ZF Marine Transmissions ZF 2500 Series

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ZF Marine Transmissions
ZF 2500 Series
3082 758 103c
ZF MARINE GMIJH
r Work safety ZF 2500 Series
The following safety instructions appear in this manual:
NOTE
Refers to special processes, techniques, data, use of
auxiliary equipment, etc.
.-I<C . _ _ _ _ _ __
CAUTION - - •• ~-
This is used when incorrect, unprofessional working
•. -
practices could damage the product.
~-
& DANGER
i This is used when lack of care could lead to personal
Iinjury or death. , •
,--~-.,.,.
Technical modifications reserved
Copyright by ZF
Copying in whole or in part requires our prior written approval.
Printed in Germany
Edition 06.95 - 100
Date 08.96
3082 758 103c

ZF 2500 Series Table of contents
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Description of basic transmission

1.I Power, speed, rotation direction, ratio, type plate .. . .. .. . ... . .... . . . . . . ... .... . . . . . . . . . .... . 4
1.2 General layout .. ...... . .. . . . .. . . ... . . . . ... ... . . . .. . . ... . ... . .. . . . ..... ... .......... . 5
1 Views of transmission
1. 1 ZF 2500, ZF 2550 (basic transmission) ...... .. ... . .. ..... . . . . ..... . .. .. . ... ... . ... ... .. . . 6
1.2 ZF 2500, ZF 2550 (special version with trolling) . . . ....... . ... . . .. . . . ..................... . 8
=:! ~~ ~~05o~~t£U~~~h~~~;a'I';e~~i~~' ~i;h' ~~ili~~) : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :

9
10
3 Monitoring data
3. 1 Monitoring data, ZF 2500 series .. . .. ... . . . . . . . ....... . . . .... . ... . . .. . ... .. ..... .... . .. . 12
3.2 Monitoring data, ZF 2500 series (without trolling) ......... . .. . . . . . ......•....•............ . 13
4 Function description . ... . ....... .. ....... . ... . .. . . ... . ... .. . .... ... . ........ ....•... 14
Oil supply and transmission cooling

5.1 Control unit and tran smi ssion actuation 15
6 Actuation
6.1 Mechanical transmission actuation 16
6.2 Pneumatic transmission actuation .................... .. . .... . .... .. ... . . ... .. ...... . .. . . 16
6.3 Electrical transmission actuation 19
7 Operation
.1 Change-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
.1.1 Change-over from "Neutral" to "Ahead" or "Neutral" to "Astern" .. . ............ . .. . . . .... . .. . 18
7. 1.2 Change-over from "Ahead" to "Astern" with vessel moving at low speed ............ ... . .. ..... . 18
7. 1.3 Change-over from "Ahead" to "Astern" with vessel moving at higher speed ...... . . .. ... .. . ..... . 18
. 1.4 Emergency change-over in case of danger ... . . ...... .. . . . .. ...... . ..... .... . . . . . . .... . ... . 18
7.2 Operation with engine stationary and propeller trailing .. . . . . ... .. .. ..... ... ....... . ....... . . 18
.2. 1 Occasional trailing operation ............ . .... . .... . . . ........ . .............. . . . ....... . 18
7.2.2 Regular trailing operation . . . . .. . .. .. . . . ... . ... . .. . . . .. ..... . . . .... . . . . . . . ............ . 19
7.3 Special versions / special scope of suppl y . ... . .. ........... .. .. ..... . .. .... .. ... . . . .. . ... . 19
.3. 1 Special scope of supply - transmissions with auxi liary trailing oil pumps .. . ...... . ....... . . ... . . 19
8 Operation with manual actuation

8. 1 Transmission with mechanica l actuation .... . . .. . . . ... .......... . .. . ...•...... .. ... .. . .. .. 20
8.2 Transmission with pneumatic actuation ..... . .......... . .. .. . . .. .. . . .. . . ... .... . ... . . ... . . 20
8.3 Transmission with electrical actuation .. . . ... .. ................ . . ............... . . . .. . . . . . 20
Table of contents ZF 2500 Series
9 Trolling device
9.1 Transmission with trolling device . . . . . • . . . . ..•... . . .. . . . . . • . . . . .... . . • .. . ... . . .. . . . . . • .. 23
9.2 Applications and operating range ........ .. .. . ....... . .... . . ......... . .... . . . ........... 21
9.3 Functions description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21
9.4 Shift setting check . . . .. .... . . . ...... . ...... . .. .. . ... . .... .... . . ....... . .... ..• . ...... 22
9.5 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23
9.6 Additional requirements for transmission monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24
9.7 Additional requirements for maintenance ....... . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.8 Retrofit of trolling valve ............ . ........ . ......•.................... • .....•...... 24
10 Troubleshooting notes .. ..... . . .. . . .. . .. . ...... . ...... . ... ... .. ........ .. ............ 25
11 Spare parts order / service point details 28
12 Maintenance
12. 1 Application group P . . . . .. . .. . . .. . .. .. . .. . . .. . . .. . . . . . .. .. .. .. . . .. . . . .. . .. . .. .. . .. . ... 29
12.2 Application group L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29
12.3 Application group M .....•....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29
12.4 Application group C ................ . ......... . .. ..... ... ... ... .. ..... . ........ .. .... 29
13 Maintenance schedule
13. 1 Regular maintenance work. . .. . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . .. . . . .. .. . 30
13.2 Additional one-off maintenance work for new or overhauled transmission ....... .. .. . .. .. . . .. . . . 30
13.3 Anti-corrosion measures ............. .. . .. ..... . ..... . .. ......... .. . ............ . ..... 30
14 Maintenance work plan

14. 1 Maintenance work ......... . ... . . .... ... . . .... . .... .. . . ... . .. . ... . .. .. . ... . . . . . . . . . .. 31
15 Tool set for maintenance

13.1 Tool set WI................ . . . .. ... •... . . . ... .............. . ... . . . . ... . .. .... ...... . 32
16 Maintenance system job sbeets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Job sheets . .......... . .. . . .......... . . . ..... . . .. . . .. . .. ................. . . .. .... . .35 - 78
Anti-corrosion measures and preservation ......... . . .. . . . ........... . . . . .. . . .... . .. Appendix
2
ZF 2500 Series Foreword
Operating instructions ZF-marine transmissions

1st edition
ZF 2500, ZF 2550
ZF 2500 U, ZF 2550 U
ZFW25 0
ZF2560 ~~--
ZF 2555
ZF 2555 U
ZF 2560 P
ZF 2500 A, ZF 2550 A
ZF 2555 A
ZF 2500 NR, ZF 2550 NR

ZF 2500 NRU, ZF 2550 NRU
ZFW2500NR
ZF 2560NR
ZF 2555 NR
ZF 2555 NRU
ZF 2565 NR
ZF 2500 NRA, ZF 2550 NRA
ZF 2555 NRA
The operating instructions 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 from those in the technical or commercial specification, then the data in the specifications apply.
important!
Ensure that these operating instructions are always on-hand. Read the operating instructions carefully, paying
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.
3
'Description ZF 2500 Serie
1 Description
1.1 Power, speed, rotation direction, ratio, type

plate
ZF marine transmissions are designed and manufactured

according to the regulations of the various classification
societies, The input powers approved by the classifica-
tion societies depend on input speed, the class of the
craft and the differing design regulations currently in Model 10 Intermittent operation
force. In most cases, the maximum torques approved by 2 Serial no. very widely differing
ZF are also fully accepted by the classification 3 Parts list no. engine speeds
societies. 4 Customer ref. no. II Intermittent operation
o 5 Transmission ratio differing engine speed
Upon request, either a full test or factory acceptance and ID letter for 12 Intermittent operation
test can be carried out by the classification society oil pump ratio widely differing engi
specified by the customer. 6 Oil capacity speeds
7 Mass (dry) 13 Continuous operatio
Normally, the input shaft rotates in a clockwise 8 Lubricants, see ZF max. engme power
direction (looking at the transmission input flange). List of lubricants
Transmissions which are specially designed for an anti- TE-ML 04
clockwise input shaft rotation (looking at the 9 Clutch oil pressure
transmission input flange) have an arrow on the (nominal)
transmission input end to show the rotation direction.
The respective ratio is stamped on the transmission type NOTE

plate which is mounted on top of the transmission For items 10 - 13, also refer to Section 12
housing. "Maintenance"
Data included on the type plate: Information under I, 2, 3 and 5 must be quoted whe
querying problems and ordering spare parts etc.
The letter stamped after the transmission ratio unde

has the following meanings:
Letter Rated engine speed Engine idling

during cont. operation speed
A 1650 to 2500 <: 415
B 1I00tol650 <: 275
004 6SS
Oil pump ratio A is the standard version.
4
ZF 2500 Series Description
1.2 General layout To ensure long life and low operating noise levels, the
teeth of all power-transmitting gears are designed with
The ZF 2500 Series consists of triple-shaft reversing high safety levels in mind, i.e. case-hardened, ground
and reduction transmissions with double clutch on the and subsequently subjected to special treatment.
transmission input shaft. The main components subject The shafts run in anti-mction bearings. Thrust bearing
to wear are concentrated on the input shaft and are are incorporated in the transmission to absorb propelle
therefore easily accessible. The output shaft is arranged thrust. The reversing clutches arranged on the input
below the input shaft. shaft are multi-disc clutches with steeVsinter discs
arranged alternately and operated by means of oi I
pressure.
The high delivery rate ofthe oil pump ensures rapid
clutch response. During gearshift procedure, the contac
pressure of the clutches is regulated to ensure smooth
f- ._ . _ - - - operation.
- - = Standard
version At the same time, there is an increased supply of oil to
f--
r;
--i I ----- = U version
r- 1-._._-- --It the clutch being operated, i.e. to ensure quick
r- --II
,- dissipation of the heat created during shift procedure
enabling the clutches to operate efficiently under
extreme load conditions.
The heat caused by trolling operation is also reliably
dissipated, even during continuous operation.
The cast-housings are very torsionally rigid and (with
the exception of the ZF W 2500) are made from a An easily-replacable control unit is installed on the
largely sea-water resistant light metal alloy. transmission housing, fitted with all valves, sl ides and
The ZF W 2500 transmission housing is made fTom control equipment required for the operating and
grey casting. The machined surfaces and threaded lubricating oil circuits.
connections required for transmission and bell housing
mountings are included as standard. The control unit on the basic version is actuated
mechanically by means of a control lever. Pneumatic o
electrical actuation systems are also available if
required.
Deviations in the NR series:

The ZF NR series is a range of step-up transmissions
with a clutch arranged on the transmission input shaft
Depending on version, the output rotation direction ca
be the same or opposite to the input rotation direction
Otherwise, design and external dimensions are exactly
the same as the ZF series.
· Transmission views (basic transmission) ZF 2500, ZF 255
2 Transmission views
2.1 Transmission views (basic transmission)

