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Manual de Operacion

MANUAL DE OPERACIÓN TRASMISIÓN ZF2050

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100% found this document useful (3 votes)

1K views

Manual de Operacion

MANUAL DE OPERACIÓN TRASMISIÓN ZF2050

Uploaded by

luis

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 162

OPERATING INSTRUCTIONS

Z F 2 0 0 0 S ERIES

MA RI NE P ROPU LSION SYSTEMS

This document is protected by copyright. Complete or partial reproduction

or dissemination of this document is prohibited without the consent of
ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution.
This document is a translation of the German original.
Table of Contents

Table of Contents

Table of Contents ................................................................................................................................................ 3

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

2 Product overview .............................................................................................................................................. 15

2.1 Transmission overview ............................................................................................................................. 15
2.1.1 General design principle ............................................................................................................... 15
2.1.1.1 Oil supply and transmission cooling ................................................................................ 15
2.1.1.2 Control unit and transmission actuation .......................................................................... 15
2.1.1.3 Transmission as A and parallel version ............................................................................ 15
2.1.1.4 Transmission as V and U version ..................................................................................... 16
2.1.1.5 Transmission as B version ............................................................................................... 17
2.1.2 Installation position on the ship .................................................................................................... 17
2.1.2.1 Engine-transmission arrangement "standard" .................................................................. 17
2.1.2.2 Engine-transmission arrangement in "U and V shape" ..................................................... 17
2.1.3 Propeller rotation direction during ahead travel ............................................................................. 19
2.1.4 Transmission views ....................................................................................................................... 20
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 ............................ 20
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 ................................................................................................................. 22

EN 3100 758 101g - 2015-07 3

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 .................................................................................................................. 24
2.1.4.4 ZF 2150 NC .................................................................................................................... 26
2.1.4.5 ZF 2000 NRB ................................................................................................................. 28
2.1.4.6 ZF 2200 / ZF 2250 / ZF 2260 / ZF 2270 / ZF 2275 /
ZF 2200 NR / ZF 2250 NR / ZF 2260 NR / ZF 2270 NR / ZF 2275 NR ............................ 30
2.1.4.7 ZF 2200 B ...................................................................................................................... 32
2.1.4.8 ZF 2300 / ZF 2350 / ZF 2360 / ZF 2370 / ZF 2375 / ZF W2300 / ZF W2350 /
ZF 2300 NR / ZF 2350 NR / ZF 2360 NR / ZF 2370 NR / ZF 2375 NR / ZF W2300 NR /
ZF W2350 NR ................................................................................................................ 34
2.1.4.9 ZF W2400 / ZF W2450 / ZF W2400 NR / ZF W2450 NR ............................................... 36
2.1.4.10 ZF 2350 U ...................................................................................................................... 38
2.2 Technical data ......................................................................................................................................... 40
2.2.1 Cooler data ................................................................................................................................... 41
2.2.2 Cooler data ZF 2000 NRB ............................................................................................................. 41
2.2.3 Oil types ....................................................................................................................................... 41
2.2.4 Oil quantities ................................................................................................................................ 41
2.2.5 Transmission ratio ......................................................................................................................... 42
2.2.6 Transmission weight ..................................................................................................................... 42
2.2.7 Transmission description .............................................................................................................. 42
2.2.8 Monitoring values for ZF 2000/2150/2200/2300/W2300/W2400 series ....................................... 44

3 Description - basic transmission and variants .................................................................................................. 45

3.1 Functions ................................................................................................................................................ 45
3.1.1 Transmission as parallel version .................................................................................................... 45
3.1.2 Transmission as A version ............................................................................................................. 46
3.1.3 Transmission as V version ............................................................................................................. 46
3.1.4 Transmission as U version ............................................................................................................. 47
3.1.5 Transmission as B version ............................................................................................................. 47
3.1.6 Transmission as NRB version ........................................................................................................ 48
3.1.7 Oil supply ..................................................................................................................................... 48
3.1.8 Hydraulic multi-disc clutch ............................................................................................................ 48
3.1.9 Transmission cooling .................................................................................................................... 48
3.1.10 Control unit and transmission actuation ........................................................................................ 49

4 Initial installation and start-up .......................................................................................................................... 51

4.1 Initial installation ...................................................................................................................................... 51
4.1.1 Transmission support in the foundation ........................................................................................ 51
4.1.2 Connection to the engine ............................................................................................................. 52
4.1.3 Connection to propeller shaft ........................................................................................................ 52
4.1.3.1 Shaft installation with only one bearing for the propeller shaft (Fig. A) ............................ 54
4.1.3.2 Shaft installation with two or more bearings for the propeller shaft (Fig. B) .................... 54
4.1.4 Connection to the joint shaft ......................................................................................................... 55
4.1.5 Alignment of the transmission ...................................................................................................... 56
4.1.6 Trolling ......................................................................................................................................... 57
4.1.6.1 Electrical actuation device for trolling operation .............................................................. 57
4.1.6.2 Retrofitting the trolling valve ........................................................................................... 58
4.1.6.3 ZF AUTOTROLL .............................................................................................................. 58
4.1.7 Transmission cooling (cooling systems) ........................................................................................ 58
4.1.7.1 Open sea water circuit .................................................................................................... 58
4.1.7.2 Closed cooling water circuit ........................................................................................... 58
4.1.8 Transmission cooling (cooler design) ............................................................................................ 59
4.1.8.1 Requirements for the cooling water circuit ...................................................................... 59
4.1.8.2 Earthing .......................................................................................................................... 60
4.1.8.3 Drainage of the transmission oil cooler ........................................................................... 60

4 EN 3100 758 101g - 2015-07

4.1.9 Transmission cooling (pipework) .................................................................................................. 60
4.1.9.1 Installation ...................................................................................................................... 60
4.1.9.2 Flow velocity .................................................................................................................. 60
4.1.9.3 Materials for cooling water pipes .................................................................................... 61
4.1.9.4 Earthing for the cooling water pipe ................................................................................. 61
4.1.10 Transmission cooling (general information) ................................................................................... 61
4.1.10.1 Clearance for maintenance jobs ...................................................................................... 61
4.1.11 Oil filling and oil level control ........................................................................................................ 61
4.1.12 Connection of monitoring equipment ............................................................................................ 61
4.2 Installation control and commissioning .................................................................................................... 61
4.3 Commissioning after standstill ................................................................................................................. 62
4.3.1 Standstills of 3 to 6 months .......................................................................................................... 62
4.3.2 Standstills of 6 to 9 months .......................................................................................................... 62
4.3.3 Standstills of 36 months and more ............................................................................................... 62
4.4 Operation monitoring .............................................................................................................................. 63
4.4.1 Minimum transmission monitoring ................................................................................................ 63
4.4.2 Additional transmission monitoring ............................................................................................... 63

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

6 Special equipment / special versions ............................................................................................................... 83

6.1 Trolling .................................................................................................................................................... 83
6.1.1 Functional description .................................................................................................................. 83
6.1.2 Electrical trolling ........................................................................................................................... 83
6.1.3 ZF AUTOTROLL ............................................................................................................................ 84
6.2 Trailing oil pump (trailing pump) .............................................................................................................. 84
6.3 PTO=Power Take-Off ............................................................................................................................... 85

EN 3100 758 101g - 2015-07 5

7 Troubleshooting ................................................................................................................................................ 87
7.1 Troubleshooting information .................................................................................................................... 87
7.2 Table of possible malfunctions ................................................................................................................. 88
7.2.1 Table of possible malfunctions (overall transmission) .................................................................... 88
7.2.2 Table of possible malfunctions (transmission oil cooler) ................................................................ 90
7.3 Clearing faults (transmission oil cooler) .................................................................................................... 92
7.3.1 Leaking pipes ............................................................................................................................... 92
7.3.2 Leaking O-rings ............................................................................................................................ 92
7.4 Diagnosis for ZF AUTOTROLL (Special scope of delivery) ......................................................................... 92

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

9 Annex .............................................................................................................................................................. 157

9.1 Guidelines for marine transmissions concerning corrosion protection, packing types,
storage conditions and storage periods ................................................................................................. 157
9.2 Guideline for conserving marine transmissions during storage at ZF branches and
intermediaries. ....................................................................................................................................... 158
9.2.1 Conservation procedure .............................................................................................................. 158
9.2.1.1 Renewing conservation ................................................................................................ 158
9.2.1.2 Measures to be taken before delivering stored transmissions ........................................ 158
9.3 Corrosion protection and conservation for ZF transmissions installed in a ship ....................................... 158
9.3.1 K1 Conservation ......................................................................................................................... 159
9.3.1.1 Renewing conservation ................................................................................................ 159
9.3.1.2 Commissioning after K1 conservation ........................................................................... 159
9.3.2 K2 Long-term conservation ......................................................................................................... 159
9.3.2.1 Commissioning after K2 long-term conservation ........................................................... 159

6 EN 3100 758 101g - 2015-07

Foreword
Foreword

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.

EN 3100 758 101g - 2015-07 7

Foreword

8 EN 3100 758 101g - 2015-07

Safety
Safety

1 Safety 1.2 General information

1.1 Conventions for safety information in text 1.2.1 General

In addition to these Operating Instructions, generally

DANGER valid local, legal and other compulsory regulations on ac-
cident prevention and environmental protection are to be
Describes a dangerous situation that will lead to observed. This transmission was constructed according
serious injuries or death when not avoided. to the current state of the art and the applicable rules and
regulations. However, the transmission can still present
WARNING personal and physical risks, through:

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

NOTICE The transmission is designed exclusively for the purpose

Describes a situation which can lead to material defined in the contract and/or as foreseen at delivery.
Any other or further use is considered as not being in ac-
damage when not avoided. cordance with the 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.

1.2.4 Spare parts

Only ZF original spare parts may be used when replacing

components or subassemblies. All liability and warranty
claims against the manufacturer of the transmission will
become void for damage resulting from the use of other
spare parts.

EN 3100 758 101g - 2015-07 9

Safety

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.

1.4.3 Operation of power plant

 Wear hearing protection while engine is running.

 Ensure good ventilation of machine room.
 Immediately wipe up leaked or spilled service fluids or
soak up with corresponding absorbent.
 Inappropriate shielding of electrical parts can cause
severe electric shock and subsequent injuries.
 Never remove water, oil, compressed air or hydraulic
lines while the engine is running.

10 EN 3100 758 101g - 2015-07

Safety

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.

EN 3100 758 101g - 2015-07 11

Safety

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.

12 EN 3100 758 101g - 2015-07

Safety

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.

1.6.1 Transmission without suspension bracket

Lifting lugs are screwed on machined surfaces used for

attaching the suspension bracket.
 Do not use lifting lugs other than for transmission
transport. They must not be used for transporting the
complete power unit (engine and transmission).
 Remove the lifting lugs before attaching the suspen-
sion bracket.

1.6.2 Transmission with suspension brackets

If the transmission is delivered with original ZF suspen-

sion brackets, the outer reinforcing ribs are designed to
be used as lifting lugs.
 Always use these holes for all sling gear (e.g. shackle
A4 according to DIN 82101, not supplied by ZF).
 If suspension brackets are not supplied by ZF, the
shipyard or engine manufacturer must provide an
appropriate transmission suspension.

1.6.3 Lowering the transmission after transport

 Always lower the transmission on a flat, solid surface.

 Observe condition, load capacity of the floor and/or
surface.
 Never place the transmission on the oil sump unless
expressly authorized by ZF for the individual transmis-
sion.

EN 3100 758 101g - 2015-07 13

Safety

14 EN 3100 758 101g - 2015-07

Product overview
Product overview

2 Product overview 2.1.1.1 Oil supply and transmission cooling

The transmission housing is designed as an oil container.
2.1 Transmission overview A continuous delivery gear pump serves for delivering the
oil flow for transmission lubrication, transmission cooling,
2.1.1 General design principle and for pressuring the multi-disc clutch.
The transmission housing has threaded holes for con-
ZF marine transmissions are designed and manufactured
necting sensors for monitoring purposes as standard. The
in accordance with the regulations of the individual Clas-
following oil supply values can be measured on the trans-
sification Societies. The power rating approved by the
mission: Transmission oil temperature, oil pressure be-
Classification Society depends on the input speeds, the
fore the filter (when using a gap filter), lubricating oil
class of the ship, and the various applicable construction
pressure and clutch oil pressure.
specifications. In most cases, the maximum torques ap-
proved by ZF are also approved by the Classification So- An oil cooler made of sea water resistant material is
ciety up to the same maximum values. mounted on the transmission housing for cooling the
transmission oil. This oil cooler has a pipe bundle design.
Full testing or final inspection by the Classification Soci-
ety specified by the customer is possible on request. An oil filter with one filter cartridge or a gap filter serves
for cleaning the transmission oil.
The normal input direction is clockwise as viewed on the
transmission input flange. A corresponding arrow is fixed
2.1.1.2 Control unit and transmission actuation
on the transmission input side for special version trans-
missions with anticlockwise input direction (left as The control unit is fitted as complete subassembly on the
viewed on the transmission input flange). transmission housing and comprises the following essen-
tial components:
ZF 2000 series transmissions are hypoid reversing and
reduction transmissions with triple gearing. One hydrau-  Control piston (filling and venting of multi-disc clutch)
lic multi-disc clutch is located on the input shaft and one  Control valve (clutch pressure level)
on the intermediate shaft (also reversing shaft) of the
transmission.  Timer (modulating clutch pressure)

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.

EN 3100 758 101g - 2015-07 15

Product overview

U version
The shafts in the transmission are arranged on parallel
axes. The transmission type has suffix "U", for example,
ZF 2350 U.

Fig. 1: Parallel version

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

2.1.1.4 Transmission as V and U version

In this version, input and output flanges are located on
the same transmission side. The flange of the transmis- Fig. 4: V version
sion input shaft is always above the flange of the output
shaft. The vertical axial distance between the two shafts
is measure "A".

16 EN 3100 758 101g - 2015-07

Product overview

2.1.1.5 Transmission as B version

The flange of the transmission input shaft is always lo-
cated below the flange of the output shaft. The vertical
axial distance between the two shafts is measure "A".
Transmission input and output are located on opposite
sides of the housing. The transmission type has suffix "B",
for example, ZF 2200 B.

007693.2

Fig. 7: Down angle

The transmission can be mounted on the engine as
"free-standing" or "flanged".

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.

2.1.2.2 Engine-transmission arrangement in "U and V

shape"
For arrangement in U or V shape, transmissions are used
with input and output flange on the same transmission
006778.2
side. In U shape, transmission and engine are fitted in-
clined towards the longitudinal axis by angle „β1“ or „β2“.
Fig. 6: Vertical offset

EN 3100 758 101g - 2015-07 17

Product overview

A distinction is made between two arrangements de-

pending on the installation position of the joint shafts: W
and Z arrangement, each under the condition that both
joint angles are equal (β1 = β2). For installation instruc-
β1 tions and alignment guidelines, see Sections 4.1.2 Con-
β2 nection to the engine and 4.1.4 Connection to the joint
shaft.

β2 β1

006779.2

Fig. 8: U drive (U arrangement) 004_971.1

Fig. 10: W arrangement with β1 = β2

In V shape, engine and transmission are connected on
one level by means of a joint shaft. In the same manner
as the output flange of the transmission, the propeller
shaft is inclined towards the longitudinal axis of the β2
power unit by angle "α".

