ZF Marine Transmission - Operating Manual

Operating Instructions ZF 7500, ZF 7549, ZF 7550 ZF 7500 NR, ZF 7549 NR, ZF 7550 NR ZF 7600, ZF 7650 ZF 7600 NR, ZF 7650 NR ZF 7540, ZF W 7540 ZF 7540 NR, ZF W 7540 NR ZF 7640, ZF 7641, ZF 7645, ZF 7646 ZF 7640 NR, ZF 7641 NR ZF 7645 NR, ZF 7646 NR ZF 7550 A, ZF 7550 NRA ZF 7550 V, ZF 7550 NRV ZF 7600 A, ZF 7650 A ZF 7600 NRA, ZF 7650 NRA ZF 7600 V, ZF 7650 V ZF 7600 NRV, ZF 7650 NRV ZF 7550 NR2H, ZF 7550 NR2 ZF 7550 NR2B ZF 7600 NR2H, ZF 7600 NR2 ZF 7600 NR2B ZF 7650 NR2H, ZF 7650 NR2 ZF 7650 NR2B ZF W 7500, ZF W 7510 ZF W 7500 NR, ZF W 7510 NR ZF 7561, ZF 7566 ZF 7561 NR, ZF 7566 NR ZF 7661, ZF 7666 ZF 7661 NR, ZF 7666 NR ZF W 7610, ZF W 7615 ZF W 7610 NR, ZF W 7615 NR ZF 7549 C, ZF 7500 C, ZF 7850 C ZF 7549 NRC, ZF 7500 NRC, ZF 7850 NRC

ZF Marine Transmission ZF 7500/7600 Series 3084 758 101

Important note General information The following safety instructions appear in this manual. NOTE: Refers to special processes, techniques, data, use of auxiliary equipment etc. CAUTION This is used when incorrect, unprofessional working practices could damage the product

DANGER!

This is used when lack of care could lead to personal injury or death.

Subject to alterations in design

Copyright by ZF These operating instructions are protected by copyright. Any reproduction and dissemination in whatever form – al so in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or electronic reproduction or as a storage in data-processing equipment or data networks without approval by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law

Edition:

2006-09

ZF Friedrichshafen AG D-88038 Friedrichshafen, Customer service Telefon: (07541) 77-0

Important note General information The following safety instructions appear in this manual. NOTE: Refers to special processes, techniques, data, use of auxiliary equipment etc. CAUTION This is used when incorrect, unprofessional working practices could damage the product

DANGER!

This is used when lack of care could lead to personal injury or death.

Subject to alterations in design

Copyright by ZF These operating instructions are protected by copyright. Any reproduction and dissemination in whatever form – al so in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or electronic reproduction or as a storage in data-processing equipment or data networks without approval by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law

Edition:

2006-09

ZF Friedrichshafen AG D-88038 Friedrichshafen, Customer service Telefon: (07541) 77-0

ZF 7500/7600 Series

Contents

Contents Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 1

1.1 2

2.1 2.1

Forewo Foreword rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

ZF-Tra ZF-Transm nsmiss ission ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Monit Monitori oring ng valu values. es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Moni Monito tori rinng data data for for ZF ZF 7550 550 NR2 NR2/N /NR R2B 2B/N /NR2 R2H, H, ZF 7650 NR2/NR2B/NR2H, ZF 7600 NR2/NR2B/NR2H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3

Summar Summary y of tec techn hnica icall data data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4

Direct Direction ion of prop propell eller er rota rotatio tion n for for forwa forward rd driv drivee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

5

Descri Descripti ption on of of basic basic trans transmis missio sion n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

5.1 5.2 5.2 5.3 5.3 5.3.1 5.3.1 5.3.2 5.3.2 5.3.3 5.3.3 5.3.4 5.3.4 5.3.5 5.3.5 5.3. 5.3.66 5.3.7 5.3.7 5.3. 5.3.88

Power, Power, speed speed,, rotat rotation ion direct direction ion,, ratio ratio,, type type plate plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Gene Ge nera rall desi design gn (se (seee end end of of sect sectio ionn for for diffe differe renc nces es in the the “N “NR” R” serie series) s) . . . . . . . . . . . . . . . . . . . .14 Tran Transm smis issi sion on view viewss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 View View of transm transmiss ission ionss ZF 7500 7500,, ZF 7550 7550,, ZF 7549 7549,, ZF 7600 7600,, ZF 7650 7650 . . . . . . . . . . . . . . . . . . .15 View View of tran transmi smiss ssion ionss ZF 750 7500A, 0A, ZF 7550A 7550A,, ZF 760 7600A, 0A, ZF 7650 7650A A . . . . . . . . . . . . . . . . . . . . .17 View View of tran transmi smiss ssion ionss ZF 750 7500V, 0V, ZF 755 7550V, 0V, ZF 7600 7600V, V, ZF ZF 7650V 7650V . . . . . . . . . . . . . . . . . . . . .20 View View of transm transmiss ission ionss (left (left versio version) n) ZF ZF 755 7550NR 0NR2H, 2H, ZF 7600 7600 NR2H, NR2H, ZF ZF 765 76500 NR2H NR2H . . . . . . .22 View View of transm transmiss ission ionss (rig (right ht vers version ion)) ZF 755 75500 NR2H NR2H;; ZF 760 76000 NR2H, NR2H, ZF 765 76500 NR2H NR2H . . . . . 24 View View of of tran transm smis issi sion onss ZF 7550 7550 NR2 NR2B, B, ZF ZF 7600 7600 NR2B NR2B,, ZF 7650 7650 NR2B NR2B . . . . . . . . . . . . . . . . . .26 View View of tran transmi smiss ssion ionss ZF 755 75500 NR2, NR2, ZF ZF 7600 7600 NR2, NR2, ZF 7650 7650 NR2 . . . . . . . . . . . . . . . . . . . . . .28 View View of trans transmi miss ssio ions ns ZF 7540 7540,, ZF ZF 754 7541, 1, ZF 7545 7545,, ZF 7546, ZFW 7540, 7540, ZF 7640, ZF 7641, ZF 7645, 7645, ZF 7646 . . . . . . . . . . . . . . . . . . . . . . . . . . .30 5.3. 5.3.99 View View of of tran transm smis issi sion onss ZFW ZFW 7500 7500,, ZFW ZFW 7510 7510,, ZF 766 7661, 1, ZF 7666, ZF 7561, 7561, ZF 7566, ZFW 7610, ZFW 7615 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 5.3.10 5.3.10 View of of transmiss transmissions ions ZF 7549 C, ZF 7500 C, ZF 7850 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 5.4 5.4 Func Functio tiona nall des descr crip iptio tionn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 5.5 5.5 Oil Oil supp supply ly and and tra trans nsmi miss ssio ionn coo cooli ling ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 5.6 Contro Con troll unit unit and transmi transmissi ssion on actu actuati ation on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 5.7 5.7 Chec Ch ecks ks and and sto stora rage ge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 6

6.1 6.2 6.3 6.3.1 6.4 6.4.1 6.4.1 6.4.2 6.4.3 6.5 6.6 6.7

Insta Installa llatio tion n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Permis Permissib sible le inst install allati ation on posi positio tionn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Transm Transmiss ission ion attac attachme hments nts for transp transport ortati ation. on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Transm Transmiss ission ion mount mounting ing on founda foundatio tionn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Casting Casting resin resin base base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Connec Con nectio tionn to the eng engine ine.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 “Normal” “Normal” engin enginee arrangem arrangement ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 U/V-drive U/V-drive arrange arrangement ment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 U/V-drive installation diagram when drive shaft is in W-arrangement W-arrangement . . . . . . . . . . . . . . . . . . . .47 . 47 Connection to propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Aligning the transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Connections for transmission cooling cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 3

Contents

6.8 6.9 6.9.1 6.9.2 6.9.3 6.10 6.10.1 6.10.2 6.11 6.11.1 6.11.2 7

ZF 7500/7600 Series

Connection of monitoring devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Transmission actuation devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Mechanical actuation of transmission (Not with NR2, NR2H, NR2B type transmissions) . . . . 52 Electrical actuation of transmission (Not with NR2, NR2H, NR2B type transmissions. For these transmissions see section 6.9.3) . 54 Electrical actuation of NR2, NR2H, NR2B type transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 55 Transmission monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Minimum transmission monitoring facilities (for values, see section „Monitoring values“) . . 56 Additional transmission monitoring (for values, see section „Monitoring values“) . . . . . . . . . . 57 Necessary measures before operating the transmission for the first time . . . . . . . . . . . . . . . . . . 58 Oil fill, oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Installation check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7.1 7.1.1 7.1.2

Change-over procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Change-over from “neutral” to “ahead” or “neutral” to “astern” . . . . . . . . . . . . . . . . . . . . . . . . 59 Change-over from “ahead” to “astern” with vessel moving at low speed (not applicable for non-reversing transmissions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 7.1.3 Change-over from “ahead” to “astern” with vessel moving at higher speed (not applicable for non-reversing transmissions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 7.1.4 Emergency change-over in case of danger (not applicable for non-reversing transmissions) . . 59 7.2 Operation with engine stationary and propeller trailing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 7.2.1 Occasional trailing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 7.2.2 Regular trailing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 7.3 Operation with the manual mechanical actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 7.3.1 Mechanical emergency operation of mechanical transmission actuation . . . . . . . . . . . . . . . . . . 61 7.3.2 Mechanical emergency operation of the electrical transmission actuation (except NR2, NR2H, NR2B type transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 7.3.3 Mechanical emergency operation of the electrical transmission actuation of NR2, NR2H, NR2B type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 7.3.3.1 Mechanical emergency control for version with auxiliary screws . . . . . . . . . . . . . . . . . . . . . . . 63 7.3.3.2 Mechanical emergency control for version with push / pull slider . . . . . . . . . . . . . . . . . . . . . . . 64 7.4 Operation with emergency shift („Come home screws“, not with NR2, NR2B, NR2H transmissions) . . . . . . . . . . . . . . . . . . . . . 66 8

8.1 8.2 8.3 8.4 8.4.1 8.5 8.6 9

4

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Protection against corrosion, preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Maintenance work plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Special versions / Special scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Special scope of supply - Transmissions with additional trailing oil pump (item 18) . . . . . . . . 71 Trouble shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 ZF service stations, Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Maintenance system job sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ZF 7500/7600 Series

Foreword

ZF 7500/7600 Operating Instructions 1

Foreword

1.1

ZF-Transmission

The description, operation and maintenance sections are applicable to the standard transmission version. Variations are possible according to special customer requirements and operating conditions. If the data contained in the operating instructions are different to the data contained in the technical or commercial specifications, the data in the specifications shall apply. Important!

Ensure that these operating instructions are always kept to hand. Carefully read the operating instructions. Pay particular attention to the safety instructions. Some of the illustrations contained in the operating instructions may differ from your installed transmission. Furthermore, safety devices and covers may sometimes be omitted to enable clearer illustration.

5

Foreword

ZF 7500/7600 Series

Important Note:

1. The warranty conditions agreed with ZF apply for these transmissions. However, ZF can only honour warranty claims if: – the transmission has been installed, monitored, operated and maintained in accordance with these operating instructions, – ZF-approved lubricants have been used, – the limit values specified on the transmission for the ratio of input power to input speed and for input speed are respected according to the transmission application group. 2. The transmission manufacturer, as a supplier of one single component in the vessel drive system, cannot be held responsible for vibrations or vibrational problems occurring in this system. Therefore, ZF will not accept liability for transmission noise or damage to the transmission, flexible coupling or other parts of the drive unit caused by such vibrations. We therefore recommend that vibrations are recorded and calculated including, where appropriate, transmissioncomponents not subject to load.

6

ZF 7500/7600 Series

- n C i o , t a M c , i l L , p p P a n o i t a c i l p p e C a r u t a n r e o p - i t a m c H t e M i , l 2 l L p R i , p N O P a

/ B 2 R N / 2 l R i N o g 0 i n 0 t e 6 a c r 7 i s r u F b s Z u e , L r p H 2 R N / B 2 R N / 2 R N 0 e 5 r 6 u 7 s F s e Z r p , l i H o 2 h R t c N u / l B C 2 R n N / o i 2 t a R n N i 0 r m a 5 t e t 5 i n l 7 o F c F s e Z u r l o a f v t a a g d n i g r i o n r t o i t n i o n o M M

2

1 . 2

) 8

n o g i n t i a l i r a r e p T o

1 4 , 2 1 , 1 1

2 2

n o i t a r e p o l a m r o N

_ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _

” l n a r o t i t u i s e o N P “

_ _ _ _ _ _ _ _ _ _

C ° 0 3

_ _ _ _ _ _ _ _ _ _

C ° 0 3

) 2 1 ) 8

e s i ) ) 4 4 w r r e n a a n o b b i 1 2 g i t ) n t a – + 9 e - o N N r n r K K e t ) o t i t n u 7 P P i p N = = s u t o o u K K K P C o P P P n o i e t s a t r i o w e r t - t e n n u u i p o g t C n u „ e o

_ _ _ _ _ _ _ _ _ _

r a b _ 8 _ _ + _ K _ P _ _ = _ F _ V _ P

n x i a m m ) 1

t e n d i o o p m g g n n i r i t u s a r a e e p M O

) 6 1

_ _ _ _ _ _ _ _ _ _

r o s n e C s ° C e ° 5 r u 5 0 t 7 1 a r e p ) 2 m e C t ° r o C C ) ° 0 ° 2 2 0 5 1 h c 0 0 o t 1 1 t i 0 w r s e e t r ) e t 2 u C ° m a 0 o r e 2 p 1 C C m ° ° r e m t o 0 5 h e 9 9 T T 0 r a b 6 o r t o 0 h e c g ) t 2 _ i u a _ w _ s g _ e r e r a _ r u u b _ s r _ s s s a 5 _ e b 2 . _ r e r 5 0 _ P p

) 1 1 ) 8

_ _ _ _ _ r _ a r _ b a _ 5 b _ . _ 3 7

) 9

5

_ _ _ _ _ _ _ _ _ _

_ _ _ _ _ r _ a _ b _ 4 _ . _ 0

) 9

7 2 , 1 2 , 2

Monitoring values

e u y l a a v l p l i s a d n . i e u m m l o o a N N v

_ _ _ _ _ _ _ _ _ _ ) 6 ) 5 ) 2

r a b 3 – N K

P =

K

P ) 5 ) 2

r a b 1 3

r a b 5 2 o t 0 e g u a g e r u s s e r P h c t i w s e r u s s e r P

) 4 1

e e v v o o b b a a e e l l y b a b a l a t t p n i s i n i d d d e t e e g d o d u n u i l l m c s c e n a r n i i e t r t o o o r c n N F N I ) ) ) 5 1 6 1 7 1 ) 2 . d 7 n e a d n h t t o s n i a t n n l i c e l e d i s t m e s i u o f t d i c n c r o e a f e d t p l s s a . a e r s i c t e t o i s n e a a l l h r a e c p u n ( e e i s t r s g e p e c l n y r i l t e e p f i e h c h h t p o c e t i r p t s w p n u l o r n c e d i e o n l d v e t a i r a p r n i o r d m , e m a p t g o n t s o n n i e r r d o e r o n s h i l F c T b a ) u ) 8 7

r a b 5 2 o t r 0 o )

) 6 6 1

h r c o t i s n w s e s e r e r u u s s s s e r e r P p e g ) u 3 a r g a b e r 0 u 4 s s o e r t P 0

) 4 1

g g i n n i r r o t o t i i n n o o m m l g m a n n u i o i t n m i i r n d a i d W M A

2 n o i t c e s o t r e f e r , s l i a t e d r e h t r u f r o F

e r u s s e r r p t e l l e i i r o f u e s h r s c f o t e r u e l p c b l i l e g o a r n h n u i i s c m s s t a e u o e r l r N P C c e = = = D

N F K K V

P P P

F Z d r a d n a t s e h t n i h e t i v o w b t a o n p ( n e o l m i b u p t a a p m t r ) e u n g y p i n p l i o l p d g i l p e n a d a i u r l s t u i m l f r t a c r o u n o t o n i e h t r t i h i p o o t o F N W W c s ) ) ) 9 ) 0 1 2 1 1 1

g n i r u s s a 0 e 1 m o t f o 3 t n n e e e e m r g t e u w n t e i g b a n n r r f a e a r p o r w y a m a ) c e l r i t n e d o i o t s l f e r d i u c a s o 3 e e o s . y i c 5 i m p C p i i a m ° t n h r s d s o o 0 n i t n 8 h t t y a u i a c r b o t b l e w t i s n a t r C g d e u o o i s ° i n d s t i i s d 0 n r v e t r n v o 6 r e f r a s e i o t o p R p F U A W ( ) 1 ) 2 ) 3 ) 4 ) 5

y l p p u s f o e p o c s e F v o Z b a d r a e d l b n a t a t n i s e h d t e n d u i h l t c n i i w t o o t N N ) ) 3 1 4 1

t f i h s n i n e h w g n i n o i t c n u f t o n o t t e s ” e l a r b t t u s e u N m “ g n n i o i n t i r a s p W o ) 6 7

Monitoring values

- n C i o , t a M c , i l L , p p P a n o i t a c i l p p e C a r u t a n r e o p - i t a m c e M , i l t L l i , p O P p a

l i o g n i t e a c r i s r u b s u e r L p

H 2 R N , B 2 R N , e 2 R r u N s s e n r o p i l s i r o e h v c t t u u o l C h t i w n o s i e t i a r n e i S m r 0 a e t 0 l n 6 t i 7 F o c / 0 0 5 7 F Z r o f a t a d g n i r o t i n o M 8

