ZF Marine Transmissions ZF 2500 Series Operating Instructions Manual 3082758103e – PDF DOWNLOAD

Operating Instructions

ZF Marine Transmissions ZF 2500 Series

3082 758 103e

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Work safety

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.

Technical modifications reserved

Copyright by ZF Copying in whole or in part requires our prior written approval.

Printed in Germany

Edition

06.1995 / 06.2005 / 11.2006

Date

11.2006

3082 758 103e

ZF 2500 Series

ZF 2500 Series

Table of contents

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

1 1.1 1.2

Description of basic transmission Power, speed, rotation direction, ratio, type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 5

2 2.1 2.2 2.3 2.4

Views of transmission ZF 2500, ZF 2550 (basic transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ZF 2500, ZF 2550 (special version with trolling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ZF 2500, ZF 2550 U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ZF W 2500, ZF 2560 (special version with trolling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 8 9 10

3 3.1 3.2

Monitoring data Monitoring data, ZF 2500 series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Monitoring data, ZF 2500 series (without trolling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 13

4

Function description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

5 5.1

Oil supply and transmission cooling Control unit and transmission actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

6 6.1 6.2 6.3

Actuation Mechanical transmission actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic transmission actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical transmission actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 16 19

7 Operation 7.1 Change-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . .

7.1.3 Change-over from „Ahead“ to „Astern“ with vessel moving at higher speed . . . . . . . . . . . . . . . . . . . . . .

7.1.4 Emergency change-over in case of danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Operation with engine stationary and propeller trailing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2.1 Occasional trailing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2.2 Regular trailing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Special versions / special scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.1 Special scope of supply - transmissions with auxiliary trailing oil pumps . . . . . . . . . . . . . . . . . . . . . . . .

18 18 18 18 18 18 18 19 19 19

8 8.1 8.2 8.3

20 20 20

Operation with manual actuation Transmission with mechanical actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission with pneumatic actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission with electrical actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Table of contents

ZF 2500 Series

9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8

Trolling device Transmission with trolling device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applications and operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Functions description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shift setting check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional requirements for transmission monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional requirements for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Retrofit of trolling valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 21 21 22 23 24 24 24

10

Troubleshooting notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

11

Spare parts order / service point details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

12 12.1 12.2 12.3 12.4

Maintenance Application group P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Application group L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Application group M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Application group C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 29 29 29

13 13.1 13.2 13.3

Maintenance schedule Regular maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional one-off maintenance work for new or overhauled transmission . . . . . . . . . . . . . . . . . . . . . . .

Anti-corrosion measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 30 30

14 Maintenance work plan 14.1 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

15 Tool set for maintenance 13.1 Tool set WI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

Maintenance system job sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

16

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 ZF W 2500 ZF 2560 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 ZF W 2500 NR ZF 2560 NR ZF 2555 NR ZF 2555 NRU ZF 2565 NR ZF 2500 NRA, ZF 2550 NRA ZF 2555 NRA

004 661 004 661

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 Series

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 classification societies depend on input speed, the class of the craft and the differing design regulations currently in force. In most cases, the maximum torques approved by ZF are also fully accepted by the classification societies.

Upon request, either a full test or factory acceptance test can be carried out by the classification society specified by the customer.

Normally, the input shaft rotates in a clockwise direction (looking at the transmission input flange).

Transmissions which are specially designed for an anticlockwise input shaft rotation (looking at the transmission input flange) have an arrow on the transmission input end to show the rotation direction.

004 659

1 Model 2 Serial no.

3 Parts list no.

4 Customer ref. no.

5 Transmission ratio and ID letter for oil pump ratio 6 Oil capacity 7 Mass (dry) 8 Lubricants, see ZF List of lubricants TE-ML 04 9 Clutch oil pressure (nominal)

10 Intermittent operation at very widely differing engine speeds 11 Intermittent operation at differing engine speeds 12 Intermittent operation at widely differing engine speeds 13 Continuous operation at max. engine power

The respective ratio is stamped on the transmission type plate which is mounted on top of the transmission housing.

NOTE For items 10 - 13, also refer to Section 12 „Maintenance“

Data included on the type plate:

Information under 1, 2, 3 and 5 must be quoted when querying problems and ordering spare parts etc.