β1

α 004_971.2

Fig. 11: Z arrangement with β1 = β2

Both the V and U arrangement require free-standing in-
stallation of engine and transmission. The transmission is
supported rigidly or elastically in the foundation. The en-
gine is normally elastically supported. Engine and trans-
006779.3
mission are connected via a joint shaft allowing a length
Fig. 9: V drive (V arrangement) change between these two units, with compensation in
all operating states.
A flexible clutch is fitted on the engine side for vibrational
decoupling of engine and transmission.
Radial and axial forces occur on the joint shaft. Additional
support points may be required depending on the length
of the joint shafts used. If one support point between the
flexible clutch of the engine and joint shaft is sufficient, it
is fitted on the engine as a bell housing. Alternatively, the
joint shaft can be supported directly in the foundation.

18 EN 3100 758 101g - 2015-07

Product overview

2.1.3 Propeller rotation direction during ahead travel

Normal engine arrangement

One-engine installation Two-engine installation

V and U arrangement

A special version is required for input shafts rotating anticlockwise

Preferable
(as seen on the transmission flange).
Admissible

EN 3100 758 101g - 2015-07 19

Product overview

2.1.4 Transmission views

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

21 137 53
2

20 EN 3100 758 101g - 2015-07

Product overview

15 47

13
41

33
1

11 20 12

Key to drawing:

1 Transmission fastening surface 26 Output

2/21 Measuring points for clutch oil pressure 28 Flanging surface for bell housing
8 Input (input flange, special scope of delivery) 33 Oil filter
10 Engine-dependent oil pump 34 Emergency control
(primary oil pump) (counter-engine wise rotation)
11/12 Measuring points for oil temperature 41 Measuring point for oil temperature
13 Water connection flange 44 Emergency control (engine wise rotation)
15 Oil cooler 46 Oil filler hole
18 Position for trailing oil pump 47 Inspection cover
20 Oil drain 53 Measuring point for oil temperature after
cooler
22 Measuring point for lubricating oil pressure 137 Neutral switch
23 Transmission vent
25 Oil dipstick

EN 3100 758 101g - 2015-07 21

Product overview

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.

34
44

2 21 137 53

8
28

22 EN 3100 758 101g - 2015-07

Product overview

15 47
22

13
41

12
11 20

Key to drawing:

1 Transmission fastening surface 26 Output

EN 3100 758 101g - 2015-07 23

Product overview

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.

2 21 137 53

24 EN 3100 758 101g - 2015-07

Product overview

15 47

8
13

41
33

1
10

11 20 12

Key to drawing:

1 Transmission fastening surface 26 Output

2/21 Measuring points for clutch oil pressure 28 Flanging surface for bell housing
8 Input (input flange, special scope of delivery) 33 Oil filter
10 Engine-dependent oil pump 41 Measuring point for oil temperature
(primary oil pump)
11/12 Measuring points for oil temperature 44 Emergency control (engine wise rotation)
13 Water connection flange 46 Oil filler hole
15 Oil cooler 47 Inspection cover
18 Position for trailing oil pump 53 Measuring point for oil temperature after
cooler
20 Oil drain 137 Neutral switch
22 Measuring point for lubricating oil pressure
23 Transmission vent
25 Oil dipstick

EN 3100 758 101g - 2015-07 25

Product overview

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

21
2 53

8
28

26 EN 3100 758 101g - 2015-07

Product overview

11 12
20

Key to drawing:

1 Transmission fastening surface 26 Output

2/21 Measuring points for clutch pressure 28 Flanging surface for bell housing
8 Input (input flange, special scope of delivery) 33 Oil filter
10 Engine-dependent oil pump 41 Measuring point for oil temperature
(primary oil pump)
11/12 Measuring points for oil temperature 46 Oil filler hole
13 Water connection flange 47 Inspection cover
15 Oil cooler 53 Measuring point for oil temperature after
cooler
18 Position for trailing oil pump
20 Oil drain
22 Measuring point for lubricating oil pressure
23 Transmission vent
25 Oil dipstick

EN 3100 758 101g - 2015-07 27

Product overview

2.1.4.5 ZF 2000 NRB

Your transmission may vary from the Figures shown here with regard to structure, connections, and pipework.

25
23

18
8
20
12

137 46
53
21

28
26

28 EN 3100 758 101g - 2015-07

Product overview

47
15

13
41

Key to drawing:

1 Transmission fastening surface 26 Output

2/21 Measuring points for clutch pressure 28 Flanging surface for bell housing
8 Input (input flange, special scope of delivery) 33 Oil filter
10 Engine-dependent oil pump 34 Emergency control
(primary oil pump) (counter-engine wise rotation)
11/12 Measuring points for oil temperature 41 Measuring point for oil temperature
13 Water connection flange 46 Oil filler hole
15 Oil cooler 47 Inspection cover
18 Position for trailing oil pump 53 Measuring point for oil temperature after
cooler
20 Oil drain 137 Neutral switch
22 Measuring point for lubricating oil pressure
23 Transmission vent
25 Oil dipstick

EN 3100 758 101g - 2015-07 29

Product overview

2.1.4.6 ZF 2200 / ZF 2250 / ZF 2260 / ZF 2270 / ZF 2275 /

ZF 2200 NR / ZF 2250 NR / ZF 2260 NR / ZF 2270 NR / ZF 2275 NR
Your transmission may vary from the Figures shown here with regard to structure, connections, and pipework.

21 53
137 47

30 EN 3100 758 101g - 2015-07

Product overview

13
41

10 26

11 20 12

Key to drawing:

1 Transmission fastening surface 26 Output

EN 3100 758 101g - 2015-07 31

Product overview

15 47

41
33

1
34

12
11
20

Key to drawing:

1 Transmission fastening surface 26 Output

EN 3100 758 101g - 2015-07 35

Product overview

2.1.4.9 ZF W2400 / ZF W2450 / ZF W2400 NR / ZF W2450 NR

Your transmission may vary from the Figures shown here with regard to structure, connections, and pipework.

46
34

44 25

10 23

21 137
2 53

36 EN 3100 758 101g - 2015-07

Product overview

15 47

41
33

1
34

12
11
20

Key to drawing:

1 Transmission fastening surface 26 Output

EN 3100 758 101g - 2015-07 35

Product overview

2.1.4.9 ZF W2400 / ZF W2450 / ZF W2400 NR / ZF W2450 NR

Your transmission may vary from the Figures shown here with regard to structure, connections, and pipework.

46
34

44 25

10 23

21 137
2 53

36 EN 3100 758 101g - 2015-07

Product overview

15 47

41 33

11 12
20

Key to drawing:

1 Transmission fastening surface 26 Output

2/21 Measuring points for clutch pressure 28 Flanging surface for bell housing
8 Input (input flange, special scope of delivery) 33 Oil filter
10 Engine-dependent oil pump 34 Emergency control
(primary oil pump) (counter-engine wise rotation)
11/12 Measuring points for oil temperature 41 Measuring point for oil temperature
13 Water connection flange 44 Emergency control (engine wise rotation)
15 Oil cooler 46 Oil filler hole
18 Position for trailing oil pump 47 Inspection cover
20 Oil drain 53 Measuring point for oil temperature after
cooler
22 Measuring point for lubricating oil pressure 137 Neutral switch
23 Transmission vent
25 Oil dipstick

EN 3100 758 101g - 2015-07 37

Product overview

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

21 137
2 53

38 EN 3100 758 101g - 2015-07

Product overview

13 22

44
26

12
11 20

Key to drawing:

1 Transmission fastening surface 26 Output

2/21 Measuring points for clutch pressure 28 Flanging surface for bell housing
8 Input (input flange, special scope of delivery) 33 Oil filter
10 Engine-dependent oil pump 41 Measuring point for oil temperature
(primary oil pump)
11/12 Measuring points for oil temperature 44 Emergency control (engine wise rotation)
13 Water connection flange 46 Oil filler hole
15 Oil cooler 47 Inspection cover
18 Position for trailing oil pump 53 Measuring point for oil temperature after
cooler
20 Oil drain 137 Neutral switch
22 Measuring point for lubricating oil pressure
23 Transmission vent
25 Oil dipstick

EN 3100 758 101g - 2015-07 39

Product overview

2.2 Technical data

The normal input direction is - as viewed on the transmission input flange - clockwise. A corresponding arrow is fixed
on the transmission input side for special version transmissions with anticlockwise input direction (left as viewed on
the transmission input flange).

Engine Transmission Engine

Transmission
001 614

ZF 2200 B

Fig. 12: Direction of rotation, transmission input shaft (standard version)

Observe maximum admissible loads (forces) on the transmission input in accordance with Section 4.1.2 Connection
to the engine. On the front side of the input shaft, additional forces must not exceed 2,000 N in radial direction and
1,000 N in axial direction.
Section 4.1.3 Connection to propeller shaft describes the alignment of transmission and propeller shaft. The maxi-
mum admissible radial force is 500 N (A = up to 279.8 mm) and 1,000 N (A = 280 mm, A = 335 mm and
A = 390 mm) when assembling and/or centring the transmission output flange and propeller shaft.
Alignment accuracy of the propeller shaft varies for the individual transmission versions and is shown in the following
Table:

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

Tab. 1: Alignment accuracy of propeller shaft

40 EN 3100 758 101g - 2015-07

Product overview

2.2.1 Cooler data

 Maximum admissible cooling water flow volume: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,000 dm3/h

 Minimum admissible cooling water flow volume: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,900 dm3/h
 Pressure loss between cooling water inlet / outlet at 12,000 dm³/h: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5 bar
 Maximum admissible water pressure at cooling water inlet: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 bar
 Maximum cooling water inlet temperature for P, L, M applications:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40°C
 Maximum cooling water inlet temperature for ZF 2070, ZF 2270 (P application) . . . . . . . . . . . . . . . . . . . . . . 32°C
 Maximum cooling water inlet temperature for C applications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50°C
 Maximum transmission ambient temperature: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°C

2.2.2 Cooler data ZF 2000 NRB

 Maximum admissible cooling water flow volume: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,000 dm3/h

 Minimum admissible cooling water flow volume: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,900 dm3/h
 Pressure loss between cooling water inlet / outlet at 8,000 dm³/h: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 bar
 Maximum admissible water pressure at cooling water inlet: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 bar
 Maximum cooling water inlet temperature:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 °C
 Maximum transmission ambient temperature: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 °C

2.2.3 Oil types

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

2.2.4 Oil quantities

 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 20 dm3
 ZF 2150 NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 20 dm3
 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 . . . . . . . . . . . . . . . . approx. 21 dm3
 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 . . . . . . . . . . . . . . . . . approx. 21 dm3
 ZF 2000 NRB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 21 dm3
 ZF 2200 / ZF 2250 / ZF 2260 / ZF 2270 / ZF 2275 / ZF 2200 NR / ZF 2250 NR / ZF 2260 NR /
ZF 2270 NR / ZF 2275 NR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 21 dm3
 ZF 2300 / ZF 2350 / ZF 2360 / ZF 2370 / ZF 2375 / ZF W2300 / ZF W2350 / ZF 2300 NR /
ZF 2350 NR / ZF 2360 NR / ZF 2370 NR / ZF 2375 NR / ZF W2300 NR / ZF W2350 NR . . . . . . . . approx. 27 dm3
 ZF W2400 / ZF W2450 / ZF W2400 NR / ZF W2450 NRapprox. 36 dm3
 ZF 2350 U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 27 dm3

EN 3100 758 101g - 2015-07 41

Product overview

2.2.5 Transmission ratio

The relevant ratio is shown on the transmission type

plate. (See Section 2.2.7 Transmission description for ex-
planations) 1 2

2.2.6 Transmission weight 3 4

The overall weight of the transmission depends on the 5 5a 5b

transmission version and the special equipment supplied. 6 7 9
The overall weight is shown on the transmission type
plate. 10 11 12 13

2.2.7 Transmission description

The type plate is located on the same side of the housing

as the output flange and is also clearly visible after instal- Fig. 14: Type plate (example)
lation.
Specifications on the type plate:
If the transmission has been classified, the certificate
number and seal of the Classification Society are em- 1) Design
bossed on the housing next to the type plate. 2) Serial number
3) Parts list number
Type plate/classification
4) Customer reference number
5) Overall transmission ratio and code letter for oil
pump ratio
5a) Main transmission ratio
5b) Primary transmission ratio (if applicable)
6) Oil capacity
7) Weight (dry)
9) Clutch oil pressure (nominal)
10 ) Maximum performance ratio/speed ratio for
intermittent operation with very high differences
in engine speeds
11) Maximum performance ratio/speed ratio for
intermittent operation with high differences
in engine speeds
12 ) Maximum performance ratio/speed ratio for
intermittent operation with different engine speeds
Fig. 13: Transmission ZF 2000 (example) 13) Maximum performance ratio/speed ratio for
continuous operation with maximum engine
performance
Fields 1 to 3 and 5 are mandatory should questions arise
on transmission, troubleshooting, servicing, spare part
orders, ordering optional equipment, etc.
See Chapter 8 Maintenance, Section 8.1 Application
area for further details on fields 10 to 13.
The respective ratio installed is embossed on the type
plate.

42 EN 3100 758 101g - 2015-07

Product overview

The code letter entered in field 5 after the overall ratio

refers to the primary oil pump ratio. Oil pump ratio A is
standard version.

Code letter Design engine Engine idle

speed during speed [rpm]
continuous per-
formance [rpm]
A 1,650 to 2,600 ≥ 500
Tab. 2: Primary oil pump ratios

EN 3100 758 101g - 2015-07 43

2.2.8 Monitoring values for ZF 2000/2150/2200/2300/W2300/W2400 series

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

wise or coun- wise“

ter-engine wise“
Rated value --- --- PKN 7) --- --- --- ---
Nominal dis- Min --- --- 4) 3.5 bar 0.4 bar 30°C ---
PK = PKN-1 bar
play value 20) 4)
Max 26 bar --- PK = PKN+3 bar 14 bar 13 bar 90°C 75°C 8) 11)
28 bar 20) 22) 95°C 8) 12)
Warning 20) 2) 5) 2) 5) 6) 18) 19) --- 2) 5) 2) 5) ---
26 bar 5 bar PK= PKN-3 bar 0.25 bar 95°C
20) 22) 23)
28 bar
Minimum monitoring 14) Druckschalter Druckschalter Pressure gauge 0 to 40 bar --- Thermometer 0 to 120°C
14) --- --- 16) Pressure switch or pres-
Additional monitoring Pressure switch or pressure sensor Temperature switch 2) or
0 to 40 bar sure gauge 0 to 16 bar
temperature sensor 16) 0 to
120°C

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

EN 3100 758 101g - 2015-07

Description - basic transmission and variants
Description - basic transmission and variants

3 Description - basic transmission and variants

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.