) 8

n o g i n t i a l i r a r e p T o

1 4 , 2 1 , 1 1

2 2

n o i t a r e p o l a m r o N

_ _ _ _ _ _ _ _ _ _ ) 9

” l n a r o t i t u i s e o N P “

7 2 , 1 2 , 2

r e t n n o u i o t a c t r o o r e s ) e s i 9 i n w w o e i n e t i n i s g i o n g n P E e

5

r e o n n ) e i o 9 s g i t “ i n e a l w a r t r e e t n t o r u i n e e g u s N n o i „ E c w

ZF 7500/7600 Series

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _

) 1 1 ) 8

) 2 1 ) 8

C C ° ° 5 5 0 7 1

_ _ _ _ _ _ _ _ _ _ ) 2

C ° 0 3

C ° 0 0 1

C ° 5 0 1 ) 2

C ° 0 3

C ° 0 9

C ° 5 9

) 2

r r a a b b 4 . 5 . 0 4

r a b 5 2 . 0

r a b r a 5 . b 3 6

_ _ _ _ _ _ _ _ _ _ ) 6 ) 5 ) 2

) 4

) 4

r r a a b b 1 2 – +

N K ) P 7 N = K K

N K

P =

K

P P P

_ _ _ _ _ _ _ _ _ _

r a b _ 6 _ _ + _ K _ P _ _ = _ F _ V _ P

r a b 3 – N K

P =

K

P ) 8 1 ) 5 ) 2

) 9 1 ) 5 ) 2

r r a a b b 4 6 2 2

n x i a m m e u y l a a v l p l i s a d n . i e u m m l o o a N N v

r o s n e s e r u t a r e p m e C t ° r o 0 ) 2 2 1 h c o t t i 0 w r s e e t r e t u C ° m a 0 o r e 2 m p 1 r e m t o h e T T 0 r a b 6 o r t o 0 h e c g t _ i u a _ w _ s g _ e e r _ r u _ u s _ s s _ e s _ r e r _ P p

r a b 5 2 o t 0 e g u a g e r u s s e r P h c t i w s e r u s s e r P

) 4 1

) 1

t e n d i o o p m g g n n i r i t u s a r a e e p M O

) 6 1

g n i n r a W

e e v v o o b b a a e e l l y b a b a l a t t p n i s i n i d d d e t e e g d o d u n u i l l m c s c e n a r n i i e t r t o o o r c n N F N I ) ) ) 5 1 6 1 7 1 ) 2 . d 7 n e a d n h t t o s n i a t n n l i c e l e d i s t m e s i u o f t d i c n c r o e a f e d t p l s s a . a e r s i c t e t o i s n e a a l l h r a e c p u n ( e e i s t r s g e p e c l n y r i l t e e p f i e h c h h t p o c e t i r p t s w p n u l o r n c e d i e o n l d v e t a i r a p r n i o r d m , e m a p t g o n t s o n n i e r r d o e r o n s h i l F c T b a ) u ) 8 7

r a b 5 2 o t r 0 o )

) 6 6 1

h r c o t i s n w s e s e r e r u u s s s s e r e r P p e g ) u 3 a r g a b e r 0 u 4 s s o e r t P 0

) 4 1

g g i n n i r r o t o t i i n n o o m m l m a n u i o t m i i n d i d M A

n o i t c e s o t r e f e r , s l i a t e d r e h t r u f r o F

r r a a b b 5 . 6 1 7 1 = =

e r u s N N s e K K r r P p P e t h l l e t i i t i r o f w h i u e s w h r s n c f n o t e o r o u e i i l s p s c b s l s i i l i e g o a m r m s n h i n u s i n s s n c s a t m a a e r t u o r e t r l r N r P C c o r e o = F D = = N F ) F ) K K V P P P 8 1 9 1

F Z d r a d n a t s e h t n i h e t i v o w b t a o n p ( n e o l m i b u p t a a p m t r ) e u n g y p i n p l i o l p d g i l p e n a d a i u r l s t u i m l f r t a c r o u n o t o n i e h t r t i h i p o o t o F N W W c s ) ) ) 9 ) 0 1 2 1 1 1

g n i r u s s a 0 e 1 m o t f o 3 t n n e e e e m r g t e u w n t e i g b a n n r r f a e a r p o r w y a m a ) c e l r i t n e d o i o t s l f e r d i u c a s o 3 e e o s . y i c 5 i m p C p i i a m ° t n h r s d s o o 0 n i t n 8 h t t y a u i a c r b o t b l e w t i s n a t r C g d e u o o i s ° i n d s t i i s d 0 n r v e t r n v o 6 r e f r a s e i o t o p R p F U A W ( ) 1 ) 2 ) 3 ) 4 ) 5

t f i h s n i n e h w g n i n o i t c n u f t o n o t t e s ” e l a r b t t u s e u N m “ g n n i o i n t i r a s p W o ) 6

y l p p u s f o e p o c s e F v o Z b a d r a e d l b n a t a t n i s e h d t e n d u i h l t c n i i w t o o t N N ) ) 3 1 4 1

ZF 7500/7600 Series

3

Summary of technical data


Direction of rotation, transmission input shaft

(standard version)

Identification mark for the oil pump ratio

Design engine speed

A

approx. 1 650 to 2 300

>/=

B

approx. 1 100 to 1 650

>/= 275

Engine idling speed

415

Additional forces on transmission input in accordance with section 6.4 (Loads applicable to the face end of input shaft) •

in radial direction

max. 4 000 N

•

in axial direction

max. 1 500 N

Alignment accuracy of the propeller shaft (also refer in to section 6.5)

Dimension „A“ Max permissible Transmission according section 5.2 angle error “x”

[mm] A = 340 A = 448

Max. shift displacement “y”

Smallest permissible distance “L” to first bearing depending on propeller shaft diameter „d“

[mm]

[mm] 500 for d < 120

0.05

0.10 1 000 for d > /= 120

ZF 7500/7600 Series

800 for d < 150 A = 450 A = 600

0.1

0.15

1 200 for d 150 to 200 2 000 for d > 200

Permitted radial force on propeller shaft for centering on transmission output flange (refer to section 6.5) max. 1000 N

9


ZF 7500/7600 Series

Cooler data ZF 7500 Series without NR2/NR2B/NR2H type transmissions without ZF 7540, 7550 transmissions and ZF 7600 Series

• Largest permitted cooling water flow rate

17 500 dm 3/h

• Smallest permitted cooling water flow rate

5 400 dm 3/h

• Loss of pressure between cooling water inlet/outlet

at

17 500 dm 3/h

0.5 bar

• Max. permitted water pressure at cooling water inlet

4 bar

• Highest cooling water inlet temperature

40 °C

• Highest transmission ambient temperature

60 °C

Cooler data ZF 7540, 7550 transmissions and ZF 7600 Series without ZF 7500 Series and NR2/NR2B/NR2H type transmissions


17 500 dm 3/h


5 400 dm 3/h


at

17 500 dm 3/h

0.5 bar


4 bar

• Highest cooling water inlet temperature

32 °C

• Highest transmission ambient temperature

60 °C

Cooler data NR2/NR2B/NR2H type transmissions


12 000 dm 3/h


3 900 dm 3/h


at

12 000 dm 3/h

1 bar


4 bar

• Highest cooling water inlet temperature ZF 7550 NR2/NR2B/NR2H

40 °C

• Highest cooling water temperature ZF 7600, 7650 NR2/NR2B/NR2H

32 °C

• Highest gearbox ambient temperature

60 °C

10

ZF 7500/7600 Series

Oil types


The relevant valid ZF list of lubricants TE-ML 04 for ZF marine gears is binding. This list is available from any ZF After-Sales Service Point and on the internet under www.zf.com. Then choose „Service“, „Technical Information“, „ZF List of Lubricants“, „List of Lubricants (English)“ then under TE-ML 04 choose the PDF download. Viscosity classes SAE 30 or SAE 40 at oil sump temperature < 80 °C Viscosity class SAE 40 at oil sump temperature > 80 °C

Oil quantities

ZF 7500, ZF 7549, ZF 7550, ZF 7600, ZF 7650

approx. 75 dm 3

ZF 7550 A, ZF 7650 A, ZF 7550 V, ZF 7650 V

approx. 75 dm 3

ZF 7550 NR2, ZF 7650 NR2

approx. 50 dm 3

ZF 7550 NR2B, ZF 7650 NR2B

approx. 50 dm3

ZF 7550 NR2H, ZF 7650 NR2H

approx. 50 dm 3

ZF 7540, ZF 7640, ZF 7641, ZF 7645, ZF 7646, ZF W 7540

approx. 80 dm 3

ZF 7661, ZF 7666, ZF W 7500, ZF W 7510 ZF 7561, ZF 7566, ZF W 7610, ZF W 7615

approx. 120 dm 3

ZF 7549C, ZF 7500C, ZF 7850C

approx. 75 dm 3

transmission ratio

refer to transmission type plate

transmission weight

depending on scope of supply, refer to transmission type plate

11

Direction of propeller rotation for forward drive

4

12

Direction of propeller rotation for forward drive

ZF 7500/7600 Series

ZF 7500/7600 Series

Description of basic transmission

5


5.1

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 the input speed, the class of the craft and the different design regulations currently in force. In most cases, the maximum torques approved by ZF are also fully accepted by the classification societies. If requested, the classification society specified by the customer can carry out a full test or factory acceptance test (test stand). Normally, the input shaft rotates in a clockwise direction (looking at the transmission input flange). Transmissions which are specially designed for anti-clockwise input shaft rotation (looking at the transmission input flange) have an arrow on the transmission input end to show the rotation direction.

Key

1 2 3 4 5 6 7 8 9 10 11 12 13

Model Serial no. Parts list no. Customer reference no. Total ratio and code letter for oil pump ratio Oil capacity Mass (dry) Lubricant, see ZF List of Lubricants TE-ML 04 Clutch oil pressure (nominal) Max. power/speed ratio for intermittent operation at very widely differing engine speeds Max. power/speed ratio for intermittent operation at widely differing engine speeds Max. power/speed ratio for intermittent operation at differing engine speeds Max. power/speed ratio for continuous operation at max. engine power

NOTE

For items 10 to 13, also refer to section 8 “Maintenance”.

The total ratio is stamped on the transmission type plate which is located on top of the transmission housing.

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

Data included on the type plate:

The code letter stamped after the total ratio in box 5 signifies the following: Letter

Rated engine speed for continuous operation

Engine idle speed

2

A

1650 to 2300

> 415

4

B

1100 to 1650

> 275

FRIEDRICHSHAFEN - GERMANY MODEL

SERIAL NO.

1 PARTS LIST NO.

REFERENCE NO.

3 RATIO TOTAL

MAIN GEAR

SPUR GEAR

MASS DRY (kg)

CLUTCH OIL PRESSURE (bar)

5 OIL CAPACITY (dm 3 )

6

6

7

PLEASURE kW/RPM

8

10

LIGHT

11

8

Oil pump ratio A is the standard version.

9 MEDIUM

CONTINUOUS

12

13

OIL CHANGE: AFTER FIRST 50 HOURS OPERATION AND EVERY 1000 HOURS OR 12 MONTHS, WHICHEVER OCCURS FIRST. LUBRICANT SEE ZF LIST TE-ML04 SAE 30 OR 40

13


5.2

General design (see end of section for differences in the “NR” series) A= 0 mm ZF 7549 C ZF 7550 C ZF 7850 C A= 340 mm ZF 7500 ZF 7550 ZF 7550 NR2H ZF 7550 NR2 ZF 7550 NR2B ZF 7600 ZF 7650 ZF 7650 NR2H ZF 7650 NR2 ZF 7650 NR2B ZF 7600 NR2H ZF 7600 NR2 ZF 7600 NR2B

A

V-version

A

8°

006779.4

A-version

A=600 mm ZFW 7500 ZFW 7510 ZF 7561 ZF 7566 ZF 7661 ZF 7666 ZFW 7610 ZFW 7615 A=450 mm ZF 7540 ZFW 7540 ZF 7640 ZF 7641 ZF 7645 ZF 7646 ZFW 7640 ZFW 7645 A=448 mm ZF 7500A ZF 7500V ZF 7600A ZF 7600 V ZF 7650 A ZF 7650 V

“ZF 7500/7600” series transmissions are abaxial 3-shaft reversing and reduction gears with one clutch on both the inputshaft and the reversing shaft. NR2 NR2H and NR2B type transmissions are specially designed for the non reversing function. They have a 2-shaft designe with one clutch on the input shaft. The coaxial „C“ type transmissions have a 4-shaft design with one clutch on each of the two intermediate shafts.The principal components exposed to wear are accessible through an opening in the housing whilst the transmission is still installed. In the ZF 7500/7600 series of transmissions with an offset „A“ of 600 mm, the upper and lower housing sections can be separated at the middle of the output shaft. In the ZF 7500 series with an offset „A“ of 0 mm the housing can be seperated at the middle of the output shaft and the reversing shaft. The cast transmission housings have exceptional torsional rigidity and consist of a light alloy which is largely resistant to salt water. 14

ZF 7500/7600 Series

The housing of the transmissions with an offset „A“ of 600 mm are made of grey cast iron.The housing of the transmissions with an offset A=450 mm can be either grey cast iron or light alloy. Light alloy are ZF 7540; ZF 7640, ZF 7645. The machined faces and tapped holes for attaching the transmission mountings are included as standard. With transmissions with an offset „A“ of 600 mm, the rigid supports are cast onto the transmission housing and then machined. In order to ensure long service life and quiet operation, all power-transmitting gears are configured for high safety levels, case-hardened, ground and then specially treated. The shafts run in roller bearings. Propeller thrust bearings are installed in the transmission (not NR2/NR2H/NR2B type transmissions). The reversing clutches arranged on the input and reversing shafts are of multi-disc type with steel/sinter friction pairing.They are pressed together by oil pressure. The high pump discharge rate ensures that the clutches respond rapidly when actuated. During the gearshift process, the clutch contact pressure is modulated to ensure a smooth shift. At the same time the engaged clutch is fed with an increased flow of oil so that the heat generated during the gearshift process is rapidly dissipated, meaning the load capacity of the clutches is higher. In the event of a fault in the operating oil circuit, the two multi-disc clutches can be pressed together mechanically by means of 3 bolts accessible from the outside (only when the transmission is at a standstill). This emergency control method (not available with NR2, NR2H, NR2B transmissions) permits either enginewise or counter-enginewise rotation of the output shaft. For gearshifts, there is an easily interchangeable controlunit with all the necessary valves, slide valves and othercontrol modules for the operating and lubricating oil circuits mounted on the transmission casing. The control unit is operated mechanically via a lever or electrical. NR2, NR2H, NR2B type transmissions are intended for electrical actuation only. Differences in the „NR“ Series: ZF 7500/7600 series (except NR2, NR2H, NR2B)

The NR.... series transmissions are reduction gears with one clutch, which can be arranged either on the input shaft or the reversing shaft. The output shaft rotates in either the opposite or the same direction as the input shaft, depending on the transmission-version. Otherwise, the design and external dimensions are identical as in the reversing transmission. NR2 NR2H and NR2B type transmissions

NR2 NR2H and NR2B type transmissions have a specially designed 2-shaft arrangement with one clutch on the input shaft. The output shaft rotats in the opposite direction of the input shaft. The external dimensions are different to the dimensions of the reversing transmissions.

ZF 7500/7600 Series

5.3


Transmission views

5.3.1 View of transmission ZF 7500, ZF 7550, ZF 7549, ZF 7600, ZF 7650

The add-ons, connections and pipes on your transmission may be different to those pictured here. 41

46

34

26 18 11 16

10

37

19

12

18

2

22

21

27

25 23 7

44

33 20

32 15


ZF 7500/7600 Series

Key:

1

Mounting faces for transmission(mounting brackets not included in scope of supply for basic version)

25

Oil dipstick

26

Output

2, 21, 27

Pressure measuring point for clutch oil

32

Oil chamber drain

7

Oil sludge drain plug for filter

33

Oil filter

8

Input

34

Emergency control (counter-enginewise rotation)

10

Engine-driven oil pump

35

Coolant inlet

11, 12, 41

Oil temperature measuring points

36

Coolant outlet

15

Oil cooler

37

16

Pressure connection for stand-by pump

Inspection cover, (on transmission housing)

18

Position for trailing oil pump

44

19

Suction side connection for standby pump

Emergency control (enginewise rotation)

20

Oil drain plug

46

Oil fill hole

22

Pressure measuring point for lubricating oil

105

Mechanical selector lever for manual actuation

23

Transmission breather

16

ZF 7500/7600 Series


5.3.2 View of transmissions ZF 7500A, ZF 7550A, ZF 7600A, ZF 7650A

The add-ons, connections and pipes on your transmission may be diffrent to those pictured here.

34 44

26 20

16

10

18

46 22 5

7

33 32 25 23

17


ZF 7500/7600 Series

18 8

35 36

1

19

27

21

18

2

20

ZF 7500/7600 Series


Key:

1


2, 21, 27


5

Oil pressure measuring point upstream of oil filter

7


8

Input

10


11, 12, 41 Oil temperature measuring points 15

Oil cooler

16


18


19


20

Oil drain plug

22


23


25

Oil dipstick

26

Output

32

Oil chamber drain

33

Oil filter

34


35

Coolant inlet

36

Coolant outlet

37


44


46

Oil fill hole

105


19


ZF 7500/7600 Series

5.3.3 View of transmissions ZF 7500V, ZF 7550V, ZF 7600V, ZF 7650V

The add-ons, connections and pipes on your transmission may be different to those pictured here.