1 Transmission mounting surface
b 41 33
2,21,27 Clutch oil pressure measuring
points
JO Engine-dependent oil pump
11, 12, 41 Oil temperature measuring poi
14 Coolant inlet/outlet
10
15 Oil cooler
20 Oil drain
26 Output
26
33 Oil filter
b Suspension lugs for

transportlhondling
II 20
QO.l61 3/ 1
27
()()..4 61411
6
ZF 2500, ZF 2550 Transmission views (basic transmission)
T,'allslllission with clutch bell alldjlexible

coupling (special scope of supply)
2, 2 J elwch oil pressure measuring point
5 Measuring poinljor oil pressure

upstream offilter
7 Filter chamber, sediment drain
8 Input
20 Oil drain
22 Lube oil pressure measuring point
25 Oil dipstick
28 Flange surface for bell hal/sing
46 Oil fill point
a Rated clutch pressure (stamped)
46 5 25 22
21
27
00.164 811
\
7
Transmission views ZF 2500 Series
2.2 Special trolling version and trailing pump
18---------------/
004 61611
18 Tioailing pump (Special equipment)
c Trolling valve (Special equipment)
-
8
ZF 2500, ZF 2550 U Transmission v
2.3 ZF 2500, ZF 2550 U
Input and output 011 the same side

Transmission views ZF W 2500, ZF 2560
2.4 Transmission views
Transmission with c1utclt bell

7 5 37 a (special scope of supply)
1 Transmission mounting surfaces
8 5 Measuring point for oil pressure

upstream offilter
7 Filter chamber, sediment drain
8 Input
1
10 Engine-dependent oil pump
11, 12 Oil temperature measuring poillls
14 Coolant inlet/outlet
IS Oil cooler
18 Trailing pump (special version)

004885
20 Oil drain
27 33 10 22 Measuring point for lube oil pressure
25 Oil dipstick
27 Measuring pointfor clutch oil pressure
27 28 Flange surface for bell housing
25 14 26 Output
18 33 Oil filter
37 Inspection hole cover (transmission

housing) with oil jill hole
26
15
a Rated clutch pressure (stamped).
II 20 12 004884
10
ZF 2500, ZF 2550 A Transmission views
ZF 2500, ZF 2550 A
ZF 2500, ZF 2550 A
006379
ZF 2500, ZF 2550 V
006376
II
~
N ZF 2500, ZF 2550 '8) ZF 2560 '8) ZF 2555 ZF 2565 ZF 2550 A

eM
ZF 2500 U, ZF 2550 U' 8 ) ZFW 2500 '8) ZF2555 U ZF 2500 A ZF2555 A ....
•
Filter
contamination
C lutch oil pressure Lube oil
pressure
Oil temperature
~
::
Measuring point I) 5 2,21,27 22 II , 12, 41 _.
~
"'l
Operating condition "Neutral" 9) Shift position 9) Shi ft position 9) Operating temp. Trai1ing-
::
IrQ
" enginewise or "englllcwise or "Neutral~' temperature 8) Q.
~
counter-enginewise ' counter-enginewise < It
Rated value PKN 7) As shift
Nom. display min PK ~ PK( 4 ) position"engine- 0.4 bar 30 + 80°C '0) 30°C
value wise or COllDter-
max PVFK ~ PK + 6 bar PK ~ PKN + 1.5 bar eng. -wise" 5 bar max. 90 °c 17) 750C 8)11)
1050C 8) 12 )
Warning 20 bar s 2) 15 ) PK ~ PKN - 3 bar t 2) 5) 0.25 bar t 2) 95°C s 2)

24 bar s 2) 13)
Mi~imum monitoring '4) Pressure switch Pressure gauge 0 to 25 bar ThemlOmeter 0 to 120 °C
Additional Pressure gauge Pressure switch 2) 6) or pressure sensor 16) Pressure switch Temperature switch 2) or temperature
monitoring 14) oto 40 bar 3) or pressure gauge sensor )6) 0 _ 120 ·oC
0- 6 bar
Forfilrther details. refer 10 Section J3.1 8} For operation with sIOliol1a1), engine and current- f7} Must nol be exceeded during continuolls operation.
I} Refer 10 monitoring plan in inslallalioll manual for driven propeller (also refer 10 Section 2 of 80 - 90 °C temperature range causes worsening of
schemalic arrangement; refer to instalfation Operating instructions) heat transmission in the oil cooler after longer
drawing or operating instructions for arrangement 9} For normal operation \Vithout trolling periods of operation.
011 transmission 18} Wilh trolliflg or n'olling preparation
fO} Normal range. Water f low rate mllst he controlled
2} For optical and acoustic warning by the transmission cooler in this range (ensure 19) Not included in Jable above
3) Use distributor piece 111in.lmax. permisSible water volumes). Increasing
s
II) Witholiltrailing pump
4)
5}
60 °(' 10 80 °C oil lemperature
lVith lillie delay 5 - lOs f2} With trailing pump
Decreasing
~
h Clutch oil pressure N
J3} When PKN > 14 bar Ul
6} III shift position " trolling 011 {'. lI'amingjimcliol1 PKN Rated clutch oil pressure Q
Q
mllst be switched off f4} Not supplied as standard by ZF
P VFK Pressure upstream offilter and oil cooler Vl
~
7} The rated clutch pressure is specified in the binding
technical documents (order-specific) and also on
the type plate and in 'he control hal/sing.
15}
16}
WhenPKN J4bar
For remote display

--
"'t
~
'"
ZF 2500, ZF 2550 '9) ZF 2560 19) ZF 2500 NR, ZF 2550 NRI9) ZF 2560 NR '9)
ZF 2500 U, ZF 2550 U ") ZF W 2500 19 ) ZF2500NRU, ZF2550NRU'9) ZF W 2500 NR ,.)
~
N
(Jl
Filter- Clutch oil pressure Lube oil Oil temperature Q
contamination Q
pl"essure
Measuring point I) 5 2.21. 27 22 II. 12.4 1 _.
00-
tI>
"I
tI>
Operating condition ,.Neutral" Shift position Operating temp.
Shift position Trailing-
'"
"enginewise or ..englllewise or "Neutral" temperatureS)
counter-e nginewise" counter-enginewise"
Rated value PKN 7) As shift position

Nom. display min PK ~ PK( 4 ) "enginewise" or 30 + 80°C 30 °C
0.25 bar )0)
value "Collnter-
max PVfK ~ PK +6 bar PK ~ PKN + 1.5 bar enginewise" 7.00 bar max. 90°C 17)
I
105 0C 8)
Warning 20 bar s 2) 15) PK ~ PKN - 3 bar t 2) 5) 0.25 bar t 2) 95 °C s 2)
24 bar s 2) 13)
Minimum monitoring 14) Pressure switch Pressure gauge 0 - 25 bar Thermometer 0 - 120 °C
Additional Pressure gauge Pressure switch 2) or pressure sensor 16) Pressure switch Temperature switch 2) or temperarure
monitoring 14) 0- 40 bar 3) or pressure gauge sensor 16) 0 _ 120 °C
O-IObar
For jurther details, refer to Sec/ioll /3.1 8) For operation with stational], engine alld curren/- 17) Mllst not be exceeded during continllotls operation.
1) Refer to monitoring plan in installalion mallual for driven propeller (also refer to Section 2 of 80 - 90°C temperature range callsesworsening of
schematic arrangement; refer to illstallation Operating Instructions) heat transmission in the oil cooler ajier longer
drawing or operating instructions for arrangement 9) Not included in table above periods of operation
on transmission 18) Not included in table above
10) Normal range. Waterflow rate must be controlled ~
2) For optical and acollstic warning by the transmission cooler in/his range (ensure 19) Wirhout trolling and trolling preparation •N
3) Use distributor piece 111;I1'/mox. permissible water volulIles). Increasing
s
~
4) 60 °C t - 80 °C Oil temperature 11)
12)
Without trailing pllmp
Not included in table above
Decreasing Q
_.
::
5)
6)
With time delay 5 - lOs
Not included ill table above 13) When PKN > 14 bar
PK
PKA'
Clutch oil pressure
Rated clutch oil pressure

S_.
"I
7) The rated clutch pressure is specified ill the binding 14) Not supplied as standard by ZF
::
(JQ
Pr FK Pressure upstream a/filter and oil cooler
technical documents (order-specific) alld also on 15) When Pm 14 bar Q.
the type plate alld in the COl1lrol hOllsing.
16) For remote display
....:.>:.>
'"
Description ZF 2500 Se
4 Functions description
Transmission and powerflow diagram ZF ...

(ZF NR ... only has clutch 0 or E)
Gears are in
mesh
A - Input shaft Powerflow during:

B - Reversing shaft
C - Output shaft .....- - - - - - - A 4- Counter-enginewise
o - Clutch for counter- rotation
enginewise rotation
E - Clutch for enginewise ____..r-..JB!.....-r-- A 4- Enginewise rotation
rotation 4-C
The transmission and powerflow diagram shows the Full engine power is transmitted in both rotation
power transmission for "counter-enginewi se" output directions. The reduction stated on the type plate
rotation (input and output rotate in opposite directions) applies to both output rotation directions, i.e. the
as well as for the "enginewise" output rotation (input type of transmission can be used for multi-engin
and output rotate in the same direction). installations. This requires fewer spare parts and
permits the use of standardized replacement asse
14
ZF 2500 Series
5 Oil supply and transmission cooling 5.1 Control unit and transmission actuation
The transmission housings are used as the oil reservoir. The control unit is a complete assembly unit located on
An oil pump is installed to supply oil for transmission the transmission housing. In incorporates:
lubrication , transmission cooling and multi-disc clutch
operation. • Th.e valve spool for filling and ventilation of
Thi s pump supplies oil to the hydraulic system and is transmission clutches
dependent on transmission input shaft speed. A high
• The control valve for clutch pressure level
delivery capacity pump is used to ensure a large
quantity of oi l is supplied for transmission lubrication • The lime switch for clutch pressure modulation
and cooling, even at low transmission input speeds.
The valve spool moves axially in the respective shift
An oil pressure control valve is installed in the oil position. This occurs mechanically, pneumatically or
circuit to ensure oil flow remains constant and improve electrically depending on the type of actuation. The oil
transmi ssion efficiency. The valve redirects the surplus flowing out of the control unit is used to lubricate and
oil supplied at high engine speeds directly to the pump cool the clutch discs, tooth contacts and bearing points.
intake point.
For mechanial transmission actuation, the valve spool is
The oi l pump is driven by a spur gear set on the moved by means of the control lever mounted on top of
transmission input shaft. The spur gear ratio the control unit. The sLlift position selected is displayed
corresponds to the engine speed. on a scale. The basic transmission version has
mechanical transmission actuation.
A sea-water resistant oil cooler is integrated in the
transmission housing for transmission oi l cooling. After For pneumatic transmission actuation, the valve spool is
cooling, the oi l flows first through an oi l filter (slot- moved axially by means of compressed air. The
type filter), then into the control unit and finally to the compressed air cylinder with air connection points is a
clutches and lubrication points in the transmission. complete actuation device and is flange-mounted onto
the control unit. T he control lever for mechanical
The test unions on the transmission for monitoring the transmission actuation is retained and is dragged into
transmission temperature, oil pressure upstream of the the required position. Special versions of the
filter, lubricating oil pressure and clutch oil pressure transmission have pneumatic transmission actuation.
are fitted as standard. Refer to the transmission views
in Section 2 for positions and designations. For electrical transmission actuation, the valve spool is
moved axially by means of oi I pressure. The required
oi l flow is obtained from the control unit and controlled
electrica lly by solenoid valves. The hydraulic cylinder
with solenoid valves is a complete electrical actuation
device and is flange-mounted on the control unit. The
control lever for mechanical transmission actuation is
retained and is dragged into the required position.
Special versions of the transmission have electrical
transmission actuation.
15
Actuation ZF 2500 Series
6 Actuation The control lever is located on top of the control unit.

