.
These Operating Instructions serve avoiding malfunctions and damage during operation and should therefore be
made available for maintenance and operating personnel.
The warranty terms and conditions agreed upon with ZF Friedrichshafen AG for the transmission are to be applied.
ZF Friedrichshafen AG will only accept warranty claims when:
The transmission is installed, monitored, operated and maintained according to these Operating Instructions.
Lubricants approved by ZF are used (ZF TE-ML 04).
Limit values for the maximum engine output speed ratio according to the type plate as well as the engine speed
according to the transmission classification have not been exceeded.
ZF Friedrichshafen AG does not assume any liability or warranty obligations for damage and defects resulting from
unauthorized changes or modifications to the transmission and transmission components.
These Operating Instructions apply to standard transmissions. Differences due to customisation and operating condi-
tions are possible. The information in the specifications is binding when the information in the Operating Instructions
deviates from these technical and/or commercial specifications.
Describes a dangerous situation that can lead to Usage other than the intended use
serious injuries or death when not avoided. Operating, servicing and commissioning by unquali-
fied personnel
CAUTION Changes or modifications
Describes a dangerous situation that can lead to minor Noncompliance with safety information
or moderate injuries when not avoided.
1.2.2 Intended use
Serves to draw attention to special procedures, The manufacturer of the transmission does not assume
methods, information, use of aids and tools, etc. any liability for damage resulting from such use. The risk
will be borne solely by the user. The intended use also in-
This document specially highlights safety information ac- cludes compliance with the Operating Instructions as
cording to US standard ANSI Z535 by marking the text well as compliance with the Service and Repair Instruc-
with the above signal words according to the degree of tions. Limit special and emergency running states to the
danger. maximum admissible time or number of cycles according
to the Operating Instructions.
1.1.1 Safety information
1.2.3 Changes or modifications
1. Ensure that you read and understand all warnings
prior to commissioning or repairing the product! Unauthorized changes to the transmission impair the
2. Also pass on all safety information to operating, serv- safety.
ice, and repair personnel and/or transport personnel! ZF Friedrichshafen AG will not assume any liability or
warranty obligations for damage resulting from unauthor-
ized changes or modifications.
1.3 Personnel and organisational requirements 1.4 Safety regulations for service and repair
work
1.3.1 Demands on personnel
1.4.1 Safety regulations for commissioning
Work on transmissions may only be carried out by trained
and instructed qualified personnel. Based on their appro- Before using the transmission for the first time, install and
priate training and experience, the qualified personnel connect it to the monitoring system according to these
must be capable of recognizing risks and avoiding possi- Operating Instructions.
ble hazards which may be caused when operating or re-
Ensure for every use of the transmission and/or plant:
pairing the transmission.
All service and repair work has been completed
Observe the minimum legal age.
All loose parts of rotating machine parts have been
The Operating Instructions must be read and understood
removed
by the personnel.
Nobody is within the danger area of moving machine
The responsibilities of the personnel for operation, serv-
parts.
ice, and repair are to be defined.
Immediately after commissioning the transmission and/or
1.3.2 Organisational measures the plant, ensure operating and display instruments and
monitoring, signalling, and alarm systems operate prop-
Pass these Operating Instructions on to the operating, erly.
service, repair and/or transport personnel. Always keep
them readily available at the site where the transmission 1.4.2 Safety regulations for operation
is operated and accessible to the operating, service, re-
pair and/or transport personnel. The operator must be familiar with the operating and
Instruct personnel on handling and repairing the trans- display elements.
mission using these Operating Instructions and pay par- The operator must be aware of the effects of every
ticular attention to information relevant for safety. This operating step to be performed. The operator must
applies especially to personnel only working occasionally perform individual operating steps according to the
on the transmission. Such personnel should be instructed instructions.
repeatedly.
During operation, observe display instruments and
1.3.3 Work clothing and protective equipment monitoring assemblies constantly according to the
momentary operating states to ensure compliance
Wear work clothing corresponding to safety require- with limit values as well as warning and alarm mes-
ments during all work. sages.
If a malfunction is detected on the system or is reported
Depending on the type of the work, use additional by the system:
protective equipment, e.g. goggles, protective
gloves, safety helmet, apron. Inform the responsible supervisory personnel.
Work clothing must fit tightly to ensure that it does not Evaluate the message.
get caught by rotating or protruding parts. Do not wear Perform possible emergency measures, e.g. operating
jewellery (rings, necklaces, etc.). with the emergency control.
1.4.4 Servicing and repair Do not load lifting lugs from the side.
Pay particular attention to cleanness when performing
An essential safety factor is compliance with the Service
service and repair work on the power plant. Make sure
and Repair Instructions.
no loose parts are in/near the machinery after com-
pleting service and repair work.
Observe the following points before starting maintenance
and repair work:
1.4.5 Welding work
Unless expressly approved, do not carry out servicing
and/or repair work while the engine is running. Welding on the transmission or attached equipment is
not allowed!
Secure engine against unintended start.
Never place the welding cable above or near cable
Attach a "Do not operate" sign in the operator room or
harnesses of ZF plants.
on the control unit.
Do not connect the ground connection of the welding
Keep uninvolved persons away!
device more than 60 cm from the welding location.
Never clear malfunctions or perform repairs with-
1.4.6 Pressing on and off
out the required experience or special tools.
Leave all service and repair work to authorized quali- Only use press on/off devices specified in the Work Plan
fied personnel. as well as in the Assembly Instructions. Do not exceed
the maximum admissible slip-on pressure for the press
Only use calibrated tools suitable for the function.
on/off device. High-pressure lines for hydraulic pressing
Do not work on transmissions or components only on and off are tested with 3,800 bar.
held by lifting devices or a crane. Always support
Do not bend lines under pressure or apply force!
these with suitable means and according to regula-
tions before starting any service or repair work. Before starting the pressing process, observe the fol-
lowing:
Before turning the engine, make sure nobody is within
the danger area of the power plant. After completing Vent the press on/off device, the pumps as well as the
work on the transmission, check that all protective pipework used at the positions intended for the rele-
equipment has been fitted and all tools and loose vant unit (e.g. open vent screws, pump until oil dis-
parts have been removed from the transmission. charges free of air, tighten vent screws).
Seal all openings using caps and covers when remov- To press on, screw the device on with the plunger
ing or opening lines. retracted.
Do not damage pipes and tubes during service and/or To press off, screw the device on with the plunger
repair work. extended.
Apply correct torque when tightening connections fit- When using a press on/off device with central widen-
ted between lines. Ensure all brackets and dampers ing pressure application, screw the spindle into the
are installed properly. shaft end until the sealing effect is achieved.
Ensure all electrical cables and oil pressure lines have During hydraulic pressing on and off of components,
enough clearance to prevent contact with other com- make sure nobody is in close vicinity of the compo-
ponents. nent to be pressed on.
Collect service fluids in a container, soak up spilled There is a risk that the component to be pressed on
liquids using absorbent and/or wipe up. suddenly "jumps off" the pressure connection when
the system is under pressure.
When working above body height, use ladders and
working platforms meeting safety requirements. Check the devices in specified intervals prior to use
Ensure stable positioning of transmission parts put (crack detection test).
down!
Adults must not carry or lift more than a maximum of
10 kg to 30 kg, depending on age and sex, to avoid back
injuries when lifting components, therefore:
Use lifting equipment or get help.
Make sure all chains, hooks, eyes, etc. are tested and
approved, have sufficient load capacity and hooks are
positioned correctly.
1.4.7 Working on electric/electronic subassemblies Do not perform welding work on pipes and parts con-
taining oil or fuel!
Obtain the authorization of the responsible supervi-
Clean with non-combustible liquid before starting
sory personnel before starting any service and repair
welding work.
work and/or shutting off parts of the electronic sys-
tem. Always keep suitable extinguishing equipment (fire
extinguisher) ready and be aware and capable of its
Disconnect the relevant electric supply before starting
usage.
any work on subassemblies. The documentation
draws attention to specific measures requiring power.
1.5.2 Noise
Do not damage cables during dismantling work and
refit the cables so that these are not damaged through Noise can increase the risk of accidents when perception
contact with sharp edges, rubbing on parts or contact of acoustic signals, warning cries or noises indicating
with hot surfaces during operation. danger is impaired.
Do not attach cables to lines carrying liquid! Wear hearing protection (protective cotton, ear plugs
or earmuffs) at all work places with a sound pressure
Reconnect and fasten any cables removed after com-
level above 85 db(A)!
pleting service and/or repair work!
After every repair, perform a functional inspection of 1.5.3 Environmental protection
the device and/or the installation using corresponding
functional tests. Separate inspection of the repaired Dispose of used service fluids, cleaning agents, and
component without integration in the component filter in accordance with local regulations.
assembly is not sufficient.
Do not drain service fluids and cleaning agents into
Use suitable cable clamps to fasten cables fitted close soil, ground water or sewer systems.
to mechanical components with a risk of fraying!
Request and observe Safety Data Sheets from the
Do not use cable straps for fastening because cable responsible environmental agency for relevant prod-
straps removed during service and/or repair work ucts.
might not be refitted.
Collect used oil in container of sufficient size.
Store spare parts properly until used for replacement,
Observe manufacturer's regulations when handling
i.e. protected against moisture in particular.
service fluids and cleaning agents.
Pack defective electronic components or subassem-
blies properly for transporting for repair work, i.e. pro- 1.5.4 Service fluids and consumables
tected against moisture in particular, shockproof and,
where necessary, in antistatic foil. Only use service fluids tested and approved by ZF
(lubricant list TE-ML 04)!
1.4.8 Operating electric devices
Store service fluids and consumables in suitable and
correctly labelled containers!
Certain parts of electric devices are live during operation.
Failure to comply with warnings applicable for the de- Observe safety regulations applicable for the product
vices can result in severe injuries or material damage. when handling service fluids and other chemical sub-
stances.
1.5 Consumables and service fluids, fire and Take care when handling hot, undercooled or caustic
environmental protection substances.
1.5.1 Fire prevention Avoid contact with ignition sources, do not smoke,
when handling flammable substances!
Repair oil leaks immediately because small amounts
of oil or cleaning agent on hot parts can cause fires. 1.5.5 Used oil
Always keep the transmission clean. Used oils can contain combustion residues harmful to
Do not leave cloths impregnated with service fluids on health.
the transmission. Apply skin barrier cream to hands!
Do not store combustible objects/material near the Clean hands after contact with used oil!
power plant.
1.6 Transport
Always use the lifting lugs or suspension brackets pro-
vided to suspend the transmission.
Never use transmission components such as cooler,
oil pump, pipework, brackets, sensors, input or output
shafts for attaching lifting devices.
Do not stand under the transmission and stay clear of
the danger area during lifting and lowering.
Observe centre of gravity of transmission. When trans-
porting, always keep the transmission in the installa-
tion position with a maximum admissible inclined
hoist of 10 degrees.
Always keep the lifting rope or chain a minimum dis-
tance of 20 mm away from the transmission compo-
nents.
The load capacity of the lifting device must be at least
4,000 kg.
Secure the transmission against tilting during trans-
port. Secure the transmission against slipping and tilt-
ing when using slopes and ramps.
ZF 2000 NR series transmissions are reduction transmis- Transmission actuation is made electrically or mechani-
sions with a multi-disc clutch that can be fitted on either cally using a pilot valve located on top of the control unit.
the input shaft or intermediate shaft. The output direction Electrical actuation is part of the transmission basic ver-
is either against or the same as the input direction de- sion.
pending on the version.
2.1.1.3 Transmission as A and parallel version
The cast iron housings of the transmissions have high tor-
The flange of the transmission input shaft is always lo-
sion resistance and are mainly made of light alloy resist-
cated above the flange of the output shaft. The vertical
ant to sea water. Machined surfaces required for fitting
axial distance between the two shafts is measure "A".
transmission mounting brackets and bell housing, includ-
ing threaded holes are provided as standard. Transmission input and output are located on opposite
sides of the housing.