37

105 22 5

8

33 7

32 23 25 12 26 15

11 46

35

36

44 20

20

18

ZF 7500/7600 Series


27 21 2

41

10

16

1

19

20

Key:

1


25

Oil dipstick

26

Output

2, 21, 27


32

Oil chamber drain

5


33

Oil filter

35

Coolant inlet

7


36

Coolant outlet

8

Input

37

10



44


46

Oil fill hole

105



Oil cooler

16


18


19


20

Oil drain plug

22


23


21


ZF 7500/7600 Series

5.3.4 View of transmissions (left version) ZF 7550NR2H, ZF 7600 NR2H, ZF 7650 NR2H

The add-ons, connections and pipes on your transmission may be different to those pictured here. 15 13

26

(11)

(20)

(12)

18

11

20 12 10

8 1

1

20

22

ZF 7500/7600 Series


21 27 23 25

46

37

22

2

5

33 7 32

Key:

1


26

Output

32

Oil chamber drain

2, 21, 27


33

Oil filter

5


37


7


46

Oil fill hole

8

Input

10


11, 12


13

Water connection flanges

15

Oil cooler

18


20

Oil drain plug

22


23


25

Oil dipstick

23


ZF 7500/7600 Series

5.3.5 View of transmissions (right version) ZF 7550 NR2H; ZF 7600 NR2H, ZF 7650 NR2H


13

26

10

11 20 12

18

(11)

(20)

(12)

8

1

20

24

ZF 7500/7600 Series


5

22 25 2 27

7 32

21

33

23 46 37

Key:

1


26

Output

32

Oil chamber drain

2, 21, 27


33

Oil filter

5


37


7


46

Oil fill hole

8

Input

10


11, 12


13


15

Oil cooler

18


20

Oil drain plug

22


23


25

Oil dipstick

25


ZF 7500/7600 Series

5.3.6 View of transmissions ZF 7550 NR2B, ZF 7600 NR2B, ZF 7650 NR2B


18 26

1

33

10

5 15

13

25 23

11 20 12

26

(11) (20) (12)

ZF 7500/7600 Series


15

2

21

27

22 8

46 37 20

Key:

1


2, 21, 27


5


8

Input

10


11, 12


13


15

Oil cooler

18


20

Oil drain plug

22


23


25

Oil dipstick

26

Output

33

Oil filter

37


46

Oil fill hole

27


ZF 7500/7600 Series

5.3.7 View of transmission ZF 7550 NR2, ZF 7600 NR2, ZF 7650 NR2


15 13 33 10

8 5

25 23

1

1

26

11 20 12 2

(11)(20)(12)

21 27 22 37 46

20 006779

28

ZF 7500/7600 Series


Key:

1


22


23


2, 21, 27


25

Oil dipstick

5


26

Output

33

Oil filter

8

Input

37

10



11, 12


46

Oil fill hole

13


15

Oil cooler

18


20

Oil drain plug

29


ZF 7500/7600 Series

5.3.8 View of transmissions ZF 7540, ZF 7541, ZF 7545, ZF 7546, ZFW 7540, ZF 7640, ZF 7641, ZF 7645, ZF 7646


105

10

22 16

33 7 5 25 23 32 34

44 1

26 11 20

19

12

15 35

8

36

18

2

21 27

20

37 46

30

ZF 7500/7600 Series


Key:

1


2, 21, 27


5


7


8

Input

10



Oil cooler

16


18


19


20

Oil drain plug

22


23


25

Oil dipstick

26

Output

32

Oil chamber drain

33

Oil filter

34


35

Coolant inlet

36

Coolant outlet

37


44


46

Oil fill hole

105


31


ZF 7500/7600 Series

5.3.9 View of transmissions ZFW 7500, ZFW 7510, ZF 7661, ZF 7666, ZF 7561, ZF 7566, ZFW 7610, ZFW 7615


Key:

1

Transmission mounting face (cast-on rigid supports)

8

Input (Flange not part of basic equipment)

35

Coolant inlet

36

Coolant outlet

32

ZF 7500/7600 Series


25 23

7

Filter area (sludge drain)

25

Oil dipstick

11

Oil temperature measuring point

26

Output

12A

Temperature sensor(not part of basic ver sion)

32

Oil chamber drain plug

33

Oil filter

34


41A

Thermometer(not part of basic version)

19

Suction connection for stand-by pump

20

Oil drain plug

22


23


33


ZF 7500/7600 Series

2A

Pressure switch(not part of basic version)

27A

Pressure gauge (not part of basic version)

5A

Oil pressure measuring point upstream of cooler and filter

37

Inspection cover (on transmission housing)

41A

Thermometer(not part of basic version)

44


46

Oil fill hole

105


10


15

Oil cooler

16


23


25

Oil dipstick

34

ZF 7500/7600 Series


5.3.10View of transmissions ZF 7549 C, ZF 7500 C, ZF 7850 C


1

8 37

46

22

44

25

23

34

20

35


ZF 7500/7600 Series

7

33

21 27

32

41

5

2 10

15

16 35 36

26 11

19

12

20

26

Output

32

Oil chamber drain

33

Oil filter

34


35

Coolant inlet

36

Coolant outlet

37


44


46

Oil fill hole

Key:

1

Transmission mounting face (cast-on rigid supports)

2, 21, 27


5


7


8

Input

10



Oil cooler

16


18


19


20

Oil drain plug

22


23


25

Oil dipstick

36

ZF 7500/7600 Series

5.4


Functional description

Transmission and power flow diagram ZF 7500, ZF 7549, ZF 7550, ZF 7600, ZF 7650, ZF 7540, ZF 7640, ZF 7641, ZF 7645, ZF 7646, ZF W 7540, ZF W 7500, ZF W 7510, ZF 7661, ZF 7666, ZF 7561, ZF 7566, ZFW 7610, ZFW 7615

(for ZF 7500 NR, ZF 7549 NR, ZF 7550 NR, ZF 7600 NR, ZF7650 NR, ZF 7640 NR, ZF 7641 NR, ZF 7645 NR, ZF 7646 NR, ZF 7540 NR,ZF 7661 NR, ZF 7666 NR, ZF W 7540 NR, ZF W 7510 NR, ZF W 7500 NR, ZF 7561 NR, ZF 7566 NR, ZFW 7610 NR, ZFW 7615 NR only have either clutch D or E) D A

A

Gears are in mesh

B

B C

E C

A = Input shaft B = Reversing shaft C = Output shaft D = Clutch for counter-enginewise rotation E = Clutch for enginewise rotation

A

Power flow during: Counter-enginewise rotation

A

Enginewise rotation

C B

C

001 635

transmission and power flow diagram for ZF 7550A, ZF 7550V, ZF 7600 A, ZF 7600 V, ZF 7650 A, ZF 7650 V (ZF 7550 NRA, ZF 7550 NRV, ZF 7600 NRA, ZF 7600 NRV, ZF 7650 NRA, ZF 7650 NRV only have either clutch D or E) V-version

A-version D

D A

A

Gears are in mesh

B

B

E

E

C

C

A

Power flow during: counter-enginewise rotation

A A CC

C

B C

Gears are in mesh

A

enginewise rotation

A A B

A - Input shaft B - Reverse shaft C - Output shaft D - Clutch for counterenginewise rotation E - Clutch for engine wise rotation

CC 001 645

37


ZF 7500/7600 Series

transmission and power flow diagram for ZF 7550NR2, ZF 7550NR2H, ZF 7550NR2B, ZF 7600 NR2, ZF 7600 NR2H, ZF 7600 NR2B, ZF 7650 NR2, ZF 7650 NR2H, ZF 7650 NR2B D A

A

C

C

A C

Power flow in counter- enginewise rotation

001 635_1

A - Input shaft C - Output shaft D - Clutch

transmission and power flow diagram for ZF 7549C, ZF 7500C, ZF 7850C (ZF 7549 NRC, ZF 7500 NRC, ZF 7850 NRC, only have clutches E or F) F

C

Gears are in mesh

B

C

D A B

A - Input shaft B - Reverse shaft C - Clutch shaft F - Clutch for counterenginewise rotation E - Clutch for engine wise rotation

008 143_1

E D

A

Power flow in: counter- enginewise rotation

C B A

D

engine-wise rotation

B D

38

A

ZF 7500/7600 Series

ZF 7500/7600 Series (except NR2, NR2H, NR2B)

The transmission and powerflow diagram shows the flow of power for “enginewise rotation” (output shaft rotating in same direction as input shaft) and for “counterenginewise rotation” (output shaft rotating in opposite direction to input shaft). Full engine power can be transmitted in both directions of rotation. The ratio indicated on the type plate applies for both rotation directions of the output shaft. Identical transmissions can therefore be used for multi-engine installations. This requires fewer spare parts and permits the use of standardized exchange units. NR2, NR2H, NR2B type transmissions


Connecting unions are included as standard for monitoring transmission temperature, oil pressure upstream of the filter, lubricating oil pressure and clutch oil pressure. For locations and descriptions, see section 5.3. 5.6

Control unit and transmission actuation

The control unit is a complete module fitted on the transmission housing. It comprises: • a spool valve for charging and draining the clutch packs • a control valve for the clutch pressure level • a time switch for modulating the clutch pressure

The transmission and powerflow diagram shows the flow of power for “counter-enginewise rotation” (output shaft rotating in opposite direction to input shaft) only since these transmissions have a specially designed 2shaft arrangement.

The spool valve is moved axially into the respective shift position. Depending on the actuation system, the valve is moved mechanically, or hydraulically. The oil flowing out from the control unit is used to lubricate and cool the clutch discs, meshing gears and bearing locations.

5.5

If the transmission is mechanically actuated (not NR2, NR2H, NR2B), the spool valve is moved via the selector lever located on top of the control unit. A dial shows the current shift positionengaged. The basic transmission version is mechanically actuated (not NR2, NR2H, NR2B).

Oil supply and transmission cooling

The transmission housings are designed as oil reservoirs. One gear pump is installed to supply oil for transmission lubrication and cooling as well as multi-disc clutch engagement. This pump feeds oil to the pressure oil circuit at a rate de pendent on the speed of the transmission input shaft. In order to ensure ample oil for transmission lubrication and cooling even at a low transmission input speed, a high capacity pump is used. The operating efficiency of the transmission is improved by means of a valve in the oil circuit which is controlled by oil pressure. This valve returns excess oil directly to the inlet (suction) side of the pump at high engine speeds. The oil pump is driven by a spur gear set of the inputshaft. The spur gear ratio is adapted to the engine speed. Transmission oil is cooled by a transmission-mounted oil cooler, made from salt water-resistant material.After cooling, the oil passes through an oil filter (slot-type filter) to the control unit and then on to the clutches and the transmission lubrication points.

If the transmission is electrically actuated, the spool valve is moved axially by means of oil pressure. The required oil flow is taken from the control unit. The oil flow itself is controlled electrically by solenoid valves.The hydraulic cylinder with solenoid valves is flange-mounted to the control unit and forms a complete electrical actuator. The selector lever used for mechanical transmission actuation is retained and is automatically pulled into the relevant selected position. Electrically actuated transmissions are part of the special scope of supply (standard with NR2, NR2H, NR2B transmissions). 5.7

Checks and storage

Before ZF marine gears are supplied to our customers, they are tested on test rigs/benches. During this test, every function, oil pressures, temperature and noise level are checked thoroughly. During the test run, the inside of the transmission is flushed with oil to preserve it. The trans-

39


mission can then be stored in a dry place for up to 12 months without the need for further special measures. Any necessary preservation of the outside of the transmission depends on storage conditions and should be undertaken by the customer. Preservation measures for long storage periods must be specified when ordering.

40

ZF 7500/7600 Series

ZF 7500/7600 Series

6

Installation

When planning what powerpack to use, care must be taken to ensure sufficient free space for removing the oil cooler, oil filter, oil pump, clutch packs and discs and for withdrawing the dipstick. (The dimensions required for these procedures are specified on the transmission installation drawings). It is possible to remove clutch packs and discs whilst the transmission is still installed. The oil drain plugs must also be easily accessible. If there is not enough space available to place a pan under the oil drain openings for collecting the oil during oilchanges, it is advisable to permanently fit a suction pipe on the transmission in place of the oil drain plug.The oil must then be removed by suction during oil changes. CAUTION

The screw connections listed below are to be provided by the customer and must be rated in acc. with the operating loads supplied: •

suspension brackets to transmission (provided this does not fall within ZF scope of supply); • suspension brackets to foundation; • flexible coupling to engine or transmission; • propeller shaft to transmission The safety equipment required for rotating components must be in place, e.g.: • protective covers for output flange, flexible cou pling and/or engine flywheel and drive shaft, • protective covers and guard equipment for universal joint shafts.

Installation

6.1

Permissible installation position

The installation documents specified in the transmission supply contract shall apply. 6.2

Transmission attachments for transportation

The lifting tackle for transportation should only be attached to the lugs provided. On transmissions without attached mounting brackets,

lifting eyes are screwed onto the pads intended for taking up the suspension brackets during delivery. These retaining lugs are only used for transporting the transmission. They must not be used to transport the engine and transmission unit in the “flange-mounted-on-the-engine version”. Afterwards, these lifting eyes must be removed so that the suspension brackets can be attached. On transmissions where the mounting brackets have already been fitted , the lifting tackle should be attached

to the eyes of the mounting brackets. On the mounting brackets supplied by ZF, the corresponding outer bracing ribs have been provided with eyes. If the mounting brackets are manufactured by the shipyard or by the engine manufacturer, suitable means of attachment must be provided. Under no circumstances may the lifting gear be attached in other places, particularly not to the input shaft, the out put shaft, the covers, the oil pumps or the pipes.

41

Installation

6.3

ZF 7500/7600 Series

Transmission mounting on foundation

There are machined pads and mounting threads on the side of the transmission housing for attaching the mounting brackets. If the mounting brackets are manufactured at the shipyard, care must be taken to ensure that the vertical distance between the transmission output shaft and the foundation support surface of the mounting bracket is correct. This distance “x” must be within the following range: x < (0,6 • A) and > (-0,2 • A)

A

A low foundation rigidity can cause resonance and then lead to high levels of load on transmission components. As a result, these components will fail prematurely. If the propeller thrust is taken up by the transmission (propeller thrust bearings for ahead and astern thrust are installed in the transmission), the bearing elements must also be appropriate for taking up the propeller thrust. When operating a flexible transmission mounting and rigidly connected propeller shaft, the alignment must not be permanently distorted in operation. If you have any queries, do not hesitate to contact us. To align the transmission on the foundation (see connection to propeller shaft), very strong supports must be used. Individual supports - only around the individual foundation bolts - are not permissible. The mounting brackets supplied by ZF are provided with aligning screws. These screws must be removed again after the supports have been placed in position. We recommend the use of fitted bolts to secure the mounting brackets to the foundation. If through bolts are used, solid stops should be fitted, at least in the direction “ahead propeller thrust”. The size of the mounting bolts (No., diameter, grade) depends on the operating loads, and is to be specified by the shipyard.Care should be taken to ensure that the transmission mounting takes up not only the propeller thrust and the weight, but also the reaction forces of the input torque and ratio-dependent output torque.

+ X

-

Support surface

A + X

-

Support surface 007691

The surfaces of the mounting bracket on the same side as the transmission must be machined flat. If required, dowels can be used at points specified in the transmission installation drawing. The transmission can be installed separately in the foundation or, (in versions where it is flange-mounted to the engine) it can be installed either rigidly or flexibly together with the engine. During mounting, the transmission must not be braced to the foundation, i.e. all mounting brackets lie equally flat on the foundation. When selecting bearing elements for a flexible transmission mounting, care must be taken to ensure that the natural frequency of the flexibly installed

42

transmission does not coincide with the excitation frequency of the engine unit or the propeller. The foundation rigidity must also be taken into consideration when calculating the natural frequency.

ZF 7500/7600 Series

Installation

6.3.1 Casting resin base

The support surface of the ZF mounting bracket (flexible and rigid) has been designed for direct mounting on a rigid surface (e.g. foundation frame). If the transmission is to be mounted onto casting resin, it may be necessary to enlarge the support surface using an adapter plate supplied by the ship yard. The space between the foundation frame and the adapter plate is cast. In such instances, the adapter plate should be designed in a way that makes it possible to remove and install the transmission without destroying the casting resin base. In addition to this, rigid pads should be fitted for transmitting the propeller thrust to the foundation. Once the casting resin has hardened, the transmission should only be supported by the casting resin and not by the alignment screws or any other alignment aids. When aligning the transmission, the way in which the casting resin reacted to shrink fitting during hardening should be taken into consideration. We recommend that plans for the design of any mountings made of casting resin are made in conjunction with the casting resin suppliers and/or a certified specialist company. A specialist company is able to provide advice at an early stage and is able to create the calculations and drawings required for approval from a classification society and to submit these for approval.

