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ZF Marine Transmission - Operating Manual
ZF Marine Transmission - Operating Manual
ZF Marine Transmission
ZF 7500/7600 Series
3084 758 101
Important note
General information
The following safety instructions appear in this manual.
NOTE:
Refers to special processes, techniques, data, use of auxiliary equipment etc.
CAUTION
This is used when incorrect, unprofessional working practices could damage the product
DANGER!
This is used when lack of care could lead to personal injury or death.
Copyright by ZF
These operating instructions are protected by copyright. Any reproduction and dissemination in whatever form also
in adapted, paraphrased or extracted form in particular as a reprint, photomechanical or electronic reproduction or
as a storage in data-processing equipment or data networks without approval by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law
Edition:
2006-09
ZF Friedrichshafen AG
D-88038 Friedrichshafen,
Customer service
Telefon: (07541) 77-0
ZF 7500/7600 Series
Contents
Contents
Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1
1.1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
ZF-Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2
2.1
Monitoring values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Monitoring data for ZF 7550 NR2/NR2B/NR2H,
ZF 7650 NR2/NR2B/NR2H, ZF 7600 NR2/NR2B/NR2H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5
Description of basic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.1
Power, speed, rotation direction, ratio, type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.2
General design (see end of section for differences in the NR series) . . . . . . . . . . . . . . . . . . . .14
5.3
Transmission views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.3.1
View of transmissions ZF 7500, ZF 7550, ZF 7549, ZF 7600, ZF 7650 . . . . . . . . . . . . . . . . . . .15
5.3.2
View of transmissions ZF 7500A, ZF 7550A, ZF 7600A, ZF 7650A . . . . . . . . . . . . . . . . . . . . .17
5.3.3
View of transmissions ZF 7500V, ZF 7550V, ZF 7600V, ZF 7650V . . . . . . . . . . . . . . . . . . . . .20
5.3.4
View of transmissions (left version) ZF 7550NR2H, ZF 7600 NR2H, ZF 7650 NR2H . . . . . . .22
5.3.5
View of transmissions (right version) ZF 7550 NR2H; ZF 7600 NR2H, ZF 7650 NR2H . . . . .24
5.3.6
View of transmissions ZF 7550 NR2B, ZF 7600 NR2B, ZF 7650 NR2B . . . . . . . . . . . . . . . . . .26
5.3.7
View of transmissions ZF 7550 NR2, ZF 7600 NR2, ZF 7650 NR2 . . . . . . . . . . . . . . . . . . . . . .28
5.3.8
View of transmissions ZF 7540, ZF 7541, ZF 7545,
ZF 7546, ZFW 7540, ZF 7640, ZF 7641, ZF 7645, ZF 7646 . . . . . . . . . . . . . . . . . . . . . . . . . . .30
5.3.9
View of transmissions ZFW 7500, ZFW 7510, ZF 7661,
ZF 7666, ZF 7561, ZF 7566, ZFW 7610, ZFW 7615 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
5.3.10 View of transmissions ZF 7549 C, ZF 7500 C, ZF 7850 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5.4
Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
5.5
Oil supply and transmission cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.6
Control unit and transmission actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.7
Checks and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.1
Permissible installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.2
Transmission attachments for transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.3
Transmission mounting on foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
6.3.1
Casting resin base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
6.4
Connection to the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6.4.1
Normal engine arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6.4.2
U/V-drive arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6.4.3
U/V-drive installation diagram when drive shaft is in W-arrangement . . . . . . . . . . . . . . . . . . . .47
6.5
Connection to propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6.6
Aligning the transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6.7
Connections for transmission cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
3
Contents
6.8
6.9
6.9.1
6.9.2
ZF 7500/7600 Series
51
51
52
7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1
Change-over procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1
Change-over from neutral to ahead or neutral to astern . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2
Change-over from ahead to astern with vessel moving at low speed
(not applicable for non-reversing transmissions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3
Change-over from ahead to astern with vessel moving at higher speed
(not applicable for non-reversing transmissions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.4
Emergency change-over in case of danger (not applicable for non-reversing transmissions) . .
7.2
Operation with engine stationary and propeller trailing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1
Occasional trailing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2
Regular trailing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3
Operation with the manual mechanical actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.1
Mechanical emergency operation of mechanical transmission actuation . . . . . . . . . . . . . . . . . .
7.3.2
Mechanical emergency operation of the electrical transmission actuation
(except NR2, NR2H, NR2B type transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3
Mechanical emergency operation of the electrical transmission actuation
of NR2, NR2H, NR2B type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3.1 Mechanical emergency control for version with auxiliary screws . . . . . . . . . . . . . . . . . . . . . . .
7.3.3.2 Mechanical emergency control for version with push / pull slider . . . . . . . . . . . . . . . . . . . . . . .
7.4
Operation with emergency shift
(Come home screws, not with NR2, NR2B, NR2H transmissions) . . . . . . . . . . . . . . . . . . . . .
59
59
59
66
8
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2
Protection against corrosion, preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3
Maintenance work plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4
Special versions / Special scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.1
Special scope of supply - Transmissions with additional trailing oil pump (item 18) . . . . . . . .
8.5
Trouble shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6
ZF service stations, Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
68
69
70
71
71
71
75
6.9.3
6.10
6.10.1
6.10.2
6.11
6.11.1
6.11.2
54
55
56
56
57
58
58
58
59
59
59
59
59
60
61
61
61
63
63
64
ZF 7500/7600 Series
Foreword
Foreword
1.1
ZF-Transmission
The description, operation and maintenance sections are applicable to the standard transmission version.
Variations are possible according to special customer requirements and operating conditions. If the data contained in
the operating instructions are different to the data contained in the technical or commercial specifications, the data in
the specifications shall apply.
Important!
Ensure that these operating instructions are always kept to hand. Carefully read the operating instructions. Pay particular attention to the safety instructions.
Some of the illustrations contained in the operating instructions may differ from your installed transmission. Furthermore, safety devices and covers may sometimes be omitted to enable clearer illustration.
Foreword
ZF 7500/7600 Series
Important Note:
1. The warranty conditions agreed with ZF apply for these transmissions. However, ZF can only honour warranty
claims if:
the transmission has been installed, monitored, operated and maintained in accordance with these operating instructions,
ZF-approved lubricants have been used,
the limit values specified on the transmission for the ratio of input power to input speed and for input speed are
respected according to the transmission application group.
2. The transmission manufacturer, as a supplier of one single component in the vessel drive system, cannot be held
responsible for vibrations or vibrational problems occurring in this system. Therefore, ZF will not accept liability
for transmission noise or damage to the transmission, flexible coupling or other parts of the drive unit caused by
such vibrations.
We therefore recommend that vibrations are recorded and calculated including, where appropriate, transmissioncomponents not subject to load.