To achieve a long service life and a high degree of quiet-
ness in operation, all power-transferring gearing is de-
Parallel version
signed to highest safety standards, case-hardened,
polished, and subsequently submitted to a special treat- Also referred to as vertical arrangement because of the
ment. The shafts rotate in antifriction bearings. Propeller vertical distance between input and output shaft (meas-
thrust bearings are incorporated in the transmission to ure "A"). The shafts in the transmission are arranged on
absorb the propeller thrust. The clutch fitted on the input parallel axes.
shaft and the intermediate shaft is a multi-disc clutch The transmission identifier is just transmission type
with steel/sinter friction interface. It is pressured by oil "ZF 2000" without a letter as suffix.
pressure and thus closed.
U version
The shafts in the transmission are arranged on parallel
axes. The transmission type has suffix "U", for example,
ZF 2350 U.
A version
The axis of the output shaft is inclined towards the axis of
the input shaft by angle "α". The transmission type has
Fig. 3: U version
suffix "A", for example, ZF 2000 A.
V version
The axis of the output shaft is inclined towards the axis of
the input shaft by angle "α". The transmission type has
suffix "V", for example, ZF 2000 V.
Fig. 2: A version
007693.2
Free-standing installation
The transmission is rigidly or elastically supported in the
foundation and the engine is normally elastically sup-
ported. A flexible clutch serves as drive connection be-
tween engine and transmission. The clutch serves as
torsional vibration damper and must also compensate ax-
ial, angular, and, to a minor extent, radial displacement
of connected equipment.
Fig. 5: B version
Select the elasticity of the engine bearing and alignment
of engine and transmission so that the admissible loads
2.1.2 Installation position on the ship
acting on the transmission in axial and radial direction
due to the aligning forces of the flexible connection are
2.1.2.1 Engine-transmission arrangement "standard"
not exceeded.
Flanged installation
The engine is connected to the transmission via the
transmission bell housing.
This ensures good centring between engine and trans-
mission. The flexible clutch does not need to compensate
additional forces which could otherwise occur due to
shaft displacement.
β2 β1
006779.2
β1
α 004_971.2
V and U arrangement
2.1.4.1 ZF 2000 / ZF 2050 / ZF 2060 / ZF 2070 / ZF 2075 / ZF 2150 / ZF 2000 NR / ZF 2050 NR / ZF 2060 NR /
ZF 2070 NR / ZF 2075 NR / ZF 2150 NR
Your transmission may vary from the Figures shown here with regard to structure, connections, and pipework.
46 34
25
23
44
18
21 137 53
2
28
20
15 47
22
13
41
33
1
26
10
11 20 12
Key to drawing:
2.1.4.2 ZF 2000 A / ZF 2050 A / ZF 2060 A / ZF 2070 A / ZF 2075 A / ZF 2150 A / ZF 2000 NRA / ZF 2050 NRA /
ZF 2060 NRA / ZF 2070 NRA / ZF 2075 NRA / ZF 2150 NRA
Your transmission may vary from the Figures shown here with regard to structure, connections, and pipework.
46
25
23
34
44
18
2 21 137 53
8
28
20
15 47
22
13
41
33
26
10
12
11 20
Key to drawing:
2.1.4.3 ZF 2000 V / ZF 2050 V / ZF 2060 V / ZF 2070 V / ZF 2075 V / ZF 2150 V / ZF 2000 NRV / ZF 2050 NRV /
ZF 2060 NRV / ZF 2070 NRV / ZF 2075 NRV / ZF 2150 NRV
Your transmission may vary from the Figures shown here with regard to structure, connections, and pipework.
46
25
23
18
2 21 137 53
28
20
15 47
22
8
13
41
33
1
10
26
44
11 20 12
Key to drawing:
2.1.4.4 ZF 2150 NC
Your transmission may vary from the Figures shown here with regard to structure, connections, and pipework.
46 47
25
23
10
18
21
2 53
8
28
20
15
22
13
41
33
26
11 12
20
Key to drawing:
34
25
23
33
10
18
8
20
12
137 46
53
21
28
26
20
47
15
22
13
41
11
Key to drawing:
46
25
23
44
18
21 53
137 47
28
20
15
22
34
13
41
33
10 26
11 20 12
Key to drawing:
15 47
22
13
41
33
1
34
26
12
11
20
Key to drawing:
46
34
44 25
10 23
18
21 137
2 53
28
20
15 47
22
13
41
33
1
34
26
12
11
20
Key to drawing:
46
34
44 25
10 23
18
21 137
2 53
28
20
15 47
22
13
41 33
26
11 12
20
Key to drawing:
2.1.4.10 ZF 2350 U
Your transmission may vary from the Figures shown here with regard to structure, connections, and pipework.
46 47
25
23
10
18
21 137
2 53
28
20
15
13 22
41
33
44
26
12
11 20
Key to drawing:
ZF 2200 B
Measure "A“ Max. admissible align- Max. shaft align- Min. admissible bearing spacing "L" -
according to ment error "x" in [mm] ment offset "y" in depending on propeller shaft diameter
Section 2.1.1 Gen- [mm] "d" (see Section 4.1.3) in [mm]
eral design princi-
plein [mm]
A = up to 279.8 0.05 0.10 500 for d<70
1,000 for d=70 to 100
2,000 for d>100
A = 280 0.10 0.15 500 for d<90
A = 335 1,000 for d=90 to 120
A = 390 2,000 for d>120
The valid ZF lubricant list TE-ML 04 is binding for ZF marine transmissions. This list is available from all ZF Service
branches. It can be downloaded free of charge on the internet in PDF format under www.zf.com.
Viscosity class SAE 30 or SAE 40 for oil sump temperatures < 80°C
Viscosity class SAE 40 for oil sump temperatures > 80°C
44
Filterverschmutzung Clutch oil pressure Lubricating oil pressure Oil temperature
1) 20) 21) 2, 21 22 11, 12, 41
Measuring point 5 127
Operating state 9) --- --- Operation Trailing ope-
Shift position Shift position9) Shift position 9)
"Neutral“, "Engine "Engine wise or counter-engine "Neutral" ration 8)
Product overview
1) Location of measuring points on the transmission – see 7) The rated clutch pressure is specified in the binding, 17) Not included in the above Table
Section 2.1.4 Transmission views on page 20 order-specific technical documents and also embossed
18) Warning point measured by a pressure sensor
on the type plate
2) For optical and acoustic warning
19) Disable the warning in trolling operation
8) During operation with engine switched off and propeller
3) Not included in the above Table
driven by current (Section 5.3 Trailing operation) 20) only using a gap filter
4) At 60°C to 80°C oil temperature
9) During normal operation 21) only using a changeover filter
5) Warning with time delay of 3 to 10 s (the monitoring de-
10) Not included in the above Table 22) ZF 2060/2260/2360 series,
vices described in the monitoring plan are supplied by
ZF 2070/2270/2370 series
ZF). A superordinate monitoring system, not supplied by 11) Without trailing pump
ZF, is required for processing these signals (e.g. for 23) Customer must disable the warning for an oil temperature
12) With trailing pump (not supplied by ZF)
warning purposes) < 35°C
13) Not included in the above Table
6) Disable the warning in "Neutral" shift position. Increasing
14) Not part of standard ZF scope of delivery
Decreasing
15) Not included in the above Table
PK Clutch oil pressure
16) For remote display
PKN Rated clutch pressure
3.1 Functions
The transmission and power flow diagram shows the power transmission for the "engine wise rotation" output direc-
tion (input and output rotate in same direction) and for the "counter-engine wise rotation" output direction (input and
output rotate in opposite directions). The engine performance can be transmitted to the full extent in both output di-
rections. The ratio shown on the type plate applies for both output directions. This means fully identical transmission
versions can be used for installations with several engines. This reduces spare parts and enables using uniform re-
placement units.
A A
B
Gears
meshed C
B together
C
A = Input shaft
B = Intermediate shaft
C = Output shaft
A CEW D = Clutch for CEW
C E = Clutch for EW
B A EW
C
Fig. 15: Power flow diagram of the parallel version
(example, EW = engine wise rotation, CEW = counter-engine wise rotation)
A A
Gears B
meshed
B together C
A = Input shaft
A CEW B = Intermediate shaft
C = Output shaft
C
D = Clutch for CEW
B A EW E = Clutch for EW
A
A
Gears
meshed
B together B
C
E
A A
B
Gears
meshed
B together C
A = Input shaft
B = Intermediate shaft
CEW A C = Output shaft
C D = Clutch for CEW
E = Clutch for EW
EW A
C B
C C
E
B
B Gears A
meshed
together
A
A = Input shaft
D B = Intermediate shaft
C = Output shaft
C
A CEW D = Clutch for CEW
E = Clutch for EW
C
B A EW
C
B
B
E
A
C
D
A
A = Input shaft
B = Intermediate shaft
C = Output shaft
D = Clutch for CEW
C
CEW A
Fig. 20: Power flow diagram of the NRB version (example, CEW = counter-engine wise rotation)
The engine-dependent primary oil pump is driven by the transmission intermediate shaft via a driver. The continuous
delivery gear pump operates according to the positive displacement principle and is largely self-priming.
The delivery rate of this primary oil pump depends on the speed of the transmission input shaft. The gear pump has a
high delivery rate to ensure sufficient oil for lubrication and cooling of the transmission is available, also at low input
speed. The high delivery rate also ensures rapid response of the respective clutch switched.
Actuating the hydraulic multi-disc clutch effects even and reliable shift procedure. During switching, the contact pres-
sure of the clutch is modulated which results in smooth creation and/or interruption of the power flow in the transmis-
sion. An increased oil flow is supplied to the switched multi-disc set to dissipate heat occurring during the shift
procedure more quickly and thus increase the load capacity of the clutch.
A mechanical emergency control is available for operating should malfunctions occur in the pressure oil circuit. For
this purpose, the multi-disc clutch(es) is/are pressed together mechanically using three screws accessible from the
outside while the transmission is idle.
This emergency control can be used to operate reverse transmissions with "engine wise rotation" (EW) or "coun-
ter-engine wise rotation" (CEW) input direction.
The transmission oil cooler is designed according to the pipe bundle principle as a compact and lightweight unit.
All standard transmission versions are fitted with an oil filter equipped with one filter cartridge.
The cooled oil flows through an oil filter, from there into the control unit and finally to the clutches and lubricating
points of the transmission.
The control piston is moved axially to the relevant shift position "Neutral" / "Engine wise rotation" / "Counter-engine
wise rotation". This is done either mechanically or hydraulically depending on the actuation version. The oil flowing
out of the control unit is used for lubricating and cooling the clutch discs, meshing gears and bearings.
With mechanical transmission actuation, the control piston is moved axially through oil pressure via a mechanically
operated pilot valve. The pilot valve is mounted on top of the control unit.
With electrical transmission actuation, the control piston is moved axially through oil pressure via an electrically oper-
ated pilot valve. The pilot valve is mounted on top of the control unit. Electrical transmission actuation is included in
the basic transmission version.
4.1 Initial installation Machined surfaces and fastening threads are provided on
the side of the transmission housing for attaching the
When planning the power plant, provide sufficient clear- suspension bracket. If suspension brackets are provided
ance for disassembling the oil cooler, oil filter, oil pump, by the shipyard, attention must be paid to the vertical dis-
transmission clutch and/or clutch discs and for removing tance between transmission output shaft and foundation
the oil dipstick. Disassembling the transmission clutch contact surface of the suspension bracket. This distance
and/or clutch discs is possible with the transmission in- measure "x" must be within the following range:
stalled.
x < (0.6 • A) and > (-0.2 • A)
Dimensions for disassembly are specified in the
transmission installation documents.