43

Installation

6.4

Connection to the engine

ZF 7500/7600 Series

6.4.1 “Normal” engine arrangement

If rigid connection between engine and transmission is not possible due to the vibration calculation, the engine torque must be transmitted to the transmission by means of a flexible coupling. This is to prevent any detrimental vibration resonances within the operation speed range by controlling the natural frequency of the engine, transmission and propeller. If, in special cases, a critical speed within the operating speed range is inevitable, a limiting range must be specified for certain speeds. This is dependent on the value of the calculated vibration amplitude. 006778.2

The flexible coupling to be used is generally selected by the engine manufacturer with the aid of a torsional vibration calculation. The transmission data necessary for this calculation can be taken from our “Data for torsional vibration calculation” sheet. If a flexible coupling is supplied by ZF according to the selection of the engine manufacturer or as stipulated by the shipyard, ZF can in no way be held responsible for the suitability or durability of the flexible coupling. Assembly and disassembly of the clutch hub or the input flange, i.e. the part of the flexible coupling on the input side facing the transmission side must be carried out according to the workshop manual of this transmission series.

007693.2

The transmission can be installed “separately” or “flange-mounted on the engine”. If the transmission is installed separately, the foundation mounting will either be rigid or flexible. Normally, the engine is mounted flexibly. The torsionally flexible input connection must also be capable of absorbing misalignments of the engine axis relative to the transmission axis. The elasticity of the engine mounting as well as the alignment accuracy of engine to transmission must (related to the transmission) be selected so that the axial and radial forces bearing on the transmission due to the retroactive forces of the flexible coupling do not exceed the permissible limit (see „summary of technical data“).

If the transmission is installed “flange-mounted on the engine”, the bell housing connects the transmission to the engine. In this instance, the two units are properly centred. The flexible connection then no longer has to absorb any additional forces caused by shaft misalignment.

44

ZF 7500/7600 Series

Installation

6.4.2 U/V-drive arrangement

U-drive arrangement

006779.2

These forces and bending moments are absorbed at the transmission end by the transmission input shaft, transmission housing and mounting bracket; at the engine end by the flexible coupling, crankshaft and engine housing. The torsionally flexible coupling must therefore be fitted with additional suspension elements between the primary and secondary side. If the flexible coupling or the engine crankshaft cannot absorb forces and bending moments generated by the drive shaft, an additional bearing must be installed between the drive shaft and the flexible coupling. This bearing can be supported by a flange on the engine. Alternatively, an intermediate shaft can be installed and mounted in the foundation. The forces and bending moments generated by the drive shaft occur periodically at double the engine speed of rotation. The maximum value for additional load on the transmission input shaft (refer to section 3) must not be exceeded. The mounting bracket for the engine and/or intermediate shaft, transmission and foundation should have its dimensions calculated to ensure that unacceptable levels of distortion cannot occur. If they do occur, this would lead to noise and vibration. If necessary, the foundation must be strengthened.

V-drive arrangement

006779.3

transmissiones with input and output flanges at the same end of the transmission are used for the U- or V-drive arrangement (... U or ... V). The same conditions as in section 6.4 apply to the connection between the engine and the transmission, but an additional, variable-length drive shaft is used between the torsionally flexible coupling and the transmission input flange. The joints of the drive shaft create radial forces and bending moments. In addition, axial forces are produced by changes in the distance between the engine and transmission. These axial forces are of a size which can be transmitted by the variablelength section of the drive shaft. It must be ensured that the variable-length section also functions when under load (axial forces only produced by longitudinal friction, no canting, no excessive greasing) and that the stroke is also sufficient for extreme situations (shock loads). The size of all these forces and bending torques depends on the torque transmitted, on the drive shaft length and on the size of the joint angle.

The size of drive shaft to be used depends on the engine output, engine speed, size of the joint angle and the lifetime required for the drive shaft. The drive shaft manufacturer usually recommends a shaft size by studying the actual operating conditions which the vessel is likely to encounter. To ensure that the drive shaft operates at the optimum kinematics, the joint angles must be the same at both ends and the joint forks must be mounted on the same plane. It should be ensured the joint angles are as small as possible. In transmissiones with parallel input and output shafts (Udrives), not more than max. 7° – 8°. The output shaft in V-drive transmissiones is already tilted by 8°, i.e. the drive shaft angle can be reduced to the minimum value required for the joint bearing of the drive shaft. We recommend to use the advantage of the tilted output shaft and do not exceed a joint angle of max. 3°. You should try to use a drive shaft centre part with a dynamic rotating mass as small as possible.

45

Installation

ZF 7500/7600 Series

DANGER! Fit a safety device to all parts of the drive shaft at which the rotating shaft presents a possible danger to people and material. The user and/or operator should comply with all relevant safety precautions. It is essential that the appropriate safety equiment (e. g. retaining bracket, stable guard grill) is fitted to prevent parts of the drive shaft being thrust out of the unit.

The drive shaft manufacturer’s technical documents contain more detailed information about drive shafts. The drive shaft can be arranged in two ways • W-arrangement with β 1 = β 2 β2

β1

004_971.1

To check the joint angles when aligning the engine , two alignment shafts of equal lenght can be installed in place of the drive shaft. The engine will be properly aligned (and joint angles of equal size) when the ends of the two alignment shafts meet (see installation diagram). • Z-arrangement with β 1 = β 2 β2

β1 004_971.2

To check the joint angles when aligning a leaser based aligning device can be used. The engine will be properly aligned (and joint angles of equal size) when the engine crank shaft and the transmission input shaft are in parallel.

46

ZF 7500/7600 Series

Installation

6.4.3 U/V-drive installation diagram when drive shaft is in W-arrangement

004 971

1

Engine

5

2

Self-centering torsionally flexible connection. Specified according to engine output and torsional vibration calculation.

Marine transmission with input and output at the same end

6

Installation to help in the correct alignment of the engine and transmission, i.e. to achieve equal joint angles ß1 = ß2. Install two alignment shafts in place of the drive shaft. The shafts must be of equal length. Align the two units so that the ends of the shafts meet and that the center line of the shafts belong to the same plane. Finally, remove the alignment shafts and install the drive shaft.

3

Variable length drive shaft Selected in accordance with manufacturer’s recommendations. Comply with installation regulations (ß1 = ß2, joint forks mounted in the same plane).

4

Propeller shaft

47

Installation

6.5

Connection to propeller shaft

The dimensions of the connection depend on the operating loads and must be specified by the shipyard. The transmission output flange is designed to ensure that the maximum permissible transmission torque is transmitted by means of friction contact. For this purpose the following bolts must be used for all bolt holes. ZF 7549, ZF 7500, ZF 7549C, ZF 7500C, ZF 7850C

M22x1.5Quality 10.9min. tensile strenght 1000 N/mm² ZF 7550 /A/V/NR2/NR2H/NR2B ZF 7600 /A/V/NR2/NR2H/NR2B ZF 7650 /A/V/NR2/NR2H/NR2B

M24x1.5Quality 10.9 min. tensile strenght 1000 N/mm² ZF 7541, ZF 7545, ZF 7546; ZF 7540, ZFW 7540, ZF 7640, ZF 7641, ZF 7645, ZF 7646, ZFW 7500, ZFW 7510, ZF 7661; ZF 7666, ZFW 7610, ZFW 7615

M30x2 Quality 10.9 min. tensile strenght 1000 N/mm² If fit bolts are used, the bores of the propeller-shaft flange and transmission output flange (material strength 750 to 900 N/mm 2) may be opened out together by drilling and reaming.

ZF 7500/7600 Series

6.6

Aligning the transmission

If the transmission mounting is relatively flexible, the connection between the transmission output flange and the propeller shaft must normally be capable of absorbing relative movements (e.g. joint coupling or flexible coupling). This does not apply if the propeller shaft is also extremly flexible. If the propeller shaft is connected rigidly to the transmission output flange, the transmission must be aligned with the propeller shaft. To do this, the vessel must be fully fitted-out and afloat. If necessary, the alignment procedure must be repeated before the vessel goes into service. Shafts with only one propeller-shaft bearing (Fig. A)

It must be possible to move the propeller shaft axially and radially so that the propeller-shaft flange can be inserted into the transmission output flange centre. The transmission must be aligned so that the permissible angle error “x”, based on measuring radius “r”, does not exceed the value specified in the „summary of technical data“ section 3 value “y” is disregarded.

See „Summary of technical data“

48

ZF 7500/7600 Series

Installation

Shafts with two or more propeller-shaft bearings (Fig. B)

It must be possible to move the propeller shaft axially so that the propeller-shaft flange can be fitted in the centre of the transmission output flange. The transmission must be aligned so that the permissible errors x (based on measuring radius r) and y do not exceed the values stated in the table. Both errors x and y may be present at the same time. If the shaft is very thin and the distance L is very great, it may not be possible to measure the value “y”. If the propeller shaft can be installed in the centre of the transmission output flange, with a maximum radial force not exceeding the value specified in the „summary of technical data“ section 3, the “y” value can be disregarded. If this is the case, the alignment instructions for “shafts with only one propeller-shaft bearing” apply. NOTE

The values given for x and y only apply when the distance L between the propeller-shaft flange and the last shaft bearing is large enough in relation to the shaft diameter d.

49

Installation

6.7

Connections for transmission cooling

(Data applies only to coolers fitted as standard at ZF) The volume of heat generated in the transmission is partly radiated from the housing surface and partly dissipated through the oil cooler. The oil cooler included in the basic transmission version is mounted on the housing. All the necessary oil lines are securely attached and ready for use. The coolant inlet and outlet connections are located on the side of the cooler and blanked off during shipment. The blanking-off flanges can be used as welding flanges when installing the coolant pipe. The positions of the coolant inlet and outlet connections are shown on the relevant transmission installation drawing. The direction of water flow must be maintained, i.e. water inlet and outlet must not be interchanged. For permissible water flow rate and pressure loss between coolant inlet and outlet, refer to technical data. The specified water pressure at the coolant inlet must not be exceeded. The cooler is designed to ensure adequate heat dissipation at a transmission ambient temperature of 60°C and a water inlet temperature as specified in section 3 - even at full transmission load and maximum engine speed.

ZF 7500/7600 Series

The correct transmission temperature is obtained by adjusting the coolant flow rate. A replaceable orifice, valve or similar must be included in the circuit for this purpose. For this reason, the transmission oil cooler water circuit should be connected in parallel to the engine coolant circuit. The max. permissible temperature increase for the coolant in the transmission oil cooler is 3°C and is of no significance to the engine oil circuit. The stated maximum coolant flow rate through the transmission oil cooler must not be exceeded since this may lead to cavitation in the cooler. Similarly, the minimum flow rate must always be maintained, otherwise sludge may form in the cooler after only a relatively short period of operation The pipes and shut-off valves for the sea water circuit must be made from copper or material containing copper for operation in seawater or brackish water. Galvanized steel pipes must not be used due to the risk of the zinc coating partly eroding as a result of galvanic processes and rust debris being deposited on the webs and flanged pipes in the cooler. Within a short period of time, this would lead to the cooler being damaged by pitting corrosion. The water pipes must to be connected to the cooler in such a way that stresses and recoil forces caused by thermal expansion are avoided. If routing of the water pipes makes this impossible, flexible connections must be fitted, arranged as close as possible to the cooler.

50

ZF 7500/7600 Series

6.8

Installation

Connection of monitoring devices

The minimum monitoring facilities specified in the section 2 must be provided at all times (monitoring equipment is not included in the standard scope of supply). The required equipment should be installed in such a way that reliable instrument readings can be taken at any time, even under unfavorable operating conditions. The display scales of the monitoring equipment should be selected so as to achieve the maximum possible pointer deflection in the operating range. In addition to the specified minimum monitoring facilities, futher indicating or warning equipment can be connected to the points which are sealed by screw plugs. 6.9

Transmission actuation devices

Mechanical and electrical transmission actuators are available as required. The mechanical actuator is fitted as standard. with the ZF 7500/7600 Series except NR2, NR2H, NR2B transmissions. With NR2, NR2H, NR2B transmissions there is electrical actaution only. The actuation mechanism must be designed so that a gear change can only occur when the engine throttle control lever is in idling position. This can best be obtained with “single lever control” whereby engine throttle control and transmission control are interlocked. When using “dual lever control”, a locking device should be incorporated in the transmission actuation system so that a gearchange can only be carried out when the engine throttle control lever is in idling position. A cutout device for the the transmission actuator should also be provided for “single lever control”, so that the engine can be run at high speed for inspection or warming-up purposes without the need to actuate the transmission.

51

Installation

ZF 7500/7600 Series

6.9.1 Mechanical actuation of transmission (Not with NR2, NR2H, NR2B type transmissions)

In mechanically actuated transmissions, the spool valve in the control unit is moved in an axial direction by means of the control shaft rotary motion.

Key to drawings

103 Selector position for counterenginewise rotation 104 Selector position for enginewise rotation 105 Selector lever for mechanical actuation

137

105

121 Selector limit stop 122 Undefined selector position (pass through this area quickly) 123 Safe neutral area 124 Neutral detent setting 137 Switch for interrupting warning signal (special scope of supply)

The lever is situated on top of the control unit. The selector lever should be at an angle of approx. 90° to the shift linkage when in neutral position. After removing the lateral clamping screw on the selector shaft, the selector lever can be rotated by approx. 11° on the selector shaft. The control positions are shown on the quadrant situated on the control unit and the marks on the graduated circle on the selector shaft. The exact shift angles of the individual control positions required for establishing the required stroke and linkage connection can be seen on the sketch “Mechanical transmission actuator”. The linkage connection bore on the selector lever depends on the stroke of the shift mechanism. Select a distance between the bore and the selector lever pivot point which ensures that the specified shift angle (see drawing) can be reliably attained. Information about the mechanical emergency operation of the mechanical transmission actuation is given in section 7.3.1.

DANGER!

Mechanical transmission actuator

52

The transmission clutches are disengaged in „Neutral“ shift position. The propeller shaft can still keep turning. If you require the propeller shaft to be stationary, then it is necessary to provide a propeller shaft brake or another shaft interlock.

ZF 7500/7600 Series

Installation

The bore may be between 45 and 95 mm away from the selector lever pivot point. If necessary, the existing hole (105 mm away) may be used. The relationship between shift travel, bore spacing and shift force is shown in the following table Shift travel of selector unit Neutral ahead Neutral astern H [mm] 30 40 50 60

Distance ofconnecting hole from pivot point

Shift force required

r [mm]

F [N]

approx. 47 approx. 62 approx. 78 approx. 93

56 42 34 28

After the selector device has been adjusted, the selector lever must be firmly fixed to the selector shaft using a clamping screw. The shift angles must then be checked as shown in the Figure. Special care must be taken that the undefined ranges between - neutral position and operating position for enginewise rotation or - neutral position and operating position for counterenginewise rotation are passed through quickly. Operations within the undefined ranges may damage the reversing clutches. For this reason, shift movements in the transmission must be checked at regular intervals and following all repairs/overhauls, and adjusted if necessary. If the distance between the actuator and transmission selector lever is too large, it is difficult to maintain the specified control position by mechanical means. In such cases we recommend the use of the electrical transmission actuator.

53

Installation

6.9.2 Electrical actuation of transmission (Not with NR2, NR2H, NR2B type transmissions. For these transmissions see section 6.9.3)

ZF 7500/7600 Series

respective shift position. If there is a failure in the power supply, the transmission can be actuated manually by using the selector lever. NOTE

The basic version of this reversing transmission shifts back to neutral automatically if the power supply fails. A special version is also available: “shift position retained during power failure” for water jet or variable pitch propeller applications with non reversing transmissions). In accordance with customer wishes or some classification society requirements, „reversing“ transmissions can also be supplied as this special version. Before initial operation, check which version is choosen by the vessel manufacturer. Information about the mechanical emergency operation of the electrical transmission actuation is given in section 7.3.2.

DANGER!

The transmission clutches are disengaged in „Neutral“ shift position. The propeller shaft can still keep turning. If you require the propeller shaft to be stationary, then it is necessary to provide a propeller shaft brake or another shaft interlock. 101 Electrical actuator 106 Electrical connection 140 Actuating pin for Item 141 141 Valve for mechanical auxiliary operation 142 Setting for electrical operation 143 Setting for mechanical auxiliary operation

In the case of electrical transmission actuation, the spool valve is moved axially by means of oil pressure. The required data for electrical connections and soldering procedure for the plug element are shown in the documentation supplied with the equipment. If the transmission is electrically actuated, the manual selector lever is moved simultaneously into the 54

ZF 7500/7600 Series

Installation

6.9.3 Electrical actuation of NR2, NR2H, NR2B type transmissions

Version where the manual mechanical actuation is carried out by push/pull slider

With the electrical transmission actuation, the spool valve is moved axially by means of oil pressure. The required data for electrical connection and soldering procedure for the plug element are shown in the documentation supplied with the equipment. In case of a power failure the transmission can be manual mechanical actuated. With regard to the manual mechanical actuation there are two versions available.

101

Version where the manual mechanical actuation is carried out by screws.

101

101 electric actuation device NOTE

In case of a power failure the shifting position prior to the power failure remains unchanged. For description of operation with manual mechanical actuation see section “Operation”.

106

006 626

101 electric actuation device 106 electrical connections (plug connection included in ZF scope of supply) NOTE

In case of a power failure the shifting position prior to the power failure remains unchanged. For description of operation with manual mechanical actuation see section “Operation”.