PVF= PK + 8 bar
max
Pressure gauge
0 to 40 bar 3)
1 bar 4)
2) 5) 6)
__________
7 bar
3.5 bar
__________
Position 9)
Neutral
2)
2)
105 C
100 C
30 C
2)
__________
Thermometer 0 to 120 C
95 C
90 C
30 C
__________
__________
75 C 8) 11)
105 C 8) 12)
__________
__________
Trailing
operation 8)
P, L, M, Capplication
Decreasing
Increasing
C
application
Normal operation
11, 12, 41
P, L, Mapplication
Oil temperature
Pressure switch or
Temperature switch 2) or temperature sensor 16)
pressure gauge 0 to 6 bar 0 to 120 C
__________
0.25 bar
5 bar
0.4 bar
__________
__________
22
Lubricating oil
pressure
Pressure switch or
pressure sensor 16) 0 to 25 bar
6)
PK = PKN 3 bar
PK = PKN + 2 bar 4)
PK = PKN
PKN 7)
4) At 60 C to 80 C oil temperature
Additional monitoring
Pressure switch
14)
31 bar
2) 5)
__________
min
__________
Warning
Nom. display
value
Nominal value
CounterPosition 9)
engine-wise
Counter-engine-wise
output rotation9) output rotation
Operating mode
2, 21, 27
Measuring point 1)
2.1
Filter
contamination
Monitoring values
2
ZF 7500/7600 Series
Monitoring values
PVF= PK + 6 bar
max
Pressure gauge
0 to 40 bar 3)
2) 5) 6)
__________
6 bar
3.5 bar
2)
2)
105 C
100 C
30 C
2)
__________
Thermometer 0 to 120 C
95 C
90 C
30 C
__________
__________
75 C 8) 11)
105 C 8) 12)
__________
__________
Trailing
operation 8)
P, L, M, Capplication
Decreasing
Increasing
C
application
Normal operation
11, 12, 41
P, L, Mapplication
Oil temperature
Pressure switch or
Temperature switch 2) or temperature sensor 16)
pressure gauge 0 to 6 bar 0 to 120 C
__________
0.25 bar
4.5 bar
0.4 bar
__________
__________
22
Lubricating oil
pressure
Pressure switch or
pressure sensor 16) 0 to 25 bar
6)
PK = PKN 3 bar
PK = PKN + 2 bar 4)
PK = PKN 1 bar
4) At 60 C to 80 C oil temperature
Additional monitoring
Pressure switch
14)
2) 5) 19)
24 bar
26 bar
Warning
2) 5) 18)
__________
min
PKN 7)
__________
Nominal value
Nom. display
value
__________
Position 9)
Enginewise or counterengine-wise rotation
Neutral 9)
Enginewise or
counter-enginewise rotation
Operating mode
4)
Position 9)
Neutral
2, 21, 27
Measuring point 1)
Filter
contamination
Monitoring data for ZF 7500/7600 Series without version NR2, NR2B, NR2H
Monitoring values
ZF 7500/7600 Series
ZF 7500/7600 Series
Identification mark
for the oil pump ratio
>/= 415
>/= 275
Additional forces on transmission input in accordance with section 6.4 (Loads applicable to the face end
of input shaft)
in radial direction
max. 4 000 N
in axial direction
max. 1 500 N
Transmission
Dimension A
Max permissible
according section 5.2 angle error x
[mm]
A = 340
A = 448
Max. shift
displacement y
[mm]
[mm]
500 for d < 120
0.05
0.10
1 000 for d >/= 120
ZF 7500/7600
Series
0.1
0.15
Permitted radial force on propeller shaft for centering on transmission output flange (refer to section 6.5) max.
1000 N
ZF 7500/7600 Series
Cooler data ZF 7500 Series without NR2/NR2B/NR2H type transmissions without ZF 7540, 7550 transmissions and ZF 7600 Series
Largest permitted cooling water flow rate
17 500 dm3/h
5 400 dm3/h
at
17 500 dm3/h
0.5 bar
4 bar
40 C
60 C
Cooler data ZF 7540, 7550 transmissions and ZF 7600 Series without ZF 7500 Series and NR2/NR2B/NR2H
type transmissions
Largest permitted cooling water flow rate
17 500 dm3/h
5 400 dm3/h
at
17 500 dm3/h
0.5 bar
4 bar
32 C
60 C
12 000 dm3/h
3 900 dm3/h
at
12 000 dm3/h
1 bar
4 bar
40 C
32 C
60 C
10
ZF 7500/7600 Series
Oil types
The relevant valid ZF list of lubricants TE-ML 04 for ZF marine gears is binding.
This list is available from any ZF After-Sales Service Point and on the internet under
www.zf.com.
Then choose Service, Technical Information, ZF List of Lubricants, List of Lubricants
(English) then under TE-ML 04 choose the PDF download.
Viscosity classes SAE 30 or SAE 40 at oil sump temperature < 80 C
Viscosity class SAE 40 at oil sump temperature > 80 C
Oil quantities
transmission ratio
approx. 75 dm3
approx. 75 dm3
approx. 50 dm3
approx. 50 dm3
approx. 50 dm3
approx. 80 dm3
approx. 75 dm3
11
12
ZF 7500/7600 Series
ZF 7500/7600 Series
5.1
Key
1
2
3
4
5
6
7
8
9
10
11
12
13
Model
Serial no.
Parts list no.
Customer reference no.
Total ratio and code letter for oil pump ratio
Oil capacity
Mass (dry)
Lubricant, see ZF List of Lubricants
TE-ML 04
Clutch oil pressure (nominal)
Max. power/speed ratio for intermittent operation
at very widely differing engine speeds
Max. power/speed ratio for intermittent operation
at widely differing engine speeds
Max. power/speed ratio for intermittent operation
at differing engine speeds
Max. power/speed ratio for continuous operation
at max. engine power
NOTE
For items 10 to 13, also refer to section 8 Maintenance.
The code letter stamped after the total ratio in box 5 signifies the following:
Letter
Engine idle
speed
1650 to 2300
> 415
1100 to 1650
> 275
FRIEDRICHSHAFEN
- GERMANY SERIAL NO.
MODEL
1
PARTS LIST NO.
REFERENCE NO.