ZF FRIEDRICHSHAFEN AG The letter stamped after the transmission ratio under 5 has the following meanings:

MADE IN GERMANY MODEL SERIAL NO

1

2

PART LIST NO

REFERENCE NO

3 TOTAL

SPUR GEAR

Rated engine speed during cont. operation

Engine idling speed

A

1650 to 2500

= 415

B

1100 to 1650

= 275

MAIN GEAR

5

RATIOS

Letter

4

OIL CAPACITY

6

MASS DRY dm3

7

kg

LUBRICANT SEE

8 ZF-LIST OF LUBRICANTS TE-ML 04 004 658

4

Oil pump ratio A is the standard version.

ZF 2500 Series

1.2

Description

General layout

The ZF 2500 Series consists of triple-shaft reversing and reduction transmissions with double clutch on the transmission input shaft. The main components subject to wear are concentrated on the input shaft and are therefore easily accessible. The output shaft is arranged below the input shaft.

= Standard version = U version

004 660

The cast-housings are very torsionally rigid and (with the exception of the ZF W 2500) are made from a largely sea-water resistant light metal alloy.

The ZF W 2500 transmission housing is made from grey casting. The machined surfaces and threaded connections required for transmission and bell housing mountings are included as standard.

To ensure long life and low operating noise levels, the teeth of all power-transmitting gears are designed with high safety levels in mind, i.e. case-hardened, ground and subsequently subjected to special treatment.

The shafts run in anti-friction bearings. Thrust bearings are incorporated in the transmission to absorb propeller thrust. The reversing clutches arranged on the input shaft are multi-disc clutches with steel/sinter discs arranged alternately and operated by means of oil pressure.

The high delivery rate of the oil pump ensures rapid clutch response. During gearshift procedure, the contact pressure of the clutches is regulated to ensure smooth operation.

At the same time, there is an increased supply of oil to the clutch being operated, i.e. to ensure quick 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.

An easily-replacable control unit is installed on the transmission housing, fitted with all valves, slides and control equipment required for the operating and lubricating oil circuits.

The control unit on the basic version is actuated mechanically by means of a control lever. Pneumatic or 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 can be the same or opposite to the input rotation direction.

Otherwise, design and external dimensions are exactly the same as the ZF series.

5

Transmission views (basic transmission)

2

Transmission views

2.1

Transmission views (basic transmission) b

41

26

11

20 004 613/1

27

12

15

14

1 004 614/1

6

1

Transmission mounting surfaces

2, 21, 27

Clutch oil pressure measuring points

10

Engine-dependent oil pump

11, 12, 41

Oil temperature measuring points

14

Coolant inlet/outlet

15

Oil cooler

20

Oil drain

26

Output

33

Oil filter

b

Suspension lugs for transport/handling

33

10

1

ZF 2500, ZF 2550

ZF 2500, ZF 2550

Transmission views (basic transmission)

7

a

20

28

46

5

Transmission with clutch bell and flexible coupling (special scope of supply)

8

2, 21

Clutch oil pressure measuring point

5

Measuring point for oil pressure upstream of filter

7

Filter chamber, sediment drain

8

Input

20

Oil drain

22

Lube oil pressure measuring point

25

Oil dipstick

28

Flange surface for bell housing

46

Oil fill point

a

Rated clutch pressure (stamped)

004 615/1

25

22

21

27

2 004 648/1

7

Transmission views

2.2

ZF 2500 Series

Special trolling version and trailing pump

C

18

004 616/1

18

Trailing pump (Special equipment)

c

Trolling valve (Special equipment)

8

ZF 2500, ZF 2550 U

2.3

Transmission views

ZF 2500, ZF 2550 U

Input and output on the same side

004 657

9

Transmission views

2.4

ZF W 2500, ZF 2560

Transmission views

5

7

37

Transmission with clutch bell (special scope of supply)

a

1

Transmission mounting surfaces

5

Measuring point for oil pressure upstream of filter

7

Filter chamber, sediment drain

8

Input

10

Engine-dependent oil pump

8

1

11, 12 Oil temperature measuring points 28

14

Coolant inlet/outlet

15

Oil cooler

18

Trailing pump (special version)

20

Oil drain

22

Measuring point for lube oil pressure

25

Oil dipstick

27

Measuring point for clutch oil pressure

27

28

Flange surface for bell housing

14

26

Output

33

Oil filter

37

Inspection hole cover (transmission housing) with oil fill hole

a

Rated clutch pressure (stamped).

1

004885

27

25

33

10

18

26

15

11

10

20

12

004884

ZF 2500, ZF 2550 A ZF 2500, ZF 2550 A

Transmission views

ZF 2500, ZF 2550 A

006379

ZF 2500, ZF 2550 V

006376

11

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

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