55

Installation

ZF 7500/7600 Series

6.10 Transmission monitoring

5

41

21

27

2

22

12 11

The monitoring facilities stated in section 6.10.1 are essential for checking operating reliability of the transmission and must always be installed. In addition, the transmission is provided with measuring points for additional monitoring equipment (see section 6.10.1). 6.10.1 Minimum transmission monitoring facilities (for values, see section „Monitoring values“)

Pressure reading upstream of oil cooler and filter (measuring point 5). This measuring point is intended as a means of monitoring the oil filter. Any rise in pressure indicates that the filter is becoming increasingly blocked. A pressure-sensing switch must be used for monitoring. It should be set to change over when pressure rises above the preset value, and transmit a warning signal. Clutch oil pressure (measuring point 2)

Depending on the transmission version and its inputtorque, the clutch oil pressure setting will vary. The nominal clutch oil pressure is confirmed in the technical documentation which is included with each order, and is also stamped on the transmission type plate (see section 5). The clutch oil pressure indication applies to both the enginewise and counter-enginewise shift positions. In Neutral, the oil pressure at this measuring point drops to a

56

006 791

value given in the section „Monitoring values“, depending on input speed and oil temperature. To monitor clutch oil pressure, a pressure gauge must be used. If clutch oil pressure is in accordance with the specified values and the conditions stated above apply, transmission lubrication will be assured. For this reason, separate monitoring of lubricating oil pressure (measuring point 22) is unnecessary. Oil temperature (measuring point 12)

A thermometer must be used to monitor transmission oil temperature. The volume of water flowing through the transmission oil cooler must be regulated until the transmission oil temperature remains within the recommended normal range during normal operation. The maximum transmission oil temperature must not be exceeded during continuous operation.

ZF 7500/7600 Series

6.10.2Additional transmission monitoring (for values, see section „Monitoring values“)

Additional measuring points are provided on the transmission if a higher level of transmission function monitoring is desired. The relevant values are the same as those at the measuring points for the minimum monitoring facility.

Installation

Oil temperature (measuring point 11)

An additional temperature sensor can be connected to measuring point 11 for a remote thermometer or a tem perature warning switch. The temperature switch must be set to the warning value specified for the transmission version in question. Measuring point 41

Pressure reading upstream of oil filter (measuring point 5). If monitoring is to take place by means of a pressure gauge and a warning device, a T-union can be attached at measuring point 5 for simultaneous connection of a pressure gauge and pressure-sensing switch. It is also possible to use a pressure sensor with built-in switch contact for an alarm device if a remote reading instrument is needed.

This measuring point can be used in transmission versions equipped with a trailing oil pump. CAUTION

Measuring point 41 is not located in the oil sump. It can only be used for monitoring oil temperature if the oil is being circulated (engine running or rotating propellershaft with fitted trailing pump).

Clutch oil pressure (measuring points 21 and 27)

Measuring points 21 and 27 can be used to connect additional pressure-sensing switches in conjunction with a warning device or pressure gauge. When monitoring is via a pressure-sensing switch, this must be adjusted so that the alarm signal is transmitted, if pressure drops below the warning limit. In neutral transmission setting, oil pressure will drop below the trip value for the pressure-sensing switch, i.e. alarm goes off in neutral even if oil pressure is normal. To prevent this happening, the warning device should be deactivated when the transmission is in Neutral e.g. by means of a switch controlled by the transmission actuator (ZF special scope of supply). To prevent the alarm from tripping in the period between operation of the control unit and build-up to full clutch oil pressure (approx. 1 to 2 s), a delay timer must also be installed in between, with settings of min. 3 s and max. 10 s. Lubricating oil pressure (measuring point 22)

Lubricating oil pressure can be monitored at measuring point 22 using either a pressure gauge or a pressure-sensing switch. Depending on the transmission input shaft speed and transmission oil temperature, the lubricating oil pressure will be in the area stated in section „Monitoring values“. When monitoring with a pressure-sensing switch, adjust it so that a warning signal is transmitted if lubrication oil pressure drops below the warning value specified in section „Monitoring values“.

57

Installation

6.11 Necessary measures before operating the transmission for the f irst time 6.11.1Oil fill, oil level check

See Maintenance section for correct procedure. 6.11.2Installation check

• By hand rotate the engine and then the propshaft. Check for ease of operation. • Check that clamping bolts of mounting brackets on transmission and foundation are securely tightened. • Check that connecting bolts between propeller shaft flange and transmission output shaft flange are tightend securely. • Check that connecting bolts on the transmission input end are tightened securely. • Check that connections have monitoring instuments. • Check that oil cooler is connected to the coolant system. • If a remote mounted cooler is used. Check that this oil cooler is safely connected with the transmission lubrication system. • Check that all rotating components have protective covers. • Check that all transmission components (pipes, sensors, plugs, wires) are not damaged. • Check that all electrical interfaces to the transmission are finally wired and all cable/wire entrances are sealed. • Check that all hoses, wires and cables are fitted free of scuffing.

Function check on selector mechanism

On mechanically actuated transmissions each shift position can be read using the scale on the control unit and the circular markings on the selector shaft. Mechanically actuated transmissions in particular must be carefully checked to see whether the specified shift positions are assured. On electrically actuated transmissions check operating voltage or power consumption at an appropiate place as near as possible to the plug connection for the electrical control unit.

58

ZF 7500/7600 Series

ZF 7500/7600 Series

7

Operation

During operation, the transmission does not require any attention except for monitoring of the indicators for transmission temperature and oil pressures.

DANGER!

The transmissions clutches are disengaged in “Neutral” shift position. The propeller shaft can still keep turning. If you require the propeller shaft to be stationary , then it is necessary to provide a propeller shaft brake or other shaft interlock. 7.1

Change-over procedure

In our experience, the change-over procedures described in the following sections give the best results with regard to the shortest possible time required for changing the travel direction of the vessel and, at the same time, the greatest possible protection for the transmission reversing clutches and the entire power transmission system. We would therefore strongly recommend that the change-over sequences specified here are adhered to. Shift procedures from neutral to ahead or astern, or vice versa, should be carried out rapidly. It is forbidden to remain in the undefined areas between shift positions.

Operation

7.1.3 Change-over from “ahead” to “astern” with vessel movin g at higher speed (not applicable for non-reversing transmissions)

Move engine throttle control to idling. Leave transmission control lever in “ahead”, in order to utilize the engine braking effect on the propeller until the engine speed has dropped to approx. 1.2 x idling speed. Now move transmission control lever to “astern“ and keep it in this position for approx. 1 or 2 secs. before increasing the engine speed to the required operating speed. 7.1.4 Emergency change-over in case of danger (not applicable for non-reversing transmissions)

In case of emergency, it is of course possible to carrry out a change-over from “ahead” to “astern” at higher engine speeds, too. However, in this case as well, we would recommend a time lag of approx. 1 or 2 secs. after the “astern” direction has been engaged, before increasing the engine speed. During such manoeuvres, please note that in many cases (depending on the type of vessel etc.), the time needed to bring the vessel to a stop is not shortened at all or only very slightly compared with the change-over sequence described above. Therefore, in spite of the increased load on the propulsion unit, in most cases, the chances of avoiding a collision are not greatly reduced.

7.1.1 Change-over from “neutral” to “ahead” or “neutral” to “astern”

7.2

(The propeller shaft is at rest or only rotates very slowly)

7.2.1 Occasional trailing operation

Move engine throttle control to idling, select desired travel direction and keep lever in this position for 1 or 2 secs. before increasing the engine speed to the required operating speed. 7.1.2 Change-over from “ahead” to “astern” with vessel moving at low speed (not applicable for non-reversing transmissions)

Move engine throttle control to idling. Move transmission control lever from present travel direction to opposite direction and keep it in this position for approx. 1 or 2 secs. before increasing the engine speed to the required operation speed.

Operation with engine stationary and propeller trailing

It is possible to carry out occasional trailing operations with the basic transmission version installed (without trailing oil pump). The transmission oil temperature must be monitored (measuring points 11 and 12 located in oil sump). The max. oil temperature must not exceed 75°C. If the tem perature exceeds this level, the vessel speed must be reduced. If necessary, the engine can be started up for a short time until the transmission oil temperature falls below the max. permissible value as a result of coolant circulation (transmission in forwards or neutral position). Trailing operation of max. 15 hours is permissible in emergencies.

59

Operation

7.2.2 Regular trailing operation

If regular trailing operation lasting more than 5 hours without interruption is necessary, a trailing oil pump must be installed. This oil pump is fitted on the transmission housing in the output shaft area. It is driven by the transmission output shaft via a gear train. The oil pumps always delivers oil to the oil circuit in the same direction, irrespective of the output rotation direction. When the engine is at a standstill and the output shaft is turning, this oil pump supplies lubricating oil to the transmission. This means that it is permissable to operate the unit as long as is required when the engine is at a standstill and the propeller is rotating. The oil temperature must be monitored and may not exceed 105°C (the oil sump temperature is approximately equal to the clutch disc temperature). If the oil temperature is too high, it can be cooled either by reducing the trailing speed of the ship or by passing water through the transmission oil cooler. The coolant can either be taken via a special valve from the operating engine coolant system , or it can be supplied through a separately driven water pump. For dimensions, reckon on a coolant capacity equal to max. 25% of the water capacity during normal operation. If the transmission oil temperature rises to above 90°C, the transmission must remain in neutral after the engine has been started until the tempe rature drops below 90°C. Only then is normal operation permitted.

60

ZF 7500/7600 Series

ZF 7500/7600 Series

7.3

Operation with the manual mechanical actuation

If a fault develops in the actuating system, the transmissions can be shifted manually using the manual mechanical actuation on the transmission. For reasons of safety, the normal actuating system must be rendered non-operational before the manual control is used. Comply with the gear shift instructions in section 7.1. The correct shift setting can be checked in each case using the scale on the control unit (with NR2, NR2H, NR2B type transmissionwith the position of the push/pull slider).

7.3.1 Mechanical emergency operation of mechanical transmission actuation

This section applies if the transmission has a mechanical transmission actuation (see section 6.9.1) DANGER!

Engine and transmission components can get very hot (danger of burns). In addition in the engine room there is danger of rotating parts. Take appropriate safety precautions. Mechanical emergency actuation is to be performed in the following sequenz: - Stop the engine - Unhook the push-pull cable or the linkage of the mechanical remote control - Move the selector lever manually to the “Neutral” position - Start the engine and set it to idling speed - Move the selector lever manually to the desired shifting position until it stops. The selector lever remains in that position. Appropiate measures must be taken to secure the selector lever and prevent it from jumping out of the “ahead” or “astern” position which might occure e. g. due to vibrations.

Operation

DANGER!

When the mechanical emergency operation is used the remote transmission control for this transmission does not function. It is essential that the person in charge of the craft is aware of this situation. In port or when travelling on a narrow or busy waterway, stop the engine and have the craft towed. To deactivate the mechanical emergency actuation, stop the engine and hook the linkage for the remote mecanical actuator onto the seleector lever of the control unit. Check the setting.. 7.3.2 Mechanical emergency operation of the electrical transmission actuation (except NR2, NR2H, NR2B type transmission)

This section applies if the transmission has an electrical transmission actuation as discribed in section 6.9.2. For NR2, NR2H, NR2B see section 7.3.3 DANGER!

Engine and transmission components can get very hot (danger of burns). In addition in the engine room there is danger of rotating parts. Take appropriate safety precautions.

61

Operation

ZF 7500/7600 Series

Standard version

If the power supply fails, the transmission automatically shifts to neutral. This version has the cap nut and the actuating PIN 140 (see sketch in this section).

142

140

141

143

In order to change over manually using the selector lever of the control unit, it is necessary to change over the mechanically shifted valve (see sketch in this section, items 141). This is done by installing the actuating PIN 140 the other way round. This actuating PIN can be accessed once the cap nut has been screwed off. The cap nut must then be screwed back on. The selector lever can now be manually shifted as with the mechanical transmission actuation version. Special version

If electrical power fails, the shift position is retained. This version has not the cap nut and the actuating PIN 140 (see sketch in this section).

0

With this version shifts can be performed manually on the selector lever without installing the actuating PIN the other way round. 101 106

011 749

101 101

Elect Electric ric tra trans nsmi missi ssion on act actua uati tion on

106 106

Elec Electr tric ical al conn connec ecti tion on

140 140

Actu Actuat atin ing g pin pin for for item item 141 141

141

Valve Valve for mechani mechanical cal emergen emergency cy actuat actuation ion

142 142

Setti Setting ng for for ele elect ctric rical al act actua uatio tion n

143

Settin Setting g for for mecha mechanic nical al auxili auxiliary ary actuat actuation ion

NOTE:

There are two versions of electrical transmission actuation. These are: • stan standdard ard ver version sion • special ver versi sioon

62

Appart from some reversing transmissions alle non reversing transmissions have the special version. Mechanical emergency actuation is to be performed in the following sequenz: • Set the the engi engine ne spe speed ed to to idli idling ng spe speed ed • Remove Remove plug plug on elec electri trical cal actu actuatio ationn (see (see sketch sketch in in this section item 106) With standard version only: • Change Change over over the the mechan mechanica ically lly shif shifted ted valv valvee (see (see sketch in this section). This is done by installing the actuating PIN 140 the other way round (accessible once cap nut has been unscrewed). A small oil leak is possible when cap nut is removed. The cap nut must be tightened again. • Move Move the selec selector tor lever lever manual manually ly to the the desir desired ed shifting position until it stops. The selector lever remains in that position. Appropiate measures must be taken to secure the selector lever and prevent it from jumping out of the “ahead” or “astern” position which might occure e. g. due to virbrations.

ZF 7500/7600 Series

DANGER!

Operation

7.3.3.1Mechanical emergency control for version with auxiliary screws

When the mechanical emergency operation is used the remote transmission control for this transmission does not function. It is essential that the person in charge of the craft is aware of this situation. In port or when travelling on a narrow or busy waterway, stop the engine and have the craft towed.

101

To deactivate the mechanical manual actuation • Stop top th the en engine • Fit plug plug on on electr electrica icall actuat actuation ion (see (see sketc sketchh in this this section, item 106) • With “standa “standard rd versi version“ on“ only only:: Change Change over over the mechanically shifted valve (see sketch in this section, item 141 • Check Check that that plug plug and cap scre screw w are fitted fitted and and tightened

106

1

006 626

106

7.3.3 Mechanical emergency emergency operation operation of the the electrielectrical transmission actuation of NR2, NR2H, NR2B type transmission

101

Should problems arise with the electrical transmission actuation or should the power supply fail, the transmission can be shifted manually. DANGER!

Engine and transmission components can get very hot (danger of burns). In addition in the engine room there is danger of rotating parts. Take appropriate safety precautions. NOTE:

There are two versions of mechanical emergency control. These are: Mechanical emergency control with auxiliary screw - Mechan Mechanica icall emerge emergency ncy con contro troll with with push push / pull pull slider

2 006 625

101 101 elec electri tricc actua actuatio tion n devic devicee 106 106 elec electri trica call conn connec ecti tion on 1, 2 screw rew plug lug NOTE:

For mechanical emergency control an actuating PIN max. diameter 6 mm, min length 80 mm is required. Small oil leak is possible when screw plug 1 or 2 is removed.

63

Operation

Shifting process: Engage • Set Set engi engine ne spe speed ed to to neut neutra rall spee speedd • Remove Remove plug plug (item (item 106 106)) on elect electric rical al actua actuatio tionn device (item 101) • Remove Remove screw screw plug plug 1 (scre (screw w 2 with with NR2H “left “left version”) • Place Place PIN PIN (max. (max. diamet diameter er 6 mm, mm, min. min. lengt lengthh 80 mm) mm) into opening and move control valve until it stops • Fit screw screw plug plug 1 (2 with with NR2H NR2H “left “left versio version”) n”) Disengage • Set Set engi engine ne spe speed ed to to idl idlin ingg spee speedd • Remove Remove plug plug on on electr electrica icall actuati actuation on devic devicee (item (item 101) • Remove Remove screw screw plug plug 2 (scre (screw w 1 with with NR2H “left “left version”) • Place Place PIN PIN (max. (max. diamet diameter er 6 mm, mm, min. min. lengt lengthh 80 mm) mm) into opening and move control value until it stops • Fit screw screw plug plug 2 (1 with with NR2H NR2H “left “left versio version”) n”)

ZF 7500/7600 Series

7.3.3.2Mechanical emergency control for version with push / pull slider

106

101

NR2H „left version“ 106

101

B

DANGER!

When the mechanical emergency operation is used the remote transmission control for this transmission does not function. It is essential that the person in charge of the craft is aware of this situation. In port or when travelling on a narrow or busy waterway, stop the engine and have the craft towed. To deactivate mechanical manual actuation • Stop en engine • Fit plug plug (ite (item m 106) 106) on elect electric rical al actuat actuation ion devi device ce (item 101) • Check Check that that plug plug (item (item 106) 106) and and screw screw 1 and 2 are are fitted and tightened

64

A C NR2H „right version“ C

Push/pull slider

B

Wing nut

A

Protective cover

101 101 elec electri tricc actua actuatio tion n devic devicee 106 106 elec electri trica call conn connec ecti tion on

Shifting process: • Set engin enginee spee speedd to idli idling ng spe speed ed • Unfast Unfasten en wing wing nut nut and and remove remove prot protect ective ive cove cover. r. • Rotate Rotate prot protect ective ive cove coverr 180° 180° upward upwardss and fix fix it again with wing nut to ensure it does not become mislaid. • Remove Remove plug plug (item (item 106 106)) on elect electric rical al actua actuatio tionn device (item 101) • To enga engage ge clut clutch ch push push slider slider towar towards ds contr control ol housing (limited by a stop) • To disen disengag gagee clutch clutch pull pull slider slider away away from from the control housing (limited by a stop) st op)

ZF 7500/7600 Series

Operation

DANGER!