Oil drain plugs must also be easily accessible. If there is
not sufficient space under the oil drain for collecting oil
drained during oil changes, we recommend installing a
suction line fixed on the transmission instead of the oil A
drain plug. In this case the oil must be sucked off during +
X
oil changes.
-
The bolts of the mechanical emergency control must be
accessible to allow manual closing of the multi-disc
clutch(es). See the transmission installation documents Contact surface
for required clearances.
As manufacturer of an individual component of a ship
propulsion system, the transmission manufacturer cannot
be held responsible for vibrations or vibration problems
occurring in this system. Accordingly, ZF will not assume
any liability for transmission noises or damage to the A +
transmission, the flexible coupling or other parts of the X
power chain caused by such vibrations.
We therefore recommend performing a vibration calcula- -
tion and, where applicable, also including unloaded
transmission parts. Contact surface
See the binding installation documents valid for the Fig. 21: Transmission with assembly dimensions
transmission delivery contract for the admissible installa- (example)
tion position in the ship.
Suspension bracket surfaces on the transmission side
The following screw connections listed are to be per- must be machined plane.
formed by the customer and must be sized according to
The transmission can be installed as free-standing in the
their respective loads:
foundation or flanged on, supported either rigidly or elas-
Transmission mounting bracket – transmission (when tically together with the engine.
not supplied by ZF)
Do not brace the transmission on the foundation during
Transmission mounting bracket – foundation installation, i.e. all support brackets must be flat on the
foundation. When selecting support elements for elastic
Flexible clutch – engine / transmission
support of transmissions, ensure the inherent frequency
Propeller shaft – transmission of the elastically supported transmission does not coin-
cide with the excitation frequency of the power plant or
Required safety equipment for rotating and moving parts
the propeller. Consider foundation rigidity as well when
must be present:
calculating the inherent frequency.
Guard on the transmission output flange
Low foundation rigidity can cause resonance and thus
Guard on the flexible clutch extreme loads on transmission components. This reduces
the service life of these components.
Guard on the engine fly wheel and input shaft
Guard and arresting device in joint shaft proximity Recommendations for the foundation rigidity are
contained in the relevant drawings of the elastic
transmission support.
If the propeller thrust is absorbed by the transmission Specifying an exclusion range for certain speeds may be
(the propeller thrust bearings for forward and reverse necessary when, in special cases, a resonance speed
thrust are integrated in the reverse transmission), the within the operating speed range cannot be avoided.
support elements must also be suitable for absorbing the This range depends on the magnitude of the calculated
propeller thrust. For elastic transmission suspension and vibration amplitudes.
a rigidly connected propeller shaft, transmission shift
Normally, the flexible clutch is selected by the engine
should not have a lasting effect on alignment. Please
manufacturer using a torsional vibration calculation. The
contact us in case of doubt..
torsional vibration calculation must also include excita-
Use solid supports for aligning the transmission on the tions induced by the motor controller. Details concerning
foundation (see Section 4.1.3 Connection to propeller the transmission required for the calculation can be
shaft). Individual supports - in the area of the foundation found in our calculation sheet "Data for torsional vibration
bolts only - are not allowed. Suspension brackets sup- calculation". No warranty can be assumed for the suita-
plied by ZF include alignment bolts. Remove the align- bility or durability of the torsionally flexible connection
ment bolts used after the supports have been installed. when the torsionally flexible connection is supplied by ZF
according to a selection made by the engine manufac-
We recommend using fitting bolts for securing suspen-
turer or a specification made by the shipyard.
sion brackets in the foundation. Fit fixed end stops at
least in "forward propeller thrust" direction when using Perform assembly and disassembly of clutch hub or input
through bolts. Fitting and fastening bolt dimensions flange and/or the transmission-side part of the torsionally
(quantity, diameter, quality) depend on the operational flexible input connection in accordance with the instruc-
load and must be defined by the shipyard. Ensure that tions of the Service Manual for this transmission series.
not only the propeller thrust and the weight are sup-
The engine-transmission unit can be fitted rigidly or flexi-
ported on the transmission support but also the reaction
bly in the foundation. Ensure the conditions according to
forces of the torque and the ratio-dependent output
Section 4.1.1 Transmission support in the foundation are
torque.
maintained when using elastic support.
The contact surface of the ZF suspension bracket (flexi-
ble and rigid) is designed for direct support on a rigid sur- 4.1.3 Connection to propeller shaft
face (e.g. foundation frame). If the transmission support
is to be made on cast resin, it may be necessary to en- Connection dimensioning depends on the operating load
large the contact surfaces using an adapter plate sup- and must be defined by the shipyard.
plied by the shipyard.
The transmission output flange is designed so that the
The space between ship foundation and adapter plate is highest admissible transmission output torque can be
filled with cast resin. Design the adapter plate so that transmitted through frictional contact.
transmission disassembly and assembly are possible
For this purpose, use the following bolts for all existing
without severely damaging the cast resin foundation.
bolt holes:
Also provide fixed end stops for transmission of the pro-
peller thrust on the foundation. After the cast resin has
hardened, the transmission should be supported through
the cast resin only and not through the alignment bolts or
other alignment tools. Cast resin shrinkage during hard-
ening must already be considered during transmission
alignment.
We recommend working with the cast resin supplier and/
or a qualified expert company when planning support on
cast resin. Such an expert company can provide relevant
preliminary consultation and is capable of preparing the
calculations and drawings required for approval by a
Classification Society and submitting these for approval.
4.1.3.1 Shaft installation with only one bearing for the 4.1.3.2 Shaft installation with two or more bearings for
propeller shaft (Fig. A) the propeller shaft (Fig. B)
Axial and radial movement of the propeller shaft must be Axial movement of the propeller shaft must be so flexible
so flexible that the propeller shaft flange can be inserted that the propeller shaft flange can be inserted in the cen-
in the centring of the transmission output flange. Align tring of the transmission output flange. Align the trans-
the transmission so that admissible angular misalignment mission so that admissible angular misalignment "x"
"x" relative to measured radius "r" does not exceed the relative to measured radius "r" does not exceed the value
value specified in the Table "Alignment accuracy of the specified in the Table "Alignment accuracy of the propel-
propeller shaft" in Section 2.2 Technical data (value "y" is ler shaft".
not considered).
Both errors "x" and "y" may occur at the same time.
Measuring value "y" is often not possible when using very
thin shafts and a large distance "L". Value "y" can be ig-
nored when the propeller shaft can be inserted in the
centring of the transmission output flange with a radial
force not exceeding the value specified in the Table
"Alignment accuracy of the propeller shaft" in Section 2.2
Technical data. In this case, the specifications for "shaft
installations with only one bearing for the propeller shaft"
are applicable.
Fig. B L
3 to 5
r y
d
004 972
4.1.4 Connection to the joint shaft The output shaft is already inclined by 10° on transmis-
sions in V arrangement. This allows reducing the joint an-
The specifications according to Section 4.1.2 Connection gle to the minimum value required for the joint bearings
to the engine apply to the rotary joint between engine of the joint shafts. It is recommended to utilize the benefit
and transmission, complemented by the use of a joint offered by the inclined output shaft and not to exceed a
shaft with length compensation between the flexible maximum joint angle of 3°. Keep the dynamic rotating
clutch and transmission input flange. Radial forces and mass of the joint shaft centre body as small as possible.
bending moments are generated by the joints of the joint
For detailed information on joint shafts, see the
shaft. In addition, length changes between engine and
technical documents of the joint shaft manufac-
transmission create axial forces in a magnitude that can
turer.
be transmitted by the length compensation of the joint
shaft. Ensure that length compensation remains opera- Two alignment shafts of equal length can be fitted in-
tional under load (axial forces only due to longitudinal stead of the joint shaft to control the joint angles when
friction, no tilting, no excess lubrication) and that the aligning the engine. The engine is aligned correctly (both
stroke is sufficient even in extreme situations (shock joint angles are equal) when the tips of the two align-
loads). The magnitude of all these forces and bending ment shafts meet - see Installation diagram (page 56).
moments depends on the torque transmitted, the joint After alignment, remove the alignment shafts and fit the
shaft length and the size of the joint angles. joint shaft.
On the transmission side, these forces and bending mo-
ments are supported on the foundation through the
transmission input shaft, transmission housing, and sus-
pension bracket, and on the engine side through the flex-
ible clutch, crankshaft, and engine housing. Therefore,
equip the flexible clutch with additional bearing elements
between the primary and secondary sides. Install an ad-
ditional bearing between joint shaft and flexible clutch
when the flexible clutch or the engine crankshaft cannot
absorb the forces and bending moments generated by
the joint shaft. Bearing support can be provided by a bell
housing on the engine, or an intermediate shaft installed
and supported in the foundation.
The forces and bending moments generated by the joint
shaft occur periodically at double engine speed. The
maximum value for the additional load on the transmis-
sion input shaft (see Section 2.2 Technical data) must
not be exceeded. Dimension suspension brackets for en-
gine and/or intermediate shaft and transmission as well
as for the foundation adequately so that inadmissible de-
formations are excluded. This would result in noise and
vibrations. Reinforcement of the foundation may be nec-
essary.
The joint shaft size to be used depends on the engine
performance, engine speed, size of the joint angle, and
the required service life of the joint shaft. A recommenda-
tion is normally given by the joint shaft manufacturer ac-
cording to the specific application case.
To ensure proper kinematic operation of the joint shafts,
the joint angles must be the same size on both sides and
the joint forks mounted on one level. Keep joint angles as
small as possible. The reference value for transmissions
with parallel input and output shafts is maximum 7° to
8°.
= =
1 2 3
ß2
ß1
4 5
004 971
Joint angles β1 and β2 may only deviate from each Use suitable safety devices (e.g safety bows, stable pro-
other by maximum 0.5°. tective grids) to prevent joint shaft parts being catapulted
out or ejected.
1 Engine 4.1.5 Alignment of the transmission
2 Flexible clutch with self-centring mechanism.
Size and design according to engine performance A highly flexible support of the transmission normally re-
and torsion vibration calculation. quires a torsionally flexible connection between transmis-
sion output flange and propeller shaft in order to enable
3 Joint shaft with length compensation. absorption of relative movements (e.g. joint clutch or
Selection according to manufacturer’s recommen- flexible clutch). This is not necessary when the propeller
dation. shaft also has a very flexible design.
Observe Installation Instructions (β1 = β2, joint
forks installed on one level). Align the transmission to the propeller shaft in propeller
shaft installations with rigid connection to the transmis-
4 Propeller shaft. sion output shaft. To do so, the ship must float on water
5 Marine transmission with input and output on one and be fully equipped. It might be necessary to repeat
side. the alignment procedure prior to commissioning.
6 Auxiliary device for aligning the engine and trans-
mission to achieve equal joint angles β1 = β2.
A laser-based alignment device can be used to control
the joint angles during alignment. The engine is aligned
correctly when the two joint angles are the same size.
Provide a catch device for the joint shaft at all positions
where the rotating shaft presents a hazard. The user and/
or operator must take adequate safety measures.
4.1.6 Trolling
Operating voltage
This Section is only applicable for transmissions
with a mounted and controlled trolling valve. The
trolling valve does not belong to the standard ZF
scope of delivery.
Trolling operation allows operating at propeller speeds
below those possible in non-trolling operation.
4.1.6.2 Retrofitting the trolling valve 4.1.7 Transmission cooling (cooling systems)
The electrical trolling valve can be fitted afterwards. Ret-
rofitting the trolling valve must be carried out by a quali- Specifications in this Section only apply for coolers fitted
fied technician authorized to carry out the work. as standard!