3.1.1 Transmission as parallel version

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)

EN 3100 758 101g - 2015-07 45

Description - basic transmission and variants

3.1.2 Transmission as A version

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

Fig. 16: Power flow diagram of the A version

(example, EW = engine wise rotation, CEW = counter-engine wise rotation)

3.1.3 Transmission as V version

A
A
Gears
meshed
B together B

C
E

CEW A A = Input shaft

B = Intermediate shaft
C
C = Output shaft
EW A D = Clutch for CEW
B E = Clutch for EW
C

Fig. 17: Power flow diagram of the V version

(example, EW = engine wise rotation, CEW = counter-engine wise rotation)

46 EN 3100 758 101g - 2015-07

Description - basic transmission and variants

3.1.4 Transmission as U version

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

Fig. 18: Power flow diagram of the U version

(example, EW = engine wise rotation, CEW = counter-engine wise rotation)

3.1.5 Transmission as B version

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

Fig. 19: Power flow diagram of the B version

(example, EW = engine wise rotation, CEW = counter-engine wise rotation)

EN 3100 758 101g - 2015-07 47

Description - basic transmission and variants

3.1.6 Transmission as NRB version

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)

3.1.7 Oil supply

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.

3.1.8 Hydraulic multi-disc clutch

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.

3.1.9 Transmission cooling

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.

48 EN 3100 758 101g - 2015-07

Description - basic transmission and variants

3.1.10 Control unit and transmission actuation

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.

EN 3100 758 101g - 2015-07 49

Description - basic transmission and variants

50 EN 3100 758 101g - 2015-07

Initial installation and start-up
Initial installation and start-up

4 Initial installation and start-up 4.1.1 Transmission support in the foundation

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.

EN 3100 758 101g - 2015-07 51

Initial installation and start-up

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.

4.1.2 Connection to the engine

Fit a flexible clutch between engine and transmission.

The flexible clutch has the task of influencing inherent
frequencies of the rotating masses of the engine, trans-
mission, and propeller so that no detrimental vibration
resonance occurs within the operating speed range.

52 EN 3100 758 101g - 2015-07

Initial installation and start-up

Bolts M18 x 1.5

Quality 10.9
Min. tensile strength 1,000 N/mm²
for
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
ZF 2150 NC
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
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

Bolts M20 x 1.5

Quality 10.9
Min. tensile strength 1,000 N/mm²
for
ZF 2200 / ZF 2250 / ZF 2260 / ZF 2270 / ZF 2275
ZF 2200 NR / ZF 2250 NR / ZF 2260 NR /
ZF 2270 NR / ZF 2275 NR
ZF 2200 B
ZF 2300 / ZF 2350 / ZF 2360 / ZF 2370 / ZF 2375 /
ZF W2300 / ZF W2350
ZF 2300 NR / ZF 2350 NR / ZF 2360 NR /
ZF 2370 NR / ZF 2375 NR / ZF W2300 / ZF W2350 NR
ZF W2400 / ZF W2450 / ZF W2400 NR / ZF W2450 NR
ZF 2350 U
When using fitting bolts, the holes of the propeller shaft
flange can be bored and reamed together with those of
the transmission output flange (material strength 750 to
900 N/mm2).

EN 3100 758 101g - 2015-07 53

Initial installation and start-up

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. A x [mm] = maximum admissible alignment error

y [mm] = maximum admissible shaft offset

x L [mm] = minimum admissible bearing spacing

r [mm] = measurement radius
3 to 5 d [mm] = propeller shaft diameter
r
d

Fig. B L

3 to 5
r y
d

004 972

Fig. 22: Propeller shaft alignment (example)

The values for "x" and "y" are only valid when dis-
tance "L" between propeller shaft flange and last
shaft bearing is large enough depending on shaft
diameter "d".

54 EN 3100 758 101g - 2015-07

Initial installation and start-up

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°.

EN 3100 758 101g - 2015-07 55

Initial installation and start-up

= =

1 2 3

ß2

ß1

4 5

004 971

Fig. 23: Installation diagram for joint shafts in W arrangement (example)

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.

56 EN 3100 758 101g - 2015-07

Initial installation and start-up

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.

4.1.6.1 Electrical actuation device for trolling Power consumption,

solenoid valve
operation

Transmissions with a trolling device are not fitted

with a speed safeguard for the trolling operation. A
speed safeguard installed additionally by the ship-
yard can block an inadmissible speed range during
trolling operation and therefore prevent incorrect
operation.
The electrical actuation device for trolling operation com-
prises a directional valve operated electrically for switch-
ing the trolling function on or off as well as a proportional
valve for setting the clutch pressure. The shipyard is re- Chopper frequency
sponsible for actuation of both valves. The directional
Overall current
valve is actuated continually with 24 V voltage and 18 W range
capacity during trolling operation, see position 147 in Fig.
24. A current input in the range 150 to 450 mA is speci- Fig. 24: Electrical circuit diagram (example)
fied for the proportional valve with a resistance of 23.5 to
26.5 Ohm, see position 150 in Fig. 24, for setting the 101 Electrical actuation device for trolling operation
clutch pressure. A high current input creates a low clutch (ZF scope of delivery)
pressure and therefore a low propeller speed. On the 106 Electrical plug connection (ZF scope of delivery)
other hand, a low current input creates a high clutch
pressure and therefore a high propeller speed. Specifica- 108 Deck switch (not ZF scope of delivery)
tions concerning the electrical connections are contained 120 Switch to switch trolling operation on and off
in the associated installation documents. Direct current (not ZF scope of delivery)
can also be used for the proportional valve instead of the
chopper frequency specified in the installation docu- 125 Trolling control (not ZF scope of delivery)
ments.The chopper frequency only has a positive effect 130 Deck switch trolling MIN/MAX
on the response behavior. The trolling function switches (not ZF scope of delivery)
off automatically after a power failure.
147 Solenoid valve (ZF scope of delivery)
The delivered sign with operating instructions for 150 Proportional valve (ZF scope of delivery)
trolling operation must be fitted visible and as
close as possible to the trolling shift lever, and be Maximum admissible engine speed in trolling
easily readable during operation. operation
For submerged standard propellers (with parabolic pro-
Refer to the Operating Instructions of the actuation peller curve): 50% of maximum admissible operating
manufacturer on operating the trolling actuation. speed (engine speed), however up to a maximum of
1,000 rpm.
For surface propellers: Engine idling speed up to the
maximum operating speed (engine speed) of 700 rpm.

Maximum admissible lubricating oil temperature in

trolling operation
The maximum lubricating oil temperature in trolling oper-
ation is 90°C.

EN 3100 758 101g - 2015-07 57

Initial installation and start-up

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!

4.1.6.3 ZF AUTOTROLL 4.1.7.1 Open sea water circuit

The electronically controlled trolling device
ZF AUTOTROLL can be used in connection with the elec-
trical transmission actuation. Propeller speeds below the 1
engine idle speed are possible when using this trolling
device.

Separate installation instructions can be requested

from ZF Customer Service for fitting the electroni- 2
cally controlled trolling device ZF AUTOTROLL.
3

Fig. 25: Position of the transmission oil cooler in the

open sea water circuit (example)
1 Transmission oil cooler
2 Sea water pump
3 Control device
In an open cooling water circuit, sea water flows through
the transmission oil cooler as cooling medium. Design
pipework so that, in case of plant standstill, either the
feed or return line of the transmission oil cooler can drain.
Connect the respective line to the lower connection of
the transmission oil cooler.

4.1.7.2 Closed cooling water circuit

2 3

Fig. 26: Position of the transmission oil cooler in the

closed cooling water circuit (example)
1 Transmission oil cooler
2 Sea water pump
3 Control device
Here, the cooling water circuit for the engine and trans-
mission is separate from the sea water circuit.

58 EN 3100 758 101g - 2015-07

Initial installation and start-up

Heat transmission from the engine/transmission cooling Temperatures

circuit to the sea water runs via a separate heat ex- Maximum cooling water inlet temperature:
changer or via surface area coolers in the outer shell of See transmission installation drawing and Section 2.2
the ship. Normally, the heat transfer medium in the en- Technical data.
gine cooling circuit is a mixture of water and a corrosion
preventative. Corrosion in the cooling system is thus Flow rates
largely reduced. The purity of the cooling medium means
Maximum admissible cooling water flow rate:
the transmission oil cooler is hardly exposed to siltation
See transmission installation drawing and Section 2.2
or pitting corrosion.
Technical data.
4.1.8 Transmission cooling (cooler design) Minimum admissible cooling water flow rate:
See transmission installation drawing and Section 2.2
Technical data.
Water inlet
Water pressure
Maximum permissible water pressure at the cooling wa-
ter inlet: See transmission installation drawing and
Section 2.2 Technical data.
Water outlet Filtration
Oil outlet Oil inlet Suction filter on the water side required with mesh size:
See transmission installation drawing.

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).

Position of the transmission oil cooler in the cooling

water circuit
The correct transmission temperature is set by adjusting Fig. 28: Contamination (wood chips) caused by a filter
the cooling water flow rate. For this purpose, provide a screen where the mesh size is too large
replaceable gland, a valve or a similar device in the pipe- (example)
work. Therefore, locate the water circuit of the transmis-
sion oil cooler in the "bleed off" of the engine cooling The required flow rates will not be achieved when
water circuit [see Section 4.1.6 Trolling]. The closed cooling pipes are clogged. This may cause depos-
cooling circuit is preferable due to its clean cooling wa- its or fouling which then lead to pitting corrosion.
ter.

EN 3100 758 101g - 2015-07 59

Initial installation and start-up

4.1.8.2 Earthing Drainage of water for longer idle time

To avoid galvanic corrosion, it is important that there is Drain the water off with the sea water circuit open when
no electric potential difference on components transport- the system is to be switched off for a longer period of
ing sea water. This means the transmission and, there- time (for standstill time, see Chapter 8 Maintenance,
fore, the transmission oil cooler, as well as all other Section 8.2.2 Maintenance work before taking out of op-
components transporting sea water, must be connected eration/standstill).
to the earth bus to be electroconductive.
This is only required when the transmission oil
Material: Copper
cooler is not automatically drained when the cool-
Minimum diameter: 16 mm2
ing water pump is idle.
Before connecting, ensure the junctions of the earth strap
Provide a drain plug or drain valve in the pipe to allow
are free from paint or other electrically insulating materi-
draining the cooling circuit. Position the connection
als.
lower than the transmission oil cooler to ensure complete
drainage of the transmission oil cooler.
Free-standing transmission
4.1.9 Transmission cooling (pipework)

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.

4.1.8.3 Drainage of the transmission oil cooler 4.1.9.2 Flow velocity

Ideally, plan the cooling water circuit so that the trans- Minimum flow velocity: 1.5 m/s
mission oil cooler is automatically drained when the cool- Maximum flow velocity: 3.0 m/s
ing water pump is idle. Plan pipe diameters so that, at nominal speed, the mini-
mum flow velocity is reached and the maximum flow ve-
Bacteria in the standing water create decomposi- locity is not exceeded.
tion products which deposit in the transmission oil
cooler. This can lead to pitting corrosion when
transmission oil cooler surfaces have not been pas-
sivated yet. Surface passivation only builds up after
some time of operation in water rich in oxygen.

60 EN 3100 758 101g - 2015-07

Initial installation and start-up

Fig. 32: Required clearance for disassembling the pipe

bundle (example)

4.1.11 Oil filling and oil level control

ZF marine transmissions are not filled with oil when leav-

Fig. 31: Fouling: Organic deposits on the pipe bundle
ing the factory. A corresponding sign is attached to the
caused by a low flow velocity and a long
transmission for delivery.
standstill time (example)
Every transmission receives an initial filling and is con-
4.1.9.3 Materials for cooling water pipes nected to the oil circuit of the test rig for the functional
When choosing materials for water pipes, take into ac- test performed at the factory. After the successful test
count that different materials cannot be combined at ran- run, rinsing with conserving oil serves to conserve the
dom. Less precious metal will corrode when combined transmission interior.
with more precious metal. For suitable oil types, see "ZF lubricant list TE-ML 04 for
Material for pipes and stop valves in the sea water circuit: marine transmissions". A lubricant list valid at the time of
Copper alloy (e.g. CuNi10Fe1Mn). delivery is included with the transmission.

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.

EN 3100 758 101g - 2015-07 61

Initial installation and start-up

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).

62 EN 3100 758 101g - 2015-07

Initial installation and start-up

4.4 Operation monitoring Oil temperature (measuring point 12)

The minimum monitoring specified in Section 2.2 Techni- Use a thermometer to monitor the transmission oil tem-
cal data, 2.2.8 Monitoring values for ZF 2000/2150/ perature. Regulate the water flow rate through the trans-
2200/2300/W2300/W2400 series is required for assess- mission oil cooler so that the transmission oil
ing operational safety of the transmission and must be in- temperature is within the recommended normal range
stalled. In addition to the obligatory minimum monitoring, during normal operation. The maximum transmission oil
further display or warning devices can be connected to temperature must not be exceeded during continuous
the measuring points sealed with blind plugs. operation.

4.4.1 Minimum transmission monitoring 4.4.2 Additional transmission monitoring

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

EN 3100 758 101g - 2015-07 63

Initial installation and start-up

monitoring using a pressure switch, set the switch so

that the alarm is triggered for a lubricating oil pressure
below the alarm value according to Section 2.2.8 Moni-
toring values for ZF 2000/2150/2200/2300/W2300/
W2400 series.
Oil temperature (measuring point 11)
Measuring point 11 can be used for additional installation
of a temperature sensor for a remote thermometer or a
temperature switch for monitoring devices. Set the tem-
perature to the alarm value specified for the relevant
transmission version.
Oil temperature (measuring point 41)
Additional use of this measuring point is possible for ver-
sions with a trailing oil pump.
Measuring point 41 is not located in the oil sump. It may
only be used for monitoring the oil temperature when oil
circulation is available - with the engine running or pro-
peller shaft rotating with the trailing oil pump mounted.
Neutral switch
The Neutral switch checks whether the control piston in
the control unit is in "Neutral" shift position.

64 EN 3100 758 101g - 2015-07

Operation
Operation

5 Operation

5.1 Operating elements

Control units with mechanical and electrical transmission actuation are available. Electrical transmission actuation is
included as standard in the ZF 2000 series scope of delivery.
Actuation units must be constructed so that shift operations on the transmission are only possible when the engine is
idling. The safest way to achieve this is using a "single-lever control" where the engine throttle control and the trans-
mission actuation are coupled to each other. When using a "two-lever control", install a locking device in the transmis-
sion actuation unit which only allows shifting the transmission when the movement lever is in idle position.
The "single-lever control" must have an emergency shutoff option for transmission actuation to allow high engine
speeds for inspection or warm-up purposes without switching in the transmission.
The following transmission actuation variants are possible:

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)

Tab. 3: Electrical transmission actuation variants for the ZF 2000 series

Transmission See Section

5.1.4 Mechanical transmission actuation (for ZF 2000 series) on
ZF 2000 series
page 75

Tab. 4: Mechanical transmission actuation for the ZF 2000 series

EN 3100 758 101g - 2015-07 65

Operation

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

Risk of injury due to rotating parts.