The shift positions can be seen on the scale marked on the
6.1 Mechanical transmission actuation control nnit and the markings on the control lever shaft.
CAUTION
Please ensure that the shift position for counter-
--
enginewise rotation, enginewise rotation and neutral
can be safely obtained. Furthermore, it is important that
the undefined shift range between "neutral" and
1,enginewise rotation'" and between "neutral" and
"counter-enginewise rotation" are bypassed quickly.
Operation whil st the lever is positioned in the undefined
shift range can cause damage to the reversing clutches.
To avoid errors of this kind, the shift linkage must be

install ed and adjusted in accordance with specifications
(see Installation Manual, order no. 3000 765 00 I).
Check the shift position after any repair or maintenance

work is carried out on the transmission as well as at
regular intervals. Correct if necessary.
6.2 Pneumatic transmission actuation
III 11 3 110 103 104 114
122--II---P'
105---l+---/
004 496
103 Shift position for coullter-enginewise rotatioll

104 Shift position for enginewise rotation
105 Control lever for mechanical actuation
121 Shift SlOp
122 Undefined shift position
(this position must be quickly bypassed)
123 Safe "neutral" range 103 Shift position for counter-engillewise rotation
124 Detent position for neutral 104 Shift position for enginewise rotation
110 Pneumatic actuatioll device
111 Air supply connection for counter-enginewise
rotation
113 Air supply connection for enginewise rotation
114 Detent
16
ZF 2500 Series Actuation
For pneumatic transmission actuation, the control lever 106 Electrical connection
is moved to the desired shift position by means of a ]40 Actuation pin for item 141
valve spool installed in the control unit. 141 Valve for auxiliary actuation
If there is no compressed air, the transmission can be 142 Settingfor electrical actuation
mechanically actuated by means of the control lever. 143 Setting for mechancial auxiliary actuation
For electrical transmission actuation, the valve spool is

'& DANGER
moved axia lly by means of oil pressure.
If there is no compressed air, the transmission
When the transmission is electrically actuated, the
automatically shifts to neutral.
manual control lever is moved simultaneously into the
This can cause the vessel to become unmanouevrable.
required shift position.
If there is a failure in the power supply, the transmission
can be manually actuated by means of the control lever.
6.3 Electrical transmission actuation
& DANGER - '

If the power supply fails, the transmission auto-
matically shifts to neutral.
This can cause the vessel to become unmanoucverable.
Actuation tension must always be on during operation,

do not use pushbutton.
NOTE: If contacting the boat manufacturer or ZF with

regard to the standard or special version, always quote
the information on the type plate. From June 1994
onwards, almost all transmissions were special versions
for use in conjunction with MTU engines.
A special version includes an actuation system whereby

the shift position is retained following power failure
(requirement of certain classification societies)
[fthe power supply fails, "ahead" or "astern" position

is retained. Power failure may not be noticed and can
cause the vessel to become unmanoueverable.
oos 220
101 Electrical transmission actuation
17
Operation ZF 2500 Series
7 Operation idling speed. Now, move transmission control lever to

"Astern" and keep in this position for approx. I to 2
During operation, the transmission requires little seconds. Then, increase engine speed to required
attention apart from monitoring the display device for operating speed.
transmission temperature and transmission oi l
pressures. 7.1.4 Emergency changeover in case of danger
In case of emergency, it is of course possible to carry

7.1 Changeover procedure out a changeover from "Ahead" to "Astern", even at
higher engine speeds.
According to our experience, the changeover
procedures as described in the following sections are However, in this case as well, we would recommend
optimum, i.e. shortest possible time for changing the that there is a time lag of approx. I to 2 seconds after
travel direction of the vessel and, at the same time, the "Astern" direction has been selected before increasing
greatest possible protection for the transmission the engine speed.
reversing clutches and the entire driveline.
We therefore strongly recommend that the changeover During such manoeuvres, please note that in many
procedures specified here are adhered to. cases (depending on the type of vesse l etc.), the time
Shifts from neutral to forwards or reverse position or needed to bring the vessel to a stop is not shortened at
vice versa must be carried out quickly; delays in the all or only very slightly compared with the changeover
undefined ranges between the shift positions are not sequence described above. Therefore, in spite of the
permissible. increased load on the propulsion unit, the chances of
avoiding a collision are not greatly reduced in most
7.1.1 Changeover from "Neutral" to "Ahead" cases.
or from "Neutral" to "Astern"
Move engine throttle control to idling position. Select 7.2 Operation with engine stationary and
desired travelling direction and keep lever in this propeller trailing
position for I to 2 seconds . Then, increase engine (trailing operation)
speed to required operating speed.
7.2.1 Occasional trailing operation
7.1.2 Changeover from "Ahead" to "Astern"
with vessel moving at low speed The basic transmission version (without trailing oil
(not for BU ... ) pump) allows occasional trai ling operation.
Move engine throttle control to idling position. Change The transmission oil temperature must be monitored
position of transmission control lever from current (measuring points 11 and 12 are in the oil sump) and
travel direction to opposite direction and keep in this must not exceed 75°C. If the oil temperature is too
position for approx. 1 to 2 seconds. Then, increase high, the vessel speed must be reduced. If required, the
engine speed to required operating speed engine can also be operated for a short time until the
transmission oil temperature falls below the max.
7.1.3 Changeover from "Ahead" to "Astern" permissible value as a result of coolant circulation
with vessel moving at higher speed (translnission in "forwards" or "neutral" position).
(not for BU ...) In emergencies, trailing operation is permitted up to a
period of15 hours.
Move engine throttle control to idling position. Leave
transmission control lever in "Ahead" position in order
to utilize the engine braking effect on the propeller
until the engine speed has dropped to approx. 1.2 x
18
ZF 2500 Series Operation
7.2.2 Regular trailing operation Operation notes (see Section 7.2)
If regular trailing operation is planned and lasts longer For operation with stationary engine and rotating
than 5 hours without interruption, a trailing oil pump propeller shaft. the transmission actuation device must
(see Section 7.3) must be installed. be in "neutral" position.
The oil temperature must be monitored and not exceed
105°C max. (sump temperature corresponds Monitoring notes
approximately to disc temperature). If the oil
temperature is too high, the vessel speed must be There is no need to monitor the oil pressures when the
reduced or coolant directed through the transmission engine is stationary. Only the transmission oil
oil cooler. The coolant quantity can either be obta ined temperature requires monitoring (refer to data in
by means of a special valve in the operative engine Section 7.2).
units or supplied via a separately-driven water pump. Furthermore, an auxiliary measuring point (41) is
Given the dimensions, a coo lant quantity equal to avai lable for measuring oil temperature (see Section 2).
approx. 20 % of the water quantity used during normal
operation can be reckoned with. Maintenance notes
However, if transmission oil temperature exceeds
90 °C, ensure that the transmission remains in Maintenance work 101 and \02 must also be carried out
"neutral" position until the transmission oil on a daily basis, even during operation with stationary
temperature has fallen below 90 °C after starting the engine and rotating propeller (see Section 12.1)
engine. Normal operation as described under Section 1
is only permissible after this point.
7.3 Special versions! Special scope of supply
If there are differences in operation and maintenance

for special versions or special scope of supply and
these are not described in the following sections, the
data must be obtained from the specification which
applies in each case.
7.3.1 Special scope of supply - transmission

with auxiliary trailing oil pump (item 1)
This oil pump is installed on the transmission housing

(transmission end opposite the input).
It is driven by a countershaft rulming from the
OQ.I 66S11
transmission output shaft. The oil pump always
supplies oi l to the oil circuit in the same direction
independent of output rotation direction. 1 Trailing pump (Trailing oil pump)
I f the engine is stationary and the output shaft is
rotating, this oil pump supplies lube oil to the
transmission. This means it is permissible to operate
the unit as long as required when the engine is
stationary and the propeller is rotating.
19
ZF 2500 Series
8 Operation with mechanical auxiliary 8.2 Transmission version with pneumatic actuation
actuation
+
104
+
005221
005 222~
If a fault develops in the actuation device, the 102 Disengaged position neutral
transmission can be operated manually using the 103 Engaged position: counter-enginewise rotation
mechanical control lever. For reasons of safety, the 104 Engaged position: enginewise rotation
normal actuation device must be rendered non- 115 Control position J 04: locked
operational before the manual control is used. Follow 116 Control position J 03: locked
specifications as per Section I. The shift position can
be checked in each case using the scale on the control The pnewnatic actuation device which is attached to
unit. the transmission control unit is designed so that when
there is no compressed air, the transmission is shifted
into neutral position by spring load. There is a locking
8.1 Transmission version with mechanical device attached to the lever of the control unit. In order
actuation to shift manually, the lever is moved into the desired
shift position against the spring load and held in this
Disconnect the push-pull cable or the linkage of the position . Then, the clamping bolt of the locking device
mechanical remote control on the control lever is loosened,.the locking device is moved into the
attached to the control unit. Then, move the control locking position and the clamping bolt is retightened.
lever manually to the required shifting position until it
stops. The control lever remains in this position.
Suitable measures must be taken to prevent the control 8.3 Transmission version with electrical actuation
lever from moving independently out of forwards or (see picture 6.3)
reverse shift position and into the undefined shift
range, e.g. as a result of vibrations. The electrical actuation device which is attached to the
control unit is designed so that when the power fails, the
transmission shifts automatically into neutral position. In
order to change over manually using the control lever of
the control unit, it is necessary to change over the
mechanically shifted valve (refer to drawing, page 21,
item 141). This is done by installing the actuating pin
140 the other way round. Unscrew cap nut to gain access
to this pin. The cap nut is then re-tightened. The control
lever can now be shifted manually as in the transmission
version with mechanical actuation. The control lever
remains in the position selected.
20
Trolling device
ZF 2500 Series
Function and actuation
9 Trolling device 9.3 Functions description
9.1 Transmission with trolling device Controlled slipping of the clutch discs assures propeller
speed is reduced at given engine speed. In addition, the
Additional information for description, installation, clutch oil pressure (which is used to press the clutch
operation and maintenance of transmission version discs together) is reduced to such an extent during
with trolling device. trolling operation that a certain level of slipping is
maintained. A considerably increased quantity of oil is
Applies for transmission models: used for lubrication and dissipation of friction heat
during trolling operation. This oil is passed through the
ZF 2500 ZF 2500 S clutch discs. The valves which control this increased
ZF 2550 ZF 2550 S lube oil quantity are preset and installed in the
ZF 2550 A transmission. The trolling valve used to change the
ZF 2555 clutch oil pressure is installed on the side of the
ZF 2555 S transmission control unit. This valve is mechanically
ZF 2560 ZF 2565 actuated by means of a selector lever.
9.2 Applications and operating range
With the trolling device, propeller speeds may be lower