3
RATIO TOTAL
MAIN GEAR
SPUR GEAR
PLEASURE
kW/RPM
10
LIGHT
11
9
MEDIUM
CONTINUOUS
12
13
13
5.2
V-version
A
8
006779.4
A-version
A=600 mm
ZFW 7500
ZFW 7510
ZF 7561
ZF 7566
ZF 7661
ZF 7666
ZFW 7610
ZFW 7615
A=450 mm
ZF 7540
ZFW 7540
ZF 7640
ZF 7641
ZF 7645
ZF 7646
ZFW 7640
ZFW 7645
A=448 mm
ZF 7500A
ZF 7500V
ZF 7600A
ZF 7600 V
ZF 7650 A
ZF 7650 V
14
ZF 7500/7600 Series
ZF 7500/7600 Series
5.3
Transmission views
46
34
26
18
11
16
10
37
19
12
18
22
21
27
25
23
7
44
33
20
32
15
ZF 7500/7600 Series
Key:
1
25
Oil dipstick
26
Output
2, 21, 27
32
33
Oil filter
Input
34
Emergency control
(counter-enginewise rotation)
10
35
Coolant inlet
11, 12, 41
36
Coolant outlet
15
Oil cooler
37
16
Inspection cover,
(on transmission housing)
18
44
19
Emergency control
(enginewise rotation)
20
46
22
105
23
Transmission breather
16
ZF 7500/7600 Series
34
44
26
20
16
10
18
46
22
5
33
32
25
23
17
ZF 7500/7600 Series
18
8
35
36
19
27
21
18
20
ZF 7500/7600 Series
Key:
1
2, 21, 27
Input
10
Oil cooler
16
18
19
20
22
23
Transmission breather
25
Oil dipstick
26
Output
32
33
Oil filter
34
Emergency control
(counter-enginewise rotation)
35
Coolant inlet
36
Coolant outlet
37
Inspection cover,
(on transmission housing)
44
Emergency control
(enginewise rotation)
46
105
19
ZF 7500/7600 Series
37
105
22
5
33
7
32
23
25
12
26
15
11
46
35
36
44
20
20
18
ZF 7500/7600 Series
27 21 2
41
10
16
19
20
Key:
1
25
Oil dipstick
26
Output
2, 21, 27
32
33
Oil filter
35
Coolant inlet
36
Coolant outlet
Input
37
10
Inspection cover,
(on transmission housing)
44
Emergency control
(enginewise rotation)
46
105
Oil cooler
16
18
19
20
22
23
Transmission breather
21
ZF 7500/7600 Series
5.3.4 View of transmissions (left version) ZF 7550NR2H, ZF 7600 NR2H, ZF 7650 NR2H
The add-ons, connections and pipes on your transmission may be different to those pictured here.
15
13
26
(11)
(20)
(12)
18
11
20 12 10
20
22
ZF 7500/7600 Series
21 27
23 25
46
37
22
33
7
32
Key:
1
26
Output
32
2, 21, 27
33
Oil filter
37
Inspection cover,
(on transmission housing)
46
Input
10
11, 12
13
15
Oil cooler
18
20
22
23
Transmission breather
25
Oil dipstick
23
ZF 7500/7600 Series
5.3.5 View of transmissions (right version) ZF 7550 NR2H; ZF 7600 NR2H, ZF 7650 NR2H
The add-ons, connections and pipes on your transmission may be different to those pictured here.
15
13
26
10
11 20 12
18
(11)
(20)
(12)
20
24
ZF 7500/7600 Series
22 25
2 27
7 32
21
33
23
46
37
Key:
1
26
Output
32
2, 21, 27
33
Oil filter
37
Inspection cover,
(on transmission housing)
46
Input
10
11, 12
13
15
Oil cooler
18
20
22
23
Transmission breather
25
Oil dipstick
25
ZF 7500/7600 Series
18
26
33
10
5
15
13
25
23
11
20
12
26
(11)
(20)
(12)
ZF 7500/7600 Series
15
21 27
22
46
37
8
20
Key:
1
2, 21, 27
Input
10
11, 12
13
15
Oil cooler
18
20
22
23
Transmission breather
25
Oil dipstick
26
Output
33
Oil filter
37
Inspection cover,
(on transmission housing)
46
27
ZF 7500/7600 Series
15
13
33
10
8
5
25
23
26
11 20 12
2
21 27
22
37
46
20
006779
28
ZF 7500/7600 Series
Key:
1
22
23
Transmission breather
2, 21, 27
25
Oil dipstick
26
Output
33
Oil filter
Input
37
10
Inspection cover,
(on transmission housing)
11, 12
46
13
15
Oil cooler
18
20
29
ZF 7500/7600 Series
22
16
33
7
5
25
23
32
34
44
26
11 20
12
19
15
35
36
18
21 27
20
37
46
30
ZF 7500/7600 Series
Key:
1
2, 21, 27
Input
10
Oil cooler
16
18
19
20
22
23
Transmission breather
25
Oil dipstick
26
Output
32
33
Oil filter
34
Emergency control
(counter-enginewise rotation)
35
Coolant inlet
36
Coolant outlet
37
Inspection cover,
(on transmission housing)
44
Emergency control
(enginewise rotation)
46
105
31
ZF 7500/7600 Series
Key:
1
35
Coolant inlet
36
Coolant outlet
32
ZF 7500/7600 Series
25
23
25
Oil dipstick
11
26
Output
12A
32
33
Oil filter
19
34
20
22
41A
23
Transmission breather
33
ZF 7500/7600 Series
2A
27A
5A
37
41A
10
44
15
Oil cooler
46
16
105
23
Transmission breather
25
Oil dipstick
34
ZF 7500/7600 Series
8
37
46
22
44
25
23
34
20
35
ZF 7500/7600 Series
33
21 27
32
41
2
10
16
15
35
36
26
11
19
12
20
26
Output
32
33
Oil filter
34
Emergency control
(counter-enginewise rotation)
35
Coolant inlet
36
Coolant outlet
37
Inspection cover,
(on transmission housing)
44
Emergency control
(enginewise rotation)
46
Key:
1
2, 21, 27
Input
10
Oil cooler
16
18
19
20
22
23
Transmission breather
25
Oil dipstick
36
ZF 7500/7600 Series
5.4
Functional description
Transmission and power flow diagram ZF 7500, ZF 7549, ZF 7550, ZF 7600, ZF 7650, ZF 7540, ZF 7640,
ZF 7641, ZF 7645, ZF 7646, ZF W 7540, ZF W 7500, ZF W 7510, ZF 7661, ZF 7666, ZF 7561, ZF 7566,
ZFW 7610, ZFW 7615
(for ZF 7500 NR, ZF 7549 NR, ZF 7550 NR, ZF 7600 NR, ZF7650 NR, ZF 7640 NR, ZF 7641 NR, ZF 7645
NR, ZF 7646 NR, ZF 7540 NR,ZF 7661 NR, ZF 7666 NR, ZF W 7540 NR, ZF W 7510 NR, ZF W 7500 NR,
ZF 7561 NR, ZF 7566 NR, ZFW 7610 NR, ZFW 7615 NR only have either clutch D or E)
D
A
Gears are in
mesh
B
C
E
C
A = Input shaft
A
Enginewise rotation
B = Reversing shaft
C = Output shaft
001 635
transmission and power flow diagram for ZF 7550A, ZF 7550V, ZF 7600 A, ZF 7600 V, ZF 7650 A, ZF 7650
V
(ZF 7550 NRA, ZF 7550 NRV, ZF 7600 NRA, ZF 7600 NRV, ZF 7650 NRA, ZF 7650 NRV only have either
clutch D or E)
V-version
A-version
D
D
A
Gears are
in mesh
Power flow
during:
counter-enginewise rotation
AA
CC
C
B
C
Gears are
in mesh
enginewise
rotation
A
A
B
A - Input shaft
B - Reverse shaft
C - Output shaft
D - Clutch for counterenginewise rotation
E - Clutch for engine
wise rotation
CC
001 645
37
ZF 7500/7600 Series
transmission and power flow diagram for ZF 7550NR2, ZF 7550NR2H, ZF 7550NR2B, ZF 7600 NR2, ZF
7600 NR2H, ZF 7600 NR2B, ZF 7650 NR2, ZF 7650 NR2H, ZF 7650 NR2B
D
A
A
C
Power flow in
counter- enginewise
rotation
001 635_1
A - Input shaft
C - Output shaft
D - Clutch
C
Gears are
in mesh
D A
B
A - Input shaft
B - Reverse shaft
C - Clutch shaft
F - Clutch for counterenginewise rotation
E - Clutch for engine
wise rotation
008 143_1
E
D
C
B
A
engine-wise rotation
B
D
38
ZF 7500/7600 Series
Connecting unions are included as standard for monitoring transmission temperature, oil pressure upstream of
the filter, lubricating oil pressure and clutch oil pressure.