Ensure the pilot valve is not in emergency actua-
tion prior to starting operation. Death or serious injury possible.
 Install propshaft brake or propshaft lock.
5.1.1.1 Electrical transmission actuation elements
 Shift position "Engine wise rotation“ The propeller shaft can still rotate even when the trans-
Electromagnet "a" pointing towards the output is mission clutch is open in "Neutral" shift position. Provide
responsible for output direction the same as input a propeller shaft brake or other shaft locking device when
direction. the propeller shaft must be idle.
 Shift position "Counter-engine wise rotation“
Electromagnet "b" opposite the output is responsible WARNING
for output direction against the input direction.
Risk of accident due to a non-functioning operating
element.
Actuation unit
Death or serious injury possible.
a
d  Adapt driving method when on open waters.
 Do not drive in tight and heavily-frequented waters.
f  Allow the ship to be towed.

The transmission switches to the "Neutral" shift position

b automatically when a power failure occurs. This can
make the ship unmanoeuvrable.

5.1.1.2 Mechanical emergency actuation with two

solenoid valves (for ZF 2000 series without NR)
Manual actuation of the transmission is possible (i.e.
emergency actuation) in case of actuation device mal-
functions.
Fig. 33: Electrical transmission actuation elements
(example)
WARNING
a - Electromagnet for "Engine wise rotation"
shift position Risk of accident due to an inadequate access to the
b - Electromagnet for "Counter-engine wise rotation" tool for emergency actuation.
shift position Death or serious injury possible.
 Ensure a free access.
d - Pilot valve for "Engine wise rotation" and
"Counter-engine wise rotation" shift positions
f - Control unit

66 EN 3100 758 101g - 2015-07

Operation

Unscrewed: Approx. flush with plane surface

WARNING (set screw protrudes approx.
0.2 to 0.3 mm)
Risk of accident due to a insufficient clearance to Screwed in: Screwed in approx. 6.0 to 6.2 mm
actuate mechanical emergency actuation. (dimension, plane surface-set screw)
Death or serious injury possible.
Neutral shift position
 Provide a clearance of at least 20 cm.
Electromagnet "a": Set screw unscrewed (approx. flush
with plane surface, set screw pro-
Mechanical emergency actuation of electromagnets "a" trudes approx. 0.2 to 0.3 mm)
("Engine wise rotation" shift position) or "b" ("Counter-en-
gine wise rotation" shift position) of the actuation unit is Electromagnet "b": Set screw unscrewed (approx. flush
performed manually using a set screw with the tool fitted with plane surface, set screw pro-
on the control unit (hexagon socket wrench, opening 3 trudes approx. 0.2 to 0.3 mm)
mm). The set screw is located on the front side of the
electromagnets.

a/188

Fig. 35: Pilot valve in "Neutral" shift position

Engine wise rotation shift position

Electromagnet "a": Set screw screwed in (approx. 6.0 to
b/189 6.2 mm from plane surface)
d Electromagnet "b": Set screw unscrewed (approx. flush
with plane surface, set screw pro-
g trudes approx. 0.2 to 0.3 mm)

Fig. 34: Mechanical emergency actuation of the actu-

ation unit with electromagnets "a" and "b"
(example)
a/188 Electromagnet "a": Position of set screw for
"Engine wise rotation" shift position 6.0 to 6.2 mm
(output direction same as input direction)
b/189 Electromagnet "b": Position of set screw for
"Counter-engine wise rotation" shift posi-
tion (output direction against input direc-
tion)
d Pilot valve for "Engine wise rotation" and Fig. 36: Pilot valve in "Engine wise rotation"
"Counter-engine wise rotation" shift posi- shift position
tions
g Tool for emergency actuation of electromag-
nets "a" ("Engine wise rotation" shift posi-
tion) and "b" ("Counter-engine wise rotation"
shift position)
The set screw on electromagnets "a" and "b" on both
sides of the pilot valve of the upper actuation unit has
two positions. An intermediate position is not admissible.
Resistance (i.e. stopper) can be noticed when the end
position is reached in both positions.

EN 3100 758 101g - 2015-07 67

Operation

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

Risk of burns due to contact with hot surfaces.

Slight or moderate injury possible.
6.0 to 6.2 mm  Wear protective gloves.

1. Set the engine speed adjusting device to idling

speed.

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.

The clutch set through the corresponding electromagnet

of the upper actuation unit is always closed when the en-
gine is running. The transmission actuated mechanically
cannot be switched or reversed to the "Neutral" shift po-
sition using the movement lever.

Prior to starting operation, ensure the tool for

mechanical emergency actuation is available on
the control unit or a key for hexagon socket screws
(Allen key, opening 3 mm) is available with the
on-board tools.

68 EN 3100 758 101g - 2015-07

Operation

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.

1. Set the engine speed adjusting device to idling

Actuation unit
speed.
a
d
2. Use the tool on the control unit to unscrew the set
screw of both electromagnets "a" and "b" to the stop
(approx. flush with plane surface, set screw pro- f
trudes approx. 0.2 to 0.3 mm).
3. Return the tool to the respective holder of the control
unit. b
4. Ensure electrical transmission actuation is switched
on (e.g. by switching on the transmission control or
by connecting the plugs to the electromagnets).
5. Check whether all shift positions can be selected
with the movement lever.

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

Disable mechanical emergency actuation to allow control f - Control unit

using electrical transmission actuation. For this purpose, Activating these electromagnets allows selecting the shift
unscrew the set screws on both electromagnets "a" and position as follows:
"b" of the actuation unit until flush with the plane surface
(see Section 5.1.2.2). Neutral: Voltage is only applied
to the output-side elec-
Ensure the pilot valve is not in emergency actua- tromagnet "a".
tion prior to starting operation. Counter-engine wise rotation: Voltage is only applied
to electromagnet "b"
(opposite "a").

DANGER

Risk of injury due to rotating parts.

Death or serious injury possible.
 Install propshaft brake or propshaft lock.

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.

EN 3100 758 101g - 2015-07 69

Operation

WARNING

Risk of accident due to a non-functioning operating a

element.
Death or serious injury possible.
 Adapt driving method when on open waters.
 Do not drive in tight and heavily-frequented waters.
 Allow the ship to be towed.
b/189
The current shift position of the transmission is main- d
tained following a power failure.
g
5.1.2.2 Mechanical emergency actuation
(for ZF 2000 NR (CEW) series)
Fig. 39: Mechanical emergency actuation of the actu-
Manual actuation of the transmission is possible (i.e. ation unit with electromagnets "a" and "b"
emergency actuation) in case of actuation device mal- (example)
functions.
a Electromagnet "a“: Position of set screw for
"Neutral" shift position
WARNING
b/189 Electromagnet "b": Position of set screw for
Risk of accident due to an inadequate access to the "Counter-engine wise rotation" shift posi-
tion (output direction against input direc-
tool for emergency actuation.
tion)
Death or serious injury possible.
 Ensure a free access. d Pilot valve for "Neutral" and "Counter-engine
wise rotation" shift positions

WARNING g Tool for emergency actuation of electromag-

nets "a" ("Neutral" shift position) and "b"
Risk of accident due to a insufficient clearance to ("Counter-engine wise rotation" shift posi-
actuate mechanical emergency actuation. tion)
Death or serious injury possible.
The set screw on electromagnets "a" and "b" on both
 Provide a clearance of at least 20 cm. sides of the pilot valve of the upper actuation unit has
two positions. An intermediate position is not admissible.
Mechanical emergency actuation of electromagnets "a" Resistance (i.e. stopper) can be noticed when the end
("Neutral" shift position) or "b" ("Counter-engine wise ro- position is reached in both positions.
tation" shift position) of the actuation unit is performed
Unscrewed: Approx. flush with plane surface
manually using a set screw with the tool fitted on the
(set screw protrudes approx.
control unit (hexagon socket wrench, opening 3 mm).
0.2 to 0.3 mm)
The set screw is located on the front side of the electro-
Screwed in: Screwed in approx. 6.0 to 6.2 mm
magnets.
(dimension, plane surface-set screw)

70 EN 3100 758 101g - 2015-07

Operation

Neutral shift position 5.1.2.3 Operation using mechanical emergency

Electromagnet "a": Set screw screwed in (approx. 6.0 to actuation
6.2 mm from plane surface)
Electromagnet "b": Set screw unscrewed (approx. flush WARNING
with plane surface, set screw pro-
trudes approx. 0.2 to 0.3 mm) Risk of accident due to a non-functioning operating
element.
6.0 to 6.2 mm
Death or serious injury possible.
 Adapt driving method when on open waters.
 Do not drive in tight and heavily-frequented waters.
 Allow the ship to be towed.

The clutch set through electromagnet "b" of the actuation

Fig. 40: Pilot valve in "Neutral" shift position unit is always closed when the engine is running. The
transmission actuated mechanically cannot be switched
Counter-engine wise rotation shift position or reversed to the "Neutral" shift position using the move-
Electromagnet "a": Set screw unscrewed (approx. flush ment lever.
with plane surface, set screw pro-
trudes approx. 0.2 to 0.3 mm) Prior to starting operation, ensure the tool for
Electromagnet "b": Set screw screwed in (approx. 6.0 to mechanical emergency actuation is available on
6.2 mm from plane surface) the control unit or a key for hexagon socket screws
(Allen key, opening 3 mm) is available with the
on-board tools.

Switching on the mechanical emergency actuation

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.

1. Set the engine speed adjusting device to idling

speed.
2. Use the tool on the control unit to screw in the elec-
tromagnet set screw for the corresponding shift posi-
tion (set screw on electromagnet "a" for "Neutral"
shift position, set screw on electromagnet "b" for
"Counter-engine wise rotation" shift position) to the
stop (approx. 6.0 to 6.2 mm).
3. Return the tool to the respective holder of the control
unit.
4. Check for correct direction.

EN 3100 758 101g - 2015-07 71

Operation

Switching off the mechanical emergency actuation

Actuation unit
CAUTION a
d
Risk of burns due to contact with hot surfaces.
f
Slight or moderate injury possible.
 Wear protective gloves.

1. Set the engine speed adjusting device to idling b

speed.
2. Use the tool on the control unit to unscrew the set
screw of both electromagnets "a" and "b" to the stop
(approx. flush with plane surface, set screw pro-
trudes approx. 0.2 to 0.3 mm).
3. Return the tool to the respective holder of the control
unit. Fig. 42: Electrical transmission actuation elements
(example)
4. Ensure electrical transmission actuation is switched
on (e.g. by switching on the transmission control or a - Electromagnet for "Engine wise rotation"
by connecting the plugs to the electromagnets). shift position
5. Check whether all shift positions can be selected b - Electromagnet for "Neutral" shift position
with the movement lever.
d - Pilot valve for "Neutral" and "Engine wise rotation"
shift positions
5.1.3 Electrical transmission actuation
(for ZF 2000 NR (EW) series) f - Control unit
Activating these electromagnets allows selecting the shift
With this electrical transmission actuation, the control
position as follows:
piston is moved axially in the control unit using oil pres-
sure through one electrical actuation unit mounted on the Engine wise rotation: Voltage is only applied
control unit. The actuation unit comprises electromag- to the output-side elec-
nets "a" ("Engine wise rotation" shift position) and "b" tromagnet "a".
("Neutral" shift position) as well as a pilot valve.
Neutral: 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 5.1.3.2). DANGER

Risk of injury due to rotating parts.

Ensure the pilot valve is not in emergency actua-
tion prior to starting operation. Death or serious injury possible.
 Install propshaft brake or propshaft lock.
5.1.3.1 Electrical transmission actuation elements
 Shift position "Engine wise rotation“ The propeller shaft can still rotate even when the trans-
Electromagnet "a" pointing towards the output is mission clutch is open in "Neutral" shift position. Provide
responsible for output direction the same as input a propeller shaft brake or other shaft locking device when
direction. the propeller shaft must be idle.
 "Neutral" shift position
Electromagnet "b" opposite the output is responsible
for the "Neutral" shift position.

72 EN 3100 758 101g - 2015-07

Operation

I
WARNING

Risk of accident due to a non-functioning operating a/188

element.
Death or serious injury possible.
 Adapt driving method when on open waters.
 Do not drive in tight and heavily-frequented waters.
 Allow the ship to be towed.
b
The current shift position of the transmission is main- d
tained following a power failure.
g
5.1.3.2 Mechanical emergency actuation
(for ZF 2000 NR (EW) series)
Fig. 43: Mechanical emergency actuation of the actu-
Manual actuation of the transmission is possible (i.e. ation unit with electromagnets "a" and "b"
emergency actuation) in case of actuation device mal- (example)
functions.
a/188 Electromagnet "a": Position of set screw for
"Engine wise rotation" shift position (output
WARNING direction same as input direction)

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

Fig. 44: Pilot valve in "Neutral" shift position

EN 3100 758 101g - 2015-07 73

Operation

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

Risk of burns due to contact with hot surfaces.

Slight or moderate injury possible.
6.0 to 6.2 mm  Wear protective gloves.

1. Set the engine speed adjusting device to idling

speed.
2. Use the tool on the control unit to screw in the elec-
tromagnet set screw for the corresponding shift posi-
Fig. 45: Pilot valve in "Engine wise rotation" tion (set screw on electromagnet "a" for "Engine wise
shift position rotation" shift position, set screw on electromagnet
"b" for "Neutral" shift position) to the stop (approx.
5.1.3.3 Operation using mechanical emergency 6.0 to 6.2 mm).
actuation 3. Return the tool to the respective holder of the control
unit.
WARNING 4. Check for correct direction.
Risk of accident due to a non-functioning operating
Switching off the mechanical emergency actuation
element.
Death or serious injury possible.
CAUTION
 Adapt driving method when on open waters.
 Do not drive in tight and heavily-frequented waters. Risk of burns due to contact with hot surfaces.
 Allow the ship to be towed. Slight or moderate injury possible.
 Wear protective gloves.
The clutch set through electromagnet "a" of the actuation
unit is always closed when the engine is running. The 1. Set the engine speed adjusting device to idling
transmission actuated mechanically cannot be switched speed.
or reversed to the "Neutral" shift position using the move-
ment lever. 2. Use the tool on the control unit to unscrew the set
screw of both electromagnets "a" and "b" to the stop
Prior to starting operation, ensure the tool for (approx. flush with plane surface, set screw pro-
mechanical emergency actuation is available on trudes approx. 0.2 to 0.3 mm).
the control unit or a key for hexagon socket screws 3. Return the tool to the respective holder of the control
(Allen key, opening 3 mm) is available with the unit.
on-board tools.
4. Ensure electrical transmission actuation is switched
on (e.g. by switching on the transmission control or
by connecting the plugs to the electromagnets).
5. Check whether all shift positions can be selected
with the movement lever.

74 EN 3100 758 101g - 2015-07

Operation

5.1.4 Mechanical transmission actuation

(for ZF 2000 series)

With mechanical transmission actuation, the control pis-

ton is moved axially through oil pressure via a mechani-
cally operated pilot valve.

5.1.4.1 Mechanical transmission actuation elements

Fig. 46: Mechanical transmission actuation elements

(example)
d - Pilot valve for "Engine wise rotation" and
"Counter-engine wise rotation" shift positions
f - Control unit
g - Shift lever
The pilot valve is mounted on the top of the control unit.
The pilot valve has a lever for actuation. The shift position
is selected by moving the shift lever. The shift lever is ac-
tuated by a push/pull cable. The shift lever can be moved
40° on its own rotation axis.
The pivoting range must be limited by stops provided by
the customer. The central position between these stops
corresponds to the "Neutral" shift position. Each shift po-
sition has an internal latching position.
The following shift positions are possible (by looking onto
the shift lever):
Neutral: The shift lever is in the
latched central position.
Engine wise rotation: The shift lever is rotated
anticlockwise by approx.
20°.
Counter-engine wise rotation: The shift lever is rotated
clockwise by approx.
20°.