2 3
Fig. 27: Schematic display of cooler design (example) This is necessary to keep contamination (such as solid
matters or shells) away from the transmission oil cooler
4.1.8.1 Requirements for the cooling water circuit and the pipes because these clog the transmission oil
cooler. A clogged transmission oil cooler or individual
The amount of heat generated in the transmission is dis-
cooler pipes result in reduced cooling performance.
sipated through the transmission oil cooler. The transmis-
sion oil cooler, as part of the basic transmission version,
is mounted at or on the transmission housing.
See the technical specifications in the transmission in-
stallation drawing or Section 2.2 Technical data for the
admissible water flow rate as well as the admissible pres-
sure loss between cooling water inlet and outlet. The wa-
ter pressure shown on the cooling water inlet must not
be exceeded. The transmission oil cooler is designed so
that heat dissipation is ensured for a transmission ambi-
ent temperature of 60°C and a water inlet temperature
matching the specification in the transmission installation
drawing (also at full transmission load and maximum
speed).
4.1.9.1 Installation
All required oil pipes are connected fixed and ready for
operation. Connections for the cooling water inlet and
outlet are closed with blind flanges when delivered. For
further information, see the respective transmission in-
stallation drawings. The blind flanges can be used as
welding flanges during installation of the cooling water
pipe. Install an elastic adapter (compensator, hose piece)
between these flanges and the ship-side cooling water
Fig. 29: Earthing for free-standing transmission
pipes to enable uncoupling. The exact position of the
(example)
connections can be seen in the corresponding transmis-
sion installation drawing. Comply with the water flow di-
Flanged transmission
rection, i.e. do not swap the water inlet and water outlet.
The temperature increase of the cooling water in the
transmission oil cooler is maximum 5°C. The mixing tem-
perature of the engine cooling circuit increases by ap-
prox. 0.5°C and is therefore irrelevant. The indicated
maximum cooling water flow rate through the transmis-
sion oil cooler must not be exceeded; otherwise there is
the risk of cavitation in the cooler. The minimum flow rate
must also be adhered to otherwise the flow rate is too
low which can lead to the transmission oil cooler silting
up prematurely or the water flow being impaired by salt
Fig. 30: Earthing for flanged transmission (example) precipitation.
Do not use galvanised steel pipes because there is a risk Any lost list can be requested from every ZF Customer
that galvanic processes corrode parts of the zinc coating Service Centre. It can be downloaded free of charge in
and that iron corrosion parts can deposit on the discs or PDF format on the internet under www.zf.com.
flange pipes of the transmission oil cooler. Pitting corro- Refer to the type plate for the amount of oil required.
sion would damage the transmission oil cooler within a
short time. For correct performance of oil filling and oil level control,
see Chapter 8 Maintenance.
4.1.9.4 Earthing for the cooling water pipe
4.1.12 Connection of monitoring equipment
To avoid galvanic corrosion, it is important that there is
no electric potential difference on components transport-
Always plan the minimum monitoring specified in
ing sea water.
Section 2.2 Technical data, 2.2.8 Monitoring values for
Therefore, connect all cooling water pipes to the earth ZF 2000/2150/2200/2300/W2300/W2400 series (moni-
bus of the ship electroconductive. If there is an insulation toring equipment not supplied as standard).
separation line in the pipe (hose or compensator), it must
Arrange equipment required for monitoring so that relia-
be bridged electroconductive using an earth strap (see
ble device reading is always ensured, even under poor
Section 4.1.8.2 Earthing).
operating conditions. Indicating scales on the monitoring
equipment are to be selected so that the highest possible
4.1.10 Transmission cooling (general information)
needle deflection in the operating range is achieved.
4.1.10.1 Clearance for maintenance jobs In addition to the obligatory minimum monitoring, further
Inspect and maintain the cooler in regular intervals ac- display or warning devices can be connected to the
cording to the Maintenance Instructions. For this pur- measuring points sealed with blind plugs.
pose, provide a corresponding clearance for
disassembling the pipe bundle. 4.2 Installation control and commissioning
ZF marine transmissions are tested on test rigs prior to
delivery to our customers. All functions, oil pressures,
temperature, and noise characteristics are checked and
documented in detail within the scope of this test. Con-
servation of the transmission interior is performed by rins-
ing with anti-corrosive oil during the test run. This
ensures storage in dry rooms for up to 12 months without
further measures.
Perform the following work and a complete installation Corrosion protection of the transmission interior is per-
control prior to the first operation: formed at the factory during the test run by rinsing with
an anti-corrosive oil. This ensures storage in dry rooms
Oil filling and oil level control as described in
for up to 12 month without requiring any further special
Chapter 8 Maintenance
measures.
First rotate the engine and then the propeller shaft
manually, and check for free movement Conservation measures for long-term storage must
be specified in the transmission order.
Check fixing screws of suspension brackets on trans-
mission and foundation for tight fit
4.3.1 Standstills of 3 to 6 months
Check connecting bolts between propeller shaft
flange and transmission output flange for tight fit and Level K1 corrosion protection measures should have
fastening been performed for shutdown periods under 6 months.
Check connecting bolts on transmission input for tight An oil change according to maintenance level Z1 is re-
fit and fastening quired prior to re-commissioning depending on the con-
dition of the oil in the transmission.
Check connections of monitoring devices at the meas-
uring points Commissioning after K1 conservation
Check oil cooler for connection to cooling system Test oil for condensate (emulsion) prior to re-commis-
sioning. Perform this test immediately after switching off
Ensure all water valves to the oil cooler are opened
the engine - oil must not be milky.
When using an oil cooler installed away from the
1. Start the engine and run for approx. 5 minutes to mix
transmission, check for secure connection of the
any condensed water possibly accumulated in the
cooler to the transmission lubricating system
transmission with the anti-corrosive oil.
Check all rotating components for protective equip-
2. Drain the anti-corrosive oil off and fill the transmis-
ment
sion with the specified oil type
Check all transmission components (pipework, sen- (see Maintenance Job 141).
sors, plugs, electrical connections) for possible dam-
age 4.3.2 Standstills of 6 to 9 months
Check all electrical connections on the transmission
Level K2 conservation should have been performed for a
for complete wiring and check sealing and isolation of
shutdown period longer than 6 months.
all cable/wire connections
Commissioning after K2 conservation
Check all hoses, wires, and cables for signs of wear
1. Drain the anti-corrosive oil off until reaching the nor-
Functional test of operating mechanism mal oil level.
With mechanical transmission actuation, carefully check 2. Start the engine and run for approx. 5 minutes.
that shift positions are actually reached.
3. Drain the anti-corrosive oil off completely and fill the
With electrical transmission actuation, check the operat- transmission with the specified oil type
ing voltage (24v) or current input at suitable positions, as (see Maintenance Job 141).
close as possible to the plugs of electromagnets.
4.3.3 Standstills of 36 months and more
4.3 Commissioning after standstill
Transmissions can be decommissioned for a maximum of
In general, shutdown periods can last up to 3 months 36 months when long-term conservation K3 has been
without requiring any corrosion protection measures and performed. Alternatively, conservation level K2 can be re-
operation can be continued without removing the corro- peated every 9 months.
sion protection.
Commissioning after K3 long-term conservation
After longer shutdown periods or scheduled shutdowns
(> 3 months), measures for commissioning depend on 1. Drain the anti-corrosive oil off until reaching the nor-
the previous corrosion protection and the environmental mal oil level.
conditions of the transmission. 2. Start the engine and run for approx. 5 minutes.
3. Drain the anti-corrosive oil off completely and fill the
transmission with the specified oil type
(see Maintenance Job 141).
Oil pressure before the oil filter (measuring point 5) Additional measuring points are provided on the trans-
mission for additional transmission monitoring purposes
This measuring point is only available for transmis- in case a higher level of functional monitoring is desired
sion versions with gap filter. or required by the Classification Societies. The relevant
measuring values are equal to those at the measuring
This measuring point serves for monitoring the oil filter. points for the minimum monitoring.
An increase in oil pressure indicates increasing filter con-
tamination. Use a pressure switch for monitoring. Set this Oil pressure before the oil filter (measuring point 5)
switch so that the pressure switch switches and an alarm
is triggered should the pressure rise exceed the specified This measuring point is only available for transmis-
value. sion versions with gap filter.
Differential pressure on the oil filter A T-piece can be mounted on measuring point 5 for si-
(measuring point 127) multaneous connection of the pressure gauge and pres-
sure switch when monitoring is to be realised using a
This measuring point is only available for transmis- pressure gauge and a monitoring device. A pressure sen-
sion versions with changeover filter. sor with integrated switching contact can also be used
This measuring point is used for monitoring the differen- for the alarm device for remote pressure display.
tial pressure on the oil filter. An oil filter with a filter car- Clutch oil pressure (measuring point 21)
tridge is used on the ZF 2000 series. A protective filter in
the form of a wire sieve is fitted in the filter head to ena- An additional pressure switch can be connected to meas-
ble switching the oil filter and exchanging the filter car- uring point 21 in connection with a monitoring device or
tridge during operation. The oil filter has an integral pressure gauge. When monitoring with a pressure
differential pressure switch. switch, set the switch so that the alarm is triggered when
the pressure drops below the alarm value.
Clutch oil pressure (measuring point 2)
In "Neutral" shift position, the oil pressure drops below
The clutch oil pressure is set to different values depend- the alarm value of the pressure switch, i.e. an alarm is
ing on the transmission version and/or input torque. The also triggered for normal oil pressure in this shift position.
rated clutch pressure is specified in the technical docu- To prevent this, disable the alarm unit in "Neutral" shift
ments binding for the respective order and is also em- position and during trolling operation, e.g. using a neutral
bossed on the type plate (see Section 2.2.7 Transmission switch operated by the transmission actuation (ZF spe-
description). cial scope of delivery). Integrate a time-delay relay with a
The specified clutch oil pressure is valid for "Engine wise delay of at least 3 s and maximum 10s to prevent the
rotation" or "Counter-engine wise rotation" shift positions. alarm being triggered during the time between the con-
In the "Neutral" shift position, the oil pressure at this trol being actuated and the full clutch oil pressure being
measuring point drops to the value specified in built up (approx. 1 to 2 s).
Section 2.2.8 Monitoring values for ZF 2000/2150/2200/ Lubricating oil pressure (measuring point 22)
2300/W2300/W2400 series depending on the input
speed and oil temperature. The same applies to the Measuring point 22 can be used for monitoring the lubri-
clutch oil pressure in trolling operation. Use a pressure cating oil pressure. Monitoring can be realised using a
gauge to monitor the clutch oil pressure. Transmission lu- pressure gauge or pressure switch. The lubricating oil
brication is also ensured when the clutch oil pressure pressure is within the range of the values specified in
corresponds to the specified values under the existing Section 2.2.8 Monitoring values for ZF 2000/2150/2200/
conditions. Specific monitoring of the lubricating oil pres- 2300/W2300/W2400 series depending on the transmis-
sure (measuring point 22) is therefore not required. sion input speed and transmission oil temperature. When
5 Operation
Function "Main-
tain shift position
Transmission Number of solenoid valves See Section
during power fai-
lure" available
ZF 2000 series wit- 5.1.1 Electrical transmission actuation with two
2 (1x CEW, 1x EW) No
hout NR solenoid valves (for ZF 2000 series without NR)
ZF 2000 NR (CEW) 5.1.2 Electrical transmission actuation (for
2 (1x CEW, 1x NEUTRAL) Yes
series ZF 2000 NR (CEW) series)
ZF 2000 NR (EW) 5.1.3 Electrical transmission actuation (for
2 (1x EW, 1x NEUTRAL) Yes
series ZF 2000 NR (EW) series)
5.1.1 Electrical transmission actuation with two Activating these electromagnets allows selecting the shift
solenoid valves (for ZF 2000 series without NR) position as follows:
Neutral: No voltage is applied to
With this electrical transmission actuation, the control
electromagnets "a" and
piston is moved axially in the control unit using oil pres-
"b".
sure through one electrical actuation unit mounted on the
control unit. The actuation unit comprises electromag- Engine wise rotation: Voltage is only applied
nets "a" ("Engine wise rotation" shift position) and "b" to the output-side elec-
("Counter-engine wise rotation" shift position) as well as tromagnet "a".
a pilot valve.