For locations and descriptions, see section 5.3.
5.6
The control unit is a complete module fitted on the transmission housing. It comprises:
a spool valve for charging and draining the clutch
packs
a control valve for the clutch pressure level
a time switch for modulating the clutch pressure
5.5
5.7
39
40
ZF 7500/7600 Series
ZF 7500/7600 Series
Installation
When planning what powerpack to use, care must be taken to ensure sufficient free space for removing the oil
cooler, oil filter, oil pump, clutch packs and discs and for
withdrawing the dipstick. (The dimensions required for
these procedures are specified on the transmission installation drawings). It is possible to remove clutch packs
and discs whilst the transmission is still installed.
The oil drain plugs must also be easily accessible. If
there is not enough space available to place a pan under
the oil drain openings for collecting the oil during oilchanges, it is advisable to permanently fit a suction pipe
on the transmission in place of the oil drain plug.The oil
must then be removed by suction during oil changes.
CAUTION
The screw
connections listed below are to be provided
C
i
by the customer and must be rated in acc. with the operating loads supplied:
protective covers for output flange, flexible coupling and/or engine flywheel and drive shaft,
Installation
6.1
6.2
The lifting tackle for transportation should only be attached to the lugs provided.
On transmissions without attached mounting brackets,
lifting eyes are screwed onto the pads intended for taking
up the suspension brackets during delivery. These retaining lugs are only used for transporting the transmission.
They must not be used to transport the engine and transmission unit in the flange-mounted-on-the-engine version. Afterwards, these lifting eyes must be removed so
that the suspension brackets can be attached.
On transmissions where the mounting brackets have
already been fitted, the lifting tackle should be attached
to the eyes of the mounting brackets. On the mounting
brackets supplied by ZF, the corresponding outer bracing ribs have been provided with eyes. If the mounting
brackets are manufactured by the shipyard or by the engine manufacturer, suitable means of attachment must be
provided.
Under no circumstances may the lifting gear be attached
in other places, particularly not to the input shaft, the output shaft, the covers, the oil pumps or the pipes.
41
Installation
6.3
ZF 7500/7600 Series
+
X
Support surface
A +
X
Support surface
007691
42
ZF 7500/7600 Series
Installation
43
Installation
6.4
ZF 7500/7600 Series
007693.2
44
ZF 7500/7600 Series
Installation
U-drive arrangement
006779.2
V-drive arrangement
006779.3
45
Installation
ZF 7500/7600 Series
DANGER!
Fit a safety device to all parts of the drive
shaft at which the rotating shaft presents a
possible danger to people and material. The
user and/or operator should comply with all
relevant safety precautions. It is essential
that the appropriate safety equiment (e. g.
retaining bracket, stable guard grill) is fitted to prevent parts of the drive shaft being
thrust out of the unit.
The drive shaft manufacturers technical documents
contain more detailed information about drive shafts.
The drive shaft can be arranged in two ways
W-arrangement with 1 = 2
004_971.1
1
004_971.2
46
ZF 7500/7600 Series
Installation
004 971
Engine
Propeller shaft
47
Installation
6.5
ZF 7500/7600 Series
6.6
48
ZF 7500/7600 Series
Installation
49
Installation
6.7
ZF 7500/7600 Series
50
ZF 7500/7600 Series
6.8
Installation
6.9
51
Installation
ZF 7500/7600 Series
Key to drawings
103 Selector position for counterenginewise rotation
104 Selector position for enginewise
rotation
105 Selector lever for mechanical
actuation
137
105
52
ZF 7500/7600 Series
Installation
Shift force
required
Neutral ahead
Neutral astern
H [mm]
30
40
r [mm]
F [N]
approx. 47
approx. 62
56
42
50
approx. 78
34
60
approx. 93
28
53
Installation
ZF 7500/7600 Series
ZF 7500/7600 Series
Installation
101
106
006 626
55
Installation
ZF 7500/7600 Series
41
21
27
22
12
11
The monitoring facilities stated in section 6.10.1 are essential for checking operating reliability of the transmission and must always be installed. In addition, the transmission is provided with measuring points for additional
monitoring equipment (see section 6.10.1).
6.10.1Minimum transmission monitoring facilities
(for values, see section Monitoring values)
Pressure reading upstream of oil cooler and filter (measuring point 5).
This measuring point is intended as a means of monitoring the oil filter. Any rise in pressure indicates that the
filter is becoming increasingly blocked.
A pressure-sensing switch must be used for monitoring.
It should be set to change over when pressure rises above
the preset value, and transmit a warning signal.
Clutch oil pressure (measuring point 2)
Depending on the transmission version and its inputtorque, the clutch oil pressure setting will vary. The
nominal clutch oil pressure is confirmed in the technical
documentation which is included with each order, and is
also stamped on the transmission type plate (see
section 5).
The clutch oil pressure indication applies to both the enginewise and counter-enginewise shift positions. In Neutral, the oil pressure at this measuring point drops to a
56
006 791
value given in the section Monitoring values, depending on input speed and oil temperature. To monitor
clutch oil pressure, a pressure gauge must be used.
If clutch oil pressure is in accordance with the specified
values and the conditions stated above apply, transmission lubrication will be assured. For this reason, separate
monitoring of lubricating oil pressure (measuring point
22) is unnecessary.
Oil temperature (measuring point 12)
A thermometer must be used to monitor transmission oil
temperature. The volume of water flowing through the
transmission oil cooler must be regulated until the transmission oil temperature remains within the recommended normal range during normal operation. The maximum
transmission oil temperature must not be exceeded during continuous operation.
ZF 7500/7600 Series
Installation
This measuring point can be used in transmission versions equipped with a trailing oil pump.
CAUTION
Measuring
point 41 is not located in the oil sump. It can
C i
only be used for monitoring oil temperature if the oil is
being circulated (engine running or rotating propellershaft with fitted trailing pump).
57
Installation
58
ZF 7500/7600 Series
ZF 7500/7600 Series
Operation
DANGER!
The transmissions clutches are disengaged in
Neutral shift position. The propeller shaft can
still keep turning.
If you require the propeller shaft to be stationary , then it is necessary to provide a propeller
shaft brake or other shaft interlock.
7.1
Change-over procedure
Operation
7.2
Move engine throttle control to idling, select desired travel direction and keep lever in this position for 1 or 2 secs.
before increasing the engine speed to the required operating speed.