EN 3100 758 101g - 2015-07 75

Operation

The actuation force is approx. 25 N with a distance of

DANGER 100 mm to the rotation axis of the shift lever. To ensure
reliable shifts, check shift movements in the transmission
Risk of injury due to rotating parts. at regular intervals and after any repair or maintenance
Death or serious injury possible. work and adjust if necessary.
 Install propshaft brake or propshaft lock.
It is very difficult to maintain the specified shift
position by mechanical means when the distance
The propeller shaft can still rotate even when the trans- between the selector unit and shift lever is too
mission clutch is open in "Neutral" shift position. Provide large. ZF Friedrichshafen AG recommends using
a propeller shaft brake or other shaft locking device when an electrical transmission actuation in such cases.
the propeller shaft must be idle.

A
Angles / travels of shift lever

Rotation axis of shift lever

Actuation force F = approx. 25 N with 100 mm radius; admissible force Fmax = 75 N

Fig. 47: Shift angles of mechanical transmission actuation (example)

103 - Latching position for shift position
"Counter-engine wise rotation"
104 - Latching position for shift position
"Engine wise rotation"
121 - Shift lever stop (not supplied by ZF)
122 - Undefined shift position
(pass through this area quickly)
124 - Latching position for shift position "Neutral"

76 EN 3100 758 101g - 2015-07

Operation

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):

5.1.4.3 Operation using mechanical emergency

actuation

WARNING

Risk of accident due to a non-functioning operating

element.
g Death or serious injury possible.
 Adapt driving method when on open waters.
 Do not drive in tight and heavily-frequented waters.
 Allow the ship to be towed.
Fig. 48: Mechanical emergency actuation (example)
g - Shift lever for mechanical emergency actuation of The clutch set through the mechanical emergency actua-
the transmission tion is always closed when the engine is running. The
The shift lever for mechanical emergency actuation can transmission actuated mechanically cannot be switched
be operated manually when the mechanical transmission or reversed to the "Neutral" shift position using the move-
actuation is disconnected. ment lever.

Switching on the mechanical emergency actuation

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.

Slight or moderate injury possible.
 Wear protective gloves.

1. Set the engine speed adjusting device to idling

speed.
2 3 1 2. Move and latch the shift lever of the control unit
manually to shift position "Neutral". Remain in this
Fig. 49: Positions of the shift lever of mechanical position for approx. 0.5 s.
emergency actuation (example)

EN 3100 758 101g - 2015-07 77

Operation

Switching off the mechanical emergency actuation

WARNUNG
CAUTION
Risk of accident due to incorrect direction of motion.
Death or serious injury possible. Risk of burns due to contact with hot surfaces.
 Ensure correct direction of motion. Slight or moderate injury possible.
 Wear protective gloves.
3. Move the shift lever of the control unit manually to
the stop in the desired shift position. 1. Set the engine speed adjusting device to idling
speed.
Should vibrations influence operation, take appro-
priate measures to secure the shift lever against 2. Move and latch the shift lever of the control unit
jumping out of the current shift position and slip- manually to shift position "Neutral".
ping to the unsafe shift range. 3. Move the movement lever to shift position "Neutral".
4. Check for correct direction. 4. Hook the push/pull cable or the linkage of the
mechanical remote control on the shift lever of the
Changing from "Counter-engine wise rotation" shift control unit.
position to "Engine wise rotation" shift position
5. Check whether all shift positions can be selected
with the movement lever.
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.

5.2.1 Shifting Neutral > Ahead and Neutral > Astern

CAUTION

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.

78 EN 3100 758 101g - 2015-07

Operation

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.

EN 3100 758 101g - 2015-07 79

Operation

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.

The housing openings are sealed with screw plugs.

WARNING
Emergency control - Emergency control - Risk of accident due to a non-functioning operating
Engine wise rotation Counter-engine wise element.
(44) rotation (34)
Death or serious injury possible.
 Adapt driving method when on open waters.
 Do not drive in tight and heavily-frequented waters.
 Allow the ship to be towed.

When operated using the emergency control, the trans-

mission cannot be switched to "Neutral" or reversed us-
ing the movement lever.

5.4.1 Activating 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.

80 EN 3100 758 101g - 2015-07

Operation

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.

5.4.2 Deactivating emergency control

1. Turn off the engine and ensure the engine cannot be

restarted while switching off the emergency control.
2. Determine the switched clutch.
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

required position should be reached after maxi-
mum 120° rotary displacement.

EN 3100 758 101g - 2015-07 81

Operation

5.5 Exchanging the filter cartridge during Contanimated filter cartridge

operation
The filter cartridge of the oil filter can be exchanged dur- CAUTION
ing operation.
Risk of burns due to contact with hot oil.
The changeover filter is only available for classified Slight or moderate injury possible.
transmissions.  Wear protective googles
 Wear protective gloves.
Requierements:
 The filter cartridge is filled with a clean oil.
 Only use a lubricant from the currently valid ZF List of
3. Remove the filter cartridge with an oil filter remover
Lubricants. and collect the drained oil in a suitable container.
New filter cartridge
DANGER
4. Lubricate the O-ring of the new filter cartridge.
Risk of crushing due to rotating parts. 5. Screw the new filter cartridge onto the filter head
Death or serious injury possible. until contact is noticeable.
 Install protection devices. 6. Tighten the new filter cartridge by hand.
 Wear tight-fitting clothing.
7. Check the oil filter for leak-tightness.
 Wear a hair net.
8. Screw the vent screw in cautiously to the stop and
1. Move the change lever anticlockwise to the stop in tighten with a tightening torque of 10 Nm.
the 3 o'clock position.

Fig. 53: Vent screw on the oil filter (example)

9. Move the change lever very slowly clockwise to the
stop in the 6 o'clock position.

Fig. 51: Change lever in the 3 o'clock position

(example)
2. Unscrew the vent screw cautiously two turns to
allow the pressure to escape.

Fig. 54: Change lever in the 6 o'clock position

(example)
Fig. 52: Vent screw on the oil filter (example)

82 EN 3100 758 101g - 2015-07

Special equipment / special versions
Special equipment / special versions

6 Special equipment / special versions 6.1.1 Functional description

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.

 Towing smaller boats 6.1.2 Electrical trolling

 Sport fishing at optimum trolling speed
In trolling operation, the clutch oil pressure in the trans-
The following trolling devices are available for ZF 2000 mission is adjusted using an electrical control signal. The
series transmissions: required actuation device is not part of the transmission.
 Electrical trolling
Refer to the Operating Instructions of the actuation
 ZF AUTOTROLL manufacturer on operating the trolling actuation.
The trolling device can be used for ahead or astern travel
without time limit providing the admissible engine speed
values and lubricating oil temperature are not exceeded.

EN 3100 758 101g - 2015-07 83

Special equipment / special versions

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

6.2 Trailing oil pump (trailing pump)

Regular trailing operation is admissible only with a trail-
ing oil pump. Retrofitting such a trailing pump is possible
on all parallel, V, U, and A transmission versions.
Three transmission ratios are available for the trailing
Fig. 55: Control unit with trolling valve for pump according to the engine speed in continuous oper-
ZF AUTOTROLL (example) ation and the transmission ratio.
The ship can be reversed even during operation when us- This oil pump is mounted on the transmission housing on
ing ZF AUTOTROLL. In this case, the reversing aid inte- the transmission side opposite the input (parallel and A)
grated in the electronic system significantly improves the or on the input side (V and U versions). It is driven via a
reaction of the ship. spur gear by the transmission output shaft. Pump feed to
the oil circuit is always in the same direction irrespective
of the input direction. This oil pump ensures lubricating
oil supply to the transmission when the engine is off with
the output shaft rotating. This allows unlimited operation
with the engine off and the propeller rotating.

84 EN 3100 758 101g - 2015-07

Special equipment / special versions

Switch transmission actuation to the "Neutral" shift

position for trailing operation with the engine off
and the propeller shaft rotating!
Oil pressures do not require monitoring while the engine
is off. Monitor the transmission oil temperature accord-
ing to the specifications in Section 2.2.8 Monitoring val-
ues for ZF 2000/2150/2200/2300/W2300/W2400 series!
An additional measuring point (41) for the oil tempera-
ture is also available
(see Section 4.4 Operation monitoring).
Perform Maintenance Jobs 101 and 102 daily during op-
eration with the engine off and propeller rotating
(see Chapter 8 Maintenance).

6.3 PTO=Power Take-Off

The power take-offs are used to drive pumps, hydraulic
systems for water jet applications or even generators. All
ZF 2000 series transmissions are available as special ver-
sions with power take-off (PTO). In general, power
take-offs cannot be switched but are permanently driven
by the transmission. This is practical for most pump
transmissions because the hydraulic system must be
ready to operate immediately after engine start-up.
The dimensions of the power take-offs are designed for
various output performances and the mounting dimen-
sions are standardized according to SAE standard (A, B,
B-B, C or C-C).
The power take-off is located on the input shaft or imple-
mented in a separate housing as top PTO according to
customer requirements and the maximum torque to be
picked up.

PTO on the input shaft

Basic transmission versions are fitted with a connection
facility for a power take-off on the input shaft. This makes
retrofitting with a PTO possible at any time.

The power take-off cannot be mounted to the

input shaft on V and U transmission versions!

Top PTO with separate housing

An additional housing is required when implementing the
power take-off via the constant gearing of the input shaft.
This housing is mounted on the top of the transmission
housing. The name Top PTO is derived from the top loca-
tion.

Top PTOs are fitted at the factory and cannot be

refitted!

EN 3100 758 101g - 2015-07 85

Special equipment / special versions

86 EN 3100 758 101g - 2015-07

Troubleshooting
Troubleshooting

7 Troubleshooting

7.1 Troubleshooting information

Malfunctions in the power plant frequently suggest a transmission defect even though, in many cases, the malfunc-
tions are caused by external influences on the transmission.
The minimum monitoring specified in Section 2.2 Technical data, 2.2.8 Monitoring values for ZF 2000/2150/2200/
2300/W2300/W2400 series is required for assessing operational safety of the transmission and must be installed.
Every basic transmission version has the measuring points for minimum monitoring.

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.

EN 3100 758 101g - 2015-07 87

Troubleshooting

7.2 Table of possible malfunctions

7.2.1 Table of possible malfunctions (overall transmission)

Fault Possible cause Corrective measures

Transmission oil temperature Water flow rate through cooler too low Increase water flow rate
too high (measuring points 11*,
Oil cooler clogged Clean oil cooler
12*, and 41*)
Transmission oil temperature
Water flow rate through cooler too high Reduce water flow rate
too low
When using a gap filter: Oil Oil cooler contaminated Clean oil cooler oil-side
pressure before oil cooler and
filter too high (measuring point Oil filter contaminated Clean oil filter
5*)
In operation:
See Section 5.5 Exchanging the filter
When using a changeover filter: Filter cartridge contaminated cartridge during operation
Filter difference pressure too Not in operation:
high (measuring point 127*) See Maintenance Job 142
Warning interruption for oil temperatures <
Install warning interruption
35 °C is not installed
No oil filled in transmission Fill with oil
No operating oil pressure Incorrect transmission input direction Use special transmission version
(measuring points 2* and 21*) Display device defective Clear fault
Oil pump defective Replace oil pump
Use specified oil type (see ZF lubricant
Viscosity of oil used too low
list TE-ML 04)
Operating oil pressure too low Oil pump defective Replace oil pump
(measuring points 2* and 21*) Pressure limiting valve leaking Clear fault
Timer for pressure modulation not working See fault: Clutch slips at high engine
correctly speed
If the fault cannot be cleared, the lubricating oil supply of the transmission is also at risk.
Continue operation only at reduced input speed until next repair facility.
Operating oil pressure too high
Use specified oil type (see ZF lubricant
(measuring points Viscosity of oil used too high
list TE-ML 04)
2* and 21*)
Adjust shift angles [see Section 5.1.4
For mechanical transmission actuation:
Mechanical transmission actuation (for
Shift angles not maintained
ZF 2000 series)]
For electrical transmission actuation:
No power transmission from Fault in electric system
transmission input to transmis- Check option: Clear fault in electric system
sion output, clutch does not Normal power transmission when opera-
transfer torque ting the transmission using mechanical
emergency actuation
Possible causes and corrective measu-
No operating oil pressure res, see fault: No operating oil pressure
or operating oil pressure too low
* See monitoring values (Section 2.2.8) and transmission views (Section 2.1.4)
Tab. 5: Table of possible malfunctions (overall transmission)

88 EN 3100 758 101g - 2015-07

Troubleshooting

Fault Possible cause Corrective measures

Adjust shift angles [see Section 5.1.4
For mechanical transmission actuation:
Mechanical transmission actuation (for
Shift angles not maintained
ZF 2000 series)]
For electrical transmission actuation:
Power transmission from trans- Fault in electric system
mission input to output cannot Check option:
Clear fault in electric system
be interrupted; Normal power transmission when opera-
clutch does not open ting the transmission using mechanical
emergency actuation
Possible causes and corrective measu-
No operating oil pressure res, see fault: No operating oil pressure
or operating oil pressure too low
Corrective measure as for fault: "Ope-
rating oil pressure too low (measuring
points 2* and 21*)". If the fault cannot
be cleared on board, operation may be
Clutch slips at high engine Operating oil pressure too low (measuring continued at reduced speed - at which
speed points 2* and 21*) the clutch does not slip - until the next
repair facility is reached.
Avoid reversing and perform only with
propeller almost idle and at the lowest
possible engine idle speed.
Oil level decreases strongly Leaks at housing joint faces or oil pipes, oil
Clear mechanical fault
(determined using the measu- leaks at shaft seals
ring marks of the oil dipstick).
Oil loss through oil cooler in cooling water Clear fault, replace oil cooler, if requi-
Note: Maintenance Job 101 "Oil
system red
level control"
Oil level increases (see Mainte-
Water enters oil circuit from cooling sys-
nance Job 101 "Oil level con- Clear mechanical fault
tem
trol")
Transmission too loud in certain Torsional vibration resonance of power Avoid critical speed ranges. Use more
speed ranges plant in engine speed range suitable flexible clutches
Transmission too loud in engine Torsional vibration resonance of power
Increase engine idle speed
idle speed range plant in engine idle speed range
Engine idle speed too low Increase engine idle speed
Engine stalls when reversing
Reversing manoeuvre performed too
quickly from "ahead" to "astern" Reverse as recommended in 5.2.3
quickly or at too high ship speed

* See monitoring values (Section 2.2.8) and transmission views (Section 2.1.4)
Tab. 6: Table of possible malfunctions (overall transmission, continued)