Counter-engine wise rotation: Voltage is only applied
Disable mechanical emergency actuation to allow control to electromagnet "b"
using electrical transmission actuation. For this purpose, (opposite "a").
unscrew the set screws on both electromagnets "a" and
"b" of the actuation unit until flush with the plane surface
(see Section 5.1.1.2). DANGER
a/188
Counter-engine wise rotation shift position Switching on the mechanical emergency actuation
Electromagnet "a": Set screw unscrewed (approx. flush
with plane surface, set screw pro- Requirements:
trudes approx. 0.2 to 0.3 mm) If the mechanical emergency actuation is used, the
electrical transmission actuation must be switched off
Electromagnet "b": Set screw screwed in (approx. 6.0 to (e.g. by switching off the transmission control or by
6.2 mm from plane surface) disconnecting the plugs on the electromagnets).
CAUTION
WARNUNG
Fig. 37: Pilot valve in "Counter-engine wise rotation"
shift position Risk of accident due to incorrect direction of motion.
Death or serious injury possible.
5.1.1.3 Operation using mechanical emergency Ensure correct direction of motion.
actuation
2. Use the tool on the control unit to screw in the elec-
WARNING tromagnet set screw for the corresponding shift
position (set screw on electromagnet "a" for "Engine
Risk of accident due to a non-functioning operating wise rotation" shift position, set screw on electro-
element. magnet "b" for "Counter-engine wise rotation" shift
Death or serious injury possible. position) to the stop (approx. 6.0 to 6.2 mm).
Adapt driving method when on open waters. 3. Return the tool to the respective holder of the control
Do not drive in tight and heavily-frequented waters. unit.
Allow the ship to be towed.
4. Check for correct direction.
Switching off the mechanical emergency actuation 5.1.2.1 Electrical transmission actuation elements
Shift position "Counter-engine wise rotation“
CAUTION Electromagnet "b" opposite the output is responsible
for output direction against the input direction.
Risk of burns due to contact with hot surfaces.
"Neutral" shift position
Slight or moderate injury possible. Electromagnet "a" pointing towards the output is
Wear protective gloves. responsible for the "Neutral" shift position.
5.1.2 Electrical transmission actuation Fig. 38: Electrical transmission actuation elements
(for ZF 2000 NR (CEW) series) (example)
With this electrical transmission actuation, the control a - Electromagnet for "Neutral" shift position
piston is moved axially in the control unit using oil pres- b - Electromagnet for "Counter-engine wise rotation"
sure through one electrical actuation unit mounted on the shift position
control unit. The actuation unit comprises electromag-
nets "a" ("Neutral" shift position) and "b" ("Counter-engine d - Pilot valve for "Neutral" and "Counter-engine wise
wise rotation" shift position) as well as a pilot valve. rotation" shift positions
DANGER
The propeller shaft can still rotate even when the trans-
mission clutch is open in "Neutral" shift position. Provide
a propeller shaft brake or other shaft locking device when
the propeller shaft must be idle.
WARNING
Requirements:
6.0 to 6.2 mm If the mechanical emergency actuation is used, the
electrical transmission actuation must be switched off
(e.g. by switching off the transmission control or by
disconnecting the plugs on the electromagnets).
CAUTION
Fig. 41: Pilot valve in "Counter-engine wise rotation" Risk of burns due to contact with hot surfaces.
shift position Slight or moderate injury possible.
Wear protective gloves.
I
WARNING
Risk of accident due to an inadequate access to the b Electromagnet "b“: Position of set screw for
"Neutral" shift position
tool for emergency actuation.
Death or serious injury possible. d Pilot valve for "Neutral" and "Engine wise ro-
Ensure a free access. tation" shift positions
g Tool for emergency actuation of electromag-
WARNING nets "a" ("Engine wise rotation" shift posi-
tion) and "b" ("Neutral" shift position)
Risk of accident due to a insufficient clearance to
actuate mechanical emergency actuation. The set screw on electromagnets "a" and "b" on both
sides of the pilot valve of the upper actuation unit has
Death or serious injury possible.
two positions. An intermediate position is not admissible.
Provide a clearance of at least 20 cm. Resistance (i.e. stopper) can be noticed when the end
position is reached in both positions.
Mechanical emergency actuation of electromagnets "a"
Unscrewed: Approx. flush with plane surface
("Engine wise rotation" shift position) or "b" ("Neutral"
(set screw protrudes approx.
shift position) of the actuation unit is performed manually
0.2 to 0.3 mm)
using a set screw with the tool fitted on the control unit
Screwed in: Screwed in approx. 6.0 to 6.2 mm
(hexagon socket wrench, opening 3 mm). The set screw
(dimension, plane surface-set screw)
is located on the front side of the electromagnets.
Neutral shift position
Electromagnet "a": Set screw unscrewed (approx. flush
with plane surface, set screw pro-
trudes approx. 0.2 to 0.3 mm)
Electromagnet "b": Set screw screwed in (approx. 6.0 to
6.2 mm from plane surface)
6.0 to 6.2 mm
Engine wise rotation shift position Switching on the mechanical emergency actuation
Electromagnet "a": Set screw screwed in (approx. 6.0 to
6.2 mm from plane surface) Requirements:
If the mechanical emergency actuation is used, the
Electromagnet "b": Set screw unscrewed (approx. flush electrical transmission actuation must be switched off
with plane surface, set screw pro- (e.g. by switching off the transmission control or by
trudes approx. 0.2 to 0.3 mm) disconnecting the plugs on the electromagnets).
CAUTION
A
Angles / travels of shift lever
5.1.4.2 Mechanical emergency actuation The following shift positions are possible (by looking onto
(for ZF 2000 series) the shift lever):
Manual actuation of the transmission is possible (i.e. Neutral (3): Shift lever is in the latched central posi-
emergency actuation) in case of actuation device mal- tion. The fixing nut on the clamping
functions. screw to align the shift lever must be
Mechanical emergency actuation of the transmission (i.e. tightened with a tightening torque of
movement of the control piston) is performed manually 23 Nm.
using a shift lever. Engine wise The shift lever is rotated anticlockwise
rotation (1): by approx. 20°.
Counter- The shift lever is rotated clockwise by
engine wise approx. 20°.
rotation (2):
WARNING
Requirements:
If the mechanical emergency actuation is used, the
push/pull cable or the linkage of the mechanical
remote control on the shift lever of the control unit
must be unhooked.
CAUTION
Risk of burns due to contact with hot surfaces. 5.2 Shift procedure
Slight or moderate injury possible. During operation, the transmission does not require any
Wear protective gloves. attention apart from monitoring display devices for trans-
mission temperature and transmission oil pressures.
1. Set the engine speed adjusting device to idling According to our experience, the shift sequences de-
speed. scribed in the following provide optimal switching per-
formance with regard to a possibly short stopping
2. Move and latch the shift lever of the control unit
distance of the ship with simultaneous best possible pro-
manually to shift position "Neutral". Remain in this
tection of the transmission reversing clutches and thus
position for approx. 0.5 s.
the overall power plant. Therefore the
3. Move the shift lever of the control unit manually to ZF Friedrichshafen AG strongly recommends compli-
shift position "Engine wise rotation" to the stop. ance with the proposed shift sequences.
4. Check for correct direction. Perform shift movement from the "Neutral" shift position
to the "Ahead" or "Astern" shift position and vice-versa
Changing from "Engine wise rotation" shift position to quickly. Pausing in the undefined areas between shift po-
"Counter-engine wise rotation" shift position sitions is not admissible.
Risk of burns due to contact with hot surfaces. 1. Set the engine speed adjusting device to idling
speed.
Slight or moderate injury possible.
Wear protective gloves. 2. Select the required direction of motion and remain in
this position for approx. 1 to 2 s.
1. Set the engine speed adjusting device to idling 3. Increase the engine speed to the required operating
speed. speed.
2. Move and latch the shift lever of the control unit
manually to shift position "Neutral". Remain in this
position for approx. 0.5 s.
3. Move the shift lever of the control unit manually to
the stop in shift position "Counter-engine wise rota-
tion".
4. Check for correct direction.
5.2.2 Shifting Ahead > Astern and vice versa 5.3 Trailing operation
1. Set the engine speed adjusting device to idling Trailing or towing operation refers to operation with the
speed. engine off and the propeller being driven by the current.
Regular or occasional trailing operation is possible de-
2. Maintain the shift position in order to use the engine pending on the transmission version.
braking effect on the propeller until the engine speed
has decreased to approximately 1.2 times the idling Shift the transmission actuation to the "Neutral"
speed (max. 720 rpm). shift position for trailing operation with the engine
3. Move the movement lever to the "Neutral" shift posi- off and the propeller shaft rotating.
tion and remain in this position for approx. 0.5 s.
5.3.1 Occasional trailing operation
4. Move the movement lever further in the opposite
direction and remain in this position for approx. 1 to The basic transmission version (without trailing oil pump)
2 s. allows occasional trailing operation (< 5 hours).
5. Increase the engine speed to the required operating Monitor the transmission oil temperature (measuring
speed. points 11 and 12 are located in the oil sump). The maxi-
mum oil temperature must not exceed 75°C. Reduce ship
Not usable for reduction transmission NR! speed when the temperature exceeds this limit value. If
necessary, the engine may operated for a short period
until the transmission oil temperature has fallen below
5.2.3 Shifting in case of danger (crash stop) the maximum admissible value due to the cooling water
circulation (transmission in "Ahead" or "Neutral" shift po-
In the event of an emergency, reversing from "ahead" to sition).
"astern" is also possible even at higher engine speeds
(20% above idling speed, however, max. 720 rpm). Trailing operation is admissible for up to 15 hours
in case of an emergency.
ZF Friedrichshafen AG recommends also using the en-
gine braking effect in this case and not to increase the
5.3.2 Regular trailing operation
engine speed to the required operating speed until 1 to
2 s after selecting the "astern" shift position. During such
A trailing oil pump is required when regular trailing oper-
manoeuvres, you should consider that, in many cases
ation is intended or this condition continues for more
(among others depending on the ship type), no or only a
than 5 hours without interruption. See Chapter 6 Special
slight reduction in the stopping distance is achieved as
equipment / special versions.
against the shift sequence described above.
This oil pump ensures lubricating oil supply to the trans-
Crash stop manoeuvres create extreme loads on mission when the engine is off with the output shaft ro-
the power plant. The astern clutch of the reversing tating. This allows unlimited operation with the engine off
transmission in particular is subjected to heavy and the propeller rotating.
loads.
Monitor the oil temperature which must not exceed a
An interval of half an hour is necessary between any maximum of 95°C (the oil sump temperature roughly cor-
crash stop manoeuvres during the first trial of the ship. responds to the disc temperature). If the oil temperature
This allows components subjected to extreme thermal is too high, either reduce the ship speed or feed cooling
load during the crash stop manoeuvre to cool down to water through the transmission oil cooler.
normal temperature.
The cooling water volume can either be taken from a spe-
cial valve of the engine installation in operation or fed by
ZF Friedrichshafen AG recommends not to per-
a separately driven water pump. For dimensioning, a
form more than 1 to 5 crash stop manoeuvres for
cooling water volume corresponding to a maximum of
test purposes.
25% of the water volume required for normal operation
can be assumed.
If the transmission oil temperature should increase above
90°C, make sure that, after starting the engine, the trans-
mission remains in the "Neutral" shift position until the
transmission oil temperature has fallen below 90°C. Nor-
mal operation is not admissible until then.
5.4 Operation using the emergency control Operation using the emergency control is admissible
("Come home screws") under the following conditions:
If, despite mechanical emergency actuation, a) The oil pressure at measuring point 2 is at least
[Section 5.1.1.2 Mechanical emergency actuation with >4.0 bar at engine idle speed with the transmission
two solenoid valves (for ZF 2000 series without NR), warmed up. Operation at 50% of the maximum
5.1.2.2 Mechanical emergency actuation (for engine speed is admissible in this case.
ZF 2000 NR (CEW) series), 5.1.3.2 Mechanical emer- b) No oil pressure at measuring point 2. Sufficient oil in
gency actuation (for ZF 2000 NR (EW) series) or 5.1.4.2 the transmission (oil level between Min. and Max. on
Mechanical emergency actuation (for ZF 2000 series)] the oil dipstick). Operation at maximum 10% above
no power transmission occurs, there is a malfunction in the engine idle speed is admissible in this case.
the transmission. In such cases, the clutch discs of the
main clutches can be pressed together mechanically us- The special wrench required for operating the emergency
ing the clamping bolts integrated in the transmission. control (hexagon socket wrench, SW 10) is available
from ZF Friedrichshafen AG under Part No.
The clamping bolts of the input shaft of the V and 1X56.186.369.
U versions cannot be accessed. Only one shifting clutch may be closed on each transmis-
Three clamping bolts each are available for the clutch for sion at the same time because otherwise both output ro-
engine wise rotation and/or for the clutch for counter-en- tation directions are force-closed and the transmission
gine wise rotation and can be accessed from the outside blocks. Therefore normal transmission actuation must be
through the transmission output side. disabled during operation using the emergency control.
Requirements:
The actuation of the pilot valve has been taken out of
operation. With the electric transmission actuation,
the pilot valve is deactivated by disconnecting the
plugs and with the mechanical transmission actua-
tion, the pilot valve is deactivated by unhooking the
push/pull cable.
Fig. 50: Position of clamping bolts for engine wise and
The mechanical emergency actuation is in the "Neu-
counter-engine wise rotation (ZF 2000 A,
tral" shift position.
example)
1. Turn off the engine and ensure the engine cannot be
restarted while switching on the emergency control.
2. Determine the clutch to be switched.
3. Loosen and remove the screw plugs.
4. Insert the wrench in one of the three openings to the
stop. Rotate the engine or transmission input shaft
slowly until the clamping bolt head is positioned to
the wrench.
The direction of rotation is irrelevant because the 5. Pull the wrench back approx. 30 mm and rotate the
required position should be reached after maxi- engine or transmission input shaft slightly (approx.
mum 120° rotary displacement. 1°) until the wrench can be inserted in the clamping
bolt hexagon.
5. Pull the wrench back approx. 30 mm and rotate the
engine or transmission input shaft slightly (approx.
1°) until the wrench can be inserted in the clamping NOTICE
bolt hexagon.
Property damage caused by incomplete torque inter-
ruption possible.
NOTICE
Unscrew the clamping screws equally.
Property damage caused by incomplete torque trans- Do not tilt the clutch piston.
mission possible.
Screw in the clamping screws equally. 6. Loosen the clamping bolt anticlockwise to the stop.
Do not tilt the clutch piston. 7. Repeat this procedure for the other two clamping
bolts through the corresponding housing openings.
6. Screw the clamping bolt in clockwise to the stop.
8. In a second cycle, tighten all three clamping bolts
7. Repeat this procedure for the other two clamping with approx. 20 Nm tightening torque.
bolts through the corresponding housing openings.
9. Seal housing openings with screw plugs.
Further rotation of the transmission input shaft is not
required. 10. Enable pilot valve control. This is done by connecting
the plugs for electrical transmission actuation and by
8. In a second cycle, tighten all three clamping bolts
hooking on the push/pull cable for mechanical trans-
with approx. 35 Nm tightening torque.
mission actuation.
9. Seal housing openings with screw plugs.
After the emergency control has been set up as de-
scribed, the engine can be started and the ship navigated
to the closest service station.
Requirements:
The actuation of the pilot valve has been taken out of
operation. With the electric transmission actuation,
the pilot valve is deactivated by disconnecting the
plugs and with the mechanical transmission actua-
tion, the pilot valve is deactivated by unhooking the
push/pull cable.
The mechanical emergency actuation is in the "Neu-
tral" shift position.
A wide range of parts and accessories not manufactured Trolling operation allows operating at propeller speeds
or recommended by ZF are available on the market. Un- below those in non-trolling operation. This means trolling
authorized modifications and alterations which impair the operation is used for travelling at low ship speeds. In
function and safety are not allowed. trolling operation, the propeller speed can be reduced by
up to 0.3 - 0.7 times the propeller speed in non-trolling
Only use spare parts and accessories authorized operation.
by ZF. This reduction in propeller speed is achieved by a defined
The operating data especially approved by ZF for applica- slipping process of the clutch discs. For this purpose, in
tion classes M and C are fully accepted by the major trolling operation, the clutch oil pressure (oil pressure
Classification Societies. Type approvals or certificates for with which the clutch discs are pressed against each
classification are available on request. other) is decreased until a defined slipping process is cre-
ated.
If special scopes of delivery or versions include The transmission oil circuit is designed so that friction
deviations in operation and maintenance not heat arising in the clutch is discharged. The trolling valve
described in the following Sections, refer to the for adjusting the clutch oil pressure is located in the cen-
specifications applicable for the relevant order for tre of the clutch control.
such details.
Trolling refers to operation with slipping clutch.
6.1 Trolling Trolling operation allows reversing and manoeu-
vring in the port area. However, attention is drawn
Only for transmissions with mounted and control- to the fact that the propeller thrust generated by
led trolling valve (special scope of delivery). the low propeller speed in trolling operation might
A trolling system facilitates operation and manoeuvring at not be high enough for sufficient movement of the
slow speeds. This installation allows selecting propeller ship.
speeds below the minimum propeller speed and result Manoeuvring larger displacement boats with a relatively
from the transmission ratio and the engine idling speed. weak engine is not possible, or only slowly, in trolling op-
This enables operation at lower ship speeds than for nor- eration. On the other hand, light sport boats with more
mally switched transmissions at the lowest admissible powerful engines and planing hull show good reactions.
engine speed.
ZF Friedrichshafen AG therefore recommends
Typical applications are: testing the reaction of the ship during manoeu-
Passages at limited speed, e.g. canal passages vring in trolling operation in open water. The cap-
tain or responsible officer in charge must prohibit
Manoeuvring in ports and at landing places use in port areas when results are not satisfactory
Holding position for police boats, life boats enough.
Maximum admissible engine speed for trolling The ZF AUTOTROLL system has the following main
operation characteristics:
For submerged standard propellers (with parabolic The propeller speed set using the trolling shift lever is
propeller curve): 50% of maximum admissible operat- automatically held constant.
ing speed (engine speed), however up to a maximum
Easy manoeuvring even for displacement boats with a
of 1,000 rpm
weak engine by a reversing sequence (short-term rise
For surface propellers: Engine idling speed up to the in clutch pressure during reversing).
maximum operating speed (engine speed) of 700 rpm
Incorrect transmission operating is ruled out.
Maximum admissible lubricating oil temperature: 90°C
Transmissions with ZF AUTOTROLL are delivered
Transmissions with an electrical trolling device are not fully assembled and tested.
secured against excessive engine speeds in trolling oper-
ation. Stop trolling operation when the admissible engine The ZF AUTOTROLL scope of delivery includes:
speed values or lubricating oil temperature are exceeded.
Trolling valve mounted on the transmission
6.1.3 ZF AUTOTROLL Electronic control device mounted on the transmission
Application-based programming of the control
ZF AUTOTROLL can be used In combination with electri-
cal transmission actuation. ZF AUTOTROLL is a regulated Speed sensor on the input shaft
trolling device. In trolling operation, the propeller speed
Speed sensor on the output shaft
specified by the actuation device is adjusted via the di-
rect drive rate (i.e. through clutch slip) from the transmis- Cable harness for connecting all ZF AUTOTROLL com-
sion. ponents mounted on the transmission
The actuation device itself is not part of the transmission. Plug socket mounted on the transmission with coun-
terplug as electrical interface to the ship control
Refer to the Operating Instructions of the actuation
manufacturer on operating the trolling actuation. The ZF AUTOTROLL scope of delivery does not include:
Reading these instructions in regular intervals is
Ship-based actuation device for electrical transmis-
recommended.
sion actuation
Ship-based actuation device for trolling actuation
Voltage supply
All indicator lamps
Possible dimmer devices for indicator lamps
Ship-based cabling up to the electrical interface on
the transmission
7 Troubleshooting
Monitoring devices such as sensors, warning equipment, and display instruments are not supplied by
ZF Friedrichshafen AG as standard.
It is expressly pointed out that malfunction messages can only be displayed when the transmission uses the connec-
tion options.
The following Table of possible malfunctions shows the primary malfunctions, causes and corrective measures.
Contact your nearest ZF service branch when malfunctions cannot be cleared using the following information.
* See monitoring values (Section 2.2.8) and transmission views (Section 2.1.4)
Tab. 6: Table of possible malfunctions (overall transmission, continued)
7.3 Clearing faults (transmission oil cooler) 7.4 Diagnosis for ZF AUTOTROLL
(Special scope of delivery)
7.3.1 Leaking pipes
The ZF AUTOTROLL control not only has control func-
tions but also an intelligent diagnosis system.
If it is suspected that pipes of the pipe bundle are leak-
ing, proceed according to Chapter 8 Maintenance, The diagnosis system has the following functions:
Section Disassembling the transmission oil cooler (with-
System monitoring, monitoring operating parameters,
out extracting the pipe bundle). After the pipe plates
fault detection, generation of emergency operation
have been cleaned, the escaping medium (e.g. com-
properties
pressed air) shows which pipe is leaking. Seal the leaking
pipe from both sides. Registering faults that have occurred in the fault mem-
ory and communication with the ZF diagnosis device
1. Disassemble the transmission oil cooler as described
"TESTMAN"
in Chapter 8 Maintenance, Section Disassembling
the transmission oil cooler (without extracting the Diagnosis is active as soon as operating voltage is con-
pipe bundle). nected to the ZF AUTOTROLL control. This means that
system faults are diagnosed even in non-trolling opera-
2. Clean the defective pipe thoroughly down to the
tion.
press-in depth of the sealing plug.
A "TESTMAN" diagnosis device can be adapted to the
Keep this area free from corrosion and pitting on ZF AUTOTROLL control to support system service. Leave
the inside of the pipe. the relevant work to trained qualified personnel from the
Friedrichshafen Service Centre. The "TESTMAN" diagno-
3. Press the sealing plug in flush with a suitable tool.
sis device which is not supplied as standard with
Do not press the sealing plug in too hard otherwise ZF AUTOTROLL is also available from the Service Centre.
the adjacent rolled points can be damaged. It is
possible to seal a maximum of 10% of the pipes
without a noticeable drop in performance. It is not
possible to remove the defective pipe. If more than
10% of the pipes are defective, this repair work is
not allowed because cooling performance will
then sink too low.
Engine data for transmission classification: Operating hours per year: Unlimited
Maximum performance for intermittent operation Preferred hull type: Displacement hull, semi-planing
Operation type: Intermittent operation with widely var- hull
ying engine speeds Typical application area: Workboats
Operating hours per year: Up to approx. 500 hours Typical application examples: Towboats, pushers, sup-
Preferred hull type: Planing hull ply boats, fishing, passenger ships, freighters, ferries,
etc.
Typical application area: Fun and leisure boats for pri-
vate use
Typical application example: Fun and leisure boats for
private use
The maintenance system for ZF ship transmissions is based on a preventive maintenance concept. Preventive mainte-
nance facilitates advance planning and secures high availability.
Time intervals, according to which maintenance work is to be carried out, as well as the scope of the inspection and
maintenance work described, are the average result of operational experience and therefore may only be regarded as
guidelines. Additional maintenance work and/or changes in the maintenance intervals may become necessary for
special application conditions as well as technical requirements.
Furthermore, it is practical to adapt the operational hours stated in the maintenance schedule to the corresponding
maintenance time of the engine when this does not considerably exceed the stated operational hours. This applies to
maintenance levels A4, A5 and K in particular.
The Maintenance Job Number stated in the Maintenance System Job Sheet identifies the respective maintenance po-
sition. It serves as reference for the tools needed and the scope of parts.
Z1 50 to 100 h 12 months
Tab. 10: Additional nonrecurring maintenance work for a transmission repaired or overhauled outside the plant
Z2 --- 2 months
This is only necessary when the transmission oil cooler is not automatically drained when the cooling water
pump is idle.
Maintenance information
Refer to the ZF lubricant list TE-ML 04 for ZF marine transmissions for specifications on service fluids and list of man-
ufacturers. This list is available from every ZF Service branch. It can be downloaded free of charge on the internet in
PDF format under www.zf.com.
The following list contains consumables (cleaning agents, lubricants, and sealants) recommended by ZF Marine. As-
sociated service fluid regulations are available from the respective manufacturer. Only consumables and service fluids
complying with the ZF specification and/or approved by the respective manufacturer may be used.
Instructions on use from the respective manufacturer are binding!
Manufacturer specifications apply for maintenance of all components not listed in the maintenance schedule.
Perform a functional test after completing maintenance work!
It is also recommended to keep a maintenance protocol providing the following information:
Person in charge of, and performing the maintenance work
Maintenance level
Time of maintenance work (date, operating hours)
Cleaning agents for removing grease from tapered surfaces for oil press fits
Acetone, spirit (caution - flammable!) or conventional cleaning agents without regreasing.
Glycerine
For pressing on oil press fits. As an alternative, oil can be used for pressing on.
Grease
See ZF lubricant list TE-ML 04!
- Clean parts
Henkel Loctite Deutschland
Loctite 574
Used for sealing surfaces of - Apply sufficient material to fill gaps GmbH, Munich, Germany
Temperature resistant: housing and cover - Join parts Henkel Central Eastern Europe
-55°C to +150°C
GmbH, Vienna, Austria
- Allow material to harden
Loctite
Loctite 243
- Clean parts
Temperature resistant: Henkel Loctite Deutschland
-55°C to +180°C - Apply sufficient material to fill gaps GmbH, Munich, Germany
Used for threadlocking
Loctite 262 - Join parts Henkel Central Eastern Europe
GmbH, Vienna, Austria
Temperature resistant: - Allow material to harden
-55°C to +150°C
K1 Corrosion protection
Start the engine and run at engine idle speed or slightly above for at least 5 minutes to ensure transmission lubrica-
tion. The transmission can be in the "Neutral" or "Counter-engine wise rotation" or "Engine wise rotation" shift posi-
tion. Repeat this process every 10 to 20 days. Test oil for condensate (emulsion) prior to re-commissioning. Make this
check immediately after switching off the engine; oil must not be milky.
K2 Conservation
When operation has completed, drain the transmission oil and fill with the anti-corrosive oil to at least the bottom
measuring mark of the oil dipstick (see maintenance work for implementation). Use anti-corrosive oil C 642 or C 644
according to MIL-L-21260.
Immediately afterwards, run the engine in the "Engine wise rotation" or "Counter-engine wise rotation" shift position at
increased engine idle speed (max. 50% of nominal operating speed) for approx. 5 to 10 minutes. Switch off the en-
gine. Protect outer steel parts against corrosion.
Run the engine for approx. 5 minutes to extend the conservation by another 9 months. Then drain the conserving oil
and fill the transmission with the oil type and volume specified for operation and then restart the engine and run for at
least 15 minutes. Operate the transmission clutches several times during this time. Then perform "K2 conservation".
K3 Long-term conservation
When operation has completed, drain the transmission oil and fill with the anti-corrosive oil to at least the bottom
measuring mark of the oil dipstick (see maintenance work for implementation). Use anti-corrosive oil C 642 or C 644
according to MIL-L-21260.
Immediately afterwards, run the engine in the "Engine wise rotation" or "Counter-engine wise rotation" shift position at
increased engine idle speed (max. 50% of nominal operating speed) for approx. 5 to 10 minutes. Switch off the en-
gine. Then fill the transmission completely with the anti-corrosive oil. Protect outer steel parts against corrosion.
Commissioning after K3 long-term conservation
Drain the anti-corrosive oil off until reaching the normal oil level. Then run the engine for approx. 5 minutes. Then
drain the anti-corrosive oil off completely and fill the transmission with the specified oil type (see "Maintenance job
No. 141").
Periodic One-off
A5 A4 A3.1 A3 A2 A1 Z1 Z2
101 Check oil level None
102 Rotate rotary handle of oil filter None
103 Visual inspection None
121 Clean outside of transmission None
122 Retighten all bolts accessible from the
On-board tools
outside
123 Check shift settings None
124 Lubricate external moving parts None
141 Oil change On-board tools
142 Renew oil filter; clean changeover fil-
On-board tools
ter; clean gap filter and filter housing
161 Flexible clutch: Visual inspection None
162 Flexible engine and transmission sup-
None
port; Visual inspection
163 Clutch discs: Visual inspection On-board tools
164 Running gears: Visual inspection On-board tools
165 Check oil pumps W1
166 Check control unit W1
167 Check actuation device W1
168 Recalibrate display devices None
169 Inspect visually and clean oil cooler W1
172* Check spray line valve W1
173 Check shaft seal of input shaft None
174 Check shaft seal of output shaft None
200* Major transmission overhaul W2
T1+
T1+
T2 + T1 T1 -- -- T1 -- Required spare parts
T2
NB
* = For implementation, see Service Manual T1, T2 = Parts kits, see Spare Parts list
Others
Oil filter remover
If a version with classification is required, specify the required test type for the spare parts in addition to the
Part number.
This is also required when the transmission parts list is specified during ordering and when requesting replacement
transmissions.
Parts required according to the maintenance level can be ordered as maintenance kit or on-board kits for carrying out
periodic maintenance work.
The required spare parts are also available as repair and/or spare part kits for major overhauls of transmissions or su-
bassemblies.
ZF Service branches
If a transmission malfunction cannot be cleared with the corrective measures listed in Chapter 7 Troubleshooting,
please contact your nearest ZF branch.
Repair instructions applicable to your transmission type and up-to-date technical information, such as ZF Serv-
ice News are available from ZF Service branches and ZF dealers.
You can find the ZF Sales and Service Organization responsible for your region on www.zf.com in the top nav-
igation bar, under pull-down menu "Products & Services".
A list with the ZF Service branches with up-to-date telephone and fax numbers is available from
ZF Friedrichshafen AG in Friedrichshafen on request.
142 Renew oil filter; clean changeover filter; clean gap filter and filter housing . . . . . . . . . . . . . . . . . . . . . . . . 122
101 A1 ---------- 10
Description of
101 Check oil level
maintenance job
Wait for 10 minutes after switching engine off before removing oil dipstick otherwise risk of
Safety measures burns through hot oil spurting out.
Always switch engine off to top up oil otherwise risk of burns through hot oil spurting out.
Tools ------------------------------
Parts ------------------------------
The correct oil level is between the top and the bottom
measuring mark of the oil dipstick.
Max.
Min.
004 666
Fig. 57: Oil dipstick (example)
102 A1 ---------- 5
Description of
102 Rotate rotary handle of oil filter
maintenance job
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
103 A1 121 10
Description of
103 Visual inspection
maintenance job
Keep a safe distance when performing visual inspections on rotating parts otherwise risk of
Safety measures
being caught by the rotating part.
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
Fig. 60: Transmission ZF 2000 A (example) Fig. 62: Transmission ZF 2250 (example)
Fig. 61: Transmission ZF 2000 V (example) Fig. 63: Transmission ZF W2400 (example)
Check outlet points of input and output shafts out of the
transmission housing, connections to oil pipes and moni-
toring devices, cooling water connections as well as the
transmission oil cooler for leaks (visual inspection). Also
check the oil level (water leaking in oil or oil leaking in
water when engine is switched off).
121 A2 103 30
Description of main-
121 Clean outside of transmission
tenance job
Only use cleaning agents complying with Accident Prevention regulations valid at the site of
Safety measures
operation.
Material ------------------------------
Fig. 64: Transmission ZF 2000 A (example) Fig. 66: Transmission ZF 2250 (example)
NOTICE
Description of
122 Retighten all bolts accessible from the outside
maintenance job
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
Fig. 67: Transmission ZF 2000 A (example) Fig. 69: Transmission ZF 2250 (example)
Retighten all accessible bolt connections.
Pay particular attention to the following connections:
Engine / flexible clutch
Flywheel housing / bell housing of transmission
Angle plate / transmission
Angle plate / foundation
Also check connections "from" and "to" the transmission
oil cooler as well as monitoring device connections and
retighten when necessary.
Description of
123 Check shift settings (mechanical transmission actuation)
maintenance job
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
A
Angles / travels of shift lever
124 A2 ---------- 15
Description of
124 Lubricate external moving parts (mechanical transmission actuation)
maintenance job
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
Lightly grease moving parts of the mechanical transmission actuation (fork head on transmis-
Procedure
sion shift lever, linkage connections and connection to selector unit) with lithium soap grease.
Description of
141 Oil change
maintenance job
Oil type:
Material Admissible oils according to the currently applicable "ZF lubricant list TE-ML 04 for ZF marine
transmissions". A lubricant list valid at the time of delivery of the transmission is enclosed with
the transmission. Available from all ZF Service branches on request.
When possible, to be performed in conjunction with 7. Fit oil filler screw (46) with a new seal ring or inspec-
Maintenance Job Nos. 142, 163, and 164!. tion cover (47) with a new gasket and retighten.
8. Then check the oil level according to Maintenance
CAUTION Job No. 101.
Risk of burns due to contact with hot oil. Measurement using the oil dipstick is decisive!
Slight or moderate injury possible.
Wear protective googles
Wear protective gloves.
NOTICE 46 47
For safety reasons, do not change the filter until 30 minutes after the engine has stopped!
Otherwise hot oil under pressure will escape abruptly out of the oil filter seal! Risk of burns.
Perform cleaning and replacing elements at a maximum oil temperature of 40 - 50°C.
Safety measures
Lock engine starting device.
Collect used oil in oil collection containers of sufficient size otherwise risk of environmental pol-
lution.
Oil type:
Material Admissible oils according to the currently applicable "ZF lubricant list TE-ML 04 for ZF marine
transmissions". A lubricant list valid at the time of delivery of the transmission is enclosed with
the transmission. Available from all ZF Service branches on request.
When possible, to be performed in conjunction with Replace filter cartridge of the changeover filter
Maintenance Job Nos. 141, 163, and 164!.
The changeover filter is used for classified trans-
Replace oil filter missions.
Do not replace the filter immediately after switching of
This oil filter is only used for unclassified transmis-
the engine. For safety reasons, wait 30 minutes after the
sions.
engine has stopped before replacing the filter. Otherwise
Do not replace the filter immediately after switching of hot oil under pressure will escape abruptly out of the oil
the engine. For safety reasons, wait 30 minutes after the filter seal!
engine has stopped before replacing the filter. Otherwise
Avoid skin contact and do not inhale oil vapours.
hot oil under pressure will escape abruptly out of the oil
filter seal!