59
Operation
60
ZF 7500/7600 Series
ZF 7500/7600 Series
7.3
Operation
DANGER!
When the mechanical emergency operation is
used the remote transmission control for this
transmission does not function.
It is essential that the person in charge of the
craft is aware of this situation. In port or when
travelling on a narrow or busy waterway, stop
the engine and have the craft towed.
To deactivate the mechanical emergency actuation,
stop the engine and hook the linkage for the remote
mecanical actuator onto the seleector lever of the
control unit. Check the setting..
7.3.2 Mechanical emergency operation of the electrical transmission actuation (except NR2, NR2H,
NR2B type transmission)
This section applies if the transmission has an electrical
transmission actuation as discribed in section 6.9.2.
For NR2, NR2H, NR2B see section 7.3.3
DANGER!
Engine and transmission components can get
very hot (danger of burns). In addition in the engine room there is danger of rotating parts.
Take appropriate safety precautions.
61
Operation
ZF 7500/7600 Series
Standard version
If the power supply fails, the transmission automatically
shifts to neutral. This version has the cap nut and the actuating PIN 140 (see sketch in this section).
142
140
141
143
011 749
101
106
Electrical connection
140
141
142
143
NOTE:
There are two versions of electrical transmission actuation. These are:
standard version
special version
62
Appart from some reversing transmissions alle non reversing transmissions have the special version.
Mechanical emergency actuation is to be performed in
the following sequenz:
Set the engine speed to idling speed
Remove plug on electrical actuation (see sketch in
this section item 106)
With standard version only:
Change over the mechanically shifted valve (see
sketch in this section).
This is done by installing the actuating PIN 140 the
other way round (accessible once cap nut has been
unscrewed). A small oil leak is possible when cap
nut is removed. The cap nut must be tightened again.
Move the selector lever manually to the desired
shifting position until it stops. The selector lever
remains in that position. Appropiate measures must
be taken to secure the selector lever and prevent it
from jumping out of the ahead or astern position
which might occure e. g. due to virbrations.
ZF 7500/7600 Series
DANGER!
Operation
101
106
006 626
106
7.3.3 Mechanical emergency operation of the electrical transmission actuation of NR2, NR2H,
NR2B type transmission
101
2
006 625
63
Operation
Shifting process:
Engage
Set engine speed to neutral speed
ZF 7500/7600 Series
101
101
DANGER!
When the mechanical emergency operation is
used the remote transmission control for this
transmission does not function.
It is essential that the person in charge of the
craft is aware of this situation. In port or when
travelling on a narrow or busy waterway, stop
the engine and have the craft towed.
To deactivate mechanical manual actuation
Stop engine
Fit plug (item 106) on electrical actuation device
(item 101)
Check that plug (item 106) and screw 1 and 2 are
fitted and tightened
A
C
NR2H right version
C
Push/pull slider
B
Wing nut
Protective cover
64
ZF 7500/7600 Series
Operation
DANGER!
When the mechanical emergency operation is
used the remote transmission control for this
transmission does not function.
It is essential that the person in charge of the
craft is aware of this situation. In port or when
travelling on a narrow or busy waterway, stop
the engine and have the craft towed.
To deactivate mechanical manual actuation
Stop the engine
Fit plug (item 106) on electrical actuation device
(item 101)
Shift push/pull slider to neutral position
Fit protective cover
Check that plug (item 106) and cover are fitted and
tightened
65
Operation
7.4
66
ZF 7500/7600 Series
ZF 7500/7600 Series
Operation
2.
3.
4.
5.
6.
44
34
67
Maintenance
ZF 7500/7600 Series
Maintenance
8.1
Maintenance schedule
Regular Maintenance
Maintenance
level
Operating
hours
Limit
A1
every day
of operation
3 months
see also K1, K2
A2
500
6 months
A3
2000
2 year
A4
4000 to 6000
5 years
A5
during every
basic overhaul
of engine
operating
condition
of transmission
Procedure
Limit
Z1
50 to 100
12 months
Procedure
K1
every 10 20 days
up to 6 months
K2
at end of
operating period
9 months
K3
at end of
operating period
max. 36 months
Limit
If the period without use is less than 6 months ,we
recommend that measure K 1 be carried out every 10 to
20 days. Before the craft is put into operation again, it
may be necessary to change the oil (see Maintenance
stage Z 1), depending on the condition of the oil
already in the transmission
K 2 is a preservation measure and should be
implemented immediately at the end of operation if a
period of more than 6 months without use is intended.
K 2 may also be implemented instead of K1 in the case
of shorter periods out of use.
K 3 is a long-term preservation measure and allows for
a period of max. 36 month without marine gear use.
Preservation can also be carried out acc. to K 2 instead
of K 3. This preservation measure must, however, be
repeated every 9 months.
68
ZF 7500/7600 Series
8.2
Maintenance
69
Maintenance
8.3
ZF 7500/7600 Series
Maintenance level
Maintenance jobs
Regular
A5
A4
Tools required
One-off
A3
A2
A1
Z1
101
none
102
none
103
Visual check
none
121
none
122
123
none
124
none
141
Change oil
tool kit
142
tool kit
161
none
162
none
163
tool kit
164
tool kit
165
W1
166
W1
167
W1
------
173
none
174
none
104
tool kit
168
169
170*
172*
--
--
T1
70
W2
ZF 7500/7600 Series
8.4
Maintenance
8.5
Trouble shooting
Additional monitoring
Oil pressure need not be monitored when the engine is
stationary. The transmission oil temperature must be
monitored for compliance with the data in section 2
There is another measuring point (41) for oil
temperature monitoring available (see section 6.10.2).
Additional note for maintenance
71
Maintenance
Fault
Ecessive gear oil temperature
(measuring points 11*, 12* and 41*)
ZF 7500/7600 Series
Possible cause
Remedial action
Clogged filter
No oil in transmission
Add oil
Defective indicator
Repair fault
Renew
Repair fault
If the fault cannot be rectified, the lubricating oil supply to the transmission is also at risk.
Proceed at reduced engine speed until repairs can be carried out.
Engine stalls following rapid change
from Ahead to Astern
72
Change direction as
recommended in section 7.1.3
ZF 7500/7600 Series
Maintenance
Fault
Possible cause
Remedies
Drive between transmission input For possible causes and remedies refer
and output cannot be interrupted; to clutch not transmitting torque
clutch does not
open
*See Monitoring diagram section 6.10
73
Maintenance
Fault
ZF 7500/7600 Series
Possible cause
Remedies
Oil level sinks rapidly (as indicated Leaks at housing joints, oil pipes or
by the dipstick); see section 6.11.1 shaft seals
oil level check
Oil cooler leaking into cooling water
system
Water entering the oil circuit from the Repair mechanical fault
cooling system
74
ZF 7500/7600 Series
8.6
Maintenance
If a transmission fault cannot be rectified using the remedies in section 8.5 Trouble shooting, please contact the
nearest ZF service station.