When the mechanical emergency operation is used the remote transmission control for this transmission does not function. It is essential that the person in charge of the craft is aware of this situation. In port or when travelling on a narrow or busy waterway, stop the engine and have the craft towed. To deactivate mechanical manual actuation • Stop the engine • Fit plug (item 106) on electrical actuation device (item 101) • Shift push/pull slider to “neutral” position • Fit protective cover • Check that plug (item 106) and cover are fitted and tightened

65

Operation

7.4

Operation with emergency shift („Come home screws“, not with NR2, NR2B, NR2H transmissions)

If no power transmission occurs despite manual control, (section 7.3) there is a fault in the transmission. In such cases, the clutch discs of the shift clutches can be pressed together mechanically by means of the clamp bolts in the transmission (some transmission configurations e.g. with intermediate shaft PTO may not allow this access to the clamp bolts). The clutches for counter-enginewise direction of rotation and for enginewise direction of rotation both have three clamp bolts which are accessible from outside the transmission (front end of housing opposite the transmission input side). The openings in the housing are sealed with screw plugs. The emergency control can be used under the following conditions: a) The oil pressure at measuring point 2 must be at least 3.5 bar in the transmission at operating temperature. In this case, unrestricted operation is permissible. b) No oil pressure at measuring point 2, but lubricating oil pressure at measuring point 22 is at least 1 bar at normal operating temperature with an input speed of approx. 40% of normal operating speed. In this case, max. 50% engine speed is permissible. The special key required for operating the emergency control (SW 8 Allen key, length 280 mm) is available from ZF under order number 1X56 137 055. Only one shift clutch in the transmission may be closed at any one time, otherwise power will be transmitted in both directions of rotation and the transmission will jam. When the emergency control is in use, the normal transmission actuation system must be rendered inoperative for the same reason. The marks on the graduated circle should be aligned with the neutral position of the quadrant located on the control unit.

66

ZF 7500/7600 Series

ZF 7500/7600 Series

Operation

The emergency control must be operated as follows: 1.

Stop the engine

2.

Decide which clutch is to be used Loosen and remove the screw plugs

3.

Insert the key as far as possible in one of the three holes. Turn the engine or transmission input shaft slowly until clamp bolt contacts Allen key. (The direction of rotation is unimportant, but the required position must be reached after a maximum 120° turn.) With draw Allen key approx. 30 mm and turn engine or transmission input shaft very slightly (approx. 1°) until Allen key can be inserted in clamp bolt. 5. Tighten the clamp bolt right down by turning it several times in clockwise direction. Repeat this procedure with the other two clamp bolts by inserting the key in the appropriate openings; turning the input shaft will not be necessary. Then tighten all three bolts to a torque of approx. 50 Nm. 6. Close the bores in the housing using the screw plugs. 4.

44

Emergency control for enginewise direction of rotation

34

Emergency control for counter-enginewise direction of rotation

With the emergency control set up in this way, the engine can be started and the vessel can be taken to the nearest repair dock. To make the emergency control inoperative, proceed as above (steps 1 to 4). Then, turn clamp bolt anticlockwise as far as the stop (a torque of approx. 10 Nm is necessary). Repeat the procedure with the other two clamp bolts. Finally, seal the bores in the housing using the screw plugs.

67

Maintenance

ZF 7500/7600 Series

8

Maintenance

8.1

Maintenance schedule

The operating hours given in the maintenance schedule as well as the test and maintenance jobs given in the maintenance work plan are based on average operating data. Therefore, these are only guidelines. Under certain operating conditions, it may be necessary to change the time schedule and maintenance work plan.

Regular Maintenance Maintenance

Operating

Limit

level

hours

A1

every day of operation

3 months see also K1, K2

A2

500

6 months

A3

2000

2 year

A4

4000 to 6000

5 years

A5

during every basic overhaul of engine

operating condition of transmission

Additional maintenance jobs on new or overhauled transmissions, necessary only once Maintenance

Procedure

Limit

50 to 100

12 months

level

Z1

Necessary measures for protection against corrosion after a long period out of use Maintenance

Procedure

Also, it is useful to adapt the operating hours given in the maintenance schedule to the corresponding engine maintenance interval, as long as the operating hours given are not exceeded to a great extent. This is especially applicable for maintenance levels A 4, A 5 and K. The necessary protective measures against corrosion after a long period out of use for a transmission installed in a vessel are largely dependent on temperature fluctuations, atmospheric humidity and the salt content of the atmosphere in the machine room. Therefore the recommended measures and data can only be seen as rough guide values. In case of doubt, we recommend using the same protective measures for marine gears as for engines. For a period up to 3 months out of use, in normal cases, no protective measures against corrosion are necessary.

Limit

level

K1

every 10 – 20 days

up to 6 months

K2

at end of operating period

9 months

K3

at end of operating period

max. 36 months

If the period without use is less than 6 months ,we recommend that measure K 1 be carried out every 10 to 20 days. Before the craft is put into operation again, it may be necessary to change the oil (see Maintenance stage Z 1), depending on the condition of the oil already in the transmission K 2 is a preservation measure and should be implemented immediately at the end of operation if a period of more than 6 months without use is intended. K 2 may also be implemented instead of K1 in the case of shorter periods out of use. K 3 is a long-term preservation measure and allows for a period of max. 36 month without marine gear use. Preservation can also be carried out acc. to K 2 instead of K 3. This preservation measure must, however, be repeated every 9 months.

68

ZF 7500/7600 Series

8.2

Protection against corrosion, preservation

K 1 Protection against corrosion

Start the engine and let it run at idling speed or slightly faster for at least 5 minutes in order to lubricate the tranmission thoroughly. The tranmission can be in neutral, or in either direction of rotation. Repeat this procedure every 10 or 20 days. Before putting marine gear into service again, check the oil for condensation water (emulsion effect). This check must take place immediately after the engine has been turned off - the oil must not show any turbid aspect. K 2 Preservation

After operation, drain the transmission oil and top up with anti-corrosion oil to at least the low oil level mark on the dipstick (see description of maintenance work). Use anti-corrosion oil grades C 642 or C 644 acc. to MIL-L-21 260. Immediately afterwards, allow the engine to run in the position “enginewise rotation” or “counter-enginewise rotation” for approx. 5 to 10 minutes at increased engine speed (max. 50% of the nominal operating speed). Shut off the engine. Protect exterior steel parts against corrosion.

Maintenance

K 3 Long term preservation

Drain off the oil in the transmission after operation and fill with anti-corrosion oil up to the low oil level mark on the dipstick (see description of maintenance work). Use anti-corrosion oil C 642 or C 644 acc. to MIL-L-21 260. Immediately afterwards, allow transmission to run in the position “enginewise rotation” or “counterenginewise rotation” for approx. 5 to 10 minutes at increased engine speed (max. 50% of the nominal operating speed). Shut off the engine, then completely fill the transmission with anti-corrosion oil. Protect the exterior steel parts against corrosion. Putting into operation after the K 3 long term preservation procedure Drain off anti-corrosion oil down to usual oil level and allow the engine to run for approx. 5 minutes. Then, drain off the anti-corrosion oil completely and fill transmission with the specified oil grade (see “Maintenance work 141”).

Extension of preservation period for another 9 months Allow engine to run for approx. 5 minutes. Then, drain off the preservation oil and fill the transmission with the correct grade and amount of oil specified for operation. Start the engine again and allow to run for at least 15 minutes. During this period, the transmission selector clutches must be actuated several times. Then, repeat “K2 preservation” procedure. Putting into operation after the K 2 preservation procedure Start the engine and allow to run for approx. 5 minutes so that any condensation water which may have collected in the transmission is mixed with the anticorrosion oil. Drain off the anti-corrosion oil and fill transmission with the specified oil grade (see “Maintenance work 141”).

69

Maintenance

8.3

ZF 7500/7600 Series

Maintenance work plan

Maintenance level

Maintenance jobs

Regular

A5

A4

Tools required

One-off

A3

A2

A1

Z1 101 Check oil level 102 Turn oil filter handle

none none

103 Visual check 104

none

121 Clean outside of transmission 122 Re-tightening all screw/bolt connections accessible from outside 123 Check control position settings 124 Lubricate external moving parts

none tool kit

141 Change oil 142 Clean oil filter

tool kit tool kit

161 Visually check flexible coupling 162 Visually check flexible engine and transmission mounting 163 Visually check clutch discs 164 Visually check gearing

T1 + T1 + T1 T2 + T2 NB

--

--

70

none none tool kit tool kit

165 Check oil pump 166 Check control unit

W1 W1

167 Check actuating unit 168

W1

169 Clean oil cooler 170*

------

172* 173 Check input shaft seal 174 Check output shaft seal

none none

200* Basic transmission overhaul

W2

T1

* = See workshop manual for instructions NB = Spare parts as necessary

none none

Spare parts required T1, T2 = See spare parts list for part sets W1 = See operating instructions for tool kit W2 = See workshop manual for tool kit

ZF 7500/7600 Series

8.4

Maintenance

Special versions / Special scope of supply

If there are differences in the operation and maintenance of special versions or special scope of supply which are not dealt within the following sections, refer to the appropriate specifications. 8.4.1 Special scope of supply - Transmissions with additional trailing oil pump (item 18)

This oil pump is mounted on the transmission housing at the opposite end to the input or on the input end of the transmission housing . It is driven by a layshaft coming off the transmission output shaft. The pump supplies oil to the oil circuit in a constant direction, regardless of the direction of rotation of the output shaft (see diagram, section 6.10). During operation with engine stationary and propeller trailing, the pump is responsible for supplying lubricating oil to the transmission. It is thus permissible to operate in this mode for an unlimited period of time. Additional operating requirements (see section 7.2) During operation with engine stationary and propeller trailing, the transmission actuator must be in “neutral”.

8.5

Trouble shooting

If defects occur in the drive system, the transmission is very often assumed to be the cause. But, in many cases, faults may arise due to external influences on the transmission. The trouble shooting table below lists the principle faults which may occur, their possible causes and their remedy.

Additional monitoring Oil pressure need not be monitored when the engine is stationary. The transmission oil temperature must be monitored for compliance with the data in section 2 There is another measuring point (41) for oil temperature monitoring available (see section 6.10.2). Additional note for maintenance

If it proves impossible to rectify a fault using this information, you are advised to contact the nearest ZF service station. If you wish to repair faults or perform repairs on the transmission yourself, you should request a copy of the workshop manual and the transmission spare parts list from the service department at our Friedrichshafen plant.

The Maintenance jobs 101 and 102 must also be carried out daily during operation with stationary engine and rotating propeller (see section 7.2).

71

Maintenance

Fault

Ecessive gear oil temperature (measuring points 11*, 12* and 41*)

ZF 7500/7600 Series

Possible cause

Remedial action

Insufficient water flow through cooler

Increase water flow

Sludge in oil cooler

Clean water end of cooler,see workshop manual

Gear ratio not properly engaged, clutch slipping

Adjust shift mechanism

Transmission oil temperature too low

Excessive water flow through cooler

Decrease water flow

Pressure before oil cooler and filter too high (measuring point 5*)

Clogged filter

Clean filter and drain off oil sludge

Clogged oil cooler

Clean oil side of cooler

No oil in transmission

Add oil

Wrong rotation direction at transmission input

Use special transmission version

Defective indicator

Repair fault

Oil viscosity too low

Use a recommended oil grade (see list of lubricants)

Incorrect oil pump ratio

Select oil pump ratio in accordance with engine operating speed range

Defective oil pump

Renew

Pressure valve leaking

Repair fault

Time switch for pressure modulation defective

See remedy for clutch slipping

No operating oil pressure (measuring points 2*, 21* and 27*)

Operating oil pressure too low (measuring points 2*, 21* and 27*)

If the fault cannot be rectified, the lubricating oil supply to the transmission is also at risk. Proceed at reduced engine speed until repairs can be carried out. Engine stalls following rapid change from “Ahead” to “Astern”

72

Engine idle speed too low

Increase engine idle speed range

Change in direction effected too quickly or effected at excessive craft speed

Change direction as recommended in section 7.1.3

ZF 7500/7600 Series

Maintenance

Fault

Possible cause

Remedies

Excessive operating oil pressure (meas. points 2*, 21 * and 27*)

Oil viscosity too high

Use a recommended oil grade (see list of lubricants)

Incorrect oil pump ratio

Select oil pump ratio in accordance with engine operating speed range

Drive interrupted between transmission input and output; clutch not transmitting torque

For mechanical transmission actuation, Adjust shifting angles incorrect (see section 6.9.1) For pneumatic transmission actuation,compressed air system defective Check: Actuation of manual selector lever renders normal operation

Repair fault in compressed air system

For electric transmission actuation, electrical system defective Check: Actuation of manual selector lever renders normal operation

Repair fault in electrical system

No operating oil pressure

See remedy for no or insufficient operating oil pressure

Drive between transmission input For possible causes and remedies refer and output cannot be interrupted; to “clutch not transmitting torque” clutch does not open *See “Monitoring diagram” section 6.10

73

Maintenance

Fault

ZF 7500/7600 Series

Possible cause

Remedies

Clutch slips at high engine speeds Insufficient operating oil pressure (meas. points 2*, 21* and 27*)

See remedy for “insufficient operating oil pressure”. If the fault cannot be rectified on board, proceed with reduced engine speed - so that the clutch does not slip - until repairs can be carried out. Avoid changes in direction, but if unavoidable the vessel propeller should be almost at a standstill and the engine idle speed as low as possible.

Oil level sinks rapidly (as indicated Leaks at housing joints, oil pipes or by the dipstick); see section 6.11.1 shaft seals “oil level check” Oil cooler leaking into cooling water system

Repair mechanical fault Repair fault, renew cooler if necessary

Oil level increases (see section 6.11.1 “oil level check”)

Water entering the oil circuit from the Repair mechanical fault cooling system

Transmission too loud in certain speed ranges

Torsional vibration resonance of drive Avoid critical speed range. Install a unit in engine speed range more suitable torsionally flexible coupling (see section 6.4)

Transmission too loud in engine idle speed range

Torsional vibration resonance of drive Increase engine idle speed unit in engine idle speed range

Engine stalls during rapid change from “ahead” to “astern”

Engine idle speed too low

Increase engine idle speed

Change in direction effected too too high

Changes in direction should be quickly or with travel speed carried out as per section 7.1.3 recommendations.

74

ZF 7500/7600 Series

8.6

Maintenance

ZF service stations, Spare parts

If a transmission fault cannot be rectified using the remedies in section 8.5 “Trouble shooting”, please contact the nearest ZF service station. A list of ZF service stations with the current telex and telephone numbers can be obtained from ZF Friedrichshafen AG, or the internet www.zf-marine.com. When carrying out repairs, use only genuine ZF spare parts. Please give the following information when ordering spare parts and making enquiries - Model type - Serial number - Spec./parts list number - Transmission ratio This information is stamped on the transmission type plate. In the case of marine gears with classification, note that spare parts without classification are always supplied under the item numbers stated. If a version with classification is required, the desired type of test must be stated in addition to the item number. This is also necessary, if the transmission spec./parts list is quoted when ordering, and when requesting exchange units.

75

Maintenance

76

ZF 7500/7600 Series

ZF 7500/7600 Series

Maintenance system job sheets

9 Maintenance system job sheets

Page 101 Check oil level ...................................................................................................................................................2 102 Turn oil filter handle ..........................................................................................................................................6 103 Carry out visual check .......................................................................................................................................8 121 Clean outside of transmission..........................................................................................................................10 122 Retighten all screw/bolt connections accessible from outside.........................................................................12 123 Check control position settings........................................................................................................................14 124 Lubricate external moving parts ......................................................................................................................16 141 Change oil ........................................................................................................................................................18 142 Clean the oil filter and filter chamber..............................................................................................................20 161 Visually check flexible coupling .....................................................................................................................22 162 Visually check flexible engine and transmission mounting (if fitted).............................................................24 163 Visually check clutch discs..............................................................................................................................26 164 Visually check gearing.....................................................................................................................................28 165 Check oil pump................................................................................................................................................30 166 Check control unit............................................................................................................................................34 167 Check actuation device (mechanical, electrical)..............................................................................................38 168 Re-calibrate gauge ...........................................................................................................................................44 169 Clean oil cooler................................................................................................................................................46 173 Check input shaft seal ......................................................................................................................................48 174 Check output shaft seal ....................................................................................................................................50

1


ZF 7500/7600 Series

MAINTENANCE SYSTEM JOB SHEET Transmission type:

ZF 7500/7600 Series

Maintenance job no.

Maintenance level

If possible, to be performed in conjunction with maintenance job no.

Time required in minutes

101

A1

----------

10

Description of 101 maintenance work

Check oil level

Only withdraw the oil dipstick when the engine is at a standstill, otherwise risk of burns due to hot oil spraying out. Safety measures

Only top up the oil when the engine is at a standstill, otherwise risk of burns due to hot oil spraying out.

Tools

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

Parts

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

Material

Non-fraying cloth

Test equipment

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

Procedure

see next page

Location:

2

Date:

Page: 1

of: 2

ZF 7500/7600 Series

Maintenance system job sheets During initial fill, following repairs and after cleaning the oil filter, note that some of the oil remains in the oil cooler, in the oil lines and in the filter chamber rather than flowing back into the transmission housing. You should therefore recheck the oil level after a short period of operation.

ZF 7550 V

The correct oil level is between the upper and lower marks on the oil dipstick.

max. min.

004 666

To add oil, unscrew the oil filler plug and top up the oil.