!han those possible during nOli-trolling operation.
Typical applications include:
• When the actual vessel speed is too great at lowest

pemlissible engine speed,
• when an engine-driven PTO is being operated at

constant speed and the vessel speed needs to be
red uced.
Trolling operation is permissible for forwards or

:n"erse operation. During trolling operation the
;xope ller speed can be reduced to approx. 0.3 to 0.7 x
propeller speed during non-trolling operation .
21
Trolling device
ZF 2500 Se
Operation and transmission monitoring
The trolling valve is set in such a way that in almost all 9.7 Maintenance notes
cases, the highest possible propeller speed during
trolling operation is higher than the propeller speed Maintenance work (WA) 123 and WA 124 must a
during "non-trolling operation" and lowest engine used for the trolling actuation components.
speed.
WA 166 must also be used for the installed trolli
The ideal transmission oil temperature during trolling valve.
operation is approx. 60 to 80 °C. If the propeller speed
is set whilst the oi l is too cold and the oi l temperature
increases during trolling operation, the propeller speed 9.8 Trolling valve retrofit
will increase. In such cases, propeller speed can be
reduced by either reducing engine speed (if possible) Transmissions from the ZF 2500 series can be
or by moving the trolling lever. If B 1 / B2 is exceeded retrofitted with the trolling valve if the transmiss
due to the lower engine speed or due to the oil are prepared for trolling operation. In such cases
temperature increase in trolling operation (max. control valves for lube oi I flow in the transmissio
trolling position), the clutch closes and the trolling already installed, and the unit merely requires the
function is ineffective. actuation valve to be installed on the control unit
A lower propeller speed must be set on the trolling parts list number stamped on the transmission ty
lever to prevent this from happening. plate dictates whether the trolling device can be
retrofitted on the transmission.
NOTE
If transission oil is cold, low engine speed and low
power to the propeller can cause the clutch to remain
closed during trolling operation i.e. the clutch discs do
not slip.
Corrective measures: Brief increase of engine speed or Transm. parts lists with middle three digits S
operation at higher transmission oil temperature. e.g.
Cold transmission oil restricts the possible selecton 3082 000 ... to 3082 009 ...
range and sensitivity.
The trolling valve cali/wi be retrofitted to
transmissions with these parts list numbers.
Changeover to "non-trolling operation"
Move trolling lever to non-trolling operation position. Transm. parts lists with middle three digits
The trolling valve must be in the detent position C e.g. 3082 011 003
during non-trolling operation (see Section 9.4). are mostly retrofittable.
However, an individual test is required at the A

9.6 Supplement for transmission monitoring Sales Service in the manufacturing plant.
During trolling operation, clutch oil pressure is This also applies if there are oil supply opening
between approx. 2 and 5 bar, depending on the trolling the housing for the transmission actuation devi
speed set. The clutch oil pressure (measuring point 2)
does not require monitoring. Any clutch pressure
warning device which may be installed must be
switched off.
24
ZF 2500 Series Troubleshootin
10 Troubleshooting
If the input unit fails , it is often assumed there is a If it is not possible to rectify faults using this
problem in the transmission. However, in many cases, information, we recommend you contact the neare
external influences on the transmission can cause ZF Service Point.
fai lures.
The following troubleshooting charts describe the most

Iikely problems, their causes and corrective measures.
-
Troubleshooting ZF 2500 Series
Fault Possible causes Corrective measures

Transmission oi l • Insufficient water flow --) Increase water flow
temperature too high through cooler
(Measuring points 11 *, • Sludge in oil cooler --) Clean oil cooler, see Maintenance Work
12* and 41 *) 169
• C lutch disc damage --) Check cI utch
• Gear ratio not properly engaged, --) Adjust shift mechanism
clutch slipping
Transmission oil • Excessive water flow through --) Reduce water flow
temperature too low cooler
Oil pressure upstream • Clogged filter --) Clean filter and drain off oil sludge
of filter too high
(Measuring point 5*)
No operating oil • No oi l in transmission --) Add oil

pressure (Measuring • Wrong direction of rotation at --) Use special transmission version
points 2*, 21* and
27 *) transmission input
• Defective display unit --) Rectify fault
Operating oil pressure • Low pressure slide jamming --) Loosen piston
too low (Measuring • Oi l viscosity too low --) Use a recommended oil grade
points 2* , 21* and (see List of Lubricants)
27*)
• Spring from shift pressure valve --) Replace
contracted
• Incorrect shift pressure valve setting --) Reset using shim
• Defective oil pump --) Replace oil pump
• Fi Iter safety valve leaking --) Check for clogging/wear
• Time switch for pressure modulation --) Replace piston and sealing element
defective
• (Trolling) flow. limiting valve jamming --) Loosen piston
If the fau lt cannot be rectified, the lube oi l supply to the transmission is also at risk.
Proceed at reduced engine speed until repairs can be carried out.
Operating oil pressure • Oil viscosity too high --) Use a recommended oil grade
too high (Measuring (see List of Lubricants)
points 2* , 21* and 27*)
Drive interrupted • Incorrect shift angle for mechanical --) Adjust setting
between transmission transmission actuation
input and output; clutch • No operating oil pressure --) See remedy for no or insufficient
not transmitting torque operating oil pressure
* see Monitoring Diagram, Section 3.1

--
and 3.2 and Transmission Views Section 2
26
ZF 2500 Series Troubleshooting
Fault Possible causes Corrective measures
Drive between • Incorrect shift angle for mechanical --? Adjust setting
transmission input and
transmission actuation
output cannot be • Scored idler gear --? Contact ZF Service Point
interrupted; clutch
does not open • Clutch discs dished --? Contact ZF Service Point
• Operating oil pressure too low --? See remedy for "Operating oil pressure
Clutch sl ips at high
(Measuring points 2*, 2 1* and 27*) too low" . If the fault cannot be rectified
engine speeds
on board, proceed at reduced engine
speed until repairs can be carried out.
Avoid changes in direction. Tf this is
unavoidable, the ships propeller should
be almost at a standstill with engine
idling speed as low as possible.
• Incorrect oil --? Replace
• Discs worn --? Contact ZF Service Point
Oil level sinks rapidly • Leaks on housing joints, oil pipes- --? Correct mechanical faults
(as indicated on or shaft sealing rings
dipstick) see • Oil cooler leaking into coolant --? Repair fault, replace oi l cooler if
1aintenance Work 101 system necessary
··Oil level check"
Oil level increases see • Water entering the oi l circuit from --? Repair fault, replace oil coo ler if
Maintenance Work 101 the cooling system necessary
··Oil level check"
Transmission operates • Torsional vibration resonance of drive- --? Increase engine idling speed
100 loudly in engine unit in engine idling speed range
idling speed range
Engine stalls during • Engine idling speed too low --? Increase engine idling speed
rapid change from • Change in direction effected too --? Changes in direction as per Section
-Ahead" to "Astern" quickly or with travel speed too high 7.1.3
• Discs dished --? Contact ZF Service Point
I • Idler gear clamp, axial play too low --? Contact ZF Service Point
• see Monitoring Diagram, Section 3.1 and 3.2 and Transmission Views Section 2
27
Service Points
Spare parts orders ZF 2500 Series
11 Spare parts orders and Service Points The following information must be quoted at all times
when ordering spare parts and making enquiries:
If transmission faults cannot be corrected using the • Model
troubleshooting charts in Section 10, please contact the • Transmission no.
nearest ZF Service Point. o Parts list no.
A list of ZF Service Points including the latest telex o Transmission ratio
and telephone numbers can be ordered from ZF
Friedrichshafen AG if required. This information is stamped on the transmission type
plate.
During repairs, only use genuine ZF spare parts. In the case of transmissions with classification, note
that the 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 parts list is

quoted when ordering and when requesting exchange
translnission units.
28
ZF 2500 Series Maintenance
12 Maintenance
12.1 Application group P 12.3 Application group M
• Engine data for transmission allocation: max. power • Engine data for transmission allocation: max. power
for intermediate operation for intermediate operation
• Type of operation: Intennittent operation at extremely • Type of operation: Intermittent operation at various
wide range of engine speeds engine speeds
• Annual operating hours: approx. 500 • Annual operating hours: approx. 3500 h
• Preferred hull type: Planing • Preferred hull type: Semi-planing, planing
• Typical applications: Private, leisure and pleasure • Typical applications: Working boats, charter boats
craft
• Typical examples: Crew boats, supply boats, fishing
• Typical examples: Private, pleasure and leisure craft boats, coastguard boats, passenger boats, ferries,
yachts etc.
12.2 Application group L 12.4 Application group C
• Engine data for transmission allocation: max. power • Engine data for transmission allocation: max.
for intennediate operation continuous power
• Type of operation: Intermittent operation at extremely • Type of operation: Continuous operation at max.
wide range of engine speeds engme power
• Annual operating hours: approx. 2500 h • Annual operating hours: unlimited
• Preferred hull type: Semi-planing, planing • Preferred hull type: Displacement hull, semi-planing
hut
• Typical applications: Navy vessels, authority vessels
und gleichzustellende Schiffe, private charter boats • Typical application: Working boats
• Typical examples: Fast boats, yachts, patrol boats, • Typical examples: Tug boats, push-boats, supply
police boats, customs boats, coast guard boats, pilot boats, fishing boats, passenger boats, cargo ships,
boats, fire service boats, rescue boats, recreational ferries etc.
fishing boats etc.
29
rMaintenance SChed~le ZF 2500 Series
13 Maintenance schedule
13.1 Regular maintenance
Maintenance level Application Interval (Operating At least every

group hrs.)
Al all Everyday of 3 months see

operation also Kl; K2
A2 all 500 6 months
A3 all 1000 I year
C and M ------------------ 5 years