Avoid skin contact and do not inhale oil vapours.
3
1
4
CAUTION
Contaminated filter cartridge Cleaning the protective filter of the changeover filter
NOTICE
1
2
NOTICE
161 A4 ---------- 30
Description of
161 Flexible clutch: Visual inspection
maintenance job
Tools ------------------------------
Parts ------------------------------
Material -------------------------------
162 A4 ---------- 15
Description of
162 Flexible engine and transmission support: Visual inspection
maintenance job
Tools ----------------------------
Parts ----------------------------
Material ----------------------------
Check rubber-bonded metal bearings on engine and transmission for flawless condition.
Procedure
Rubber parts must not show cracks, embrittlement, and other damage.
Description of
163 Clutch discs; Visual inspection
maintenance job
Parts Gasket
Material ------------------------------
NOTICE
Description of
164 Running gears: Visual inspection
maintenance job
Parts Gasket
Material ------------------------------
NOTICE
Safety measures Lock engine starting device when the oil pump is to be dismantled.
Material -------------------------------
Engine-dependent oil pump (primary oil pump) Engine-dependent oil pump (primary oil pump)
Correct dimensioning in accordance with operating con-
ditions and correct installation of the gear pumps provide
structural conditions ensuring long and trouble-free oper-
ation. The pumps have low maintenance requirements
which, however, are indispensable for trouble-free opera-
tion because, according to experience, a high proportion
of the malfunctions and damage occurring are due to dirt
and insufficient maintenance.
Maintenance
Regular checks of all operating data such as filter con-
tamination degree, pressure, temperature, etc. can help
detect malfunctions at an early stage.
10
11
Removing and dismantling the oil pump Trailing operation oil pump (trailing pump)
1. Dismantle the suction and pressure pipe.
2. Remove O-rings.
3. Dismantle the pump by loosening the fixing nuts.
4. Remove the O-ring.
5. Mark positions of pump parts.
6. Remove screws on pump cover (9) and dismantle
the pump.
1 Cover 7 Steel ball 11. Mount the trailing oil pump by tightening the fixing
2 Reverse housing 8 Bearing bushing screws (with torque) on the output shaft cover.
3 Outer rotor 9 Housing 12. Mount the suction and pressure line.
4 Inner rotor 10 Drive pinion
5 Parallel key 11 Locking ring
6 Pressure spring 12 O-ring
Description of
166 Check control unit
maintenance job
Material ------------------------------
1 2
3 9
10
11 12
13 15
14
4
16
17
19 18
8
5 6
7
20
22
23 21
37
38 24
37 36
39 35
40 34 26 25
33
32
31 27
30 28
29
Checking the control unit: Readjustment of the control unit is not required
when dismantling is necessary for cleaning or re-
If possible, replace rather than dismantle the complete
placing individual pressure springs. However, a
control unit.
pressure test on the transmission is required.
Description of
167 Check actuation device (mechanical / electrical)
maintenance job
B
A
Fig. 92: Electrical actuation (example)
Fig. 91: Mechanical actuation (example) Checking the electrical actuation device:
Testing:
1. Make sure mechanical actuation (A) runs freely.
Assembling:
1. Mount mechanical actuation (A) on the control unit
by tightening the fixing screws (with torque).
Description of
168 Recalibrate display devices
maintenance job
Parts ---------------------------------
Material ---------------------------------
Option 1:
Connect calibrated display devices in parallel and com-
pare values displayed. Display errors must not exceed
10% of individual operating ranges.
Option 2:
Dismantle display devices and arrange for recalibration
and/or use replacement display devices.
Description of
169 Inspect visually and clean oil cooler
maintenance job
Material ---------------------------------
Fig. 93: Transmission oil cooler (example) Fig. 94: Transmission oil cooler design (example)
5 6 4
5
3 8 7 10 1 9 7 8 5 2
The water side can now be inspected and Disassembling the transmission oil cooler (with extrac-
mechanically cleaned. tion of the pipe bundle)
1. Clearly mark the positions of the bolted flanges to
Cleaning process on the water side
each other.
Clean the water side of the transmission oil cooler at
2. Close off all pipe lines.
least once per year. Avoid excessive contamination of the
pipes. 3. Drain the transmission oil cooler on the water side.
4. Remove the pipe lines on the water side.
Reduce time intervals for maintenance for
long-term operation of the ship in harbours and 5. Wait for at least 30 minutes after stopping the plant
other soiled waters, and according to the opera- for the oil pressure to sink.
tor's experience.
6. Remove the fixing screws on the transmission oil
The water side can be cleaned mechanically for just cooler and take the transmission oil cooler off.
slight contamination:
7. Remove receiver (2) and cover (3) by loosening the
1. Disassemble the transmission oil cooler as described screws on the receiver/cover-housing connection.
in Section Disassembling the transmission oil cooler
8. Remove the O-rings on both sides of the pipe bun-
(without extracting the pipe bundle).
dle.
2. Use a nylon brush to clean the inside of every pipe in
the pipe bundle (see Section 8.5 Tool kit).
11. Remove the O-ring. 13. Remove the O-ring on the water side of the pipe
bundle by pushing it over the pipe bundle.
Transmission Screw /
Tightening torque
type Strength
ZF 2000 series M8 / 8.8 23 Nm
Make sure the O-ring does not shear off during fit-
ting.
5. Fit spacer sheet (6) on the side opposite the water
side.
Make sure the O-ring does not shear off during fit-
ting.
3. Insert the pipe bundle into housing (1).
Testing
Check the oil side and the water side after assembly. At
the same time, ensure the pressure (oil side and water
side) does not exceed the value shown in the transmis-
sion installation drawing and on the type plate.
Transmission Screw /
Tightening torque
type Strength
ZF 2000 series M8 / 8.8 23 Nm
173 A4 121 15
Description of
173 Check shaft seal of input shaft
maintenance job
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
174 A4 121 15
Description of
174 Check shaft seal of output shaft
maintenance job
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
9 Annex
9.1 Guidelines for marine transmissions concerning corrosion protection, packing types, storage
conditions and storage periods
Level Storage period Corrosion protection at the factory Packing type Storage conditions
Internal conservation:
Anti-corrosive oil according to MIL-
L-21260 or TL 9150-0037, C-640
External conservation:
Uncoated parts with corrosion
preventative according to MIL-
C-16173D Type 4, K 19, or
Remove packing materials immediately
TL 8030-015, Type 4.
after receipt and check the external con-
Housing Transmission cov- servation. If the protective film is dam-
Max. 12 months ered with a poly- aged, touch up or completely recoat with
a) Finished by ZF using
I before first oper- water-based varnish, thene sack in a wet- a suitable corrosion preventative. Store in
ation strength, glued ply- enclosed area at a steady temperature
standard shade RAL 7001,
other shades according to wood case. and low relative humidity.
parts list. Protect from dirt and damp between
installation and first operation.
b) Wash priming by ZF, cus-
tomer must apply water-
based varnish as soon as
packing materials have
been removed.
Repack as described in
Level II for interim storage
longer than 12 months.
Internal conservation:
Anti-corrosive oil according to MIL-
Packed in drying
L-21260 or TL 9150-0037, C-640 agent in accordance
External conservation: with TL 8100-001,
Max. 36 months packing grade A by a Do not open the packing on receipt!
before installa- Uncoated parts with corrosion commissioned spe- Check for damage. Check reading on
tion + max. preventative to MIL-C-16173D cialist. Amount of humidity gauge. Store in enclosed area at
II 12 months type 4, K 19, or TL 8030-015, drying agent accord- a steady temperature and low relative
between instal- type 4. ing to DIN 55474 humidity.
lation and first Finished on housing using resp. TL 8100-004. Protect from dirt and damp between
operation water-based varnish, standard Packing contains a installation and first operation.
shade RAL 7001, other shades humidity gauge
according to parts list. which can be read
from outside.
All transmission openings are secu-
rely sealed.
More than As II
36 months In addition, after 36 months of storage,
before installa- read the humidity gauge every 4 months
tion + max. to check the humidity inside the packing.
III As II As II
12 months If humidity is too high, call in a commis-
between instal- sioned specialist to replace the drying
lation and first agent and the barrier foil and to check
operation the external conservation.
Guidelines in "Chapter Maintenance", "Section Corrosion protection and conservation" in the Operating Instruc-
tions of the corresponding transmission series apply to the period between first operation and entry into regular
operation and to shutdown periods.
9.2 Guideline for conserving marine transmissions during storage at ZF branches and
intermediaries.
Conservation measures described below must be carried out by ZF-authorized personnel. Otherwise, warranty
claims shall be deemed null and void.
Series transmissions supplied by ZF have corrosion protection according to Level I of "Guidelines for marine transmis-
sions about anticorrosion protection, packing type, storage conditions and storage periods".
Storage conditions stipulated in these guidelines apply: Store in enclosed area at a steady temperature and low rela-
tive humidity.
Renew conservation after 12 months at the latest. Transmissions may then be stored for a further 12 months. Renew
conservation every 6 months when transmissions need to be stored for a further period.
1. Fill transmission with anti-corrosive oil up to the upper measuring mark of the oil dipstick. Use anti-corrosive oil
C 642 or C 644 according to MIL- L-21260.
2. Remove inspection cover.
3. Spray internal transmission components with anti-corrosive oil while rotating the input and output shafts.
4. Close inspection cover.
5. Repeat consevation on uncoated outer steel parts.
Remove the inspection cover, inspect internal transmission components and spray with anti-corrosive oil while rotat-
ing the input and output shafts. Renew conservation on uncoated outer steel parts.
Renew conservation and drain anti-corrosive oil before delivering the stored transmission. Inform the customer that
marine transmissions purchased through ZF agencies provide corrosion protection for a maximum of 12 months.
K1 Conservation
Storage time: 12 months.
Then renew conservation every 6 months.
K2 long-term conservation
Storage time: 36 months.
Repeat every 36 months.
9.3.1 K1 Conservation
1. At the end of operation, drain transmission oil and fill with anti-corrosive oil to at least the upper measuring mark
on the oil dipstick. Refer to Maintenance Jobs for implementation. Use anti-corrosive oil C 642 or C 644 accord-
ing to MIL- L-21260.
2. Immediately afterwards, run the engine in "Engine wise rotation" or "Counter-engine wise rotation" shift position
at increased engine idle speed (max. 50% of nominal operating speed) for approx. 5 to 10 minutes. Then switch
the engine off.
3. Spray or brush uncoated outer steel parts with corrosion preventative.
4. Grease protruding shaft sections.
Remove the inspection cover and inspect internal transmission components. While rotating the input and output
shafts (if possible), spray internal transmission components with corrosion preventative. Renew conservation on un-
coated outer steel parts.
1. Start the engine and run for approx. 5 minutes to mix any condensed water possibly accumulated in the transmis-
sion with the corrosion preventative.
2. Drain corrosion preventative and fill transmission with the specified oil type (see "Maintenance Job 141").
1. As soon as possible after operation, but at the latest after 3 months, drain transmission oil and fill with anti-corro-
sive oil to the lower measuring mark of the oil dipstick (see Maintenance Jobs for implementation). Use anti-cor-
rosive oil C 642 or C 644 according to MIL-L-21260.
2. Immediately afterwards, run the engine in "Engine wise rotation" or "Counter-engine wise rotation" shift position
at increased engine idle speed (max. 50% of nominal operating speed) for approx. 5 to 10 minutes. Then switch
the engine off.
3. Then fill the transmission completely with anti-corrosive oil.
4. Spray or brush uncoated outer steal parts with corrosion preventative.
5. Grease protruding shaft sections.