ZF 7550 V 3


ZF 7500/7600 Series

During initial fill, following repairs and after cleaning the oil filter, note that some of the oil remains in the oil cooler, in the oil lines and in the filter chamber rather than flowing back into the transmission housing. You should therefore recheck the oil level after a short period of operation.

ZF 7550 NR2H

The correct oil level is between the upper and lower marks on the oil dipstick.

max. min.

004 666

To add oil, unscrew the oil filler plug and top up the oil.

ZF 7550 NR2H 4

ZF 7500/7600 Series


5


ZF 7500/7600 Series


BW 7500/7600 Series

Maintenance job no.

Maintenance level



102

A1

----------

5

Description of maintenance work

102

Safety measures

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

Tools

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

Parts

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

Material

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

Test equipment

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

Procedure

see next page

Location:

6

Turn oil filter handle

Date:

Page: 1

of: 2

ZF 7500/7600 Series


Slowly rotate the handle of the slot-type filter clockwise through 1 to 2 full turns.

ZF 7500 A

ZF 7550 A

ZF 7550 NR2H 7


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Maintenance level



103

A1

121

10


Carry out visual check

Safety measures

Always keep your distance when visually checking rotating parts, otherwise risk of getting caught in the rotating part

Tools

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

Parts

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

Material

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

Test equipment

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

Procedure

see next page

Location:

8

Date:

Page: 1

of: 2

ZF 7500/7600 Series


Check for leaks at the points the input shaft and output shaft protrude from the transmission housing as well as at the oil line ports, monitoring equipment ports and coolant ports (visual check).

ZF 7550 A

ZFW 7540

ZF 7550 NR2H

9


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Main Mainte tena nanc ncee leve levell

If poss possib ible le,, to to be be per perfo form rmed ed in conjunction with maintenance job no.


121

A2

103

30

Description of 121 121 maintenance work

Clea Clean n outs outsid idee of tran transm smis issi sion on

Safety measures

Only use cleaning products that meet the requirements of the regulations for the prevention of accidents.

Tools

Ship’s tools

Parts

Cleaning products

Material

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

Test equipment

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

Procedure

see next page

Location:

10

Date:

Page: 1

of: 2

ZF 7500/7600 Series


Clean the outside of the transmission using cleaning products to make the visual check easier – see job 103. products to come Important: Do not allow cleaning products into contact with rubber parts, hose lines and shaft seals.

ZF 7550 A

ZF 7550V

ZF 7550 NR2H

11


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Maintenance level



122

Z1

----------

20


Retighten all screw/bolt connections accessible from outside.

Safety measures

Only retighten the connections when the transmission is at a standstill.

Tools

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

Parts

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

Material

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

Test equipment

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

Procedure

see next page

Location:

12

Date:

Page: 1

of: 2

ZF 7500/7600 Series


Retighten all accessible screw/bolt connections. Pay particular attention to the following connections: •

Engine to flexible coupling

•

Flywheel housing to bell housing

•

Mounting bracket to transmission

•

Mounting bracket to foundation.

Also check the ports/connections “to” and “from” the oil cooler as well as the monitoring equipment ports/connections. Retighten them as necessary. You should retighten the bolts to the specified torque when the transmission is cold (approx. 20 °C).

ZF 7550 A

ZFW 7540

ZF 7550 NR2H

13


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Maintenance level



123

A2

----------

15


Check control position settings

Safety measures

Block the engine starting device, otherwise risk of the craft moving off.

Tools

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

Parts

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

Material

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

Test equipment

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

Procedure

see next page

Location:

14

Date:

Page: 1

of: 2

ZF 7500/7600 Series


Only required in the case of the “mechanical transmission actuation” version. Loosen the mechanical connection between the transmission control lever and the transmission linkage or pull-push cable. Select “Neutral” on controls and move the transmission control lever to “Neutral” detent position. Holes on the transmission control lever and shift linkage or on the yoke end of the pull-push cable must be aligned. Select “Ahead” on controls and move the transmission control lever as far as the “enginewise” or “counter-enginewise” detent position. Hole in the transmission control lever must be aligned with the hole in the linkage or on the yoke end.

Check the “Astern” position in the same way. The positions indicated must be safely and reliably obtainable. Adjust the mechanism on the transmission linkage if necessary. Under no circumstances must the control lever remain in the undefined range between “Neutral” and “Ahead” or “Neutral” and “Astern”.

137

105

004 974

Action forceÝ 25 N when radius is 105 mm 104

103

O

2 4 °

103 Counter-enginewise position 104 Enginewise position 105 Control lever for mechanical actuation 121 End stop 122 Undefined position (this range must be quickly bypassed) 123 Safe neutral range 124 Switch for warning interrupt (special scope of supply)

124

123

´ 3 0 ° 2 4

121 122

2 4 ° 2 4 ° 3 0 ´

1 0 ° 10 °

8,1 0 2 5 1 0 1

121

105 5 0 1

004 496

15


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Maintenance level



124

A2

----------

15


Lubricate external moving parts

(Only required in the case of the “mechanical transmission actuation” version).

Safety measures

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

Tools

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

Parts

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

Material

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

Test equipment

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

Procedure

Lightly lubricate the moving parts of the mechanical transmission actuator (yoke end on transmission control lever, linkage connections and connection to controls) with lithium saponified grease.

Location:

16

Date:

Page: 1

of: 2

ZF 7500/7600 Series


17


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Maintenance level



141

A3

142 / 163 / 164

30


Change oil

Block the engine starting device. Change the oil at an oil temperature of max. 40 – 50 °C, otherwise risk of burns. Collect used oil in a suitably large oil container, otherwise risk of environmental pollution.

Safety measures

Oil capacity: ZF 7500 / 7549 / 7550 / 7600 / 7650 ZF 7500 A/ 7550 A / 7600 A / 7650 A ZF 7500 V / 7550 V / 7600 V / 7650 V ZF 7540 / W 7540 / 7640 / 7641 / 7645 / 7646 ZFW 7500 / 7510 / 7661 / 7666 / 7561 / 7566 / W 7610 / W 7615 ZF 7550 NR2 / 7650 NR2 ZF 7550 NR2B / 7650 NR2B ZF 7550 NR2H / 7650 NR2H ZF 7549 C / 7500 C / 7850 C

75dm 3 75dm 3 75dm 3 80dm 3 120dm 3 50dm 3 50dm 3 50dm 3

Tools

Ship’s tools

Parts

New gasket/sealing rings

Material

Oil grade: Approved oils as per applicable “ZF List of Lubricants TE-EL 04 for ZF Marine Transmissions”. The currently applicable list of lubricants is supplied with the transmission. It can be ordered from any ZF service center and it is available on the internet (see section 3).

Test equipment

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

Procedure

see next page

Location:

18

Date:

Page: 1

of: 2

ZF 7500/7600 Series


If possible, perform this job in conjunction with maintenance job 142.

Withdraw the oil dipstick, unscrew the oil drain plug and drain the oil. Remove the oil by suction if the transmission is fitted with an oil suction device.

082958

After fitting a new seal, screw in and tighten the oil drain plug.

ZF 7550 A

Close the oil suction device if one is fitted.

To add oil, unscrew the oil filler plug or take off the inspection hole cover. Add fresh oil.

ZF 7550 A

Oil capacity: ZF 7500 / 7549 / 7550 / 7600 / 7650 75dm 3 ZF 7500 A/ 7550 A / 7600 A / 7650 A 75dm 3 ZF 7500 V / 7550 V / 7600 V / 7650 V 75dm 3 ZF 7540 / W 7540 / 7640 / 7641 / 7645 / 7646 80dm 3 ZFW 7500 / 7510 / 7661 / 7666 / 7561 / 7566 / W 7610 / W 7615 120dm 3 ZF 7550 NR2 / 7650 NR2 50dm 3 ZF 7550 NR2B / 7650 NR2B 50dm 3 ZF 7550 NR2H / 7650 NR2H ZF 7549 C / 7500 C / 7850 C 50dm 3

Then fit a new seal on the oil filler plug (or a new gasket on the inspection hole cover) and re-insert the oil filler plug (or re-attach the inspection hole cover). Finally, check the oil level - see maintenance job 101. Using the oil dipstick is the only way to obtain an accurate reading.

ZFW 7510 19


ZF 7500/7600 Series

MAINTENANCE SYSTEM JOB SHEET ZF 7500/7600 Series

Transmission type: Maintenance job no.

Maintenance level



142

A3

141 / 163 / 164

30


Clean the oil filter and filter chamber.

Safety measures

Block the engine starting device. Collect used oil in a suitably large oil container, otherwise risk of environmental pollution. Escaping oil quantity: Approx. 2 dm 3

Tools

Ship’s tools

Parts

Gasket

Material

Oil grade: Approved oils as per applicable “ZF List of Lubricants TE-EL 04 for ZF Marine Transmissions”. The currently applicable list of lubricants is supplied with the transmission. It can be ordered from any ZF service center and it is available on the internet (see section 3).

Test equipment

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

Procedure

see next page

Location:

20

Date:

Page: 1

of: 2

ZF 7500/7600 Series


If possible, perform this job in conjunction with maintenance jobs 141, 163 and 164.

Turn the oil filter handle as described in maintenance job 102 when the transmission is at a standstill.

B

ZF 7550 A Unscrew sludge drain plug A and bleed the filter cham ber; collect the escaping oil in a container. Escaping oil quantity approx. 2 dm 3. Open pure oil drain B and collect the escaping oil in a container.

B

The filter insert can be pulled out once the mounting bolts on the filter head have been removed. Make sure that no dirt enters the pure oil chamber in the filter housing when doing this.

A

Clean the filter insert using diesel oil or cleaning grade spirit; turn the handle several times when doing this (do not dismantle the filter). Then clean the filter chamber using diesel oil or cleaning grade spirit. Always use a brush for cleaning, never fraying cloths or mechanical means such as screwdrivers, scrapers, etc. Fit a new filter gasket and seal before installing the filter and sludge drain plug. Installation procedure is the reverse of removal procedure.

ZF 7550 A

A

B ZF 7550 NR2H 21


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Maintenance level



161

A4

----------

30


Visually check flexible coupling

Safety measures

Block the engine starting device.

Tools

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

Parts

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

Material

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

Test equipment

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

Procedure

see next page

Location:

22

Date:

Page: 1

of: 2

ZF 7500/7600 Series


Check that the rims of the flexible coupling are in perfect condition. To do this, slowly turn over the engine and check the rubber parts by looking through the inspection hole in the bell housing.

004 681

Check the rubber parts for signs of cracking, embrittlement and overheating.

004 682

Check the markings (if there are any) for distortion.

004 683

23


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Maintenance level



162

A4

----------

15


Visually check flexible engine and transmission mounting (if fitted)

Safety measures

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

Tools

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

Parts

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

Material

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

Test equipment

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

Procedure

Check that the rubber-metal mountings on the engine and transmission are in perfect condition. The rubber parts must not show any signs of cracking, embrittlement or other damage.

Location:

24

Date:

Page: 1

of: 2

ZF 7500/7600 Series


25


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Main Mainte tena nanc ncee leve levell

If poss possib ible le,, to to be be per perfo form rmed ed in conjunction with maintenance job no.


163

A4

141 / 142 / 164

15

Description of 163 163 maintenance work

Visu Visual ally ly che check ck clu clutc tch h disk diskss

Safety measures

Block the engine starting device. Remove all parts which could c ould fall into the transmission once the inspection hole cover has been opened (mechanics should empty their breast pockets).

Tools

Ship’s tools

Parts

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

Material

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

Test equipment

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

Procedure

see next page

Location:

26

Date:

Page: 1

of: 2

ZF 7500/7600 Series


It is advisable for this job to be performed when changing the oil – see maintenance job 141.

Remove the inspection hole cover.

082 477

ZF 7550 V Check the clutch discs. The discs must not show any signs of overheating and it must be possible to move them in axial direction (see table for disc play per pack). Also check the play between the individual discs

ZFW 7510

. Transmission version

Number of outer Number of outer Number of outer discs discs discs 30 3084 84 30 3022 00 0033 30 3084 84 30 3022 07 0733 0501 0501 211 211 377 377 4.00 4.00 - 0.05 0.05 mm 4.25 4.25 - 0.05 0.05 mm 4.50 4.50 - 0.05 0.05 mm

Permissible disc play

ZF 7550 A

9

1

10

2.0 - 2.4 mm

ZF 7550 V

9

1

10

2.0 - 2.4 mm

ZF 7540

9

1

10

2.0 - 2.4 mm

ZF W7540

9

1

10

2.0 - 2.4 mm

ZF 7550 NR2H

7

3

10

3.6 - 4.0 mm

27


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Maintenance level



164

A4

141 / 142 / 163

15


Visually check gearing

Safety measures

Block the engine starting device. Remove all parts which could fall into the transmission once the inspection hole cover has been opened (mechanics should empty their breast pockets).

Tools

Ship’s tools

Parts

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

Material

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

Test equipment

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

Procedure

see next page

Location:

28

Date:

Page: 1

of: 2

ZF 7500/7600 Series


It is advisable for this job to be performed when changing the oil – see maintenance job 141.

Remove the inspection hole cover.

082 477

ZF 7550 NR2H Check the clutch discs. The discs must not show any signs of overheating and it must be possible to move them in axial direction (see table for disc play per pack). Also check the play between the individual discs

ZF 7550 NR2H

29


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Maintenance level



165

A4

----------

180

Description of maintenance work

165

Check oil pump

Engine-driven pump Trailing pump

(primary pump) (secondary pump) not fitted in basic transmission

Safety measures

Block the engine starting device if you intend to remove the oil pump.

Tools

Tool kit WI

Parts

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

Material

Set of seals and gaskets

Test equipment

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

Procedure

see next page

Location:

30

Date:

Page: 1

of: 3

ZF 7500/7600 Series


Engine-driven pump (primary pump) NOTE

The oil pump is a complete part and is not generally dismantled. However, checking or cleaning work may require the pump to be dismantled. Pay particular attention to inspecting the dismantled pump for scoring, mounting play and impeller/pinion end play. Removing and dismantling

– Remove the pipes as necessary. – Remove the pump housing. – Clearly mark the pump components. – Remove the retaining ring from the pump shaft. – Pull off the drive gear. – Remove the Woodruff key. – Remove the bolts (2) from the pump cover. – Knock out the tapered pins (6) in the direction indicated by the arrow and remove the cover (1).

ZF 7550 A 1

1

Cover

2

Cover mounting bolt

3

Compression spring

4

Spring cup

5

Valve seat

3 4

6

Tapered pin

5

2

Assembling NOTE

- Carefully clean the components. - Check the components. - Apply a thin coat of oil on moving parts.

6

– If previously removed, install the spring (3) with a preload of 510+20 N. – If previously removed, insert the valve seat (5) using Loctite no. 275. – Lightly coat the mating face of the pump cover with sealant and then mount it. – Insert the Woodruff key into the pump shaft. – Heat the drive pinion to approx. 85 °C and slide it onto the pump shaft. – Clip the retaining ring into the annular groove in the pump shaft. – Lightly coat the mating face of the pump housing with sealant and then mount it. – Install the pipes.

ZF 7550 V 31


ZF 7500/7600 Series

Engine-driven pump (primary pump) NOTE

The oil pump is a complete part and is not generally dismantled. However, checking or cleaning work may require the pump to be dismantled. Pay particular attention to inspecting the dismantled pump for scoring, mounting play and impeller/pinion end play. Removing and dismantling

ZF 7550 NR2H

– – – – – – – –

Remove the pipes as necessary. Remove the pump (1) housing. Clearly mark the pump components. Remove the screws (6) from the drive gear (4). Pull off the drive gear (4). Remove the Woodruff key (2). Remove the bolts (7) from the pump cover. Remove the cover (8).

1

Pump

2

Fit-in key

3

O-ring

4

Drive gear

5

Retaining ring

6

Bolt drive gear

7

Bolt cover

8

Cover

Assembling NOTE

- Carefully clean the components. - Check the components. - Apply a thin coat of oil on moving parts. – The assembly and mounting is funded by reverse order as the removing and dismantling.

32

ZF 7500/7600 Series

Maintenance system job sheets Trailing pump (secondary pump) NOTE

A

1 2 3

4 5

The oil pump is a complete part and is not generally dismantled. However, checking or cleaning work may require the pump to be dismantled. When checking the pump, pay particular attention to ensuring that the end play is within the wear limit, see the following chart. Check the pump components for traces of running in. Component

6

1

O-ring

2

Socket head bolt

3

Woodruff key

4

Drive gear

5

Retaining ring

6

Inner rotor

7

Outer rotor

End play A In new condition Wear limit

7

Eccentric ring 0.01 - 0.055 mm max. 0.15 mm Inner rotor 0.025 - 0.055 mm max. 0.1 mm Outer rotor 0.025 - 0.055 mm max. 0.1 mm

8

Removing and dismantling

- Remove the pipes as necessary. - Unscrew the mounting bolts from the oil pump. - Lift off the oil pump (use a lever to help you if necessary). - Unclip the retaining ring (5). - Pull off the drive gear (4). - Catch the Woodruff key (3). - Remove the mounting bolts from the pump cover and take off the cover. - Remove the pump idler gear shaft and idler gear (6).

Assembling NOTE

8

Eccentric ring

A

End play

- Carefully clean the components - Check the components. - Apply a thin coat of oil on the moving parts. - Install the pump idler gear shaft and idler gear (6). - Insert the pump components into the pump housing. - Replace and securely bolt on the cover. - Insert the fitted key (3) into the pump shaft. - Heat the drive pinion (4) to approx. 85 °C and slide it onto the pump shaft. – - Clip the retaining ring (5) into the annular groove in the pump shaft.