A4
L and P ------------------ 8 years
during every operating condition

A5 all basic overhaul of gearbox
of engine
13.2 Additional one-off maintenance jobs on new

or overhauled transmissions (see also Maintenance Work 12. I)
Maintenance level interval (op. hrs.) At least every
ZI 50· 100 12 months
13.3 Anti·corrosion measures necessary after

long periods of downtime (see "Preservation" attachment)
Maintenance level Procedure Pause in operation Note: see appendix
KI all 10 to 20 days to 6 months
K2 at end of 9 months ZF Marine gears

operating period Al1li-corrosion protection
(3070 755 001)
K3 at end of max. 36 months
operating period
30
-
- . ' -, ,., •
ZF 2500 ~eries 14 Maintenance schedule
)laintenance level 14.1 Maintenance jobs Tools

required
F egular y Once
A5 A4 A3 A2 AI 21
10 1 Oil level check None

I!.
102 Turning of oil filter handl es None
t"
.- 103 Visual check None
121 Cleaning outside of tran smiss ion None

I,r iif!,
i
122 Retightening of bolt connections Tool kit
I' i accessible from the outside
123 Control position setting check None

.'Ill .'1
124 Lubrication of external moving parts None
I- F
14 1 Oil change Tool kit

Iii
142 Cleaning of oil filter Tool kit
.~J._' ,if
! "
161 Flexible coupling; visual check None
162 Transmission mounting; visllaJ check

,
(does not apply to 100% metal coupling) None
1 'ie
163 Clutch discs; visual check Tool kit
164 Gearing; visual check Tool kit
165 Oi l pump check WI
• 166 Control unit check WI
'i, II 167 Actuation device check WI

,
169 C leaning of oil cooler ~------
'III
173 Input shaft seal check None
174 Output shaft seal check None

••
200· Basic overhaul of transmission W2
TI TI TI -- -- --TI
+ +
T2 T2 Spare parts required
+
NB
• = See Workshop Manual for instructiOns T I, T2 = Part sets, see Spare Parts LIsts
NB = Spare parts as required WI = Tool set, see Operating Instructions
W2 = Tool set·,...ee Workshop Manual
31
GOO) sets for maintenance ZF 2500 Series
15 Tool set for maintenance
15.1 Tool set WI
Tool set WI consists of commercially-available tools. Commercially-available means e.g.
General tools
Open-end wrench up to width .... . ..... . .............. .. ..................... . .... 63 mm
Straight ring spanner up to width .................................................. 46 mm
Offset ring spanner up to width .. ...... .. . . . .. . . .. .......... . .. ............ ... .... 46 mm
Socket wrench set . . ..............•.... . . . . .. ..•. .. ............ .. ...... ...... 4 - 13 mm
Socket wrench set .................. .. ...................... . . . ... . ........ . I I - 32 mm
Socket wrench set . . . .......... .... .............. . .. ... . ... . . .. .. .. . .... . . .. 22 - 50 rnm
Socket wrench set for internal hex bolts/screws ..... .. ........ . . .. . ......... .. ..... 5 - 22 mm
Pliers (straight) for retaining rings (inner rings) ... . .. . . ... .. ... . . .. . . . . . . . . . ... . . I I - 4 (No.)
Pliers (straight) for retaining rings (outer rings) .. ................ . ..... . . . . . . . ... A I - 4 (No.)
Screw driver ....... .. ..... . . . .. . ........... . .. . ...... . .. . . ... . .... . ...... . .. to 13 rnm
Hammer (metal + plastic), punch
Measuring and test equipment
Torque wrenches .. . ........... . . . .... .. ............ . .. . .. .. . . ... . .... .. ... 10 - 350 Nm
Vernier caliper, depth gauge ... . .. ...... .......... . ... .. . .. .. . . Measuring range up to 300 mm
Feeler gauge ..... . ..... .. . .... . ................... . ........ Measuring range 0.05 - 1.0 mm
32
ZF 2500 Series Maintenance system job sheets
Page
16 Maintenance system job sheets
101 Oi l level check. . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . .. 35
102 Turning of oil filter handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
103 Visual check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
12 1 Cleaning outside of transmission 41
122 Retightening of bolt connections

accessible from the outside . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 43
123 Shift position setting check . . . . . . . . . . . . . . . . . . . . . . . . • . . • • • . . . • • . . . . . . . . . . . . . . . . . . . .. 45
124 Lubrication of external moving parts ......... . .................... .... ..... . ... . .. .. 47
141 Oi l change .. . ... . .......•••• ...•••...• •.. ..... ........... .. ...... . ....... . .... 49
142 Clean ing of oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
16 1 Flexible coupling; visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • . . .. 53
162 Transmission mounting; visual check (omitted for 100% metal coupling) . . . . . . . . . . . . . . . . . . . .. 55
163 Clutch discs; visual check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . .. 57
164 Gearing; visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . .. 59
165 Oil pump check .. .. .. ... . . ... ... ...... . ...... . ....... .. . .. . . ........ • .......... 61
166 Control unit check ... ... .. .... ..... . . ... . ............... . ..... ..... ..• ... ...... . 65
167 Actuation device check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . 69
169 Cleaning of oil cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 73
173 Input shaft seal check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 75
174 Output shaft seal check . .. .. ... ... .. . .. .. .... ... ... .... . .... .. . . . .. ....... . . .... " 77
33
_'" CO,C _ _ __ __ C~ -" ,. -~'-~'1
m~, '"
. .
MAINTENANCE SYSTEM JOB SHEET
- - ~,
I
Trans. type: ! ZF 2500 Series

Maintenance work
~
... - I'
." .. .
Maintenance level
~ ; .
Related maintena nce if Ir Ti~ein - ~l

no.
I: i possible as per • mm.
101 Al ---..- - 10
.- .~
!
Description of Ii
maintenance 101 Oil level check
work
,
.-.
--
Only w ithdraw oil dipstick when engine is switched off. Otherwi se, thi s can lead to hot oil
spraying out and risk of burns.
Safety ,
measures:
I Only add oil when engine is switched off. Otherwise, this can lead to hot oil spraying out and
ri sk of burns.
I _.'c.
Tools: £"
-, ..... .,-.
,
• . ~
Parts :
•
-
-~" ~..
.-,-
,.
I
Material:
"
-""
-
.
i
I
, non· textured cloth
Test equipment:
,
.. - -
_ c ...
• " ,.~
,-,
Procedure:
I see reverse
.1
IPlace.:. .~ -~.
-- "1 1 ~ .-
- -- ,~
I
Page: 1 - 'X,- "",,"
of: 2
- '. ~""~
35
During initial fill and following repair or cleaning of
oil filter, take into account that some of the oil in the
oil cooler remains in the oil lines and filter chamber
rather than flowing back into the transmission
housing. Therefore, check oil level again after a short
period of operation.
The correct oil level is between the upper and lower

marks on the oil dipstick.
max.
mln.
To fill with oil, unscrew oil f ill screw and add oil.
004629
36
1!l1lf:; ~. -- --
_.
~.
~. - .x- "''''.,
. ~ . ~,- ,~ .... - - . ......... ... .

,~, ,
if' Trans. typ;~: ZF 2500 Series

,-! Maintenance_.work
, Maintenance~el
. :- .., '.~
r' Iimei; = tlllj
~
'
Related maintenance ~
,I no. work if possible as per min.
r,' • I
102 Al ----- 5
-,
Description of
maintenance I 102 Turning of oil filter handle
work: i
j
M
- '''1''
~
I. ,~
I
I- Safety ,"1
Ii measures: ,~
~
I
I'f,
•
ii
- ~-
_,~,
Tools:
~ . . =" . 1
I
~ Parts:
"
-
Material: ~
w...." ., ~.~
" • "" ~ . -
..
~
'1*
Test equipment:
~
J1
~
~
Procedure: ! see reverse
j
I. Place:=<'" T -, -.,~
1 1 -Date
Il ~1~1-
: _'on'
~'
_
.. ' .~~
~
.
Ip;gt;.;.1 "
.~
of: 2 '\~'-;I
37
Slowly rotate the slot-type filter handle for I to 2 turns
in a clockwise direction.
004626
38
--
Im k :w'cc_~~!~~~~,
-
~~SYSTE,M
~
".
JOB SmiET ....
,
- -
Trans. type:
, ~,
MaiDtenance '~rk
~ ..'I
, 11
ZF 2500 Series
Maintenance level
c,c", ,..,...
Related maintenance ! Ir rime in :r
no. Ij work if possible as per " min.
.e, I '
' iI
103 Al 121 10
_e
= •
Description of •
maintenance 103 Visual check
work:
.~d"~
-
__ .. MA.
e_ ~
Safety Always carry out visual checks an appropriate distance away from rotating parts. Otherwise,
measures: there is danger of contact with the rotating part.
- .~~ :
Tools:
I
e,* _"'._ I
Parts:
.- '_.
Material:
j
...=".
.w -_'!i>!3!'
Test equipment: I
1' -
--.-~ .. '
Procedure: see reverse -
. ~ . :
-
_ _ _ _ LbiC3
I Place: "- '. I,-:Date: c;l'ltO ~.
I Page: 1
~,
'C'
of: 2
.~
39
Check outlet points of input / output shafts on
transmission housing, oil line/monitoring unit
connections and coolant connections for leakages
(visual check).
004667
40
~
. ,
- -,
I m~ l.
~.

'Ti -- ~-.
~-
- ._,. ,~-
'.- , ...• " .•. ,~ ,~_~m' ,.~_
Trans. type: ZF 2500 Series

..
_. --
~Ilintenance ~ork- - ~ainternce level Related":aintenance r.... ," ' Ti~e i)t~ "'--'1
no. work if possible as per mm.
121 A2 103 30
~.
'1
Description of
maintenance ,I 121 Cleaning outside of transmission
work:
--"~
I
j
il
~
Safety
measures:
I Only use cleaning products specified in the regulations for the prevention of accidents.
'~
'--.. -,.
~.-
Tools: Tool set (on-board)
._J
,,
Parts: I Cleaning product
- -:
.1
\
~aterial:
'- ~
_.
.. ---..
Test equipment:
Procedure: 'i see reverse
I. Place: ._- g;-: 1 -. . _.-.
~
1.::
~
.. , .i ", __ ,",~ .. - * Date: ~~

- Ilpa
-- of: 2
-
41
Clean outside of transmission using cleaning product
to simplify visual check (see 103).
important: Do not allow cleaning product to come

into contact with rubber parts,
hosing/piping and shaft seals.
004670
42
-
~
,~
--~ ,~'n' _c , c ~ -""".. ~,
l!tIkL
.~, , ""'" ~'"'~''''1'i1)
._-
- - ,,m .-"""'~ ""-- """"'''''' -,. ... ""~
Trans. type: I ZF 2500 Series