EN 3100 758 101g - 2015-07 89

Troubleshooting

7.2.2 Table of possible malfunctions (transmission oil cooler)

Fault Possible cause Corrective measures

Drain and disassemble transmission oil cooler
Disassemble receiver/cover
Oil escapes into the Pipes in transmission Secure pipe bundle with screw and washers
Oil level too low
water oil cooler are leaking Apply 5 bar compressed air on the jacket
Locate defective pipe on pipe plates
Seal defective pipe
Drain transmission oil cooler on the water side
and on the oil side and disassemble it
Visible oil leakage O-ring on pipe plate/
Disassemble receiver/cover
at the cover housing defective
Oil escapes from Pull the pipe bundle
transmission oil cooler Replace all O-rings
O-ring on transmis- Drain transmission oil cooler on the water side
Visible oil leak on
sion flange connec- and on the oil side and disassemble it
transmission
tion defective Replace all O-rings
Drain transmission oil cooler on the water side
Water leak into the
O-ring on pipe plate/ and on the oil side and disassemble it
oil
water chamber defec- Disassemble receiver/cover
Oil level too high,
tive Secure pipe bundle with screw and washers
milky appearance
Replace all O-rings
Water escapes from
Drain transmission oil cooler on the water side
transmission oil cooler
Visible water leak O-ring on pipe plate/ Disassemble receiver/cover
at the cover cover defective Secure the pipe bundle with screw and washers
Replace all O-rings
Visible water leak Sealing pipe connec-
Replace seal on pipe socket
at pipe connection tion defective
Tab. 7: Table of possible malfunctions (transmission oil cooler)

90 EN 3100 758 101g - 2015-07

Troubleshooting

Fault Possible cause Corrective measures

Water inlet temperature too high
Cooling water inlet
Observe nominal values in the transmission instal-
temperature too high
Cooling water out- lation drawing
flow temperature Delivery rate of cooling water pump too low
too high Water flow rate too Observe nominal values in the transmission instal-
Temperature mea- low lation drawing
surement using a Increase delivery rate
click-on sensor, Foreign material in the pipe line or transmission
determine whe- oil cooler causing clogging
ther water inlet Clean pipe line/pipe bundle
and water outlet Water flow in trans-
have a tempera- Water side more contaminated than usual (e.g.
mission oil cooler
due to thick deposits)
Transmission oil tem- ture difference of impaired
approx. 2°C to 5°C Clean the pipe bundle
perature too high
More than 10% of the pipes are leaking
Replace transmission oil cooler
Oil side more contaminated than usual (e.g. due
to thick deposits)
Clean the baffle plates and the clearance between
the pipes
Cooling water out-
Heat transfer from oil
let temperature Pipe bundle installed correctly?
to water impaired
not too high If this is not the case, assemble the pipe bundle
correctly
All pressure chambers vented?
If this is not the case, vent all pressure chambers
Tab. 8: Table of possible malfunctions (transmission oil cooler, continued)

EN 3100 758 101g - 2015-07 91

Troubleshooting

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.

7.3.2 Leaking O-rings

An O-ring of the pipe plate is defective when leakage is

discovered between the receiver or cover and the hous-
ing. The type of the escaping medium shows at which
groove of the pipe plate the defect is located. For defects
on the water side, proceed as described in Chapter 8
Maintenance, Section Disassembling the transmission
oil cooler (without extracting the pipe bundle). For de-
fects on the oil side, proceed as described in Chapter 8
Maintenance, Section Disassembling the transmission
oil cooler (with extraction of the pipe bundle).

In this case, the pipe bundle need not be removed

completely from the housing.

Spare O-rings are available from the Customer

Service of ZF Friedrichshafen AG. Fit the O-ring as
described in Chapter 8 Maintenance, Section
Assembling the transmission oil cooler (after
extracting the pipe bundle).

92 EN 3100 758 101g - 2015-07

Maintenance
Maintenance

8 Maintenance 8.1.3 Application group M

8.1 Application area  Engine data for transmission classification:

Maximum performance for intermittent operation
ZF Marine ship transmissions are classified in four appli-
cation groups according to their type of operation:  Operation type: Intermittent operation with varying
engine speeds
 P = Pleasure
 Operating hours per year: Up to approx. 4,000 hours
 L = Light
 Preferred hull type: Semi-planing hull, planing hull
 M = Medium
 Typical application area: Workboats, charter boats
 C = Continuous
 Typical application examples: Crew, supply, fishing,
The classification is based on experience from the various coastguard, passenger ships, ferries, yachts, etc.
application areas on how typical ship types are operated.
The application group for which the transmission is de- 8.1.4 Application group C
signed is indicated on the type plate. The admissible per-
formance/speed factors in the individual application  Engine data for transmission classification:
groups are specified. Maximum continuous performance
 Operation type: Continuous operation with maximum
8.1.1 Application group P engine performance

 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

8.1.2 Application group L

 Engine data for transmission classification:

Maximum performance for intermittent operation
 Operation type: Intermittent operation with widely var-
ying engine speeds
 Operating hours per year: Up to approx. 2,500 hours
 Preferred hull type: Semi-planing hull, planing hull
 Typical application area: Navy, official, and equivalent
ships, private charter boats
 Typical application examples: Fast ships, yachts,
patrol, police, customs, coastguard, pilot, fire, life,
angler boats, etc.

EN 3100 758 101g - 2015-07 93

Maintenance

8.2 Maintenance schedule

8.2.1 Maintenance schedule concept

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.

After respective operational

Maintenance level Application groups Limit value
hours

A1 All On every day of operation 3 months (see also K1; K2)

A2 All 500 h 6 months

A3.1 All --- Yearly

A3 All 2,000 h 2 years

C and M --- 5 years

A4
L and P --- 8 years

During every major reconditio- Operating state of the trans-

A5 All
ning of the engine mission

Tab. 9: Periodical maintenance work

Maintenance level Operational hours Limit value

Z1 50 to 100 h 12 months

Tab. 10: Additional nonrecurring maintenance work for a transmission repaired or overhauled outside the plant

Maintenance level Operational hours Limit value

Z2 --- 2 months

Tab. 11: Additional nonrecurring maintenance work for a new transmission

94 EN 3100 758 101g - 2015-07

Maintenance

8.2.2 Maintenance work before taking out of operation/standstill

8.2.2.1 For closed cooling circuit

The cooler can remain filled when the cooling circuit is closed.

8.2.2.2 For open cooling circuit

The transmission oil cooler can remain filled when the plant standstill will only last for a short period of time
(< 2 weeks).
Drain the transmission oil cooler on the water side when the system is to be taken out of operation for a longer period
of time.

This is only necessary when the transmission oil cooler is not automatically drained when the cooling water
pump is idle.

Cooling system Standstill time Measures

Drain transmission oil cooler on the water side.

Open system/sea water > 2 weeks Additionally rinse with clean water.
If possible, dry pipe bundle from inside with compressed air.

Tab. 12: Standstill time / draining cooling water

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!

EN 3100 758 101g - 2015-07 95

96
Sealant
Maintenance

Manufacturer Description Use Instructions for use Supply source

- 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

Varnishes and paints

Manufacturer Description Use Instructions for use Supply source

Helling GmbH, Spökerdamm 2,

For representing tooth flank
Dykem Red 24536 Heidgraben (near Ham-
surface appearances for
burg), Germany
Dykem Red DX-296/8 oz transmissions with accep-
tance specification by Classi- Tel. +49 (04122) 922-0
(Made in Germany)
fication Societies
Telefax +49 (04122) 922-201

Tab. 13: Recommended consumables and service fluids

EN 3100 758 101g - 2015-07

Maintenance

8.3 Corrosion protection and conservation

Series transmissions supplied by ZF have corrosion protection according to Level I of "Guidelines for marine transmis-
sions on anticorrosion protection, packing type, storage conditions and storage periods".
Specify conservation measures for long-term storage in the transmission order.
Measures according to the guideline for conserving marine transmissions are binding when transmissions are stored
at ZF branches and ZF distributors. Conservation measures described in the guideline must be performed by person-
nel authorized by ZF otherwise the warranty is void!
Corrosion protection measures required for longer shutdown periods for a transmission installed on a ship are very de-
pendent on temperature variations, air humidity, and salt content of the air in the engine room. Therefore, the recom-
mended measures and time specifications may only be regarded as rough guidelines. In case of doubt, we
recommend performing the corrosion protection measures on the transmission analog to those for the engine.
Shutdown periods up to 3 months do not normally require corrosion protection measures.
We recommend performing corrosion protection measure K1 every 10 to 20 days when the shutdown period is less
than 6 months. An oil change according to maintenance level Z1 may be necessary prior to re-commissioning de-
pending on the condition of the lubricating oil in the transmission.
K2 is a conservation measure and should be performed when the operation period is finished before shutdown peri-
ods longer than 6 months. K2 can also be performed instead of K1 for shorter shutdown periods.
K3 is a long-term conservation measure and allows taking the installed transmission out of operation for a maximum
of 36 months. Conservation can also be performed according to K2 instead of K3. In this case, conservation has to be
repeated every 9 months.

Maintenance level Performance Shutdown period Information (Annex)

K1 Every 10 to 20 days Up to 6 months

Guidelines for marine transmis-
At the end of the operating sions: Corrosion protection, pack-
K2 9 months
period ing types, storage conditions and
At the end of the operating storage periods
K3 Max. 36 months
period

Tab. 14: Corrosion protection measures for longer shutdown periods

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".

EN 3100 758 101g - 2015-07 97

Maintenance

Commissioning after K2 conservation

Start the engine and run for approx. 5 minutes to mix any condensed water possibly accumulated in the transmission
with the anti-corrosive oil. Drain the anti-corrosive oil and fill the transmission with the specified oil type (see "Mainte-
nance job No. 141").

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").

98 EN 3100 758 101g - 2015-07

Maintenance

8.4 Maintenance work plan

Maintenance level Maintenance work Required tools

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

Tab. 15: Maintenance levels and maintenance work

* = For implementation, see Service Manual T1, T2 = Parts kits, see Spare Parts list

NB = Spare parts as necessary W1 = Tool kit, see Operating Instructions

W2 = Tool kit, see Service Manual

EN 3100 758 101g - 2015-07 99

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8.5 Tool kit

8.5.1 Tool kit W1 for maintenance

Tool kit W1 comprises standard commercial tools.

Standard commercial implies, for example:

General hand tools

Open-end wrenches up to width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 mm
Flat ring wrenches up to width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 mm
Offset ring wrenches up to width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 mm
Set of sockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 mm
Set of sockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32 mm
Set of sockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-50 mm
Set of sockets for hexagon socket screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 mm
Tongs (flat) for locking rings (internal securing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 1-4 (No.)
Tongs (flat) for locking rings (external securing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A 1-4 (no.)
Screwdriver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . up to 13 mm
Hammers (metal + plastic), punches

Measuring and testing tools

Torque wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-350 Nm
Calliper gauge, depth gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . measurement range up to 300 mm
Thickness gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . measurement range 0.05-1.0 mm

Others
Oil filter remover

Tools for mechanical emergency actuation of transmission

Key for hexagon socket screws (Allen key), . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 mm

Tools for emergency control of transmission

Key for hexagon socket screws (ZF Part No. 1X56.186.369), . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm

Tools for cleaning oil cooler

Nylon brush (ZF Part No. AA00.335.649)

100 EN 3100 758 101g - 2015-07

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8.6 Spare parts and spare parts orders

Spare parts orders

Only ZF original spare parts may be used for maintenance work and repairs requiring replacement of components or
subassemblies.
Keep the following details, located on the transmission type plate, at hand for spare part orders and inquiries:
 Type / MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Field No. 1)
 Transmission number / SERIAL NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Field No. 2)
 Parts list number / PARTS LIST NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Field No. 3)
 Overall ratio / RATIO TOTAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Field No. 5)
The details in fields 1 to 3 and 5 on the type plate are essential for all inquiries concerning the transmission, trouble-
shooting, maintenance, order of special equipment, etc.
For transmissions with classification, note that, in general, spare parts without classification are delivered under the
specified Part numbers.

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.

EN 3100 758 101g - 2015-07 101

Maintenance

8.7 Maintenance System Job Sheets

Job Sheet contents

Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

101 Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

102 Rotate rotary handle of oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

103 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

121 Clean outside of transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

122 Retighten all bolts accessible from the outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

123 Check shift settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

124 Lubricate external moving parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

141 Oil change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

142 Renew oil filter; clean changeover filter; clean gap filter and filter housing . . . . . . . . . . . . . . . . . . . . . . . . 122

161 Flexible clutch: Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

162 Flexible engine and transmission support: Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

163 Clutch discs: Visual inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

164 Running gears: Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

165 Check oil pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

166 Check control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

167 Check actuation device (mechanical / electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

168 Recalibrate display devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

169 Inspect visually and clean oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

173 Check shaft seal of input shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

174 Check shaft seal of output shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

102 EN 3100 758 101g - 2015-07

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EN 3100 758 101g - 2015-07 103

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

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 ------------------------------

Material Lint-free cloths

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

104 EN 3100 758 101g - 2015-07

Maintenance

During the first filling following oil filter repairs or clean-

ing, consider that part of the oil remains in the oil cooler
and the oil pipes and does not flow back in the transmis-
sion housing. Therefore, check oil level again after a short
period of operation.
25

Fig. 56: Oil dipstick (25) on transmission (example)

The correct oil level is between the top and the bottom
measuring mark of the oil dipstick.

Wait for approx. 10 minutes until the oil level has

settled after switching the engine off. Now remove
the oil dipstick and read off the oil level!

Max.

Min.

004 666
Fig. 57: Oil dipstick (example)

If the oil needs to be topped up, unscrew the oil filler

screw and top up the oil.
46

Fig. 58: Oil filler screw (46) on transmission ZF 2000

(example)

EN 3100 758 101g - 2015-07 105

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

102 A1 ---------- 5

Description of
102 Rotate rotary handle of oil filter
maintenance job

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

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

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

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

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

106 EN 3100 758 101g - 2015-07

Maintenance

Fig. 59: Rotary handle on gap filter (example)

Slowly rotate rotary handle of gap filter clockwise 1 to 2
turns.

EN 3100 758 101g - 2015-07 107

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be perfor-
Maintenance Job No. Maintenance level med in conjunction with Time required in minutes
Maintenance Job No.

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 ------------------------------

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

108 EN 3100 758 101g - 2015-07

Maintenance

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).

EN 3100 758 101g - 2015-07 109

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

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.

Tools On-board tools

Parts Cleaning agent

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

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

110 EN 3100 758 101g - 2015-07

Maintenance

Fig. 64: Transmission ZF 2000 A (example) Fig. 66: Transmission ZF 2250 (example)

Do not bring the following parts into contact with

the cleaning agent:
 Rubber parts
 Hose lines
 Shaft sealing rings

NOTICE

Property damage caused by contact with aggressive

liquid possible.
 Do not bring the part into contact with aggressive liq-
uid.

1. Clean transmission exterior with a cleaning agent so

that the visual inspection can be performed.

Fig. 65: Transmission ZF 2000 V (example)

EN 3100 758 101g - 2015-07 111

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

122 Z1, A2 ---------- 20

Description of
122 Retighten all bolts accessible from the outside
maintenance job

Safety measures Do not perform retightening work while transmission is in operation.

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

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

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

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

112 EN 3100 758 101g - 2015-07

Maintenance

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.

Retighten screws according to tightening torque

while the transmission is cold (approx. 20°C).

Fig. 68: Transmission ZF 2000 V (example)

EN 3100 758 101g - 2015-07 113

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

123 Z1, A2 ---------- 15

Description of
123 Check shift settings (mechanical transmission actuation)
maintenance job

Lock engine starting device.

Safety measures
Otherwise risk of ship gaining speed.

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

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

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

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

Procedure See opposite page.

Location: Date: Page: 1 of: 3

114 EN 3100 758 101g - 2015-07

Maintenance

1. Unhook the push/pull cable or the shift linkage of the

mechanical remote control on the shift lever of the
control unit.
2. Set selector unit to shift position "Neutral".
f
3. Move and latch the shift lever of the control unit to
shift position "Neutral".

Align the holes on the shift lever of the control unit

and the shift linkage or fork head of the push/pull d
cable.
4. Set selector unit to shift position "Ahead".
5. Move the shift lever of the control unit to shift posi- g
tion "Engine wise rotation" or "Counter-engine wise
rotation" to the stop depending on the "Ahead" shift
position.
Fig. 70: Mechanical transmission actuation
Align the holes on the shift lever of the control unit elements (example)
and the shift linkage or fork head of the push/pull d - Pilot valve for "Engine wise rotation" and
cable. "Counter-engine wise rotation" shift positions
6. Set selector unit to shift position "Astern". f - Control unit
7. Move the shift lever of the control unit to shift posi- g - Shift lever
tion "Engine wise rotation" or "Counter-engine wise
rotation" to the stop depending on the "Astern" shift
position.

Align the holes on the shift lever of the control unit

and the shift linkage or fork head of the push/pull
cable.

Shift positions must be reliably reached. Make sure

the shift lever of the control unit does not stop in
an undefined shift position between shift positions
"Neutral" and "Counter-engine wise rotation" or
shift positions "Neutral" and "Engine wise rotation".
Adjust the mechanism on the transmission rods
when necessary.
8. Hook the push/pull cable or the shift linkage of the
mechanical remote control on the shift lever of the
control unit.

EN 3100 758 101g - 2015-07 115

Maintenance

A
Angles / travels of shift lever

Rotation axis of shift lever

Actuation force F = approx. 25 N for 100 mm radius; admissible force Fmax = 75 N

Fig. 71: Shift angles of mechanical transmission actuation (example)

103 Latching position for shift position "Counter-engine wise rotation"
104 Latching position for shift position "Engine wise rotation"
121 Shift lever stop (not supplied by ZF)
122 Undefined shift position (pass through this area quickly)
124 Latching position for shift position "Neutral"

116 EN 3100 758 101g - 2015-07

Maintenance

EN 3100 758 101g - 2015-07 117

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

124 A2 ---------- 15

Description of
124 Lubricate external moving parts (mechanical transmission actuation)
maintenance job

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

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

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

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

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

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.

Location: Date: Page: 1 of: 1

118 EN 3100 758 101g - 2015-07

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EN 3100 758 101g - 2015-07 119

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

141 Z1, A3 142 / 163 / 164 30

Description of
141 Oil change
maintenance job

Lock engine starting device.

Perform oil change at maximum 40 - 50°C oil temperature otherwise risk of burns.
Safety measures
Collect used oil in oil collection containers of sufficient size otherwise risk of environmental
pollution.

Tools On-board tools

Parts New gasket / seal rings

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.

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

120 EN 3100 758 101g - 2015-07

Maintenance

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.

1. Remove the oil dipstick, open oil drain screw (20)

and drain the oil.
2. Suck off the oil when an oil suction device has been
fitted to the transmission.
3. Fit a new seal ring on oil drain screw (20), insert and
tighten the screw.
20
4. Close the suction device when used.
5. To fill with oil, unscrew oil filler screw (46) or remove Fig. 72: Oil drain screw (20), ZF 2000 A (example)
inspection cover (47).

NOTICE 46 47

The use of a non-approved lubricant can lead to

property damage.
 Only use lubricant from the currently valid ZF List of
Lubricants.

6. Fill with new oil.

Oil quantities
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 approx. 20 dm3
Fig. 73: Oil filler screw (46) and inspection cover (47)
ZF 2150 NC approx. 20 dm3 for ZF 2000 A (example)
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 approx. 21 dm3
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, ZF 2000 NRB approx. 21 dm3
ZF 2200 / ZF 2250 / ZF 2260 / ZF 2270 / ZF 2275 /
ZF 2200 NR / ZF 2250 NR / ZF 2260 NR /
ZF 2270 NR / ZF 2275 NR approx. 21 dm3
ZF 2300 / ZF 2350 / ZF 2360 / ZF 2370 / ZF 2375 /
ZF W2300 / ZF W2350 / ZF 2300 NR / ZF 2350 NR /
ZF 2360 NR / ZF 2370 NR / ZF 2375 NR /
ZF W2300 NR / ZF W2350 NR approx. 27 dm3
ZF W2400 / ZF W2450 / ZF W2400 NR /
ZF W2450 NR approx. 36 dm3
ZF 2350 U approx. 27 dm3

EN 3100 758 101g - 2015-07 121

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

142 Z1, A3 141 / 163 / 164 30

142 Renew oil filter

Description of
142 Clean changeover filter
maintenance job
142 Clean gap filter and filter housing

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.

Tools On-board tools

Oil filter (Attention: Operating pressure 24 bar), gasket / seal rings

Parts
Changeover filter: Oil filter (Attention: Operating pressure 34,5 bar), seal rings

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

Procedure See opposite page.

Location: Date: Page: 1 of: 4

122 EN 3100 758 101g - 2015-07

Maintenance

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

Fig. 75: Changeover filter

1 Change lever 2 Filter head
3 Vent screw 4 Filter cartridge
5 O-ring
1. Move change lever (1) anticlockwise to the stop in
Fig. 74: Oil filter on transmission ZF 2000 A the 3 o'clock position.
(example)

CAUTION

Risk of burns due to contact with hot oil.

Slight or moderate injury possible.
 Wear protective googles
 Wear protective gloves.

1. Dismantle filter using an oil filter remover. Collect

drained oil in a container.
2. Fit filter cartridge according to manufacturer's speci-
fications:
Fig. 76: Change lever in the 3 o'clock position
a) Grease gasket. (example)
b) Screw filter in until contact noticeable. 2. Open vent screw (3) cautiously two turns to allow
c) Tighten filter manually. the pressure to escape.

d) Check filter for leaks.

EN 3100 758 101g - 2015-07 123

Maintenance

Contaminated filter cartridge Cleaning the protective filter of the changeover filter

Only clean the protective filter when the oil fil-

CAUTION ter has been switched to the protective filter due
Risk of burns due to contact with hot oil. to a filter alarm.
Slight or moderate injury possible.
 Wear protective googles
 Wear protective gloves. 5 1

3. Remove filter cartridge (4) with an oil filter remover

2
and collect the drained oil in a suitable container. 3
New filter cartridge
4
4. Oil O-ring (5) of the new filter cartridge.
5. Screw the new filter cartridge onto filter head (2)
until contact is noticeable.
6. Tighten new filter cartridge (4) by hand.
7. Check the oil filter for leak-tightness.
8. Screw the vent screw in cautiously and tighten with
a tightening torque of 10 Nm.
Fig. 78: Filter head with protective filter
9. Move change lever (1) clockwise to the stop in the 6
1 Nut 2 Screw
o'clock position.
3 O-ring 4 Protective filter
5 Filter head
1. With the engine switched off, unscrew and remove
nut (1) and screw (2) completely.
2. Remove O-ring (3).
3. Pull protective filter (4) out upwards.

Ensure no dirt penetrates the clean oil cham-

1
ber of filter head (5).

NOTICE

Property damage caused by using unsuitable cleaning

Fig. 77: Change lever in the 6 o'clock position tools possible.
(example)  Use a brush.
 Use nonlinting cloth.

4. Clean protective filter (4) thoroughly with diesel oil or

cleaning benzene.
5. Insert protective filter (4) in filter head (5).
6. Position O-ring (3) on fixing nut (1).
7. Screw screw (2) in to the stop and tighten nut (1)
with a tightening torque. At the same time, counter
screw (2) against nut (1).

124 EN 3100 758 101g - 2015-07

Maintenance

Clean gap filter and filter housing

The gap filter is used for classified transmissions.

1
2

Fig. 79: Gap filter

1 Screw 2 Seal
3 Filter head 4 Filter
5 Filter housing
1. Rotate the rotary handle of the oil filter as described
in Maintenance Job No. 102 with transmission idle.
2. Remove the four fixing screws on filter head (3) and
pull filter (4) out upwards. Ensure no dirt penetrates
the clean oil chamber of the filter housing.
3. Dismantle filter housing (5) using an SW 32
open-end wrench. Collect drained oil in a container.

NOTICE

Property damage caused by using unsuitable cleaning

tools possible.
 Use a brush.
 Use nonlinting cloth.

4. Clean filter housing (5) and filter (4) thoroughly using

diesel oil or cleaning benzene. To do this, rotate
rotary handle several times (do not dismantle filter).

Use a new filter seal when installing the filter and

filter housing.
Perform assembly in reverse disassembly sequence.

EN 3100 758 101g - 2015-07 125

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

161 A4 ---------- 30

Description of
161 Flexible clutch: Visual inspection
maintenance job

Safety measures Lock engine starting device.

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

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

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

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

126 EN 3100 758 101g - 2015-07

Maintenance

Check rubber rings of flexible clutch for flawless condi-

tion. To do this, rotate engine slowly and check elastom-
ers through inspection hole of bell housing.

Check elastomers for cracks, embrittlement, and over-

heating symptoms.

EN 3100 758 101g - 2015-07 127

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

162 A4 ---------- 15

Description of
162 Flexible engine and transmission support: Visual inspection
maintenance job

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

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

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

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

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

Check rubber-bonded metal bearings on engine and transmission for flawless condition.
Procedure
Rubber parts must not show cracks, embrittlement, and other damage.

Location: Date: Page: 1 of: 1

128 EN 3100 758 101g - 2015-07

Maintenance

EN 3100 758 101g - 2015-07 129

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

163 A4 141 / 142 / 164 15

Description of
163 Clutch discs; Visual inspection
maintenance job

Lock engine starting device.

Safety measures Remove all parts which could penetrate the transmission interior after opening the inspection
cover (keep chest pockets of technicians empty).

Tools On-board tools

Parts Gasket

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

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

130 EN 3100 758 101g - 2015-07

Maintenance

It is practical to combine this work with the oil change

(Maintenance Job No. 141).

NOTICE

Property damage caused by a falling part possible.

 Secure the part against falling.

1. Remove the inspection cover.

Fig. 80: Inspection cover - top view (example)

2. Check the multi-disc clutch.

The outer disc carrier must not show any overheat-

ing symptoms.

Fig. 81: Outer disc carrier (example)

3. Install the inspection cover.

Fig. 82: Inspection cover - top view (example)

EN 3100 758 101g - 2015-07 131

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

164 A4 141 / 142 / 163 15

Description of
164 Running gears: Visual inspection
maintenance job

Lock engine starting device.

Safety measures Remove all parts which could penetrate the transmission interior after opening the inspection
cover (keep chest pockets of technicians empty).

Tools On-board tools

Parts Gasket

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

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

132 EN 3100 758 101g - 2015-07

Maintenance

It is practical to combine this work with the oil change

(Maintenance Job No. 141).

NOTICE

Property damage caused by a falling part possible.

 Secure the part against falling.

1. Remove the inspection cover.

Fig. 83: Inspection cover - top view (example)

2. Check the gearing of wheels on input shaft, interme-

diate shaft, and output shaft. Tooth flanks must not
show pittings or similar signs of wear.

Fig. 84: View on the gears (example)

3. Install the inspection cover.

Fig. 85: Inspection cover - top view (example)

EN 3100 758 101g - 2015-07 133

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

165 A4 ------------- 180

165 Check oil pumps

Description of
Engine-dependent oil pump (primary oil pump)
maintenance job
Trailing operation oil pump (trailing pump) - special equipment!

Safety measures Lock engine starting device when the oil pump is to be dismantled.

Tools Tool kit W1

Parts Seal kit

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

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

Procedure See opposite page.

Location: Date: Page: 1 of: 4

134 EN 3100 758 101g - 2015-07

Maintenance

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.

The oil pump is a complete part and is normally

not dismantled. However, inspection or cleaning
work might require dismantling the pump.

Measures for dismantling the oil pump

All work requires highest cleanness standards. Clean the
surrounding area before loosening screw connections.
Fig. 86: Primary oil pump on ZF 2000 A (example)
 Depressurize connection lines before removal!
 Collect and dispose of leaking fluids so that all risks
for persons and environment are excluded. 1 2 3 4 5 9
 Seal pump connections and pipe lines against pene-
tration by dirt. 6
 Always use lint-free cloths for cleaning pump parts. 7

Commissioning the oil pumps 8

 Before starting a plant, ensure a sufficient amount of
transmission oil is available to avoid dry running.

Fig. 87: Primary oil pump design (example)

1 Shaft seal 7 Support ring
2 Mounting plate 8 Rubber pressure field
seal
3 Set screw 9 Pump cover
4 Double bearing 10 Hexagon screw
5 Housing 11 Gear set (shaft)
6 Seal element

EN 3100 758 101g - 2015-07 135

Maintenance

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.

Cleaning and testing the oil pump

1. Thoroughly clean parts with a lint-free cloth.
2. Check double bearing (4) for grooves.
3. Check gear set (11) for wear and indentation.
Fig. 88: Trailing oil pump on transmission ZF 2000
4. Apply thin layer of oil to movable parts. (example)

Assembling the oil pump

1. Press shaft seal (1) in mounting plate (2) from the 1
front side of the centring collar to the stop. 2
2. Insert housing (5) in mounting plate (2). 9
3
3. Lay support ring (7) and rubber pressure field seal A1 4
(8) in the first double bearing.
4. Install double bearing (4) so that the axial pressure
field points in the high-pressure side direction.
5. Mount both gear sets (11).
6. Lay support ring (7) and rubber pressure field seal 5
8
(8) in the second double bearing. 6
7. Install double bearing (4) so that the axial pressure A3 7
field points in the high-pressure side direction.
A2
8. Insert seal element (6) in housing (5).
9. Mount pump cover (9) on housing (5). A1 = Axial play, reverse housing-cover (0.1 bis 0.2 mm)
A2 = Axial play, outer rotor-reverse housing (0.02 bis 0.08 mm)
10. Secure pump cover (9) on housing (5) by tightening A3 = Axial play, inner rotor-reverse housing, 0.025 bis 0.075 mm)
the fixing screws crosswise (with torque).
11. Insert the O-ring. 11
10
12. Insert the pump in the pump flange and mount it by 12
tightening the fixing screws crosswise (with torque).
13. Insert the O-rings.
14. Mount the suction line to the pump by tightening the
fixing screws (with torque).
15. Mount the pressure line to the pump by tightening
the fixing screws (with torque).