33


ZF 7500/7600 Series



Maintenance level



166

A4

----------

120


Check control unit

Safety measures


Tools

Tool kit WI

Parts

Gaskets

Material

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

Test equipment

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

Procedure

see next page

Location:

34

Date:

Page: 1

of: 2

ZF 7500/7600 Series


1

7

2

1 8 9

12

14

3

10 11

4

5

57 56

15 16 17 18 19

13 31 32 33

20

6 34 21

35 36

22 23 24

26

25

28 29 30

55 54

53 52 51 50 49

37 38

27 39

40 47

41

46

48 45

42 44 43

Control unit (not NR2, NR2H, NR2B type transmissions) 1 Nut + bolt 20 Cover 2 Lever 21 Gasket 3 Hexagon bolt 22 Dowel 4 Hexagon bolt 23 Woodruff key 5 Rivet 24 Selector shaft 6 Plate 25 Needle cage 26 Screw plug 7 Hexagon nut 8 Adapter 27 Ball 9 Disc 28 Slotted stopper 10 Washer 29 Ball 11 O-ring 30 Orifice 12 Bracket 31 Hexagon bolt 13 Connector, upper section 32 Cover 14 Switch 33 Gasket 15 Compression spring 34 Piston 16 Washer 35 Rectangular ring 17 Washer 36 Compression spring 18 Circlip 37 Bushing 19 Detent pin 38 Washer

* Special scope of supply

39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

Compression spring Control housing Ball Stopper Gasket Screw plug Control piston Washer Control piston Stopper O-ring Piston Bushing Compression spring Disc Ball Ball Screw plug Screw plug

Check control unit: NOTE If possible, replace the control unit in its entirety rather than dismantling it. If the control unit has to be dismantled for cleaning purposes or in order to replace compression springs, it does not need to be reset afterwards. However, the transmission must undergo a pressure test .

35


ZF 7500/7600 Series 2 9

10 11

1 8

12 13

7

14

6

15 16 5

17 18

4 20 3

19

21 22

* Special scope of supply

23

Control unit NR2, NR2H, NR2B type transmissions 1 Hexagon bolt 11 Ball 2 Hexagon bolt 12 Hexagon bolt 3 Snap ring 13 Hexagon bolt 14 Cover 4 Compression spring 15 Orifice 5 Control housing 16 Piston 6 Spacer bush 17 Rectangular ring 7 Washer 18 Screw plug 8 Gasket 19 Gasket 9 Screw plug 20 Compression spring 10 Screw plug

21 22 23

Bushing Control piston Screw plug

Check control unit: NOTE If possible, replace the control unit in its entirety rather than dismantling it. If the control unit has to be dismantled for cleaning purposes or in order to replace compression springs, it does not need to be reset afterwards. However, the transmission must undergo a pressure test .

36

ZF 7500/7600 Series


37


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Maintenance level



167

A4

----------

180


Check actuation device (mechanical, electrical)

Safety measures


Tools

Tool kit WI

Parts

see part kits T1 and T2

Material

Cleaning products

Test equipment

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

Procedure

see next page

Location:

38

Date:

Page: 1

of: 5

ZF 7500/7600 Series


7

6 5 4

3

1 2

* Special scope of supply Mechanical actuation device (not with NR2, NR2H, NR2B type transmissions) 1 Hexagon bolt 5 End cover 2 Screw plug 6 Gasket 3 Screw plug 7 Hexagon bolt 4 Hexagon bolt Checking the mechanical actuation device Removing

- Remove the pipes as necessary. - Remove the cover (5) with gasket (6).

39


ZF 7500/7600 Series

25 24 23 22

17 20 19

21

18

8 7

9

16

6

14

11 10

5

13 12

4

15

3 2

* Special scope of supply Electrical actuation device, version 3MGV (not with NR2, NR2H, NR2B type transmissions) 1

1 2 3 4 5 6 7 8 9

Socket head bolt Screw plug Screw plug Socket head bolt Outer casing Gasket Screw Solenoid valve Socket head bolt

10 11 12 13 14 15 16 17 18

Screw Solenoid valve Screw Solenoid valve Connector Screw Wiring harness, complete Screw plug Intermediate housing

19 20 21 22 23 24 25

Screw plug Gasket Circlip Snap ring Piston Piston carrier Snap ring

Checking electrical actuation device, version 3MGV Removing

- Screw off the electrical connector. - Remove outer casing (5) with gasket (6). - Remove intermediate housing (18) with valves and gasket (20). - Loosen the cable lugs and remove the valves. - Pull out the piston carrier with piston from the control housing. Checking

Check the electrical actuation components for wear and replace them if necessary.

40

Assembling – mounting NOTE

- Carefully clean the components - Check the components. - Apply a thin coat of oil on the moving parts. - Renew parts according to T2.

ZF 7500/7600 Series


27 26 25 24

19 22

23

21 20

10 9

11 7

18

8

16

13 12 15

5

14

4

17

6

3

2

* Special scope of supply Electrical actuation device, version 2MGV (not with NR2, NR2H, NR2B type transmissions) 1 2 3 4 5 6 7 8 9

1

Socket head bolt Cap nut Screw plug Socket head bolt Outer casing Threaded bushing Gasket Pin Screw

10 11 12 13 14 15 16 17 18

Solenoid valve Socket head bolt Screw Solenoid valve Screw Solenoid valve Connector Screw Wiring harness, complete

19 20 21 22 23 24 25 26 27

Screw plug Intermediate housing Screw plug Gasket Circlip Snap ring Piston Piston carrier Snap ring

Checking the actuation device, electrical Removing

- Screw off the electrical connector. - Remove outer casing (5) with gasket (7). - Remove intermediate housing (20) with valves and gasket (22). - Loosen the cable lugs and remove the valves. - Pull out the piston carrier with piston from the control housing.

Assembling – mounting NOTE


Checking

Check the electrical actuation components for wear and replace them if necessary.

41


ZF 7500/7600 Series 16 17 18 19

1

10

9

11

2 8

3

12 13

14

7

28

21

6

22

27

23

5

26

4

21 20

22

24

15

25

Electrical actuation device for NR2, NR2H, NR2B type transmissions 1 Screw plug 11 Hexagon bolt 2 Screw plug 12 Screw 3 Screw plug 13 Cover 4 Hexagon bolt 14 Control housing 5 Hexagon bolt 15 Screw 6 Cover 16 Screw plug 7 Gasket 17 Ball 8 Control piston 18 Compression spring 9 Gasket 19 Dowel 10 Screw 20 Gasket

21 22 23 24 25 26 27 28

Solenoid valve Screw Gasket Outer casing Screw Wiring harness Screw Connector

Checking the actuation device, electrical

Checking

Removing

Check the electrical actuation components for wear and replace them if necessary. Check the control piston (8) and the control piston hole in the housing (14) for damage and protect against future damage.

1. Remove the pipes as necessary. 2. Screw off the electrical connectors. 3. Remove the outer casing (24) with gasket (23). 4. Remove the control housing (14) with valves and gasket (20). 5. Loosen the cable lugs and remove the valves. 6. Remove the covers (6) and (13). 7. Remove the control piston (8).

42

Assembling - mounting NOTE


ZF 7500/7600 Series


43


ZF 7500/7600 Series



Maintenance level



168

A4

----------

----------


Re-calibrate gauge

Safety measures

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

Tools

Tool kit

Parts

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

Material

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

Test equipment

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

Procedure

see next page

Location:

44

Date:

Page: 1

of: 2

ZF 7500/7600 Series


Check that the oil pressure and oil temperature gauges display the correct values. Option 1: Connect calibrated gauges in parallel and compare the displayed values. The error (difference) must not be more than 10 % in the operating range concerned. Option 2: Remove the gauges and have them re-calibrated or use replacement gauges.

45


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Maintenance level



169

A4

----------

60


Clean oil cooler

Safety measures

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

Tools

Tool kit WI

Parts

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

Material

Set of seals and gaskets

Test equipment

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

Procedure

see next page

Location:

46

Date:

Page: 1

of: 2

ZF 7500/7600 Series

General information


ZF 7550 A

Extract from manufacturer’s specifications:

Clean the heat exchangers at regular intervals to ensure consistent performance. The level of contamination will depend on the application location; therefore, you should keep track of the operating hours and determine the cleaning interval yourself. Heat exchanger disassembly procedure

1. Mark the position of the attached flanges in relation to each other. 2. Remove the pipes as necessary. 3. Unscrew the fixing nuts on the oil cooler and remove the oil cooler. 4. Unscrew the fixing bolts from the cooler. Remove the cover and water connection housing. Collect the Orings.

ZF 7550 NR2H 2. If coolers cleaned in this way a re kept in storage as spare parts, i.e. not immediately reinstalled nor flushed with transmission oil, they must be flushed with a preserving agent. Cleaning the water end

Check the contamination before cleaning the w ater end. If a greasy coating of lime is present, the water end must be degreased before cleaning. Flushing with water and anti-liming agent removes the lime; a 10 to 15% solution of hydrochloric acid may also be used. An inhibitor additive must be added to this solution to prevent it from reacting with the metal surfaces. After cleaning, thoroughly flush the water end with clean water. Then fill the oil end with the same oil that is to be used in subsequent operation. Then drain the oil.

5. Pull the pipe bundle out of the cooler housing. Collect the O-rings and bush.

Cleaning will be much more effective and cleaning time shorter if circulation is in the opposite direction to circulation during normal operation, both at the oil end and at the water end.

Cleaning the oil side

Assembling the heat exchanger

1. Flush the coolers using a suitable cleaning product. Flush against the normal oil flow direction to loosen any dirt – in particular debris from multi-disk clutches and band brakes – deposited on the oil cooler blades. This dirt will be flushed out by the cleaning product. Place a suitable filter in the main flow so that the flushed out impurities can be separated from the cleaning product. You should continue cleaning until inspection reveals that the cleaning product flowing out is as pure as the cleaning product flowing in..

6. Insert the O-ring into the cooler housing. 7. Thread the pipe bundle into the cooler housing. 8. Turn the cooler and insert the O-ring and bush. 9. Install the cover and water connection housing with O-ring. (See marking for position.) Checking After assembly, check the oil end and the water end. The pressure indicated on the drawing or the type plate (oil and water end) must not be exceeded.

47


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Maintenance level



173

A4

121

15


Check input shaft seal

(in conjunction with maintenance job 121 if possible)

Safety measures

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

Tools

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

Parts

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

Material

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

Test equipment

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

Procedure

see next page

Location:

48

Date:

Page: 1

of: 2

ZF 7500/7600 Series



Check the input shaft seal for leaks. Collect any esca ping oil. Check the oil level at suitable intervals and top up the oil as necessary. Replace the input shaft seal as soon as possible.

ZF 7550 A

ZF 7550 A

ZF 7550 NR2H 49


ZF 7500/7600 Series


ZF 7500/7600 Series

Maintenance job no.

Maintenance level



174

A4

121

15


Check output shaft seal

(in conjunction with maintenance job 121 if possible)

Safety measures

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

Tools

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

Parts

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

Material

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

Test equipment

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

Procedure

see next page

Location:

50

Date:

Page: 1

of: 2

ZF 7500/7600 Series



Check the output shaft seal for leaks. Collect any escaping oil. Check the oil level at suitable intervals and top up the oil as necessary. Replace the output shaft seal as soon as possible.

ZF 7550 A

ZF 7550 A

ZF 7550 NR2H 51


ZF 7500/7600 Series

Sealers

(extract from the manufacturer’s instructions for use) The manufacturer’s instructions for use are always binding. HYLOMAR

Grease

Universal seal SQ 32 M-Special, for use on housing and cover mating faces).

See List of Lubricants

Permanent plastic universal seal SQ 32M Special (CFC-free), MARSTON, Ölchemie GmbH, 53909 Zülpich, Germany, tel. (022 52) 2566 and 2725.

Cleaners (for removing grease from tapered surfaces

Instructions for use

Degrease the mating faces (Hylomar Cleaner) before use and then apply HYLOMAR on both sides. Wait for the sealant to dry (approx. 10 minutes) before commencing assembly. Retighten the bolts after 10-15 minutes. If the faces are planed flat, sealer only needs to be applied on one side.

for oil press fits). Acetone, spirits (caution: Highly inflammable) or standard cleaners that do not leave a greasy residue.

Glycerin for oil press fits in Series BW 160 through

195. Oil or glycerin can be used for fitting in the case of other transmission types.

We recommend you use HYLOMAR CLEANER to remove old gasket residues, oil and grease. Temperature resistant from -50 °C to +250 °C.

Loctite:

No. 640 No. 275

Loctite Deutschland GmbH, Munich Loctite Europa GmbH, Vienna Instructions for use

Clean the parts. Apply enough of the product to fill the gap. Join the parts together and let the product harden.

Dyken Read DX-296 for tooth flank contact pattern ac-

ceptance in the case of transmissions subject to classification society acceptance.

Dyken-Read DX-296/8 oz , Helling,

Sandorkai 1, 21107 Hamburg, tel. (040) 376010, telex 213611 + 2165082, fax (040) 37601100 Made in Germany. Subject to technical change without notice!

52

ZF Marine Transmissions Corrosion-proofing





Guidelines for corrosion-proofing of marine transmissions during storage at ZF agencies and intermediaries. Anti-corrosion protection and corrosion-proofing for ZF transmissions installed in marine craft.

Guidelines for marine transmissions: Anti-corrosion protection, packing types, storage conditions and storage periods Extract from: F 43258/RT 3332 Level Storage period I

Ex works anti-corrosion protection Packing type

Max. 12 months Internal corrosion-proofing: before first op- Corrosion inhibiting oil to eration MIL-L-21260 or TL 9150-0037, C-640

Storage conditions

Transmission covered with polythene sack in wetstrength, glued plywood case.

Remove packing materials immediately after receipt and check external corrosion-proofing. If protective film is damaged, touch up or completely recoat with suitable corrosion inhibitor. Store in enclosed area at steady temperature and at low relative humidity. Protect from dirt and damp between installation until first operation.

Packed in drying Corrosion inhibiting oil to agent by specialist MIL-L-21260 or TL 9150-0037, outside company C-640 in accordance with TL 8100-001, External corrosion-proofing: - Bright metal parts with corrosion in- packing grade A. hibitor to MIL-C-16173D grade 4, Quantity of drying agent calculated K 19, or TL 8030-015, grade 4. - Finish on housing: Single-compo- acc. to DIN 55474 nent synthetic resin lacquer, shade or TL 8100-004. Packing shall conRAL 7001. tain a humidity All apertures in housing must be se- gauge which can be read from outcurely sealed. side.

Do not open packing on receipt! Check for damage. Check reading on humidity gauge. Store in enclosed area at steady temperature and at low relative humidity. Protect from dirt and damp between installation and first operation.

External corrosion-proofing:

- Bright metal parts with corrosion inhibitor to MIL-C-16173D grade 4, K 19, or TL 8030-015, grade 4. - Housing a) Finished by ZF using single-com ponent synthetic resin lacquer, shade RAL 7001. b) Wash priming by ZF, client must apply either 1 or 2-component lacquer as soon as packing materials have been removed. Then, if unit is to go into interim storage for longer than 12 months, repack as described in level II. II

Max. 36 months before installation + max. 12 months between installation and first operation

III

More than 36 As II months before installation + max. 12 months between installation and first operation

Internal corrosion-proofing:

As II

As II In addition, after 36 months of storage, check humidity inside packing every 4 months by reading humidity gauge. If humidity is too high, call in specialist outside company to replace drying agent and barrier cover and to check external corrosion-proofing.

Separate “Anti-corrosion protection and corrosion-proofing” guidelines apply to the period between first operation and entry into regular operation and to downtime. See “Description, Installation, Operation and Maintenance” publication.

1. Guideline for corrosion-proofing of marine transmissions during storage at ZF agencies and intermediaries CAUTION

The corrosion-proofing measures described below must be carried out by ZF-authorized personnel. Otherwise, warranty claims shall be deemed null and void. Series transmissions supplied by ZF have anti-corrosion protection according to level I of “Guidelines for marine transmissions: Anti-corrosion protection, packing type, storage conditions and storage periods” F 43258/ RT 3332-289. The storage conditions stipulated in these guidelines ap ply: Store in enclosed area at steady temperature and low relative humidity. Renew corrosion-proofing after 12 months at the latest. The transmissions may then be stored for a further 12 months. If transmissions then need to be stored for a further period, renew corrosion-proofing every 6 months. Corrosion-proofing procedure:

– Fill the transmission with corrosion inhibiting oil, up to the upper mark on the oil dipstick. Use corrosion inhibiting oil C 642 or C 644 to MIL- L-21260. – Remove the inspection hole cover. – While rotating the input and output shafts, spray the internal components of the transmission with corrosion inhibiting oil. – Replace the inspection hole cover. – Repeat corrosion-proofing on bright external steel parts.

Renewing corrosion-proofing:

Remove the inspection hole cover and inspect the internal components of the transmission. While rotating the input and output shafts, spray the internal components of the transmission with corrosion inhibiting oil. Renew corrosion-proofing on bright external steel parts. Measures to be taken before supplying stored transmissions:

Renew corrosion-proofing and drain corrosion inhibiting oil before delivery of the stored transmission. Inform customer that marine transmissions purchased through ZF agencies offer anti-corrosion protection for a maximum of 12 months.

ZF Marine Transmission - Operating Manual

Recommend Documents