.~ :
Maintenance work
..
-- ,.': I -',--
Maintenance level
, ~.
i :-
I Related maintenance
" '-. r - - Time in = ~~
II no. III I
I work if possible as per
j
min.
"
122 Zl ---- 20
r Description of
~
II maintenance 122 Retightening of bolt connections accessible from the outside.
work: 1
.~
"W
W
~ Safety
Only retighten connections when transmission is stationary,
measures:
~
,
i
11,
1"
-- ,.
'!wr'l·
~
Tools:
III. ~1Mi$!1IIi$k'",.lm, ' ~,
Parts:
";
Material:
, _II:iI"X
- .
~
Test equipment:
l ,,'" I
'- -
I Procedure: , see reverse
I
- -,
I [Place:
'ti'
- -
N,' ' -,~
-,
,
IiD-;;t~: --
~'~, '
: 'WPage: f , of: 2_ '~-]
43
Retighten all accessible bolt connections.
Pay particular attention to the following connections
). Enginelflexible coupling
). Flywheel housing/transmission bell housing
). Mounting bracket/transmission
).. Mounting bracket/foundation .
Also check connections to and from oil cooler as well
as monitoring equipment connections. Retighten if
required.
Tighten bolts to specified tightening torque whilst

transmission is cold (approx. 20°C).
44
wJ~ ARINE
.-
'" -- MAINTENANCE
__ _
SYSTEM"
__
JOB
__
SHEET
_
"
__• ~_ ~ __."~,
-I
Trans. type: _I ZF 2500 Series
I, Related maintenance Ie-=-
. ~.,*,", '
Maiiitenancelevel ~ %~ Tim:in ~-"

,
Maintenance work -
no. work if possible as per min.
, 0', t, il' '1'
123 A2 -------- 15
-
of !
De~criptlon
mamtenance ,; 123 Control position setting check
work:
---"'''-- -
"
Safety Block engine starting device.

measures: I Otherwise, there is danger of boat setting off.
-
,
Tools:
•
Parts:
.~
-
Material:
.,
-~ -"'-" .""
Test equipment: I
..
I
I
Procedure: see reverse
I
,
- -- .- .
-.." ""'r
I[Date: I Page:." 1 "''"'"
••
~'" "k~
"-'¥,",~
-, I "'\"\ ' ""i:tW , -~
I' Place: of: 2
45
Only required for "mechanical transmission actuation"
verSIOn.
Loosen mechanical connection between transmission

shift lever and transmission rail/pull-push cable.
Set shift unit at "Neutral". Move transmission shift
lever to "Neutral" detent position.
Bores on transmission shift lever and shift rail as well
as on fork head of pull-push cable must be in line.
Move shift unit into "Forwards" position and move
transmission shift lever into "enginewise" and
"counter-enginewise" position until the stop.
The transmission shift lever bore must be in line with
the bores on the rail and fork head.
Check "Reverse" shift position in the same way. These
shift positions must be easily obtainable. If required,
the sh ift on the transmission rail must be reset. Under
no circumstances must the shift lever remain in the
• I • undefined shift range between "Neutral" and "Ahead"
104 123 I 124 103 or "Neutral" and "Astern".
~~
~t~~
.~1~ \ I, \OQ J O~ I <'¢':,':
J03
J 04
J05
Counter-enginewise position
Enginewise position
Shift lever for mechanical actuation
~
~ .--"\
\', .......-+'_
. 1-'_ _o
,
-,'r . 121 Shift stop
121~ Y~~~--~=l-L--121 J 22 Undefined position
'"
122--ft-...P' 123 Safe neutral range
124 Neutral detent position
105-tt---'"
004496
46
.. Il Ik . '--MAINTENANCE~SYSTEM
IMARINE __ ~ ~.
JOB SHEET .......-:
_ _ _ ...
.. .
R
- . - -
- Maintenance work"J
i
.
-~
,
;- ;....,.
Mamtenance level
-- .. ; _. , . ,..----
I! Related mamtenance ! I r~- Time in
.--; - '"
no. I' II work if possible as per Iii min.
..
, .
I
124 A2 ----- 15
.- ...,,....
Description of
124 Lubrication of external moving parts
maintenance
(Only required for "mechanical transmission actuation" version).
work:
. .-
... ..
,
Safety
measures:
;
, i
.1
•
Tools: J
J
Parts:
-- 'Ii:ll*iililliDIT.¥
- _.<-
!, Material:
I
... .~.~
-- 0
Test equipment: '

~
- .- " '"
~
Lightly lubricate the moving parts of the mechanical transmi ssion actuation unit using
I~
II Procedure: lithium-saponified multi-purpose grease (fork head on transmission shift lever, rail
i connections and connection to shift unit).
I· •• ,
•.. "H "",;;a;;t&""*,!l"'" "-- .. . ' ' 'i< . "1Ii~ ;%ilI, iill,}". ~"~~1IlIII
1 Date: _I Page: 1 of: 2
47
mlf:;' -=
c. ·",,~ ·
,
"''''" "'"
~
...- --
co
-
" Ma~enance work' 'i
I
.~ ~aintenancelevel I Related Ir" Tim:e in ' """-',

no. j ,I work if possible as per I!
mm.
,
-
141 A3 142) 163 1164 30
.~.",n' _
Description of
maintenance 141 Oil change
work:
I- I Block engine starting device.

Change oil at max, 40 to 50°C oil temperature, Otherwise, there is a risk of burns.
Catch used oil in an appropriately large oil container to prevent hann to the environment.
Safety
measures: Oil quantities: ZF 2500, ZF 2550 approx, 28 I
: ZF 2500 S,
BW251
ZF 2560
ZF 2550 S approx,
approx,
approx.
28
55
55
I
I
I
.~ ."J
~
Tools: • Tool set (oil-board)

.n ,
Parts: New seals
- , ,.,-
Oi l grade :
Permissible oils as per appropriate "ZF List of Lubricants TE-EL 04 for ZF marine
~aterial:
transmissions". A currently valid list of lubricants is supplied with the transmission. This can
also be ordered from any ZF Service Point
-
Test equipment:
-,
..
- ..- -- - ..- ..
~ ~
I Place: ~
I Date: I Page: 1
- .~
of: 2
49
If possible, carry out this work in conjunction with
maintenance work 142.
Remove oil dipstick. Unscrew oi l drain screw and

drain oil.
If the transmission includes an oil suction device,

remove oil by suction.
004627
Place new seal on oil drain screw. Rescrew and

tighten.
If the transmission has an oi I suction device, re-c1ose

the suction device.
004628
To add oil, unscrew oil fill screw or remove inspection

cover.
Add new oil
ZF 2500, ZF 2550 approx. 28 I

ZF 2500 S, ZF 2550 S approx. 28 I
BW251 approx. 55 I
ZF 2560 approx. 55 I
Then, apply new seal to oil fill screw and inspection

cover before retightening.
Finally, check oil level as per maintenance work 10 J.
Readings /llIISt be taken /Ising tire oil dipstick.
004629
50
""
- - ~
- - - -
lW1k
"

- - Trans. type:
c,'.
- - - - - -
_ ; ZF 2500 Series
~- - ~
.""""'~ =
-
' MaiDten ance \~ork
""" '
r IrI --
" 0" " " " - ;
Maintenance level Related maint;;na"n~e Timei;"" -
,n
no. i work if possible as per I min.

! l
142 A3 141/163/164 30
-- - I
Description of
maintenance 142 Cleaning of oil filter
work:
w
,'~-
!'l:<II~~_
i
:
i
Block engine starting device,
Safety I
Catch used oil in appropriately large oil container, to prevent harm to the environment.
measures:
!~
I Oil drain quantity: approx,2 I
I'
I~ ¥ I

II "
, -='~.--""
'M
Parts: I FiIter gasket and seal
w,*",,, .. ~ ...-,- I
Oil grade:
Permissible oils as per appropriate "ZF List of Lubricants TE-EL 04 for ZF marine
Material:
transmissions", A currently valid list of lubricants is supplied with the transmission, This can
i also be ordered from any ZF Service Point
~ ,'"' " -
II Test equipment:
,.. -
1"--
IF
, Procedure: see reverse
,
- ,
I,, Place. - ---- w-
' "~- I,Date. . I I Page.. 1; r"

,
of. 2 'i'
- 'I
51
If possible, carry out this work in conjunction with
maintenance work 141, 163 and 164.
Rotate handle of oil filter whilst transmission is

stationary as described in maintenance work 102.
Unscrew sludge drain screw and empty fi lter chamber.

Catch escaping oil in container.
Oil drain quantity approx. 2 1.
Once the securing nuts on the filter head have been

removed, remove filter insert. Ensure that no dirt
enters the pure oil section of the filter housing.
Clean filter insert using diesel oil or petroleum cleaner

turning the handle several times in the process (do not
dismantle filter).
When cleaning, only use a brush. Never use textured
cloths or tools such as screwdrivers, scrapers etc.
Use a new filter gasket and seal when re-installing the

004685 filter and sludge drain screw.
Installation procedure is the exact reverse of removal
procedure.
52
- - -
mk, ", , ~,
'~-
~
MAINTENANCE SYSTEM JOB SHEET i
- - --
J
.,
-
Trans. type: j' ZF 2500 Series
~,~
-
,~ ,~
--
.. " "
" ~ Related mailitenance I
Maintenance work-
no. ,I Maintenance level
4 work if possible as per II
Time in
min.
I .,', J iC_, ' II
161 A4 --------- 30
'0
,
Description of
maintenance 1 161 Flexible coupling; visual check
I
work:
- -- II
Safety !
measures: ia Block engine starting device.
~
;;
il.
Tools:
~- "" . .J
Parts: i
-- ~
Material: I
I
,_W" ~~ ""J' _
-
Test equipment:
". ~,~
- ,

i
.. ~ j
-- .•- -- 1
- ~1; 1 Page: 1 _ .- of: i~
M
Place: Date:-'
53
Check rims of flexible coupling are in perfect
condition. To do this, run engine slowly and check
rubber parts visually through bell housing view hole.
004681
Check rubber parts for cracks, embrittlement and

signs of overheating.
004682
Check markings (if present) for torsional distortion.
004683
54
q
mfii
----~ £- --
- - .. "
"'" w . .•. ._,
. ~. ",'
.~ - - .- _ d..' _~ •• ~ H .... _ J

-
Maintenance wo;:'k'~~ , - Maii:ienance level Related : ;::';, ~"ii' ~.-. "'Time in-
no.
I? II
possible as per
I
min.
i
162 A4 ---------- 15
Description of
maintenance
work:
i
:'
162 Flexible mountings for engine and transmission; visual check (if available)
- .",.,
."'....
Safety
measures: . ,
• ="M ,,",,,,.
., = n",
1
Tools:
.-
I
~".
Parts:
II ..-
Material: "."
I
~.
'n ~
I Testequipm~nt:
"'--- .
Check rubber-bonded metal mountings on engine and transmission are in perfect condition.
Procedure:
Rubber parts must not show any signs of cracks, embrittlement or other damage.
,
-- - - .-
''f''llM<
- --
I Place.
~ -",:
--- - ..·· 1I Page.1 of. 2 ""'"
55
- - '-
. _., _0
mk,
~'"".,,"',
,- ,- MAINTENANCE SYSTEM JOB SHEET