Fig. 89: Trailing oil pump design (example)

136 EN 3100 758 101g - 2015-07

Maintenance

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

Removing and dismantling the trailing oil pump

1. If required, dismantle the suction and pressure line.
2. Dismantle the trailing oil pump by loosening the fix-
ing screws.
3. Dismantle the trailing oil pump.
4. Remove O-ring (12).
5. Unclip locking ring (11).
6. Pull drive pinion (10) off.
7. Remove parallel key (5).
8. Remove fixing screws on cover (1) and dismantle
housing (9).
9. Measure axial play A1, A2 and A3 (see Fig. 89).
10. Disassemble pump.

Cleaning and testing the trailing oil pump

1. Thoroughly clean parts with a lint-free cloth.
2. Check inner (4) and outer rotor (3) for wear.
3. Check reverse housing (2) for wear.
4. Check bearing bushings (8) for wear.
5. Apply thin layer of oil to movable parts.

Assembling the trailing oil pump

1. Insert three pressure springs (6) in cover (1) and fill
them with grease to ensure the three steel balls (7)
stay in position.
2. Insert reverse housing (2) in cover (1).
3. Insert inner rotor (4) in cover (1).
4. Insert outer rotor (3) in reverse housing (2).
5. Place housing (9) on cover (1).
6. Mount cover (1) by tightening the fixing screws (with
torque).
7. Mount parallel key (5) on the pump shaft.
8. Heat drive pinion (10) to approx. 85 °C and mount it
on the pump shaft.
9. Clip locking ring (11) in the ring groove of the pump
shaft.
10. Insert O-ring (12).

EN 3100 758 101g - 2015-07 137

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

166 A4 ------------- 120

Description of
166 Check control unit
maintenance job

Safety measures Lock engine starting device.

Tools Tool kit W1

Parts Seal kit

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

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

138 EN 3100 758 101g - 2015-07

Maintenance

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

Fig. 90: Control unit ZF 2000 series (example)

1 Cylinder screw 20 Cover 39 Bushing
2 Cylinder screw 21 Seal 40 Screw plug
3 Cover 22 Piston
4 Seal 23 Spacer sleeve
5 Control housing 24 Screw plug
6 Slotted plug 25 Seal
7 Ball 26 Pressure spring
8 Gland 27 Retaining ring
9 Switch 28 Control piston
10 Disc 29 Screw plug
11 Pressure spring 30 Screw plug
12 Stop bolt 31 Control piston
13 Disc 32 Retaining ring
14 Locking ring 33 Pressure spring
15 Cylinder screw 34 Bushing
16 Screw plug 35 Pressure spring
17 Cover 36 Disc
18 Seal 37 Pressure spring
19 Hexagon screw 38 Control piston

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.

EN 3100 758 101g - 2015-07 139

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

167 A4 ------------- 180

Description of
167 Check actuation device (mechanical / electrical)
maintenance job

Safety measures Lock engine starting device.

Tools Tool kit W1

Parts Parts kits T1 and T2

Material Cleaning agent

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

140 EN 3100 758 101g - 2015-07

Maintenance

B
A
Fig. 92: Electrical actuation (example)

Fig. 91: Mechanical actuation (example) Checking the electrical actuation device:

Checking the mechanical actuation device: Removing:

Removing: The electrical actuation is supplied as a complete

1. Loosen fixing screws and remove mechanical actua- unit and cannot be dismantled. Replace the com-
tion (A). plete unit when the actuation unit is defective.
Testing:
The mechanical actuation is supplied as a com-
plete unit and cannot be dismantled. Replace the 1. Measure the electrical resistance (26.7 ohm +/- 8%
complete unit when the actuation unit is defective. at 20°C).

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).

EN 3100 758 101g - 2015-07 141

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

168 A4 ------------- --------------

Description of
168 Recalibrate display devices
maintenance job

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

Tools On-board tools

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

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

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

142 EN 3100 758 101g - 2015-07

Maintenance

Check display devices for oil pressures and oil tempera-

tures for correct display values.

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.

EN 3100 758 101g - 2015-07 143

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be perfor-
Maintenance Job No. Maintenance level med in conjunction with Time required in minutes
Maintenance Job No.

169 Z2, A3.1, A4 ------------- 180

Description of
169 Inspect visually and clean oil cooler
maintenance job

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

Tools Tool kit W1

Parts Seal kit

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

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

Procedure See opposite page.

Location: Date: Page: 1 of: 7

144 EN 3100 758 101g - 2015-07

Maintenance

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

Fig. 95: Schematic design of transmission oil cooler (example)

1 Housing 5 Cylinder screw 9 Pipe
2 Receiver 6 Spacer sheet 10 Baffle plates
3 Cover 7 Pipe plate
4 Pipe bundle, complete 8 O rings

Numbers in brackets refer to Fig. 95. Housing

Housing (1) serves for fitting the pipe bundle and consti-
tutes the outer pressure chamber for the oil. It is a stand-
The actual design of the transmission oil cooler
ardised cast housing made of an aluminium alloy.
may vary in details.
Receiver
Pipe bundle
Receiver (2) is fitted on the water connection side of the
Pipe bundle (4) comprises two identical pipe plates (7)
cooler. The receiver is made of bronze cast iron. The re-
opposite each other and cooling pipes (9). The cooling
ceiver is fastened on housing (1) with three screws (5).
pipes are rolled into the pipe plates. Five baffle plates
Pipe bundle (4) is fixed between the receiver and hous-
(10) are fitted on the cooling pipes on the pipe bundle.
ing over the sheet connected to the pipe plate.
These direct the oil flow through the housing. One O-ring
(8) each on the cover side and on the receiver side seal
the pipe bundle against the housing on the oil side.
Outer O-rings (8) serve for sealing the water side on
cover (3) and receiver (2). This prevents the media mix-
ing should the seals leak.

EN 3100 758 101g - 2015-07 145

Maintenance

Cover Disassembling the transmission oil cooler (without

extracting the pipe bundle)
Baffle cover (3) is fitted on the other side. This cover is
also made of bronze cast iron. The cover is fastened on 1. Clearly mark the positions of the bolted flanges to
housing (1) with three screws (5). Spacer sheet (6) is fit- each other.
ted between the cover and housing. The spacer sheet
2. Close off all pipe lines.
serves for fixing O-rings (8).
3. Drain the transmission oil cooler on the water side.
Seals
4. Remove the pipe lines on the water side.
The water side connecting flanges are sealed with gas-
5. Wait for at least 30 minutes after stopping the plant
kets. The pipe plates are sealed with four identical
for the oil pressure to sink.
O-rings (8). The oil connections of the transmission oil
cooler flanged directly onto the housing are sealed with 6. Remove the fixing screws on the transmission oil
O-rings laid in the grooves. The pipe connecting threads cooler and take the transmission oil cooler off.
of an external transmission oil cooler are sealed using a
copper ring. Steps 5 to 6 are only required for transmissions on
which cover (3) cannot be removed for reasons of
O-rings are available from ZF Friedrichshafen AG space.
Customer Service by specifying the Part No.
7. Remove receiver (2) and cover (3) by loosening the
Exchange the O-rings removed during every main-
screws on the receiver/cover-housing connection.
tenance.
8. Remove the O-rings on both sides of the pipe bun-
dle.

Fig. 96: Removing the O-rings (example)

9. Secure the pipe bundle against housing (1) with one
screw and the appropriate number of washers.

Fig. 97: Pipe bundle secured with one screw

(example)

146 EN 3100 758 101g - 2015-07

Maintenance

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).

Fig. 99: Removing the O-rings (example)

9. Remove spacer sheet (6) on the side opposite the
Fig. 98: Cleaning pipes with a nylon brush (example)
water side.
Do not use metal brushes for cleaning pipes.

Do not use tools to remove firmly adhering depos-

its. Clean the pipe bundle chemically in such
cases. This can be done in assembled condition by
spraying the chemical cleaning solution into the
pipes. Ensure the chemical solution does not affect
the condition of the O-rings. Chemical cleaning
should only be carried out by qualified personnel.

Suppliers of suitable cleaning agents are, for

example, Ashland Chemicals (www.ash-
chem.com), Henkel Oberflächentechnik
(www.henkel.com) and Ondeo Nalco
(www.nalco.com). Suppliers of complete cleaning
services are, for example, Vecom (www.vecom.nl) Fig. 100: Removing the spacer sheet (example)
and Ondeo Nalco (www.nalco.com). 10. Push the pipe bundle far enough through to the
water side (use an auxiliary tool when necessary)
until the O-ring on the opposite side is free.

EN 3100 758 101g - 2015-07 147

Maintenance

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.

Fig. 101: Removing the O-ring on the side opposite the

water side (example) Fig. 103: Removing the O-ring on the water side
(example)
12. Pull the pipe bundle out towards the water side. In
doing this, remove the pipe bundle very carefully
Assembling the transmission oil cooler (without
from the housing to avoid damaging the baffle
extracting the pipe bundle)
plates.
Assemble the transmission oil cooler in reverse disassem-
bly sequence.
1. Remove the locking screw with the washers from the
pipe bundle.
2. Grease the outer O-rings with a suitable grease and
fit these on the pipe bundle.

Fig. 102: Removing the pipe bundle (example)

Fig. 104: Fitting the outer O-ring (example)

3. Place receiver (2) and cover (3) parallel on both sides
of the transmission oil cooler and slide them evenly
onto the outer O-ring.

Make sure O-rings do not shear off when sliding

receiver (2) and cover (3) on.

148 EN 3100 758 101g - 2015-07

Maintenance

4. Tighten receiver (2) and cover (3) each with three

screws with the tightening torque (see Table 16).

Transmission Screw /
Tightening torque
type Strength
ZF 2000 series M8 / 8.8 23 Nm

Tab. 16: Tightening torques

5. If the transmission oil cooler has been removed from
the transmission housing, position and screw the
transmission oil cooler tight on the transmission
housing with the fixing screws.
6. Fit the pipe connections on receiver (2) with new
seals.
7. Connect the pipe lines on the water side. Fig. 106: Fitting the pipe bundle (example)
8. Open and refill all pipe lines. 4. Grease the O-ring for the side of the pipe bundle
9. Bleed the transmission oil cooler on the water side. opposite the water side and then insert it in the side
opposite the water side.
Assembling the transmission oil cooler (after extracting
the pipe bundle)
Assemble the transmission oil cooler in reverse disassem-
bly sequence.
1. Grease the O-ring on the water side of the pipe bun-
dle.
2. Push the O-ring carefully over the pipe bundle on the
water side to the stop.

Fig. 107: Fitting the O-ring on the side opposite the

water side (example)

Make sure the O-ring does not shear off during fit-
ting.
5. Fit spacer sheet (6) on the side opposite the water
side.

Fig. 105: Fitting the O-ring on the water side (example)

Make sure the O-ring does not shear off during fit-
ting.
3. Insert the pipe bundle into housing (1).

EN 3100 758 101g - 2015-07 149

Maintenance

12. Open and refill all pipe lines.

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

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.

Fig. 108: Fitting the spacer sheet (example)

6. Grease the outer O-rings with a suitable grease and
fit these on the pipe bundle.

Fig. 109: Fitting the outer O-ring (example)

7. Place receiver (2) and cover (3) parallel on both sides
of the transmission oil cooler and slide them evenly
onto the outer O-ring.

Make sure O-rings do not shear off when sliding

receiver (2) and cover (3) on.
8. Tighten receiver (2) and cover (3) each with three
screws with the tightening torque (see Table 17).

Transmission Screw /
Tightening torque
type Strength
ZF 2000 series M8 / 8.8 23 Nm

Tab. 17: Tightening torques

9. Position the transmission oil cooler onto the trans-
mission housing and screw it tight to the housing
with the fixing screws.
10. Fit the pipe connections on receiver (2) with new
seals.
11. Connect the pipe lines on the water side.

150 EN 3100 758 101g - 2015-07

Maintenance

EN 3100 758 101g - 2015-07 151

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

173 A4 121 15

Description of
173 Check shaft seal of input shaft
maintenance job

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

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

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

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

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

152 EN 3100 758 101g - 2015-07

Maintenance

Whenever possible, combine this work with Mainte-

nance Job 121!
1. Check shaft seal of input shaft for leaks (collect
escaping oil when necessary).

Replace the input shaft seal as soon as possible

when damage is visible.

Fig. 110: Input shaft seal ZF 2150 (example)

Fig. 111: Input shaft seal ZF 2150 V (example)

EN 3100 758 101g - 2015-07 153

Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission type: ZF 2000 series
When possible, to be per-
Maintenance Job No. Maintenance level formed in conjunction with Time required in minutes
Maintenance Job No.

174 A4 121 15

Description of
174 Check shaft seal of output shaft
maintenance job

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

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

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

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

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

Procedure See opposite page.

Location: Date: Page: 1 of: 2

154 EN 3100 758 101g - 2015-07

Maintenance

Whenever possible, combine this work with Mainte-

nance Job 121!
1. Check shaft seal of output shaft for leaks (collect
escaping oil when necessary).

Replace the output shaft seal as soon as possible

when damage is visible.

Fig. 112: Output shaft seal ZF 2150 (example)

EN 3100 758 101g - 2015-07 155

Maintenance

156 EN 3100 758 101g - 2015-07

Annex
Annex

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.

EN 3100 758 101g - 2015-07 157

Annex

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.

9.2.1 Conservation procedure

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.

9.2.1.1 Renewing conservation

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.

9.2.1.2 Measures to be taken before delivering stored transmissions

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.

9.3 Corrosion protection and conservation for ZF transmissions installed in a ship

Corrosion protection measures required for a transmission installed in a ship for longer shutdown periods strongly de-
pend on temperature variations, air humidity, and salt content of the air in the engine room. Therefore, the recom-
mended measures and time indications may only be regarded as rough guidelines. In case of doubt, we recommend
performing the corrosion protection measures for the transmission analog to those for the engine.
Shutdown periods up to 3 months do not normally require corrosion protection measures.
If the transmission shutdown period is going to be longer than 3 months, perform conservation when possible imme-
diately after the ship is taken out of operation, but within 3 months at the latest, alternatively K1 or K2 conservation is
required depending on individual requirements. Flush and clean the cooler with fresh water during the initial corro-
sion protection measures on the transmission. Do not seal the drainage opening. If draining is not possible, flush with
fresh water and fill with 20% antifreeze solution.

K1 Conservation
 Storage time: 12 months.
 Then renew conservation every 6 months.

K2 long-term conservation
 Storage time: 36 months.
 Repeat every 36 months.

158 EN 3100 758 101g - 2015-07

Annex

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.

9.3.1.1 Renewing conservation

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.

9.3.1.2 Commissioning after K1 conservation

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").

9.3.2 K2 Long-term conservation

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.

9.3.2.1 Commissioning after K2 long-term conservation

1. Drain anti-corrosive oil to normal oil level.

2. Then run the engine for approx. 5 minutes.
3. Then drain anti-corrosive oil completely and fill transmission with the specified oil type (see "Maintenance Job
141").

EN 3100 758 101g - 2015-07 159

Annex

160 EN 3100 758 101g - 2015-07

ZF Friedrichshafen AG
Marine Propulsion Systems
88038 Friedrichshafen
Deutschland - Germany
Telefon/Phone +49 7541 77-2207
Telefax/Fax +49 7541 77-4222
www.zf.com

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