A list of ZF service stations with the current telex and
telephone numbers can be obtained from ZF Friedrichshafen AG, or the internet www.zf-marine.com.
When carrying out repairs, use only genuine ZF spare
parts.
Please give the following information when ordering
spare parts and making enquiries
- Model type
- Serial number
- Spec./parts list number
- Transmission ratio
This information is stamped on the transmission type
plate.
In the case of marine gears with classification, note that
spare parts without classification are always supplied under the item numbers stated. If a version with classification is required, the desired type of test must be stated in
addition to the item number. This is also necessary, if the
transmission spec./parts list is quoted when ordering, and
when requesting exchange units.
75
Maintenance
76
ZF 7500/7600 Series
ZF 7500/7600 Series
102
103
121
122
123
124
141
142
161
162
163
164
165
166
167
168
169
173
174
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
101
A1
----------
10
Description of
101
maintenance work
Only withdraw the oil dipstick when the engine is at a standstill, otherwise risk of burns due to
hot oil spraying out.
Safety measures
Only top up the oil when the engine is at a standstill, otherwise risk of burns due to hot oil
spraying out.
Tools
------------------------------
Parts
------------------------------
Material
Non-fraying cloth
Test equipment
------------------------------
Procedure
Location:
2
Date:
Page: 1
of: 2
ZF 7500/7600 Series
ZF 7550 V
max.
min.
004 666
To add oil, unscrew the oil filler plug and top up the oil.
ZF 7550 V
3
ZF 7500/7600 Series
ZF 7550 NR2H
max.
min.
004 666
To add oil, unscrew the oil filler plug and top up the oil.
ZF 7550 NR2H
4
ZF 7500/7600 Series
ZF 7500/7600 Series
BW 7500/7600 Series
Maintenance
job no.
Maintenance level
Time required in
minutes
102
A1
----------
Description of
maintenance
work
102
Safety measures
------------------------------
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Location:
6
Date:
Page: 1
of: 2
ZF 7500/7600 Series
ZF 7500 A
ZF 7550 A
ZF 7550 NR2H
7
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
103
A1
121
10
Description of
103
maintenance work
Safety measures
Always keep your distance when visually checking rotating parts, otherwise risk of getting
caught in the rotating part
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Location:
Date:
Page: 1
of: 2
ZF 7500/7600 Series
Check for leaks at the points the input shaft and output
shaft protrude from the transmission housing as well as
at the oil line ports, monitoring equipment ports and
coolant ports (visual check).
ZF 7550 A
ZFW 7540
ZF 7550 NR2H
9
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
121
A2
103
30
Description of
121
maintenance work
Safety measures
Only use cleaning products that meet the requirements of the regulations for the prevention of
accidents.
Tools
Ships tools
Parts
Cleaning products
Material
------------------------------
Test equipment
------------------------------
Procedure
Location:
10
Date:
Page: 1
of: 2
ZF 7500/7600 Series
ZF 7550 A
ZF 7550V
ZF 7550 NR2H
11
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
122
Z1
----------
20
Description of
122
maintenance work
Safety measures
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Location:
12
Date:
Page: 1
of: 2
ZF 7500/7600 Series
ZF 7550 A
ZFW 7540
ZF 7550 NR2H
13
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
123
A2
----------
15
Description of
123
maintenance work
Safety measures
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Location:
14
Date:
Page: 1
of: 2
ZF 7500/7600 Series
124
104 123
103
24
24
121
122
30
24
24
3
10 10
8,1
120
004 974
105
Check the Astern position in the same way. The positions indicated must be safely and reliably obtainable.
Adjust the mechanism on the transmission linkage if
necessary. Under no circumstances must the control lever remain in the undefined range between Neutral
and Ahead or Neutral and Astern.
105
121
105
105
Loosen the mechanical connection between the transmission control lever and the transmission linkage or
pull-push cable.
Select Neutral on controls and move the transmission control lever to Neutral detent position.
Holes on the transmission control lever and shift linkage or on the yoke end of the pull-push cable must be
aligned.
Select Ahead on controls and move the transmission
control lever as far as the enginewise or counter-enginewise detent position. Hole in the transmission
control lever must be aligned with the hole in the linkage or on the yoke end.
137
004 496
15
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
124
A2
----------
15
Description of
124
maintenance work
Safety measures
------------------------------
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Lightly lubricate the moving parts of the mechanical transmission actuator (yoke end on
transmission control lever, linkage connections and connection to controls) with lithium
saponified grease.
Location:
16
Date:
Page: 1
of: 2
ZF 7500/7600 Series
17
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
141
A3
30
Description of
141
maintenance work
Change oil
Safety measures
Tools
Ships tools
Parts
Material
Oil grade:
Approved oils as per applicable ZF List of Lubricants TE-EL 04 for ZF Marine
Transmissions. The currently applicable list of lubricants is supplied with the transmission. It
can be ordered from any ZF service center and it is available on the internet (see section 3).
Test equipment
------------------------------
Procedure
Location:
18
Date:
Page: 1
of: 2
ZF 7500/7600 Series
082958
ZF 7550 A
To add oil, unscrew the oil filler plug or take off the inspection hole cover.
Add fresh oil.
Oil capacity:
ZF 7500 / 7549 / 7550 / 7600 / 7650
75dm3
ZF 7500 A/ 7550 A / 7600 A / 7650 A 75dm3
ZF 7500 V / 7550 V / 7600 V / 7650 V 75dm3
ZF 7540 / W 7540 / 7640 / 7641 /
7645 / 7646
80dm3
ZFW 7500 / 7510 / 7661 / 7666 /
7561 / 7566 / W 7610 / W 7615
120dm3
ZF 7550 NR2 / 7650 NR2
50dm3
ZF 7550 NR2B / 7650 NR2B
50dm3
ZF 7550 NR2H / 7650 NR2H
ZF 7549 C / 7500 C / 7850 C
50dm3
Then fit a new seal on the oil filler plug (or a new gasket
on the inspection hole cover) and re-insert the oil filler
plug (or re-attach the inspection hole cover).
Finally, check the oil level - see maintenance job 101.
Using the oil dipstick is the only way to obtain an accurate reading.
ZF 7550 A
ZFW 7510
19
ZF 7500/7600 Series
Transmission type:
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
142
A3
30
Description of
142
maintenance work
Safety measures
Tools
Ships tools
Parts
Gasket
Material
Oil grade:
Approved oils as per applicable ZF List of Lubricants TE-EL 04 for ZF Marine Transmissions. The currently applicable list of lubricants is supplied with the transmission. It can be
ordered from any ZF service center and it is available on the internet (see section 3).
Test equipment
------------------------------
Procedure
Location:
20
Date:
Page: 1
of: 2
ZF 7500/7600 Series
ZF 7550 A
Unscrew sludge drain plug A and bleed the filter chamber; collect the escaping oil in a container.
Escaping oil quantity approx. 2 dm3.
ZF 7550 A
B
ZF 7550 NR2H
21
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
161
A4
----------
30
Description of
161
maintenance work
Safety measures
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Location:
22
Date:
Page: 1
of: 2
ZF 7500/7600 Series
Check that the rims of the flexible coupling are in perfect condition. To do this, slowly turn over the engine
and check the rubber parts by looking through the inspection hole in the bell housing.
004 681
Check the rubber parts for signs of cracking, embrittlement and overheating.
004 682
004 683
23
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
162
A4
----------
15
Description of
162
maintenance work
Safety measures
------------------------------
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Check that the rubber-metal mountings on the engine and transmission are in perfect condition.
The rubber parts must not show any signs of cracking, embrittlement or other damage.
Location:
24
Date:
Page: 1
of: 2
ZF 7500/7600 Series
25
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
163
A4
15
Description of
163
maintenance work
Safety measures
Tools
Ships tools
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Location:
26
Date:
Page: 1
of: 2
ZF 7500/7600 Series
082 477
ZF 7550 V
Check the clutch discs. The discs must not show any
signs of overheating and it must be possible to move
them in axial direction (see table for disc play per pack).
Also check the play between the individual discs
ZFW 7510
.
Number of outer
discs
3084 302 003
4.00 - 0.05 mm
Number of outer
discs
3084 302 073
4.25 - 0.05 mm
Number of outer
discs
0501 211 377
4.50 - 0.05 mm
Permissible
disc play
ZF 7550 A
10
2.0 - 2.4 mm
ZF 7550 V
10
2.0 - 2.4 mm
ZF 7540
10
2.0 - 2.4 mm
ZF W7540
10
2.0 - 2.4 mm
ZF 7550 NR2H
10
3.6 - 4.0 mm
Transmission
version
27
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
164
A4
15
Description of
164
maintenance work
Safety measures
Tools
Ships tools
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Location:
28
Date:
Page: 1
of: 2
ZF 7500/7600 Series
082 477
ZF 7550 NR2H
Check the clutch discs. The discs must not show any
signs of overheating and it must be possible to move
them in axial direction (see table for disc play per pack).
Also check the play between the individual discs
ZF 7550 NR2H
29
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
165
A4
----------
180
Description of
maintenance work
165
(primary pump)
(secondary pump) not fitted in basic transmission
Safety measures
Block the engine starting device if you intend to remove the oil pump.
Tools
Tool kit WI
Parts
------------------------------
Material
Test equipment
------------------------------
Procedure
Location:
30
Date:
Page: 1
of: 3
ZF 7500/7600 Series
ZF 7550 A
1
Cover
Compression spring
Spring cup
Valve seat
3
4
Tapered pin
Assembling
NOTE
- Carefully clean the components.
- Check the components.
- Apply a thin coat of oil on moving parts.
ZF 7500/7600 Series
Engine-driven pump (primary pump)
NOTE
The oil pump is a complete part and is not generally dismantled. However, checking or cleaning work may require the pump to be dismantled. Pay particular attention
to inspecting the dismantled pump for scoring, mounting
play and impeller/pinion end play.
Removing and dismantling
ZF 7550 NR2H
Pump
Fit-in key
O-ring
Drive gear
Retaining ring
Bolt cover
Cover
Assembling
NOTE
- Carefully clean the components.
- Check the components.
- Apply a thin coat of oil on moving parts.
The assembly and mounting is funded by reverse order as the removing and dismantling.
32
ZF 7500/7600 Series
1
2 3
4 5
O-ring
Woodruff key
Drive gear
Retaining ring
Inner rotor
Outer rotor
Eccentric ring
End play
End play A
In new condition Wear limit
0.01 - 0.055 mm max. 0.15 mm
0.025 - 0.055 mm max. 0.1 mm
0.025 - 0.055 mm max. 0.1 mm
Eccentric ring
Inner rotor
Outer rotor
Assembling
NOTE
- Carefully clean the components
- Check the components.
- Apply a thin coat of oil on the moving parts.
- Install the pump idler gear shaft and idler gear (6).
- Insert the pump components into the pump housing.
- Replace and securely bolt on the cover.
- Insert the fitted key (3) into the pump shaft.
- Heat the drive pinion (4) to approx. 85 C and slide
it onto the pump shaft.
- Clip the retaining ring (5) into the annular groove in
the pump shaft.
33
ZF 7500/7600 Series
Transmission type:
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
166
A4
----------
120
Description of
166
maintenance work
Safety measures
Tools
Tool kit WI
Parts
Gaskets
Material
------------------------------
Test equipment
------------------------------
Procedure
Location:
34
Date:
Page: 1
of: 2
ZF 7500/7600 Series
2
3
4
56
5
6
57
12
14
1
8
9
10
11
15
16
17
18
19
13
31
32
33
20
34
21
35
36
22
23
24
25
55
54
53
52
51
50
49
26
27
28
29
30
37
38
39
40
47
41
42
46
48
45
44
43
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
Compression spring
Control housing
Ball
Stopper
Gasket
Screw plug
Control piston
Washer
Control piston
Stopper
O-ring
Piston
Bushing
Compression spring
Disc
Ball
Ball
Screw plug
Screw plug
ZF 7500/7600 Series
2
9
10
11
1
8
12
13
14
15
16
17
18
4
20
3
19
21
22
* Special scope of supply
23
21
22
23
Bushing
Control piston
Screw plug
36
ZF 7500/7600 Series
37
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
167
A4
----------
180
Description of
167
maintenance work
Safety measures
Tools
Tool kit WI
Parts
Material
Cleaning products
Test equipment
------------------------------
Procedure
Location:
38
Date:
Page: 1
of: 5
ZF 7500/7600 Series
6
5
4
1
2
39
ZF 7500/7600 Series
25
24
23
17
20
19
22
21
18
8
7
16
14
11
10
13
12
15
3
2
Electrical actuation device, version 3MGV (not with NR2, NR2H, NR2B type transmissions)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Screw
Solenoid valve
Screw
Solenoid valve
Connector
Screw
Wiring harness, complete
Screw plug
Intermediate housing
19
20
21
22
23
24
25
Screw plug
Gasket
Circlip
Snap ring
Piston
Piston carrier
Snap ring
40
Assembling mounting
NOTE
- Carefully clean the components
- Check the components.
- Apply a thin coat of oil on the moving parts.
- Renew parts according to T2.
ZF 7500/7600 Series
27
26
25
19
22
21
20
10
24
23
11
18
16
13
12
15
14
17
6
3
2
Electrical actuation device, version 2MGV (not with NR2, NR2H, NR2B type transmissions)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Solenoid valve
Socket head bolt
Screw
Solenoid valve
Screw
Solenoid valve
Connector
Screw
Wiring harness, complete
19
20
21
22
23
24
25
26
27
Screw plug
Intermediate housing
Screw plug
Gasket
Circlip
Snap ring
Piston
Piston carrier
Snap ring
Assembling mounting
NOTE
- Carefully clean the components
- Check the components.
- Apply a thin coat of oil on the moving parts.
- Renew parts according to T2.
Checking
Check the electrical actuation components for wear and
replace them if necessary.
41
ZF 7500/7600 Series
16
17
18
19
10
11
2
8
12
13
14
28
21
22
27
23
26
21
20
22
24
15
25
21
22
23
24
25
26
27
28
Solenoid valve
Screw
Gasket
Outer casing
Screw
Wiring harness
Screw
Connector
Checking
Removing
42
Check the control piston (8) and the control piston hole
in the housing (14) for damage and protect against future damage.
Assembling - mounting
NOTE
- Carefully clean the components
- Check the components.
- Apply a thin coat of oil on the moving parts.
- Renew parts according to T2.
ZF 7500/7600 Series
43
ZF 7500/7600 Series
Transmission type:
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
168
A4
----------
----------
Description of
168
maintenance work
Re-calibrate gauge
Safety measures
------------------------------
Tools
Tool kit
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Location:
44
Date:
Page: 1
of: 2
ZF 7500/7600 Series
45
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
169
A4
----------
60
Description of
169
maintenance work
Safety measures
------------------------------
Tools
Tool kit WI
Parts
------------------------------
Material
Test equipment
------------------------------
Procedure
Location:
46
Date:
Page: 1
of: 2
ZF 7500/7600 Series
General information
ZF 7550 A
ZF 7550 NR2H
2. If coolers cleaned in this way are kept in storage as
spare parts, i.e. not immediately reinstalled nor flushed
with transmission oil, they must be flushed with a preserving agent.
Cleaning the water end
Check the contamination before cleaning the water
end. If a greasy coating of lime is present, the water end
must be degreased before cleaning.
Flushing with water and anti-liming agent removes the
lime; a 10 to 15% solution of hydrochloric acid may
also be used. An inhibitor additive must be added to
this solution to prevent it from reacting with the metal
surfaces.
After cleaning, thoroughly flush the water end with clean water. Then fill the oil end with the same oil that is
to be used in subsequent operation. Then drain the oil.
Cleaning will be much more effective and cleaning
time shorter if circulation is in the opposite direction to
circulation during normal operation, both at the oil end
and at the water end.
Assembling the heat exchanger
6. Insert the O-ring into the cooler housing.
7. Thread the pipe bundle into the cooler housing.
8. Turn the cooler and insert the O-ring and bush.
9. Install the cover and water connection housing with
O-ring. (See marking for position.)
Checking
After assembly, check the oil end and the water end.
The pressure indicated on the drawing or the type plate
(oil and water end) must not be exceeded.
47
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
173
A4
121
15
Description of
173
maintenance work
Safety measures
------------------------------
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Location:
48
Date:
Page: 1
of: 2
ZF 7500/7600 Series
ZF 7550 A
ZF 7550 A
ZF 7550 NR2H
49
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
174
A4
121
15
Description of
174
maintenance work
Safety measures
------------------------------
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Location:
50
Date:
Page: 1
of: 2
ZF 7500/7600 Series
ZF 7550 A
ZF 7550 A
ZF 7550 NR2H
51
ZF 7500/7600 Series
Sealers
(extract from the manufacturers instructions for use)
The manufacturers instructions for use are always binding.
HYLOMAR
Universal seal SQ 32 M-Special, for use on housing and
cover mating faces).
Permanent plastic universal seal SQ 32M Special
(CFC-free), MARSTON, lchemie GmbH, 53909
Zlpich, Germany, tel. (022 52) 2566 and 2725.
Instructions for use
Degrease the mating faces (Hylomar Cleaner) before
use and then apply HYLOMAR on both sides. Wait for
the sealant to dry (approx. 10 minutes) before commencing assembly. Retighten the bolts after 10-15 minutes. If the faces are planed flat, sealer only needs to be
applied on one side.
Grease
See List of Lubricants
We recommend you use HYLOMAR CLEANER to remove old gasket residues, oil and grease.
Temperature resistant from -50 C to +250 C.
Dyken Read DX-296 for tooth flank contact pattern acceptance in the case of transmissions subject to classification society acceptance.
ZF Marine Transmissions
Corrosion-proofing
Storage conditions
II
Max. 36 months
before installation + max. 12
months between installation and first operation
Internal corrosion-proofing:
Corrosion inhibiting oil to
MIL-L-21260 or TL 9150-0037,
C-640
External corrosion-proofing:
- Bright metal parts with corrosion inhibitor to MIL-C-16173D grade 4,
K 19, or TL 8030-015, grade 4.
- Finish on housing: Single-component synthetic resin lacquer, shade
RAL 7001.
Packed in drying
agent by specialist
outside company
in accordance with
TL 8100-001,
packing grade A.
Quantity of drying
agent calculated
acc. to DIN 55474
or TL 8100-004.
Packing shall contain a humidity
gauge which can
be read from outside.
As II
As II
In addition, after 36 months of storage,
check humidity inside packing every 4
months by reading humidity gauge. If
humidity is too high, call in specialist
outside company to replace drying agent
and barrier cover and to check external
corrosion-proofing.
As II
More than 36
months before
installation +
max. 12 months
between installation and first
operation
Separate Anti-corrosion protection and corrosion-proofing guidelines apply to the period between first operation and entry into regular
operation and to downtime. See Description, Installation, Operation and Maintenance publication.
Renewing corrosion-proofing:
Remove the inspection hole cover and inspect the internal components of the transmission. While rotating the
input and output shafts, spray the internal components of
the transmission with corrosion inhibiting oil. Renew
corrosion-proofing on bright external steel parts.
Measures to be taken before supplying stored transmissions:
Renew corrosion-proofing and drain corrosion inhibiting
oil before delivery of the stored transmission. Inform
customer that marine transmissions purchased through
ZF agencies offer anti-corrosion protection for a maximum of 12 months.
Renewing corrosion-proofing:
Remove the inspection hole cover and inspect the internal components of the transmission. While rotating the
input and output shafts (if possible), spray the internal
components of the transmission with corrosion inhibitor.
Renew corrosion- proofing on bright external steel parts.
Operating after K 1 corrosion-proofing:
Start the engine and let it run for approx. 5 minutes to allow any condensation inside the transmission to mix
with the corrosion inhibitor. Drain the corrosion inhibitor and fill the transmission with the prescribed oil grade.
See maintenance job 141.
K 2 long-time corrosion-proofing:
Drain the transmission oil as soon as possible after
operation but after 3 months at the latest. Then fill
with corrosion inhibiting oil, up to at least the lower
mark on the oil dipstick. See maintenance jobs for details. Use corrosion inhibiting oil C 642 or C 644 to
MIL- L-21260.
Immediately afterwards, select enginewise or
counter-enginewise position and let the engine run
for 5 to 10 minutes at increased idle speed (max. 50%
nominal operating speed). Then stop the engine.
Fill the transmission with corrosion inhibiting oil, up
to the maximum level.
Spray or brush bright external steel parts with corrosion inhibitor.
Grease protruding shaft sections.
Operating after K 2 long-time corrosion-proofing:
Drain the corrosion inhibiting oil until the normal oil level is reached. Then let the engine run for approx. 5 minutes.
Then drain the remaining corrosion inhibiting oil and fill
the transmission with the prescribed oil grade. See maintenance job 141.