--
",- " -""'"
.._- ,
,..-~- ,~- ~~
~

_.'"" ,~, Maintenance hlvel
' ."''''' ' ..
' , ',
" Time in " .,
Maintenance work no. Related maintenance
, H ' I •
work if possible as per min.
163 A4 141/142/164 15
Description of
I maintenance 163 clutch discs; visual check
work:
I: - .• "
II ~-
I
Block engine starting device,
Safety
Remove all parts which could fal l into the transmission once the inspection cover has been
measures:
opened (anyone working on the transmission should empty their breast pockets),
,
.-,
'-
,
~
Parts:
Material:
I, ."
• , =~
~
,ITest equipment: '
1&..
- ,
IPlace: - ,~
1.2ete : "
_w
-
,,', -, _' Page:•.'.1 . ,
"~ I ~ , M :2
.~
r~-
I
57
It is advisable for this work to be carried out at the
same time as the oil change - see maintenance work
141.
RelTIOVe inspection cover.
004629
Check disc pack. The discs should not show any signs
of overheating and it must be possible to move them
axially (disc play approx. 1.2 to 3 mm per pack). Also
check di sc play between individual discs.
58
.- -
,~, -
-~ --
I. 1'III'iEi'liilid!i!W
-,-- - ~-,
Trans. type: .'j ZF 2500 Series

~ ~
II Mai: tenance work no, !

m
I Maintenance level :", ," ',

, ,Related mamtenance ~'II
[:
. I work if possible as per : •
,. Time iii-
min.
,
164 A4 141/142/163 15
Ii
-" '"
:!
Description of I
II maintenance 164 Gearing; visual check
IIwork:
.~ ...,
II
! Block engine starting device.
Safety
, Remove all parts which could fall into the transmission once the inspection cover has been
measures:
opened (anyone working on the transmission should empty their breast pockets).
i
Tools: Too l set (on-board)
I
- i
Parts:
- --
Material:
Test eqUiPment: !
---. ~
I'"Place'"t ' ' ' -

, -- I Date: -
--
,~
59
It is advisable for this work to be carried out at the
same time as the oil change - see maintenance work
141.
Remove inspection cover.
Check teeth of gears on input shaft, reversing shaft

and output shaft. The tooth flanks must not show any
signs of pitting or similar wear.
004632
60
,!lIk "~ ,~ ~AINTEN~~~ - SYSTEM JOB SHEET
--
.' .~~
~ _. " - ,.,. ~

I! Maintenance '~ork no. 1 .
~ ~.
. .. .'....
Maintenance level
I '
, ..,..
Related maintenance
.". .- Time in --
Ii ."
work if possible as per
I'
;
min.
I
165 A4 -------- 180
,.
i j
r Description of 165 Check oil pump

maintenance Engine-dependent pump (primary pump)
work: Trai ling pump (secondary pump). Not on basic transmission
.
I
i
I',
!
i Safety I If removing oil pump, ensure engine starting device is blocked.
measures:
['
- iIII<lW: '-' jf '-": - ~,
~ Tools: Tool set WI
I ~L .~" J
I,
! Parts:
I·,
r -~""" .. ~
-
Ii,
f Material: "Hylomar SQ 32-M Special" sealing compound (Marston)
I
.~ ~ - .., . .~"j
r'
,
~. ~.
, Test equipment:
.... - -, _.
I
"
-
I
..
~
- -
- IPage: 1 -." ' -" ' "
I Date: "'
~.,
~-- ' ~
1,·Place: of: 3 i
61
Engine-dependent pump (primary pump)
NOTE: The oil pump is a complete part and is not

generally dismantled. However, it is sometimes
necessary to dismantle the pump for checking or
cleaning. Items to check on the dismantled pump
particularly include tyres/rims, mounting play and
pump gear/pump pinion axial play.
Axial play:
"A" 0.03 to 0.08 mm
Removal and dismantling
Remove piping as required. Remove pump.
Unclip retaining ring (5) .
3 5 Pull off input gear (4).

Remove fitting key (3).
7 Remove bolts on pump cover.

Drive out tapered pin (I) in direction indicated by
arrow.
i = Tapered pin
2 = O-ring
6 3 = Fitting key
4 = Input gear
1 5 = Retaining ring
6 = input pinion
7 = Pump gear
A = Axial play
0 10263
Assembly
NOTE: Carefully clean parts

Check parts
Apply thin coat of oil to all moving parts
The assembly and installation procedure is the exact

reverse of the removal and dismantling procedure.
62
Trailing pump (Secondary pump)
NOTE: The oil pump is a complete part and is not

generally dismantled. However, the pump may need to
be dismantled for checking or cleaning. Items to be
particularly checked in the dismantled pump are
rims/tyres, mounting play and the axial play of pump
gear/pump pinion .
Axial play:
Pump gear and pump pinion 0.02 to 0.05 mm
Removal and dismantling
Remove piping as required. Remove pump
Unclip retaining ring. 1 = Pump gear

2 = Pump pinion
Pul l off pump gear. 3 = O-ring
Remove fitting key. Assembly
o 3082 B07 002
Remove bolts on pump cover. NOTE: Carefully clean parts

Check parts
Drive off tapered pin in direction indicated by arrow Apply thin coat of oil to all moving parts
and remove cover.
The assembly and installation procedure is the exact
Remove pump gear and pump pini on reverse of the removal and dismantl ing procedure.
63
' -....
...,,- _...... 1 ~. .._...
m~ , MAINTENANCE SYSTEM JOB SHEET
, . _. - -- «_
-'
T "
~

.. . ,- ~,.~
I
" n" . - --'IT
~ maintenanc~
l'
Maintenance \ro.·k no. Maintenance level Time in
II ,
work if possible as per iI min.
'"
166 A4 ---------- 120

., .., . ,
Description of ,
maintenance 166 Control unit check
work:
I.. ~, . . . ., t .
u, •
~
I!
,t Safety : Block engine starting device.
., measures:
.1
i"~
Tools: I Tool set WI
,-=,
n_ ..
, .~ !
~ Parts:
ij Gaskets
;i ,
lij Material:
,,
}
~
Test equipmeDt: ~
1>-
1- ' · -
,,",
1.
'.
- '- ,
-- ,
-
I P~~e: 1
<,lI,
~
~ i~- --~
, * 3
of:
65
~- 8
•
19
~
26-~
··:'"' -~
.~.
• Co
27-~
4- 28
26-~
.•~.....
:""• ~
• •C>
004622
25
~
_'~I
23
/I 122 ,
?14 I ".'
21 14- l,J
J,,-'" 12
23.11~.2 15 @ -
13
~8
~ <:€i'l
20 '~~
'"Q;" '"
"-16
}'-G:"'~~5.1
I
1-17
4 19.21 ~
45 1 '-. 0-18
'" 47I I6 I 19 ~,~~?

I
4~~~ .: ~:g'~)~@~_---:;'31;-'
19.1 ' 30
~ 26-~ !,.~
_______________ ".J' 29
hJ2
49 -r ' .' ... 34
* 50* ", ' I 35I 36
26.1-~
~ '~@.I141 40
26.2-~~
A-28 t9.r-J 42
~ -'{yl
~
-U1 43
."
I
44
y-*27.2
*27_~-*27.3
*27.1-~
004621
66
1 ~ Hex nut 22 ~ Lock washer 38 ~ Washer
2 ~ Lever 23 ~ Washer (Standard 3 pes.) 39 ~ Washer
3 ~ Hex nut 24 ~ Spool 40 ~ Piston (pressure increase)
4 ~ Hex bolt 25 ~ Control (low press. piston) 41 ~ Rect. ring
5 ~ Adaptor 26 ~ Gasket 42 ~ a-ring
6 ~ Washer 26.1 ~ Duct plate 43 ~ Cover
7 ~ Hex bolt* 26.2 ~ Gasket 44 ~ Hex bolt
8 ~ Tag 27 ~ Intermediate plate * 45 ~ Gasket
9 ~ Washer 27.1 ~ Gasket* 46 ~ Ball
10 ~ a-ring 2 7.2 ~ Cylindrical screw * 47 ~ Oil Jeed housing
11 ~ Cover 2 7.3 ~ Cylindrical screw * 48 ~ Hex bolt *
12 ~ WoodrufJkey 28 ~ Cylindrical screw 49 ~ Locking screw *
13 ~ Slotted pin 29 ~ Sealing ring 50 ~ Locking screw *
14 ~ Selector shaft 30 ~ Locking screw * ~ acc. to parts list
15 ~ Needle cage 31 ~ Sealing ring
15.1 ~ Ball 32 ~ Locking screw
15.2 ~ Threaded pin * 33 ~ Washer (Standard 5 pcs.)
16 ~ Orifice 34 ~ Compressed spring e.g. Top figure: Basic version for
17 ~ Spring e.g. 0732040320 0732040884 electrical actuation
18 ~ Detent pin 35 ~ Rect. ring (not Jar all
19 ~ Control (load piston) versions) Bottom figure: Version for
20 ~ Control piston (Shift pas.) 36 ~ Washer electrical actuation and trolling
21 ~ Spring e.g. 0732040043 37 ~ Spring prepared.
Check control unit:

Note: Ifpossible, do not dismantle control unit but
replace completely. If dismantling is required for
cleaning or changing individual springs, it is not
necessary to reset the control unit. However, a pressure
test on the transmission must be carried out.
67
- ,- - ~..;;; ;; ,,~
Imk' "
.-,~.,
__ 7
j ZF 2500 Series
- - ~ - ~ ~
""'" ~ ,~
-. -
Trans. type:
" ~::~work no. I" " "
Maintenance level
'~',.... I' Related~ maintenance
-. - Ir.- Time in ~
work if possible as per III min.
,
I! ' ,'J 11, '0
167 A4 ---- 180
"
[I
Description of
j maintenance 167 Actuation device (mechanical, electrical, pneumatic) check
; work:
l
i
!
~ Safety ~ Block engine starting device,

~ measures:
'1
--- .."','"I
"',,'-""'=.......
Tools: Tool set WI
"
,
Parts: see parts sets TI , T2

, ., I
"'"
! Material: Cleaning product
i~ ,"'"'.......
, ,
Test equipment: '
--=- "
I
. ~
, , ~~-~~.
' , -
'\ Date: \l'age: 1 of: 4
69
*6I
~~
004624
1 = Control unit 7 = Union

2 = Gasket 8 = Hex bolt
3 = Cover 9 = Hex bolt
4 = Locking sere\-\! * = ace. to parts list version
5 = Locking screw
6 = Vent
Check mechanical actuation device
Removal
oI Remove piping as required.

02 Remove cover (3) with gasket (4).
70
*
!}-10 14 *
15
~
9 13 1
. ~
~
~'
*
.
22 I
21
18 'ti9
I I
20 I
t3
..
19 ,-~-,'
24
I •25
004623
1=
Control unit 14 = Cylindrical screw 27 Protective cover
=
Hex bolt
2= 15 = Plug 28 = Cap nut
3=
Cire/ip 16 = Cylindrical screw 29 = Cylindrical screw
Piston support
4= 17 = Solenoid valve 30 = Locking screw
5 = Piston 18 = Bolts 31 = Cylindrical screw
6 = Piston 19 = Cylindrical screw
7 = Cire/ip 20 = ViJlve *= acc. to parts list version-
8 = Retaining ring 21 = Cylindrical screw
9 = Gasket 22 = Solenoid valve
10 = Locking screw * 23 = Cylindrical screw
11 = Locking screw 24 = Gasket
12 = Intermediate housing 25 = Type plate *
13 = Cable harness 26 = Threaded bush
Check electrical actuation device Check
Removal Check components of electrical actuation unit for wear.

Replace components if required.
oI Remove piping as required.
02 Unscrew electrical connection plug. Assembly - Installation
03 Remove protective cover (27) with gasket (24).
04 Remove intennediate housing (12) with valves Clean components until free of dirt
and gasket (9). Apply thin coat of oi l to all moving parts
05 Loosen cables and remove valves. Replace components as per T2
06 Unclip retaining ring (8).
07 Pull piston support with piston out of control
housing.
71
*I
13
20
~A 211 22
1 ~@ I 214 25 28
19 G@ I 26 27 I
I ~! ~
23 ~~
29 r
30 004620
J = Control unit J2 = Locking screw * 23 = Washer

2 = Hex bolt 13 = Vent * 24 = Hex nut
3 = Hex nut 14 = Locking screw * 25 = Gasket
4 = Stop J5 = Cy lindrical cover 26 = Cover
5 = Stop 16 = Hex bolt 27 = Orifice
6 = Spring retainer 17 = Orifice 28 = Insert
7 = Compressed spring 18 = Insert 29 = Hex bolt
8 = Spring retainer 19 = Selector rod 30 = Hex bolt
9 = Retaining ring 20 = a-ring
10 = Centring ring 21 = Piston * ace. to parts list version
11 = Gasket 22 = a-ring
Check actuation device Check

(Pneumatic actuation device)
Check pneumatic actuation device for wear. Replace
Removal components if required.
oI Remove piping as required. Assembly - Installation

02 Remove cylindrical cover (15) with gasket (11 ).
03 Actuate lever. This separates pneumatic part of Clean components until free of dirt
control section. Apply thin coat of oil to all moving parts
04 Lift off pneumatic part. Replace components as per T2
05 Remove cover (26) with gasket (25).
06 Remove selector rod (19) with piston (21) .
07 Unclip retaining ring (9) and collect loose parts
72
IW~ 1- ~MAINTE~ANCESYSTE~ J~B ~HEET~±±_ ,__
-'-
[Trans. type: I ZF 2500 Series
--
Main~enance work no. Ir i ; ",
Maintenance level
.
I .Reiated maint;;;ance ="
,- Tiiiie in- ,-- I
! work if possible as per min.
t" I I , ,. Ii"
169 A4 ---------- 60
i
-, -
Description of
maintenance 169 Cleaning of oil cooler
work:
I,- J
.~
II
Safety
II measures:
i~
il
I
t ,,±,, ____ J
..
l' ,.
Tools: ' Tool set WI
--- ..
L ,
~! parts~
-
._",' "
Material:
It !
ItT
I' -
,
Test equipment:
- _.- •
1,'
L ,
'"
..-
' -
.- .,' . .- .. ....
Ip -~~ ~~
I I Date.
.-·.x "' ' ,
JIPage. 1 of. 2
- '0-' I
73
II. Cleaning of water section
Check for contamination to see if the water section
requires cleaning. If a greasy-type lime scale is found,
first degrease the water section.
Subsequent rinsing with water and an anti-limescale
product will remove the limescale; it is also possible to
use a 10 to 15 % hydrochloric acid solution. This
solution must have an inhibitor additive to prevent
reaction with the metal surfaces.
004637
After cleaning, thoroughly rinse the water section using

clean water. Then, fill the oil section with the oil grade
required for operation. Subsequently, drain oil once
more. Cleaning is considerably more successful and
quicker ifboth the oil and the water are pumped around
the unit in the opposite direction to flow during normal
operation.
Assembly
I. It is absolutely necessary that any indentations be
removed from the sleeve
2. Position gasket between sleeve and piping base
3. Push piping into sleeve. Check quality of gasket.
08 B07 014 Re-align with markings
4. Install cover with gasket. Position gasket ridge as
required depending on position of oil chamber
IK<c"rr.t from manufacturers specification: Check

Before reassembling heat exchanger, screw cover onto
heat exchanger must be cleaned regularly to ensure the piping and check oil-section for leakages. This
bmst"tlt performance. As the level of contamination allows any leakages to be noticed on the piping base.
Id('pe:ndls on the application, operating times should be Check oil and water sections after reassembly. Ensure
I,"UlIICllCU to and the heat exchanger must be cleaned at pressure specified on the drawing and type plate (oi I
IrellUlar intervals as defined by the operator. and water sections) is not exceeded.
IP,coced,"re for heat exchanger disassembly

I. Mark position of bolted-on flanges.
Loosen flange bolts
Remove cover
Remove piping from sleeve
74
p~ :RelatedfuMaurtenao ce', .:ime in ' ~
1 work if possible as per ~ min.
0 ; I
173 A4 121 15
Safety
measures:
Tools:
" Parts:
"
[-~- ,
tTest equipment: :
I' '-~~""l
I,
I:,
Pro~edure:
'
" ,
I see reverse
•. ,=m0imJ
75
If possible, carry out this procedure in conjunction
with Maintenance Work 121.
Check input shaft seal for leakages. Catch escaping oil

if necessary.
Check oil level regularly and add oil if required.
Replace input shaft seal as soon as possible.
76
,.--"", ,
'"= x-,_,
~
~., ~ ,= - - ~ -~
m!'!F:;
-
I
-
- - - - """ -
.. ,~ .~~.
~- -. !
,
. Trans. type:
r
~ ,- ,~
Maintenance work no7' l r

I:
ZF 2500 Series
"M'a int enance lever"wa 1_' Relatedmaintenance
wOI'k if possible as per
II
r ·-wn ~;:.;,
• min,
,
• Tlmem
• "~"""!
i
~ , I' 1
174 A4 121 15
Il"
I!
I i Description of
maintenance 174 Output shaft seal check (if possible in conjunction with Maintenance Work 121)
work:
,- ' .~-~."
11 ,
Safety I
}
measures:
- -'''-,=
'-
, Tools:
I
I .. ~
II
I Parts:
..
II'
Material:
.,' _......_-
II
II'
i Test e<\uipment:
--~ .. ' " -

, Procedure:
f' ! see reverse
. < .«..... J
I :Place:~ .1fute: - - - I Page: 1 - T
of: 2
-·i'
- I
77
If possible, carry out this procedure in conjunction
with maintenance work 121.
Check output shaft seal for leakages. Catch escaping

oil if necessary.
Check oil level regularly and add oil if required.
Replace output shaft seal as soon as possible.
004636
78
't
ZF MARINE GmbH ZF Padova S.p.A. ZF-HURTH Marine S.p.A. ZF do Brasil S.A.

Via Penghe 48 Via S. Andrea 16 Rua Senador Vergueiro, 428
Cep. 09 52 1-90 I
D-88038 Fried ri chshafe n 1-35030 Caselle di Selvazzano .,.j,.J8062 Areo (TN) Sao Caetano do Sui - SP
Germany Padova, Italy - Italy Brasil
Phone (07541) 77-0 Phone (049) 8299-3 11 Phone (0464) 5805 55 Phone (0 11 ) 744-9 160
Fax (0754 1) 77-4000 Fax (049) 8299-550 Fax (0464) 580544 Fax (0 I I ) 744-9396

ZF Marine Transmissions ZF 2500 Series

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ZF Marine Transmissions ZF 2500 Series

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., .

"., : v :d. ~7:

3082 758 103c

The following safety instructions appear in this manual:

Technical modifications reserved

Edition 06.95 - 100

3082 758 103c

1 Description of basic transmission

=:! ~~ ~~05o~~t£U~~~h~~~;a'I';e~~i~~' ~i;h' ~~ili~~) : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :

Oil supply and transmission cooling

8 Operation with manual actuation

10 Troubleshooting notes .. ..... . . .. . . .. . .. . ...... . ...... . ... ... .. ........ .. ............ 25

11 Spare parts order / service point details 28

14 Maintenance work plan

15 Tool set for maintenance

16 Maintenance system job sbeets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Job sheets . .......... . .. . . .......... . . . ..... . . .. . . .. . .. ................. . . .. .... . .35 - 78

Anti-corrosion measures and preservation ......... . . .. . . . ........... . . . . .. . . .... . .. Appendix

Operating instructions ZF-marine transmissions

ZF 2500 NR, ZF 2550 NR

1.1 Power, speed, rotation direction, ratio, type

ZF marine transmissions are designed and manufactured

The respective ratio is stamped on the transmission type NOTE

The letter stamped after the transmission ratio unde

Letter Rated engine speed Engine idling

A 1650 to 2500 <: 415

B 1I00tol650 <: 275

Deviations in the NR series:

2.1 Transmission views (basic transmission)

JO Engine-dependent oil pump

11, 12, 41 Oil temperature measuring poi

b Suspension lugs for

T,'allslllission with clutch bell alldjlexible

2, 2 J elwch oil pressure measuring point

5 Measuring poinljor oil pressure

7 Filter chamber, sediment drain

22 Lube oil pressure measuring point

28 Flange surface for bell hal/sing

46 Oil fill point

a Rated clutch pressure (stamped)

2.2 Special trolling version and trailing pump

18 Tioailing pump (Special equipment)

c Trolling valve (Special equipment)

2.3 ZF 2500, ZF 2550 U

Input and output 011 the same side

2.4 Transmission views

Transmission with c1utclt bell

1 Transmission mounting surfaces

8 5 Measuring point for oil pressure

7 Filter chamber, sediment drain

11, 12 Oil temperature measuring poillls

18 Trailing pump (special version)

27 33 10 22 Measuring point for lube oil pressure

27 Measuring pointfor clutch oil pressure

27 28 Flange surface for bell housing

37 Inspection hole cover (transmission

N ZF 2500, ZF 2550 '8) ZF 2560 '8) ZF 2555 ZF 2565 ZF 2550 A

Warning 20 bar s 2) 15 ) PK ~ PKN - 3 bar t 2) 5) 0.25 bar t 2) 95°C s 2)

=:! 05ot£U~h~;a'I';ei~~' ~i;h' ili) : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :