reparaturanleitung u ersatzteilliste zf3m bis zf30m mechanisch

8/12/2019 Reparaturanleitung u Ersatzteilliste ZF3M Bis ZF30M Mechanisch

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S E R V I C E M A N U A L A N D S P A R E P A R T S L I S TS E R V I C E M A N U A L A N D S P A R E P A R T S L I S T

Cod. 310.01.0052f

R E

P A

I R

M A N U A

L

ZF 3 M (HBW 35)ZF 5 M (HBW 50)ZF 10 M (HBW 100)ZF 12 M (HBW 125) / HBW 10ZF 15 M (HBW 150)ZF 15 MA (HBW 150 A)ZF 15 MIV (HBW 150 V)ZF 25 M (HBW 250)ZF 25 MAZF 30 M


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Manual and Spare Parts List ZF M line

3

This ZF M manual has been preparedfor all those who have to do with ZF-HURTH Marine reversing gearbox unitsof the ZF M line, including models ZF 3M, ZF 5 M, ZF 10 M, ZF 12 M, ZF 15 M,ZF 15 MA, ZF 25 M, ZF 25 MA, ZF 30 M,ZF 15 MIV, in particular for- power plant suppliers- shipyards- craft owners

The ZF M manual is intended as an aidfor handling ZF M transmissions and willanswer all questions that may arise indaily operation and in connection with theinstallation and repair of ZF M transmis-sions.

This manual contains:

- Technical description of the gearboxunits and a number of important tech-nical data;

- Instructions for proper installation of thegearbox in the craft;

- Explanatory notes on correct operationand maintenance;

- Detailed description of all disassemblyand reassembly procedures (withdrawings);

- Troubleshooting table with possiblecauses of trouble and the required re-medial action;

- Spare parts list with stock numbers ofall sparte parts;

- Explosion-View drawings showingeach part with the reference numeralsused in the text.

No problems will be encountered in han-dling, installing and operating the ZF Mgearbox if the instructions in this manualare followed. Should a repair be neces-sary, a qualified technician will have nodifficulty in doing the repair work in ac-cordance with the detailed instructionsgiven on the following pages.

In addition, ZF M Service Stations (dis-tributors and dealers) are available forany repairs and for supplying the spareparts required. The manufacturer will al-ways be glad to name the Service Sta-tion nearest to your location.

All transmission units are covered by aworldwide guarantee given by the manu-facturer. The manufacturers warrantywill be subject to the condition that:- the instructions in this manual are

strictly observed in handling thetransmission.

- no work is performed by persons notauthorized by ZF-HURTH Marine.

- no changes or alterations of any kindare made on the transmission.

Failure to observe these points willinvalide all and any warranty claims.

Caution: never start doing any work onthe transmission unless and until theengine and the propeller have come toa complete standstill.


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Table of contents

1. Description1.1 Brief description1.2 Technical data and main

dimensions1.2.1 ZF 3 M boat reversing

gearbox unit1.2.2 ZF 5 M boat reversing




gearbox unit1.2.6 ZF 15 MA boat reversing

gearbox unit1.2.7 ZF 15 MIV boat reversing


gearbox unit1.2.9 ZF 25 MA boat reversing

gearbox unit1.2.10 Accessories1.2.11 Tools1.2.12 Ident. No.1.3 Gear casing1.4 Gear set1.5 Multiple-disc clutch and clutch

operation1.6 Shaft bearings1.7 Shaft seals1,8 Lubrication1.9 Cooling unit

2. Installation2.1 Delivery condition2.2 Transport2.3 Removal of preservative2.4 Painting the gearbox2.5 Connection of gearbox

with engine2.6 Connection of gearbox

with propeller2.7 Suspension of engine-

gearbox assembly in the boat2.8 Position of gearbox in

the boat2.9 Operation of gearbox2.10 Cooling unit2.11 Engine-gearbox compartment

3. Operation3.1 General information3.2 Initial operation3.3 Operating temperature3.4 Operation of gearbox3.5 Sailing or moving in tow3.6 Lay-up periods3.7 Preparation for re-use

4. Maintenance4.1 Transmission oil4.2 Oil quantity4.3 Oil level checks4.4 Oil change4.5 Checking the shift cable

and linkage4.6 Cooling unit4.7 Automatic transmission fluiid

List of recommended fluids

5. Disassembly5.1 Removing the cooling unit5.2 Removing and disassembling

the actuating lever cover plate5.3 Removing the bearing shields5.4 Separating the gearbox

sections and removing theinput and output shafts

5.5 Removing the shifting fork5.6 Removing the intermediate gear5.7 Disassembling the input shaft5.8 Disassembling the output shaft5.9 Disassembling the quill shaft

6. Reassembly6.1 General information6.2 Pre-assembling the intermediate

gear shaft in the gearbox sectionwithout opening

6.3 Pre-assembling the shifting forkin the gearbox section withopening

6.4 Pre-assembling the actuatinglever cover plate

6.5 Pre-assembling the gears6.6 Measuring the pre-assembled

gears to determine settingvalue a

6.7 Pre-assembling the bearingshields

6.8 Pre-assembling the actuatingmembers

6.9 Reassembling the input shaft6.10 Reassembling the output shaft6.11 Reassembling the quill shaft6.12 Final assembly of gearbox6.13 Measuring the gear sets of

input shaft and output shaft6.14 Mounting the actuating lever

cover plate6.15 Mounting the cooling unit

7. Procedure to adjust the shiftinglever cover

8. Troubleshooting

9. Spare parts list

10. Drawings (Explosion view)


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1. Description

1.1 Brief description

ZF-HURTH Marine boat reversing gear-box units of the ZF M line are servo-au-tomatically controlled helical gear trans-missions developed for use in pleasurecraft and commercial craft. The servo-operated multiple-disc clutchrequires only minimum effort for shifting,making the ZF M transmission suitablefor single-lever remote control via a rodlinkage or shift cable.

In emergency situations the ZF M per-mits direct reversing at engine speedabove idle rpm.

The torque capacity of the clutch is ex-actly rated, preventing shock loads fromexceeding a predetermined value to en-sure maximum protection of the engineand thus providing the effect of a safetyclutch.

The transmission units are characterizedby low weight and small overall dimen-sions. The gearbox castings are madeof a high-strength, corrosion-resistantaluminium alloy, chromized for improvedseawater resistance and optimumadhesion of paint.

A choice of gear ratios, a high efficiencyrating and low-noise operation are otherprominent features of the ZF M gearboxunits.

The transmissions are immersion-lubri-cated. Maintenance is restricted to oillevel checks (see Maintenance, chap-ter 4).

The shafts are supported by heavy-dutytaper roller bearings and the gearbox isdesigned to take the axial propeller thrust(for permissible values see Technicaldata, item 1.2).

Transmission sizes are available forright-hand (RH) and left-hand (LH)rotation of the input shaft, the directionof rotation being specified as seen by anobserver facing the input shaft.In gear lever positions A, the engine shaftand the propeller shaft rotate in oppo-site directions, in position B in the samedirection (Fig. 1).On model ZF 15 MIV, the directions ofrotation are the other way round (Fig. 2).

Engine manufacturers should note thatthe direction of rotation refers to an ob-server facing the flywheel, so that left-hand rotation of the engine correspondsto right-hand rotation of the gearbox in-put shaft.

Fig. 1

Fig. 2


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1.2.1 ZF 3 M

Power diagramBased on engine power B to DIN 6270;shock factorK = 1.25 to applied, if engine has 1 cylinderK = 1.20 for 2 cylindersK = 1.15 for 3 cylinders

Transmission input speed (rpm)

Transmission power input

Technical data ZF 3 M-2 R ZF 3 M-3 RShifting position A ratio 2.05:1 2.72:1

Shifting position B ratio 1.86:1 2.15:1

Input torque max. Nm (ft lb) 40 (29,5) 30 (22,1)

Power input max. kW (hp) 15 (20)

Input speed max. rpm 5000

Propeller thrust max. N (lb) 1000 (225)

Weight without fluid kg (lb) 8 (17.7)Fluid quantity liter 0.3

Fluid grade Automatic-Transmission-Fluid (ATF)


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All dimensions in mm

Fig. 3 ZF 3 M

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1.2.2 ZF 5 M

Power diagram for Pleasure Craft DutyBased on engine power B to DIN 6270;shock factorK = 1.25 to applied, if engine has 1 cylinderK = 1.20 for 2 cylindersK = 1.15 for 3 cylinders


ZF 5 M 2.045 1.864 0.0066 0.0088 18 25 20 27 20 27 5000 8 18 B/W2.722 2.150 0.0047 0.0063 13 18 14 19 17 23 5000 Max input power 15 kW

MODEL RATIO POWER / RPM INPUT POWER CAPACITY MAX WEIGHT BELL HSGS.

A Pos B Pos kW hp kW hp kW hp kW hp RPM kg lb AND NOTES

2800 rpm 3000 rpm 3600 rpm

A POS = continuous running position (normally AHEAD). B POS = reverse position.B/W = Borg Warner adaptor.Note = For all M (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine 1.25, 2 cylinder engine 1.20,3 cylinder engine 1.15.


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Fig. 4 ZF 5 M


54


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** Max. 95 Nm (70 ft lb) admissible for main travelling direction with gear

lever set to B

1.2.3 ZF 10 M




1 , 8



2800 rpm 3000 rpm 3600 rpm

ZF 10 M 1.482 1.864 0.0109 0.0146 30 41 33 44 38 51 5000 9.5 21 SAE 4, 5, B/W1.792 1.864 Max input power 38 kW.2.045 1.864 0.0095 0.0128 27 36 29 38 34 46 5000 Ratio 1.482 B Pos.2.722 2.150 0.0068 0.0091 19 26 20 27 25 33 5000 max torque 95 Nm. Ratio

1.792 B Pos. maxtorque 95 Nm.



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1.2.4 ZF 12 M

Power diagram for pleasure craftBased on engine power B to DIN 6270;shock factor K = 1.25 to applied,if engine has fewer than 4 cylinders.



ZF 12 M 2.136 1.955 0.0131 0.0176 37 49 39 53 47 63 5000 13 29 SAE 4, 5, B/W2.632 1.955 0.0111 0.0149 31 42 33 45 40 54 5000 Max input power 55 kW



2800 rpm 3000 rpm 3600 rpm



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Fig. 6 ZF 12 M

Model without mounting flange

a) Clockwise rotation b) Oil dipstick and filler screw 17 mm c) M 8/12 deep, holes same on both sides d) Oil drain plug 17 mm widthacross flats e) Spline profile similar B 10 x 23 x 29 DIN 5464 f) Minimum lever travel

Model with mounting flangeAll dimensions in mm


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** Max. 120 Nm (88.5 ft lb) admissible for main travelling directionwith gear lever set to B

1.2.5 ZF 15 M






2800 rpm 3000 rpm 3600 rpm

ZF 15 M 1.556 1.955 0.0152 0.0204 43 57 46 61 55 73 5000 13 29 SAE 4, 5, B/W, Yanmar JH1.875 1.955 Max input power 55 kW.

Ratio 1.556 B Pos.max torque 120 Nm.Ratio 1.875 B Pos. max torque 120 Nm.



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Fig. 7 ZF 15 M



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** Max. 120 Nm (88.5 ft lb) admissible for main travelling directionwith gear lever set to B

1.2.6 ZF 15 MA


Gearbox input speed (1/min)




2800 rpm 3000 rpm 3600 rpm

ZF 15 MA 1.875 1.955 0.0152 0.0204 43 57 46 61 55 73 5000 13 29 SAE 4, 5, B/W, Yanmar JH2.136 1.955 0.0131 0.0176 37 49 39 53 47 63 5000 Max input power 55 kW.

8 degrees 2.632 1.955 0.0111 0.0149 31 42 33 45 40 54 5000 Ratio 1.875 B Pos.max torque 120 Nm.Ratio 2.136 B Pos. max torque 120 Nm.



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Fig. 8 ZF 15 MA

Model without mounting flange

a) Clockwise rotation b) Oil dipstick and filler screw 17 mm c) M 8/12 deep, holes same on both sides d) Oil drain plug 17 mm width across flats e) Spline profilesimilar B 10 x 23 x 29 DIN 5464 f) Minimum lever travel g) Support for control cable h) full profile

Model with mounting flangeAll dimensions in mm


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* Max. 120 Nm (88.5 ft lb) admissible for main travelling direction withgear lever set to B.

** Max 45 kW for main travelling direction with gear lever set to B.

1.2.7 ZF 15 MIV






2800 rpm 3000 rpm 3600 rpm

ZF 15 MIV 2.134 2.224 0.0152 0.0204 43 57 46 61 55 73 5000 20 44 SAE 4, 5, B/W, Yanmar JH2.718 2.224 0.0111 0.0149 31 42 33 45 40 54 5000 Max input power 55 kW.

8 degrees 2.995 2.224 5000 Ratio 2.134 B Pos.max torque 120 Nm.

A POS = continuous running position (normally AHEAD). B POS = reverse position.

B/W = Borg Warner adaptor.Note = For all M (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine 1.25, 2 cylinder engine 1.20,3 cylinder engine 1.15.


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Fig. 9 ZF 15 MIV


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** Max. 230 Nm (170 ft lb) admissible for main travelling direction with gear lever set to B

1.2.8 ZF 25 M



Transmission power inputkW

90

80

70

60

50

40

30

20

151 2 3 4 5 6x10 3

30

40

50

60

70

80

100

120

hp



2800 rpm 3000 rpm 3600 rpm

ZF 25 M 1.880 2.095 0.0262 0.0351 73 98 79 105 80 107 5000 18 40 SAE 4, 5, B/W, Yanmar JH2.273 2.095 0.0216 0.0289 60 81 65 87 78 104 5000 Max input power 80 kW.2.737 2.722 0.0177 0.0237 50 66 53 71 64 85 5000 Ratio 1.880 B Pos.

max torque 230 Nm.




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Fig. 10 ZF 25 M


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1.2.9 ZF 25 MA

** Max. 169 Nm (125 ft lb) admissible for main travelling direction with gear lever set to B



Transmission power inputkW

90

80

70

60

50

40

30

20

151 2 3 4 5 6x10 3

30

40

50

60

70

80

100

120

hp



2800 rpm 3000 rpm 3600 rpm

ZF 25 MA 2.227 2.737 0.0215 0.0288 60 81 64 86 77 104 5000 18 40 SAE 4, 5, B/W, Yanmar JH2.737 2.737 0.0177 0.0237 50 66 53 71 64 85 5000 Max input power 80 kW.

8 degrees Ratio 2.227 B Pos.max torque 169 Nm.




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Fig. 11 ZF 25 MA

a) Clockwise rotation b) Oil dipstick and filler screw 17 mm c) M 10/15 deep, holes same on both sides d) Oil drain plug 17 mm widthacross flats e) SAE 26 teeth - DP 20/40 - 30 - Flat Root - Class t6 - f) Minimum lever travel

B

7 5


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1.2.10 Accessories

Resilient Coupling for ZF 3 M - ZF 5 M - ZF 10 M Ident-No. 254 750 - 3306 316 001

Resilient Coupling for ZF 25 M - ZF 25 MA Ident-No. 256 526 - 3307 316 001

Resilient Coupling for ZF 10 M - ZF 12 M - ZF 15 M - ZF 15 MA - ZF 15 MIV Ident-No. 254 762 - 3306 316 003

splineA 10 x 23 x 29

DIN 5464

max. torque 100 Nmmax. axial misalignment 0.25 mm

friction factor 410 Nm


DIN 5464



splineSAE 20/40

26 Z




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1.2.10 Accessories

Resilient Coupling for ZF 25 M / 25 MA Ident-No. 223 557 - 3307 316 003

Resilient Coupling PERKINS for ZF 10 M - ZF 12 M - ZF 15 M - ZF 15 MA - ZF 15 MIV Ident-No. 288 240 - 3306 316 002

Resilient Coupling PERKINS for ZF 25 M / 25 MA Ident-No. 288 238 - 3307 316 002

splineSAE 20/40

26 Z

splineSAE 20/40

26 Z

Bolt circle 142,6

Bolt circle 142,6


DIN 5464

max. torque 450 Nm

max. torque 200 Nm

max. torque 200 Nm


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1.2.10 Accessories

Adapter flange for ZF 3 M - ZF 5 M - ZF 10 M - ZF 12 M - ZF 15 M - ZF 15 MA Ident-No. 344 544 - 3306 116 001 (kit)

Adapter flange ZF 25 M - ZF 25 MA Ident-No. 345 964 - 3307 116 001 (kit)

Adapter flange ZF 15 MIV Ident-No. 345 965 - 3306 116 004 (kit)

Bolt circle 235+0.1

Bolt circle 235+0.1

Bolt circle 235+0.1


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1.2.10 Accessories

Cooler for ZF 10 M - ZF 12 M - ZF 15M - ZF 15 MA - ZF 15 MIV - ZF 25 M - ZF 25 MA Ident-No. 326 742 - 3306 107 001

M8 x DIN 931-8.8 vcad (4x)tightening torque 14 Nm

(when mounting on transmission)

1.2.11 Tools

Tool to adjust the shifing lever cover on ZF 10 M - ZF 12 M - ZF 15M - ZF 15 MA - ZF 25 M - ZF 25 MA(See Service Bulletin No. 007/03)

BRACKET P/N 20.4039.02

EXTENSION SECTION P/N 20.4039.03

377 755 - 0636 010 575

442 372 - 0630 302 090


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Model prop. turns draw. no. Id. no. weightanti engineZF 3 M 2,05:1 487926 3302 002 001 8 kg

2,72:1 487927 3302 002 002 8 kgHousing adapter Kit 344544 3306 116 001Damper plate up to 100 Nm 254750 3306 316 001ZF 5 M 2,05:1 388817 3303 002 001 8 kg

2,72:1 459413 3303 002 002 8 kgHousing adapter Kit 344544 3306 116 001Damper plate up to 100 Nm 254750 3306 316 001ZF 10 M 1,48:1 407345 3304 002 003 9,5 kg

1,79:1 407346 3304 002 004 9,5 kg2,05:1 - 3304 002 0102,72:1 467329 3304 002 005 9,5 kg

Housing adapter Kit 344544 3306 116 001Housing adapter Kit SAE 5 500013 3306 116 002Oil cooler Kit 326742 3306 107 001Damper plate up to 100 Nm 254750 3306 316 001Damper plate up to 200 Nm 254762 3306 316 003Damper plate PERKINS up to 200 Nm 288240 3306 316 002ZF 12 M 2,14:1 407205 3305 002 001 13 kg

2,63:1 407206 3305 002 002 13 kgHousing adapter Kit 344544 3306 116 001Housing adapter Kit SAE 5 500013 3306 116 002Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 254762 3306 316 003Damper plate PERKINS up to 200 Nm 288240 3306 316 002ZF 15 M 1,56:1 407208 3306 002 003 13 kg

1,88:1 407207 3306 002 004 13 kgHousing adapter Kit 344544 3306 116 001Housing adapter Kit SAE 5 500013 3306 116 002Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 254762 3306 316 003Damper plate PERKINS up to 200 Nm 288240 3306 316 002ZF 15 MA 2,0:1 407461 3306 001 004 13 kg

2,14:1 - 3306 001 003 13 kg2,5:1 407462 3306 001 005 13 kg

Housing adapter Kit 344544 3306 116 001Housing adapter Kit SAE 5 500013 3306 116 002Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 254762 3306 316 003Damper plate PERKINS up to 200 Nm 288240 3306 316 002ZF 15 MIV 2,13:1 407377 3306 003 001 20 kg

2,72:1 439386 3306 003 003 20 kg2,99:1 407378 3306 003 002 20 kg

Housing adapter Kit 345965 3306 116 004Housing adapter Kit SAE 5 500015 3306 116 003

Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 254762 3306 316 003Damper plate PERKINS up to 200 Nm 288240 3306 316 002ZF 25 M 1,88:1 408089 3307 002 001 18 kg

2,27:1 - 3307 002 007 18 kg2,74:1 408090 3307 002 002 18 kg

Housing adapter Kit 345964 3307 116 001Housing adapter Kit SAE5 - 3315 116 001Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 256526 3307 316 001Damper plate PERKINS up to 200 Nm 288238 3307 316 002Damper plate up to 450 Nm 223557 3307 316 003ZF 25 MA 2,23:1 - 3307 001 005 18 kg

2,74:1 - 3307 001 006 18 kgHousing adapter Kit 345964 3307 116 001Housing adapter Kit SAE5 - 3315 116 001

Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 256526 3307 316 001Damper plate PERKINS up to 200 Nm 288238 3307 316 002Damper plate up to 450 Nm 223557 3307 316 003

1.2.12 Gearboxes and accessories


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1.6 Shaft bearings

Both the input and the output shafts arecarried in amply dimensioned taper rollerbearings.

The propeller thrust can be absorbed bythe bearings (for permissible values seeTechnical data, item 1.2).

The intermediate gear and the movablegears are carried in sturdy needle rollerbearings.

1.7 Shaft seals

External sealing of the input and outputshafts is provided by radial sealing rings.The running surfaces on the shafts arecasehardened.

1.8 Lubrication

The transmissions are immersion-lubri-cated. The bearings are generously sup-plied with splash oil.

1.9 Cooling unit

Transmissions intended for use at highambient temperatures and for continu-ous operation at high power (especiallywhen shifting position B is used for themain direction of movement of the craft),must be supplied with a cooling unit (seeitem 2.10).

2. Installation

2.1 Delivery condition

HURTH ZF M gearbox units leave thefactory in fully assembled condition. Forsafety reasons, the gearbox is not filledwith oil for shipment. The actuating le-ver is mounted on the actuating shaft.On request, the gearbox is delivered withthe cooling unit (see item 2.10) andflange (see item 1.2) fitted, as well asthe previous damper plate between en-gine and gearbox.The multi-spline shaft is provided with anoil film and protected by a plastic cap.The bright surfaces of the coupling flangeon the output side are coated with ananticorrosive agent for shipment andstorage. The casing is chromized andthus resistant to seawater.

Fig. 12

(0.1 mm = 0.004 inches)

Before leaving the factory, each trans-mission is subjected to a test run withthe prescribed ATF oil. The residual oilremaining in the transmission after drain-ing acts as a preservative and providesreliable protection against corrosion forat least 1 year if the units are properlystored.

2.2 Transport

Care should be taken when transportingthe gearbox or the engine-gearbox as-sembly to prevent undue shocks andimpacts. This applies particulary to theinput and output shafts.

2.3 Removal of preservative

Use a suitable solvent for removing theanticorrosive agent, but never use em-ery cloth or paper, because this coulddamage the sealing surface and void thewarranty.

It is advisable, especially after long peri-ods of storage, to flush the transmissionwith the prescribed oil and remove re-sidual oil.

2.4 Painting the gearbox

Always cover the running surfaces andsealing lips of the radial sealing rings onboth shafts before painting. Make cer-tain that the breather hole on the oil fillerscrew is not covered by paint. The iden-tification plates should remain clearly leg-ible.

2.5 Connecting the gearbox with engine

Fit a recommended damping plate be-tween the engine and the transmissionto compensate for minor alignment er-rors and protect the input shaft from ex-ternal forces and loads.

If the flywheel housing of the engine isof suitable design, the gearbox unitshould be directly bolted to the housingby means of the holes provided in thegearbox.Make certain to use bolts with the rightappropriate length (see Main dimen-sions, item 1.2) and thighten them tothe correct torque, M8 =14 Nm (10 ft lb),M10 = 28 Nm (20 ft lb)using LOCTITE 242 or 262

An adapter flange and a damper plateare available on request for each gear-box unit (see Main dimensions, item1.2.10).

The radial and axial runout values shownin the drawing Fig. 12 should never beexceeded between the engine and trans-mission.

The input shaft end is provided with amulti-spline or involute spline profile (seeMain dimensions, item 1.2).


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2.6 Connection of gearbox with propeller

We recommend a flexible connectionbetween the gearbox and the propellershaft, when the engine is flexiblymounted, in order to compensate forangular deflections. The installation of aspecial propeller thrust bearing is notrequired, since the propeller thrust willbe taken by the transmission bearing,provided the value specified underTechnical data, item 1.2, is not ex-ceeded. However, the output shaftshould be protected from additionalloads. Special care should be taken toprevent torsional vibration. When usinga universal joint shaft, make certain toobserve the manufacturers instructions.

2.7 Suspension of engine gearbox assembly in the boat

Special care should be taken to protectthe gearbox from detrimental stressesand loads when the engine-transmissionassembly is not elastically suspended inthe boat or craft.

The gearbox should be conveniently ac-cessible for maintenance. If the oil drainplug of the gearbox is not accessible, theoil will have to be sucked off.

2.8 Position of gearboxin the boat

The inclination of the gearbox unit in thedirection of the shafts should not exceedan installation angle of 20 degrees (seeFig.13) and 15 for ZF 15 MIV.

2.9 Operation of gearbox

The gearbox is suitable for single leverremote control. Upon loosening the re-taining screw (7), the actuating lever (6)can be moved to any position requiredfor the control elements (cable or rod link-age). (Fig. 14).

IMPORTANTMake certain that the lever does not con-tact the actuating lever cover plate (9):the minimum distance between lever andcover must be 0.5 mm.

The control cable should be perpendicu-lar to the actuating lever in the neutralposition of the lever.The zero position of the operating leveron the control console must coincide withthe zero position of the actuating leveron the gearbox.

The shifting travel, as measured at thepivot point of the actuating lever, be-tween the neutral position and end posi-tions A and B must be at least 35 mm forthe outer and 30 mm for the inner pivotpoint.A larger amount of lever travel is in noway detrimental.

IMPORTANTHowever, if the lever travel is shorter,proper gear engagement mightbeimpeded which, in turn, would meanpremature wear, excessive heat genera-tion and resulting damage.

The position of the cover plate under-neath the actuating lever is factory-ad-

justed to ensure equal lever travel fromneutral position A and B.

IMPORTANTIf this cover is removed in exceptionalcases, proceed as described under item6.14 of this manual.

When installing the gearbox, make cer-tain that shifting is not impeded by re-stricted movability of the cable, by un-suitably positioned guide sheaves, toosmall bending radius, etc.

Fig. 13

20

Clamping screw (7) tobe tightened to torqueof 20 Nm

Minimum shifting movementfor actuating lever (6)

Do not remove coverplate (9) or loosen screws

Oil drain plugOil dipstick and oil filler screw17 mm width across flats

Min. distance ofactuating lever 0.5 mm

Fig. 14


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2.10 Cooling unit

The arrangement of the cooling unit forthe ZF 10 M, ZF 12 M, ZF 15 M, ZF 15MA, ZF 15 MIV, ZF 25 M and 25 MA (nocooling is required for ZF 3 M and 5 M)can be seen from Fig.15.

The table below shows the maximumpower output in continuous operation (le-ver position A and B) usable without cool-ing. When these values are exceeded,a cooling unit is required.

The cooling unit should be connected tothe fresh-water pressure line (externalcircuit) of the engine in accordance withFig.16. The minimum volume of flow is10 ltr/min. Retrofitting of the cooling unitinvolves no problems (see item 6.15).

2.11 Engine-gearbox compartment

Care should be taken that the enginegearbox compartment is properly venti-lated.

Fig. 15

10 liters/min2.6 gal/min

Fig. 16

Max. engine power usable without cooling

Lever position ZF 3 M ZF 10 M ZF 12 M ZF 15 MIV ZF 25 MZF 5 M ZF 15 M ZF 25 MA

ZF 15 MA A no cooling no cooling 40 kW 25 kW 40 kW

54 hp 34 hp 54 hp B no cooling 25 kW 25 kW 20 kW always with

34 hp 34 hp 34 hp cooling unit


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Correct readings up to 20 inclination in direction of shafts(15 for ZF 15 MIV)

3. Operation

3.1 General information

All ZF M boat reversing gearbox unitsare test-run on a test stand at the fac-tory prior to delivery.

For safety reasons, the oil is drainedbefore shipment.

3.2 Initial operation

Fill the gearbox with oil (ATF), (see 4.7or recommended fluids). The oil levelshould be up to the index mark on thedipstick (see fig. 17).

To check the oil level, just insert the dip-stick, do not screw in. Retighten the hexscrew with the dipstick after the oil levelcheck. Do not forget sealing ring.

3.3 Operating temperature

Normal operating temperature of thetransmission oil should be in the rangeof 50 C (122 F) to 80 C (176 F). Max.permissible ATF temperature of 100 C(212 F) may only be reached for a shorttime.

3.4 Operation of gearbox

The zero position of the operating leveron the control console must coincide withthe zero position of the actuating leveron the transmission. Shifting is initiatedby a cable or rod linkage via the shiftinglever and an actuating cam. The

completition of the gear changing opera-tion is servo-automatically controlled.Gear changing should be smooth, not tooslow, and continuous (without interrup-tion). Direct changes from forward to re-verse are permissible, since the multi-ple-disc clutch permits gear changing athigh rpm, including sudden reversing attop speeds in the event of danger.

3.5 Sailing or moving in tow

Rotation of the propeller while the boatis sailing, being towed, or anchored in ariver, as well as operation of the enginewith the propeller stopped (for chargingthe battery), will have no detrimental ef-fects on the gearbox.

IMPORTANTWhen the boat is sailing (enginestopped), the gear lever must be in zeropos-ition. Never put the gear lever in thepos-ition corresponding to the directionof travel of the boat.

Locking the propeller shaft by an addit-ional brake is not required: use the gearlever position opposite your direction oftravel for this purpose.

3.6 Lay-up periods

If the transmission is not used for peri-ods of more than 1 year it should be com-pletely filled with oil of the same gradeto prevent corrosion. Protect the inputshaft and the output flange by means ofan anticorrosive coating if required.

3.7 Preparation for re-useSee item 2.3

4. Maintenance

4.1 Transmission oil

To ensure trouble-free operation of theclutch only use Automatic TransmissionFluid (ATF).

4.2 Oil quantity

ZF 3 M 0.30 ltr 0.32 qtsZF 5 M 0.30 ltr 0.32 qtsZF 10 M 0,35 ltr 0.37 qtsZF 12 M 0.56 ltr 0.59 qtsZF 15 M 0.56 ltr 0.59 qtsZF 15 MA 0.47 ltr 0.50 qtsZF 15 MIV 1.00 ltr 1.06 qtsZF 25 M 0.75 ltr 0.79 qtsZF 25 MA 0.75 ltr 0.79 qts

min. 0.90 ltr min. 0.95 qtsZF 30 Mmax. 1.10 ltr max. 1.17 qts

Use the index mark on the dipstick as areference (see item 3.2)

4.3 Oil level checks

Check the oil level in the gearbox aboutonce a month. Correct oil level: indexmark on dipstick (see item 3.2). Alwaysuse the same oil grade when topping up.

Dont overfill the gearbox. This will cre-ate higher operating temperatures.

4.4 Oil change

Change the oil the first time after about25 hours of operation, then at intervalsof at least 1 year.

4.5 Checking the control cable linkage

The control cable or rod linkage should be

checked at shorter time intervals. Checkthe zero position of the operating lever (onthe control console) and of the shifting le-ver (on the gearbox) on this occasion. Theminimum lever travel from the neutral po-sition to operating positions (0-A = 0-B)should be 35 mm (1.38 in) for the outerand 30 mm (1.18 in) for the inner pivotpoint. Make certain that these minimumvalues are safely reached. Check the ca-ble for easy movability (see item 2.9).

4.6 Cooling

If the transmission is equipped with acooling unit, drain the cooling waterbefore long periods of non-use whentemperature is below freezing point.

Fig. 17


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34

4.7 Automatic Transmission FluidList of recommended fluidsFor ZF-HURTH ZF M Marine Transmissions Automatic Transmission Fluid (ATF) must to be used as lubricant.

ADDINOL MINERALL GMBH, KRUMPA/D ADDINOL ATF D IID

ADDINOL MINERALL GMBH, KRUMPA/D ADDINOL ATF D IIIAGIP PETROLI SPA, ROM/I AGIP ATF II DAGIP PETROLI SPA, ROM/I AGIP ATF D 309AGIP PETROLI SPA, ROM/I AGIP ATF PLUSAGIP PETROLI SPA, ROM/I AGIP DEXRON IIIAGIP SCHMIERTECHNIK, WRZBURG/D AUTOL GETRIEBEL ATF-DAGIP SCHMIERTECHNIK, WRZBURG/D AUTOL GETRIEBEL ATF III DARAL LUBRICANTS GMBH, BOCHUM/D ARAL GETRIEBEL ATF 22ARAL LUBRICANTS GMBH, BOCHUM/D ARAL GETR.L ATF 55 F-30589AVIA MINERALL-AG, MNCHEN/D AVIA FLUID ATF 86BLASER SWISSLUBE, HASLE-REGSAU/CH BLASOL 229BP OIL DEUTSCHLAND, HAMBURG/D FRONTOL UNIVERSAL-ATF 100BP OIL INTERNATIONAL, LONDON/GB AUTRAN DX IIBP OIL INTERNATIONAL, LONDON/GB AUTRAN MBXBP OIL INTERNATIONAL, LONDON/GB AUTRAN DX III (F-30370)BP OIL INTERNATIONAL, LONDON/GB AUTRAN DX III (F-30381)BUCHER+CIE AG, LANGENTHAL/CH MOTOREX ATF SUPER D-22656BUCHER+CIE AG, LANGENTHAL/CH MOTOREX ATF DEXRON III MCCALPAM GMBH, ASCHAFFENBURG/D PAMATIC FLUID 289CALPAM GMBH, ASCHAFFENBURG/D CALPAMATIC FLUID III FCALTEX PETROLEUM CORP., LONDON/GB CALTEX ATF-HDACALTEX PETROLEUM CORP., LONDON/GB CALTEX ATF-HDMCALTEX PETROLEUM CORP., LONDON/GB CALTEX TEXAMATIC 1278CALTEX PETROLEUM CORP., LONDON/GB CALTEX TEXAMATIC 7045CALTEX PETROLEUM CORP., LONDON/GB CALTEX TEXAMATIC 1205ACASTROL LTD, SWINDON/GB CASTROL TQ-D (22765)CASTROL LTD, SWINDON/GB CASTROL TQ DEXRON III F-30520CASTROL LTD, SWINDON/GB CASTROL TRANSMAX S (F-30319)CASTROL LTD, SWINDON/GB CASTROL TRANSMAX T (F-30359)CASTROL LTD, SWINDON/GB CASTROL TQ-D (21289)CASTROL LTD, SWINDON/GB CASTROL ATF 21293CEPSA, MADRID/E CEPSA ATF-70CHEVRON PRODUCTS CO., RICHMOND/USA CHEVRON ATF F-30108CITGO PETROLEUM CORP., TULSA/USA CITGO ATF DEXRON III F-30167C.J.DIEDERICHS SHNE, WUPPERTAL/D CIDISOL-HYDR.-FLUID DEXRON IID

DE OLIEBRON B.V., ZWIJNDRECHT/NL ATF DMMDE OLIEBRON B.V., ZWIJNDRECHT/NL ATF 289DEA MINERALL AG, HAMBURG/D DEAMATICDEA MINERALL AG, HAMBURG/D DEAFLUID 4011DEA MINERALL AG, HAMBURG/D DEAFLUID 3003DEUTSCHE SHELL AG, HAMBURG/D MAC ATF D-21666DUCKHAMS OIL, BROMLEY/GB UNIMATICELF LUBRIFIANTS, PARIS/F TRANSANTAR DF2ELF LUBRIFIANTS, PARIS/F ANTAR 22329ELF LUBRIFIANTS, PARIS/F ELFMATIC G2 22329ELF LUBRIFIANTS, PARIS/F HUILE RENAULT DIESEL STARMATICELF LUBRIFIANTS, PARIS/F ELFMATIC G3ELF LUBRIFIANTS, PARIS/F TRANSANTAR DF3ELLER-MONTAN-COMP., DUISBURG/D ELLMO-AUTOMATIK-FLUID 22233ENGEN PETROLEUM, CAPE TOWN/ZA ENGEN ATF 22DERTOIL SA, MADRID/E TRANSMISIONES AUTOMATICAS D2ESSO AG, HAMBURG/D ESSO ATF D (21611)ESSO AG, HAMBURG/D ESSO ATF F-30320ESSO AG, HAMBURG/D ESSO ATF D (21065)FIAT LUBRIFICANTI, VILLASTELLONE/I TUTELA GI/AFINA EUROPE SA, BRSSEL/B FINAMATIC II-DFUCHS LUBRICANTS (UK), DERBY/GB SILKTRAN MP-ATFFUCHS LUBRICANTS (UK), DERBY/GB SILKTRAN PSV ATFFUCHS MINERALLWERKE, MANNHEIM/D TITAN ATF 4000GINOUVES GEORGES SA, LA FARLEDE/F YORK LT 785GULF OIL (GB) LTD, CHELTENHAM/GB UNIFLUIDGULF OIL (GB) LTD, CHELTENHAM/GB ATF 2HANDELSMIJ NOVIOL B.V., NIJMEGEN/NL KENDALL ATF DEXRON IIDHOMBERG GMBH+CO KG, WUPPERTAL/D HOMBERG-GETRIEBE-FLUID DIGOL FRANCE, PARIS/F IGOL ATF 420INA RAFINERIJA ZAGREB/CROATIA INA-ATF SUPERITALIANA PETROLI, GENOVA/I TRANSMISSION FLUID DXJAPAN ENERGY CORP., TOKYO/JAPAN JOMO ATF KKPPLER K., STUTTGART/D SELECTOL FLUID GETR.L IID 23KLCKNER ENERGIEHANDEL GMBH, KLN/D DEUTZ OEL ATF-D

KROON OIL BV, ALMELO/NL ATF DEXRON IIDKROON OIL BV, ALMELO/NL ALMIROL ATFKUWAIT PETROLEUM, HOOGVLIET/NL Q8 AUTO 15KUWAIT PETROLEUM, HOOGVLIET/NL Q8 AUTO 14 (IID-21677)KUWAIT PETROLEUM, HOOGVLIET/NL Q8 AUTO 14 (IID)

KUWAIT PETROLEUM, HOOGVLIET/NL Q8 AUTO 14 (IID-21883)

LEPRINCE+SIVEKE GMBH, HERFORD/D LEPRINXOL FLUID CNLIQUI MOLY / MEGUIN, ULM/D ATF IIELIQUI MOLY / MEGUIN, ULM/D MEGOL ATF IIDLUBRICATION ENGIN., FORT WORTH/USA AUTOMATIC TRANSMISSION FLUIMAURAN SA, ODARS/F INTER OIL INTER MATIC ATF D2MIN.L-RAFFIN. DOLLBERGEN, UETZE/D PENNASOL FLUID-GETR.L TYP PCNMOBIL OIL, WEDEL/D MOBIL ATF 220 D20104 / D21685MOBIL OIL, WEDEL/D MOBIL ATF F-30107MOBIL OIL, WEDEL/D MOBIL ATF 220 D21412 / D22187MOBIL SEKIYU KABUS.KAISHA, TOKYO/J MOBIL ATF 220Y (D-21412)MOL HUNGARIAN OIL, KOMARON/H CARRIER ATFMORRIS LUBRICANTS, SHREWSBURY/GB LIQUIMATIC DIINAFTEC, ALGIER/DZ TASSILIANANHAI SUPERIOR LUB-OIL, CHINA NANHAI ATF (D2)NIS-RAFINERIJA NAFTE BEOGRAD/YU GALAX MATIC DACOEST G. MIN.LWERK, FREUDENSTADT/D ATF T 4011OMEX PETROLEUM PTY, BELLEVUE/AUS OMEX ATF DEXRON IIOMV AG, SCHWECHAT/A OMV ATF D II (D22427)OMV AG, SCHWECHAT/A OMV ATF III (F-30580)OPTIMOL LWERKE, HAMBURG/D OPTIMOL ATF T 4011OSWALD KLUTH, BARGFELD-STEGEN/D UNIVERSAL ATF-DPAKELO MOTOR OIL, SAN BONIFACIO/I MULTIPURPOSE TRANSM. FLUID IIDPANOLIN AG, MADETSWIL/CH PANOLIN ATF MULTI 21996PANOLIN AG, MADETSWIL/CH PANOLIN ATF DEXRON IIIPARS OIL CO., TEHRAN/IR PARS ENTEGHAL-E AUTOMATIC OILPAZ LUBRICANTS&CHEMICALS, HAIFA/IL PAZBO EZFPENNZOIL PRODUCT COMP., HOUSTON/USA PENNZOIL ATF F-30110PETRO-CANADA, MISSISSAUGA/CDN DEXRON III/MERC.ATF (F-30395)PETROL OFISI A.S., BAKANLIKLAR/TR PETROL OFISI ATF IIPETROLEX, KWIDZYN/PL VECO MATIC IIDPRINZ-SCHULTE, FRECHEN/D AERO-LINE ATF-2PRINZ-SCHULTE, FRECHEN/D AERO-LINE ATF-DREPSOL DISTRIBUCION SA, MADRID/E REPSOL MATIC ATFS.A.E.L, ALCOBENDAS/E GULF ATF DII D-22233SASOL OIL, RANDBURG/ZA SASOL ATF DXII

SCHMIERSTOFFRAFFINERIE SALZBERGEN/D WINTERSHALL ATF DSHELL ASEOL AG, BERN/CH ASEOL ATF DB UNIVERSALSHELL INTERNATIONAL, LONDON/GB SHELL DONAX TA (D-21666)SHELL INTERNATIONAL, LONDON/GB SHELL DONAX TG (F-30358)SLOVNAFT JS CO, BRATISLAVA/SLO MADIT AUTOMATICSONOL ISRAEL LTD, HAIFA/IL DEXRON 2 DSOPROGRASA SA, MADRID/E SOPRAL 164STATOIL STAVANGER/N TRANSWAY DX III (F-30373)STATOIL STAVANGER/N TRANSWAY DX IISTL TECNOL, ESCALQUENS/F TECNOL TECMATIC D2SUN OIL COMPANY, AARTSELAAR/B SUNAMATIC 149SUN OIL COMPANY, AARTSELAAR/B SUNAMATIC 153SUOMEN PETROOLI OY, HAMINA/SF TEBOIL FLUID E (F-30301)SUOMEN PETROOLI OY, HAMINA/SF TEBOIL FLUID DSVENSKA STATOIL AB, NYNSHAMN/S TRANSWAY DX III (F-30373)TAMOIL LUBES, GENEVA/CH TAMOIL ATF II DTEXACO LUBRICANTS COMP., BEACON/USA ATF MERCON / DEXRON IIITEXACO SERVICES LTD, BRSSEL/B TEXAMATIC 7045TEXACO SERVICES LTD, BRSSEL/B TEXAMATIC 4261TEXACO SERVICES LTD, BRSSEL/B TEXAMATIC 7080TEXACO SERVICES LTD, BRSSEL/B TEXTRAN PSMTEXACO SERVICES LTD, BRSSEL/B TEXAMATIC 4011TEXACO SERVICES LTD, BRSSEL/B TEXAMATIC 4291TEXACO SERVICES LTD, BRSSEL/B TEXAMATIC 9226TOTAL RAFFINAGE DISTR., PARIS/F TOTAL FLUIDE ATXTOTAL RAFFINAGE DISTR., PARIS/F TOTAL FLUIDE IIDTOTAL RAFFINAGE DISTR., PARIS/F TOTAL FLUIDE AT 42TOTAL SOUTH AFRICA, JOHANNESBURG/ZA TOTAL FLUIDE ATDTURBOTANK BSCHE+BDEKER, BREMEN/D TURBO UNIV. ATF MERCON 401UFANEFTECHIM REFINERY, UFA/RUS UFALUB ATFUNIL DEUTSCHLAND GMBH, BREMEN/D UNIL MATIC CN T 4011VALVOLINE INC., LEXINGTON/USA VALVOLINE MULTI-PURPOSE ATFVALVOLINE INTERNAT., DORDRECHT/NL VALVOLINE ATF TYPE DVEBA OEL AG, GELSENKIRCHEN/D MOVARA ATF-GETRIEBEL DIIDVEEDOL INTERNATIONAL, SWINDON/GB VEEDOL ATF-M (22764)

VEEDOL INTERNATIONAL, SWINDON/GB VEEDOL ATF DEXRON III F-3052VEEDOL INTERNATIONAL, SWINDON/GB VEEDOL UNITRANS S PLUSYACCO SA, ST PIERRE-LES-ELBEUF/F YACCO ATF DZELLER+GMELIN GMBH&CO, EISLINGEN/D DIVINOL FLUID 666


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36

5.8 Disassembling the outputshaft (66)

5.8.1 Mount support rail on a vice withthe pins pointing upwards (not on ZF 15MIV).

5.8.2 Place output shaft (66) verticallyon the support rail with the flange sidedown.

5.8.3 Remove screw (41) spacer (42)and outer bearing race (34).Only in models ZF 3 M - 5 M removealso shims (68) and in model ZF 15 MAspacer (68).

42

5.8.4 Place side of gear (65) adjacent toshaft flange against a suitable support(a divided flange or two brackets of suit-able section) and use pin of suitable sizeto press off the output shaft.Do not place the support neither againstthe gear's (65) teeth nor against the fric-tion washer (43). But place it as shownon the drawing below.

The parts removed from the upside ofthe shaft are not interchangeable with theparts removed from the flange side. Keepseparately.

5.8.5 Remove keys (67) from the outputshaft and keep in a separate place (1key for ZF 3 M and 5 M, 2 keys for ZF 10M, 12 M, 15 M, 15 MA, and 4 keys forZF 25 M, 25 MA and ZF 30 M).

Fig. 18

Fig. 19

41

34 68

65

6543


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37

5.8.6 Put off shims (53, 54, 55, 56),spacer (47) and needle bearing (45) fromthe output shaft.

5.8.7 Attach divided flange to face sideof bearing shield (2) and pull off thrustwasher (43), inner race (46) and taperroller bearing (34, 35) with shield. On ZF15 MIV only pull off taper roller bearing(34, 35).

5.8.8 Remove internal and externalclutch discs from gears (44) and (65).

5.8.9 Dismantling the gearsCompress cup springs (48) (only oneeach side for ZF 3 M - 5 M) by means ofdismantling tool. Remove circlip (50) andtake off thrust plate (49).

5.8.10 Dismantling the actuating mem-bers.Detach springs (64), watching for balls (58).

5.8.11 Remove disc carrier (57).

5.8.12 Place actuating sleeve (60) on aplane surface and press out guide sleeve(59). Watch for detent pins and springs

jumping off the guide sleeve. It will beadvisible to wrap a rag around the actu-ating sleeve (60) and the guide sleeve(59) to catch any parts that might jumpoff.

5.9 Disassembling the quill shaft (ZF 15MIV).

Note: see drawing page 38.

5.9.1 Remove grooved ring nut (83) bymeans of socket spanner and take offring (34) with sealing ring (31).

5.9.2 Place divided flange against faceside of bevel gear (80) and force bevelgear (80) spacer ring (76) and bearing(74) off quill shaft.

5.9.3 Remove key (81) and spacer ring (76).

5.9.4 Force off bearing (74) by means ofdivided flange.

Fig. 20

47

46

43

44 - 65

49

50

53 - 5455 - 56

45

34 - 35

2

Fig. 21

Fig. 22

64

575863

626160595857

48


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6. Reassembly

Note: fold out illustration sheets 1 and 2(exploded views) for reference. For ZF15 MIV use illustration sheets 3 and 4.

6.1 General information

The following points should be observedwhen reassembling the gearbox:

- Clean all parts thoroughly, especiallysealing surfaces, inspect for wear,damage and cracks, and replace if re-quired.

- Check shifting fork (15) for wear. Thecontact surfaces of this fork are pro-vided with amolybdenum coating.Should this coating be worn away atany point, replace the shifting fork. Maxwear on guiding surfaces 0.2 mm(0.008 in) on each side.

- Thrust rings (43) require replacementif wear exceeds 0.25 mm (0.0098 in).

- Internal discs (51) have a sinteredmetal coating of 0.3 mm (0.012 in) oneach side. If the surface structure (af-ter clean-ing) shows indications ofwear, replace the discs.

- Apply thin coat of oil to antifriction bear-ings before installation.

0.5 0.2 mm

not for ZF 3 M - 5 M - 10 M

6.2 Assembling the intermediategear shaft in gearbox section

side cooler

6.2.1 Insert retaining plate (25).

IMPORTANT:Note that the bevelled corners of retain-ing plates (25) have to be placed in differ-ent positions (see illustration on sheet 1).

6.2.2 Insert needle cage (27) into inter-mediate gear (26) and place completeassembly with retaining plate (25).

6.2.3 Insert second retaining plate (25).Not for ZF 3 M - 5 M.

6.2.4 Fit O-ring (23) to intermediate gearshaft (24)* and drive it into gearboxsection by knocking slightly on a drivepin.

* on ZF 3 M - 5 M insert intermediate gearshaft with seeger 23 and Loctite 574.

* on ZF 25 M - 25 MA and ZF 30 M, in-sert intermediate gear shaft (24) with-out O-ring (23) and close bore in gear-box section with sealing compound bypressing in a plug (23) with Loctite 574.(see illustration on sheet 1).

* on ZF 15 MIV insert intermediate shaft(24) and stop it in its place by knock-ing with a driver pin on the edge of thehole of the housing. Close the outsiderhole in the housing by pressing in plug(23) with Loctite 574.

6.3 Assembling the shifting fork ingearbox section side shifting cover

6.3.1 Insert shifting fork (15) into gear-box section (1) side the actuating leverin such a way that the long arm of thefork points downwards.

6.3.2 Insert shifting rod (16) throughbores in gearbox and shifting fork.

6.3.3 Fit screw plug (17) to gearbox,making certain that the clearance be-tween shifting rod (16) and screw plug(17) is min. 0.5 mm (0.02 in).Seal screw plug with Loctite 242 (ZF 3M - 5 M only O-Ring).

6.3.4 Check shifting fork for easymovability.

6.4 Pre-assembling the actuatinglever cover plate

Use punch tool to press sealing ring (8)into cover plate (9). Spread antifrictionbearing grease between sealing lips.

6.4.1 Insert actuating cam assembly (11)into cover plate (9).

6.4.2 Fit actuating lever (6).

IMPORTANT:Clearance between actuating lever andcover plate 0.5 mm (0.02 in).

6.4.3 Clamp actuating lever by meansof retaining screw (7), using a 13 mmspanner (wrench). Screw in with torqueof 20 Nm.

Fig. 23

8 11

70

6

7

Punch ToolFig. 24

8

9


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6.5 Pre-assembling the gears (65) and(44) with cup springs (48) and clutchdiscs (51 and 52)

IMPORTANT:If previously disassembled parts areused, make certain that only mating andassociated parts are reassembled.

6.5.1 Join two cup springs (48) (only onecup spring for ZF 3 M - 5 M) face to face(external diameters in contact) and placethem on the centering collar of gears (65)and (44).

6.5.2 Place thrust ring (49) on cupsprings.

6.5.3 Place circlip (50) on gear hub anduse mounting tool and press to fit circlipinto groove on hub. Don't presscompletely the cup springs and be surethat the tool presses at least on threepoints on the thrust washer (49).

6.5.4 Attach clutch discs (51 and 52), firstinternal disc (51), then alternatively ex-ternal disc (52), internal disc (51), etc.

6.6 Measuring the pre-assembledgears (65) and (44) to determinesetting value a .

If no parts had to be replaced, the previ-ously disassembled shims (53, 54, 55,56) can be re-used in their former ar-rangement and positions without anymeasuring operation.

If measuring is required, proceed as fol-lows:

6.6.1 Place pre-assembled gear (65),and subsequently gear (44) on thrustwasher (43), (end face of hub down-wards, see illustration).

IMPORTANT:On ZF 3 M - 5 M - 10 M there is a stepon the thrust washer (43). Put the sideof the washer with the step against thegear. Be sure that the needle bearinginner race (46) is fitted into it.

6.6.2 Insert needle cage (45), inner race(46) and spacer (47) into bore of gear.

6.6.3 Fit shims (53, 54, 55, 56), as re-quired, until prescribed seeting value ais obtained (see illustration).

6.6.4 Shims are available in thicknessesof 0.4 - 0.5 - 0.6 and 0.7 mm.(0.016 - 0.020 - 0.024 and 0.028 in)

Setting value a

Type mm inchesZF 3 M 8.0 0.1 0.315 0.004ZF 5 MZF 10 M 13.0 0.1 0.512 0.004HBW 10

ZF 12 MZF 15 M 12.4 0.1 0.488 0.004ZF 15 MAZF 15 MIVZF 25 M / 25 MA 16.2 0.1 0.638 0.004ZF 30 M 19.75 0.1 0.778 0.004Old versions(4+3 externalclutch discs)HBW 10(versionsfrom 01 to 08) 13.2 0.1 0.520 0.004HBW 150

(versionsfrom 09 to 14)HBW 150 V(versionsfrom 01 to 07)

Fig. 25

50

49

44 - 65

48

Fig. 26

Thrust washer (43)bronze sideupwards

53 - 5455 - 56

50

49

44 - 65

48

4546

47


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40

6.7 Pre-assembling the bearingshields (2) for the input and outputshafts

Use a driver tool to press sealing rings(30 - input and 31 - output) into shield (2).

6.8 Pre-assembling the clutchmembers

6.8.1 Fit driving pins (63), springs (61)and detent pins (62) to guide sleeve (59).

6.8.2 Place actuating sleeve (60) onplane press surface.

6.8.3 Place guide sleeve (59) on top ofactuating sleeve (60) with the three driv-ing pins (63) in alignment with the threegrooves in the actuating sleeve. Watchfor correct position of detent pins (62)relative to angular pockets of sleeve.

6.8.4 Press guide sleeve (59) into actu-ating sleeve (60) up to midway position(noticeable click).

6.8.5 Insert balls (58) into ball pocketsof guide sleeve, attach disc carrier (57),turn upside down then fit balls in oppo-site face side and attach second disccarrier (57).

6.8.6 Attach springs (64) with closed partof spring windings pointing outwards.

6.9 Reassembling the input shaft

Preheat inner races (33) of taper rollerbearings to a temperature of 100 C(212F) and, using tubular or punch tool,press races on input shaft (36) on bothsides.

IMPORTANT:Repress after cooling down, so that nogap is left.

Fig. 27

31 - 32

Punch tool

2

Fig. 28

64

5863

626160595857

Tubular tool

33

36

36

33

Punch tool

Fig. 29 Fig. 30


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41

6.10 Reassembling the output shaft

6.10.1 Place pre-assembled bearingshield (item 6.7) with seal (28) on outputshaft (66) (not applicable to ZF 15 MIV).

6.10.2 Attach outer race (34) of taperroller bearing.

6.10.3 Pre-heat inner race (35) of taperroller bearing to a temperature of approx.100 C (212 F) and press on output shaft(66) in hot condition.On ZF 15 MIV press complete bearing(68) on shaft (66).


6.10.4 Fit thrust ring (43) in such a waythat sintered surface (brown colour)faces gear.

6.10.5 Use tubular tool to press on innerrace (46) of needle bearing for gear (65).

6.10.6 Attach needle cages (45) andcompletely pre-assembled gear (65) withclutch discs (51 and 52).

6.10.7 Fit spacer (47) and shims (53, 54,55, 56) to gear (65).

6.10.8 Fit keys (67) to shaft (1 for ZF 3 M,5 M, 2 keys for 10 M, 12 M, 15 M, 15 MA,4 for ZF 25 M - 25 MA and ZF 30 M).

6.10.9 Press pre-assembled actuatingmembers (see item 6.8) on output shaft(66).

IMPORTANT:Align keys radially relative to guidesleeve (59).

Fig. 31

4241

35

66

Fig. 32

Punch tool

66

46

43

28

2

34

35

65

44

46


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42

6.10.10 Attach shims (53,54,55, 56) togear (44).

6.10.11 Attach spacer (47) to gear (44).

6.10.12 Use tubular tool to press on in-ner race (46) of needle bearing for gear(44).

6.10.13 Attach pre-assembled gear (44)with needle cage (45) and clutch discs(51 and 52).

Align external discs for proper engage-ment with actuating member.

6.10.14 Attach thrust ring (43) in such away that sintered surface (brown colour)faces gear.

6.10.15 Pre-heat inner race (35) of ta-per roller bearing to a temperature ofapprox. 100 C (212 F) and press it onshaft.


0.2 0.05mm

6.10.16 Screw on bolt (41), (supplied withLoctite) and tighten to torque:

ZF 3 M - 5 M 50 Nm 37 ft lbZF 10 M 60 Nm 44 ft lbZF 12 M - 15 M 100 Nm 74 ft lbZF 15 MA - 15 MIV 100 Nm 74 ft lbZF 25 M - 25 MA 120 Nm 89 ft lbZF 30 M 120 Nm 89 ft lb

6.10.17 (ZF 3 M, ZF 5 M only) attachshims (68) to end shaft (66). The gap hasto be 0.2 0.05 mm (0.0079 0.0019 in).

6.10.18 (ZF 15 MA only) attach spacer (68).

6.10.19 Check gears (44) and (65) forfree movability in an axial direction.

6.10.20 Attach outer race (34) of taperroller bearing.

6.11 Reassembling the quill shaftZF 15 MIV

6.11.1 Fit radial sealing ring (31) and clip(84) together with O-ring (86).

6.11.2 First bearing:Press on bearing inner race (74).Fit bearing outer race (75).

6.11.3 Fit spacer ring (76).

6.11.4 Fit key (81).

6.11.5 Press on gear (80).

6.11.6 Fit second spacer ring (76).

6.11.7 Second bearing:Press on inner race (74).Fit outer race (75).

6.11.8 Push on clip (73) together withO-ring (85).

6.11.9 Tighten grooved ring nut (83) to atorque of 95 Nm (70 lbft), using a socketspanner, and then secure by pressing riminto groove in shaft.

6.11.10 Fit radial sealing ring (31) andcup (84) together with O-Ring (86).

Fig. 33

Fig. 34

Fig. 35

41

82

81

75

74

85

73 83

31

86

84

76

80

76

75

74

86

84

31

414235

68


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43

6.12 Final assembly of gearbox

6.12.1 Place pre-assembled gearboxsection (1) - (with intermediate gear) -on side wall.

6.12.2 Place pre-assembled output shaft(66) in lower part of gearbox with flangeside towards intermediate gear side (onZF 15 MIV, bevel gear towards interme-diate gear side).

6.12.3 Place pre-assembled input shaft(36) in upper part of gearbox.

6.12.4 (ZF 15 MIV only) Place pre-as-sembled quill shaft (73) in lower part ofgearbox (watching to correct engage-ment of marked teeth).Add shims 78 on quill shaft:1.2 mm on side input shaft and 2.2 mmon side output flange.Add shims (70) on clutch shaft 2 x 0.1mm on side output flange.

6.12.5 (ZF 15 MIV only) Check backlash0.08 to 0.13 mm (0.003 to 0.005 in). Be-tween teeth of bevel gears using a dialindicator in contact with tooth surface.

Side shifting cover

Fig. 36

To correct backlash:Replace shim 78 side output flange witha thicker one to decrease backlash andvice-versa.If the correction is not enough to reachthe correct backlash, modify shimming(70) on clutch shaft side output flangeand repeat procedure.

To correct axial play (quill shaft):Check axial play 0.05 0.02 mm(0.002 0.0008 in).Compensate for difference by insertingshims (78) side input shaft.

6.12.6 Seal with LOCTITE 574 surfaceof pre-assembled gearbox section (1)(with shifting fork) and place uppersection on lower section of gearbox.

6.12.7 Insert screws (21) preferably inthe middle, and screw in low-tight to se-cure the two gearbox sections together.

6.12.8 Use a plastic hammer to align thetwo gearbox section (1) by tapping themgently into position.

6.12.9 Fit bearing shield (2) with gasket(28) to output shaft (66) by means ofspring washers (4) and screws (5), us-ing a 13 mm spanner (wrench).Tighten to torque of 14 Nm (10 ft lb).

6.12.10 Slide pre-assembled bearingshield (2) with gasket (28) over inputshaft and secure by means of springerwasher (4) and screws (5), using a 13mm spanner (wrench).Tighten to torque of 14 Nm (10 ft lb).

6.13 Measuring the gears sets of input shaft and output shaft

(see illustration)

6.13.1 Tap outer races (32) and (34) onoutput and input shafts to eliminate bear-ing play, simultaneously rotating theshafts.

6.13.2 Determine dimension b bymeans of depth gauge (see illustration).

Cover centering depthwith seal (28)


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44

6.13.3 Measure dimension c on cover(3) with gasket (28) installed, using adepth gauge (see illustration). The dif-ference between the two dimensions in-dicates the distance to be filled up withshims (37, 38, 39, 40). Shims are avail-able in thicknesses of 0.1 - 0.15-02.-03.and 0.5 mm.

On ZF 15 MIV, a hole is provided on theoutput side of the housing to permit thismeasuring operation: move shaft viagear (65) by means of a lever throughopening in gearbox (see illustration nextpage).

Cover centeringdepth with gasket (28)

Distance from gear set

Compensate for differenceby inserting shims (37, 38, 39, 40)

Compensate

for differenceby inserting shims(70, 71, 72)

T o c o r r e c t

a x i a l p l a y

T o c o r r e

c t

b a c k l a s h

C o m p e n s a t

e

f o r d i f f e r e n

c e

b y i n s e r t i n g

s h i m s ( 7 8

)

Fig. 37

b

c

b

c Cover centering depthwith gasket (28)

Distance from gear set

Compensate for differenceby inserting shims

(37, 38, 39, 40)


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45

6.13.4 Insert the required number ofshims into the bearing bores of the gear-box to obtain an axial clearance of theoutput and input shafts of 0.05 0.02mm.

If no parts had to be replaced (see item5.4.4), the previously disassembledshims (37, 38, 39, 40) can be re-used inthe previous arrangement and positions.It will be advisable, however, to checkthe bearing clearance and correct it ifrequired.

6.13.5 Mount the previously measuredcovers (3) on the output and input shaftsby means of spring washers (4) andscrews (5), using a 13 mm spanner(wrench). Tighten to torque of 14 Nm (10ft lb).

6.13.6 Place spring washers (4) under-neath all screws (21) and tighten screwsto a torque of 22 Nm (16 ft lb), using a13 mm spanner (wrench).

6.13.7 Tap output and input shafts lightlyin an axial direction while rotating theshafts, to ensure freedom of movement.

6.13.8 Axial clearance of input and out-put shafts: 0.05 0.02 mm, measuredby means of dial indicator in contact withend face of shaft (see illustration).

6.13.9 Measure axial clearence of quillshaft (on ZF 15 MIV), also with dial indi-cator in contact with end face of the shaft(see illustration).Permissible clearance: 0.05 0.02 mm.

0.05 0.02 mm

0.002 0.0008 in

Fig. 38

Fig. 39


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46

6.14 Mounting the actuating levercover plate

6.14.1 Place gasket (29) or Loctite 574on pre-assembled cover plate and fit itto gearbox. Watch for proper engage-ment of actuating cam and shifting fork.The cover plate can be mounted whenthe shifting fork is in the middle (=neu-tral) position. It is important to adjust theactuating lever to exactly midway posi-tion in neutral.Screw the cover plate in place in thisposition.The lever travel from 0 to A and from 0to B should be equal. After a lever travelof 28 to 31 mm (1.10 to 1.22 in) the trans-mission should be in gear.If the lever travel from 0 to A andfrom 0 to B is not equal adjust coverposition by light hammer blows on thecover up to reach the equal travels. Fitspring washer (4) and screw nuts (22).Tighten to a torque of 20 Nm (15 ft lb).If studs (69) need to be replaced, fit themwith Loctite 270 on the housing.

6.14.2 Fit spring washers (4) and screws(5), using a 13 mm spanner (wrench).Tighten to a torque of 14 Nm (10 ft lb).Check actuating lever for proper opera-tion.

6.14.3 Fit oil drain plug (20) with sealingring (18) and oil dipstick (19) with seal-ing ring (18).Tighten to a torque of 20 Nm (15 ft lb).

6.15 Mounting the cooling unit(if provided)

6.15.1 Attach the cooling unit on the sideopposite the cover plate (9). By meansof 4 screws M8x65 and washers (avail-able on kit pag. 23 item 1.2.10).

Fig. 40


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7. Procedure to adjust the shifting lever cover

New bracket p/n 20.4039.02 to adjust the shifting lever cover (see picture 1).

A) Before mounting the cover clean the mating surfaces and adjust the shifting forkto the neutral position.

B) Apply Loctite 574 (or alternatively 518) on the cover surface and position it withthe lever in neutral (see picture 2).Only for ZF 25 M, 25 MA: Push towards the bottom (see picture 3).

C) Lightly tighten the four nuts.

D) Adjust the cover roughly in the middle.

E) Fit the adjusting bracket p/n 20.4039.02 using only one nut lightly tighten: thecover must be free to move with light hammer taps (see picture 4).

If the shifting lever in neutral has been rotated from the original vertical positionapply on the adjusting bracket the suitable extension section P/N 20.4039.03 (seepicture 5).

F) Move the lever toward the detent A without engaging the clutch and mark theposition; repeat the same for the detent B. If the shifting lever has two holesrefer to the inner hole (see picture 6 and 7).

3ZF 25 M, ZF 25 MA

2

11

4

765


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48

G) Engage the clutch, turn back the lever to the engaging point and mark the posi-tion; repeat the same procedure for the other clutch (see picture 8 and 9).

H) Consider the centre line between the internal marks and measure the distancefrom this line and the centre of the external marks (see picture 10 and 11).

The maximum allowed distance between the centre line and the external marksmust be 24 mm.The maximum difference between the two measurements must be less than 3 mm.

A must always be < 24 mmB must always be < 24 mmA B < 3 mm

EX.:A = 20 mm, B = 24 mmA B = 4 mm > 3 mm NOT ALLOWED A = 21 mm, B = 23 mmA B = 2 mm < 3 mm OK

If the above conditions are not reached, move the cover toward the opposite direc-tion where the measurement is largest by light hammer taps and repeat the markingoperation.If it is not possible to adjust the cover to maximum 24 mm, the gearbox needs to beexchanged.

I) After the correct adjusting measurement is reached tighten the four nuts with 22Nm (16 lb.ft) torque.

6) Connect the shifting cable to the inner hole (if two holes) of the lever. Ad-just the neutral position of the cable by the middle of the play of the leverin neutral.The control cable should be perpendicular to the actuating lever in neutralposition of the lever.

7) Make sure that the way of the control cable is enough long to move the innerhole of the lever at least 30 mm.

8

9

10

A

11

B


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49

8. Troubelshooting

Possible Troubles and Remedies

Kind of trouble Noticeable effect Possible cause Remedy

Delay of gear Propeller will start rotating Detach shift cable and operateengagement with several seconds delay gearbox by hand to find whether

or only after increase in malfunctions is caused by gearengine speed. box or cable.

If caused by transmission:

Lever travel 0-A not equal to Adjust cover plate (9) until lever islever travel 0-B. exactly in midway position. Travel

0-A = 0-B = 35 mm/30 mm 1.37 in/1.18 in

Insufficient clearence between Adjust to min. clearanceactuating lever and cover plate (9). of 0.5 mm (0.02 in).

If caused by shift cable:

Shift cable fails to move lever Check total travel of shift cable.through required min. If too short, adjust accordingly.travel 0-A=0-B= 35 mm/30 mm (1.37 in/1.18 in).

Transmission Excessive effort required Insufficient clearance between Detach shift cable and operatefails to move in to move actuating lever. actuating lever and cover plate (9). lever by hand. If lever jams, adjustgear clearance to 0.5 mm (0.02 in).

Guide sheaves for shift cable Check and adjust accordingly.unsuitably positioned: radiustoo small.

Boat fails to Increased operating Use of wrong oil. Use ATF oil and check oil level.attain top temperature.speed specified Boat operated without cooling unit. Install cooling unit.

Transmission operating in upper Use suitable ZF M transmissionlimit range. unit.

Oil leakage Oil leakage visible on Corrosion effects in area of radial Check and correct oil level.transmission unit. sealing ring and shaft; damaged Remove and dismantle transmission

radial sealing rings. remachine shafts, replace radial

Improper installation of seal. sealing rings

Misalignment of output flanges. Check alignment to be within0.08 mm (0.003 in) radially.


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50

9. Spare Parts List

PrefaceThe spare parts list is only valid for the type and versions of transmission, as shownbelow.You will find the transmission type and version on your transmission name plate.If the type and version indicated differs from that printed in this Manual, the relativeSpare Parts List should be ordered from ZF -HURTH Marine.The indicated dimensions and standards are as such not enough for ordering parts.

When ordering parts, please state:

- transmission type- serial number- item no. part name, ident no. and quantity of parts required.

The spare parts list is referring to the following versions:

Name Plate

The name plate is mounted to the transmission

Transmission type

Transmission version ratioand serial number

Transmission part number

Transmission ratioShifting position B

MODEL

SER. N.

P/N.

ZF 10 M

XXXXX

3304 002 004

Production date everyyear a new progressive

letter is assigned

ZF 3 M versions 001 ; 002 HBW 35 versions 25 ; 26 ;

ZF 5 M versions 001 ; 002 HBW 50 versions 09 ; 10; 11; 12; 14

ZF 10 M versions 003 ; 004 ; 005 ; 010 HBW 100 versions 14 ; 15 ; 16; 17; 20 ; 21

ZF 12 M versions 001 ; 002 HBW 125/HBW 10 versions 15 ; 16

ZF 15 M versions 003 ; 004 HBW 150 versions 18 , 17 ; 20; 22

ZF 15 MA versions 003 ; 004 ; 005 HBW 150 A versions 01 ; 02

ZF 15 MIV versions 001 ; 002 ; 003 HBW 150 V versions 08; 09 ; 10 ; 11

ZF 25 M versions 001 ; 002 ; 007 HBW 250 versions 13; 16; 17 ; 18 ; 19; 20; 22; 23

ZF 25 MA versions 005; 006ZF 30 M versions 001; 002

iA= 1,79iB= 1,86LXXXXX

Transmission ratioShifting position A


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53/68


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56

65

ReversegearZF10M - 1.48R003Z5=41

1

3304304011

288084

65


1

3304304011

288084

65

ReversegearZF10M- 2.05R010Z5=41

1

3304304011

288084

65


1

3304304012

465466

65

ReversegearHBW100- 3R16z=41

1

3304304011

288084

65

ReversegearHBW1002L17z=41

1

3304304011

288084

65

ReversegearHBW100- 2,5R21z=43

1

3304304012

465466

65

ReversegearHBW10/ZF12M /ZF15M Z5=43

1

3306304018407235

65

ReversegearZF15MAZ5=43

1

3306304004407480

65

ReversegearHBW250- 2L20z=44

1

3307304009274240

65

ReversegearHBW250- 3L19z=49

1

3307304006288969

65


1

3307304009274240

65

ReversegearZF25M-1.88R001&22Z5=44

1

3307304009274240

65


1

3307304009274240

65

ReversegearZF25M-2.74R002&23Z5=49

1

3307304006288969

65


1

3307304006288969

65

ReversegearZF25MA- 2.23R005Z5=52

1

3307304002

-

65

ReversegearZF25MA- 2.74R006Z5=52

1

3307304002

-

65


1

3320304005

-

65


1

3320304005

-

66

Outputshaft

1

33033040043259573304304013

4394483306304019407280

330630401940728033073040114080923307304011

4080923320304011

-

67

Key

1

06315016342801300631501634

280130

67

Key

2

3306304007187841

3306304007187841

67

Key

4

33073040042061213307304004

2061213307304004

-

68a

Shim0.1

mm

1

0630004177

-

68b

Shim0.2

mm

1

0630000257337665

68c

Shim0.5

mm

1

0630004179337664

68d

Shim1.0

mm

1

0630004180337662

69

Stud

4

06366102323963300636610232

3963300636610232396330

063661023239633006366102323963300636610232

3963300636610232

-

70

Needlebearingforshiftcover

2

0635303056268620

0635303056 26862006353030562686200635303056

2686200635303056

-

72

Nut(actuatinglever)

1

06370061574557850637006157

4557850637006157455785

063700615745578506370061574557850637006157

4557850637006157

-

73

SpacerZF15MA- ZF25MA

1

3306301007407474

3307301004

-

74

Nameplate

1

3306301005

-

3306301005

-

3306301005

-

3306301005

-

3306301005

-

3306301005

-

3306301005

-

75

Oilname

plate

1

3304301016

-

3304301016

-

3304301016

-

3304301016

-

3304301016

-

3304301016

-

3304301016

-

ZF3M - ZF5M

ZF10M

HBW10/ZF12M/15M

ZF15MA

ZF25M

ZF25MA

ZF30M

Part No

Oldp/n

Part No

Oldp/n

Part No

Oldp/n

Part No

Oldp/n

P

art No

Oldp/n

Part No

Oldp/n

Part No

Oldp/n

Part name

N u m b e r

p e r

g e a r b o x

Item

No


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57

1 Housing assy 1 3306 201 004 3447682 Cover 1 3306 301 010 206450

3 Cover 1 3306 301 023 3263694 Spring washer 39 0630 302 090 4423725 Hex screw 8 0636 015 289 2158706 Actuating lever * 1 947.23.006.01 1950626 Actuating lever 1 3306 308 001 5006357 Hex. head screw * 1 0636 015 299 1998077 Hex. head screw (actuating lever) 1 0636 101 727 4423778 Shaft seal ring 1 0634 502 009 1068649 Cover 1 3306 308 002 388242

10 Dowel pin 1 0631 329 032 10455911 Actuating cam assembly 1 3306 199 008 40721112 Shift cover assembly 1 3306 108 002 407210

15 Shift fork 1 3306 208 001 22356316 Shift rod 1 3307 301 012 28867317 Plug 1 0636 301 041 44237318 Sealing ring 1 3306 301 016 32657819 Dipstick 1 3306 201 006 34548020 Oil drain plug 1 3306 301 013 22856621 Hex screw 14 0636 010 376 21586922 Hex nut 15 0637 006 157 45578523 Plug 1 0630 361 101 32238224 Intermediate shaft 1 3306 303 006 46877225 Disc 2 3307 303 002 28870226 Intermediate gear 1 3306 303 001 25473027 Needle bearing 1 3306 303 007 21587828 Gasket 2 3306 301 014 25471529 Gasket cover plate (or LOCTITE 574) 1 3306 301 015 25471630 Shaft seal, input 1 0634 301 833 21587531 Seal ring 2 0634 300 146 40164732 Tapered roller bearing 2 0635 501 597 -34 Tapered roller bearing 1 0635 370 050 -36 Input shaft HBW 150 V - 1.8R 08 z =27/22 1 3306 302 006 30408836 Input shaft ZF 15 MIV - 2.13R 001 z1/z3 =24/22 1 3306 302 008 32581136 Input shaft ZF 15 MIV - 2.72R 003 z1/z3 =18/22 1 3306 302 009 43919736 Input shaft ZF 15 MIV - 2.99R 002 z1/z3 =19/22 1 3306 302 007 313952

37 Shim 0.10 mm 2 3306 302 011 20647438 Shim 0.15 mm 2 3306 302 012 20647539 Shim 0.50 mm 2 3306 302 015 22854040 Shim 1.00 mm 2 3306 302 016 22853941 Hex head screw 1 3306 304 057 42028042 Spacer 1 3306 303 004 32625743 Thrust ring 2 3306 304 029 34478744 Gear HBW 150V - 1,8R 08 z =42 1 3306 304 015 40722144 Gear ZF 15 MIV - 2.13R 001 z2 =45 1 3306 304 014 40722044 Gear ZF 15 MIV - 2.72R 003 z2 =43 1 3306 304 016 43919844 Gear ZF 15 MIV - 2.99R 002 z2 =50 1 3306 304 013 40721945 Needle bearing 2 0635 300 148 20118746 Needle bearing 2 3306 304 021 25152447 Spacer 2 3306 304 025 25099248 Spring 4 3306 304 026 387391

* Up to letter E production date (see name plate description pag.46)

ItemNo

Part name Number per gearboxPart No Old p/n

ZF 15 MIV


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58

49 Disc 2 3306 304 030 40713950 Ring half 4 3306 304 011 326830

51 Internal clutch disc 8 3306 304 027 40723152 External clutch disc 8 3306 304 031 40723053 Shim 0.4 mm 2 3306 304 035 19571454 Shim 0.5 mm 2 3306 304 036 19571555 Shim 0.6 mm 2 3306 304 037 19571656 Shim 0.7 mm 2 3306 304 038 19571757 Disc carrier 2 3306 304 032 40723358 Ball 6 0635 460 015 10670059 Guide sleeve 1 3306 304 022 43960360 Change selector 1 3306 304 023 20681761 Pressure spring 3 3306 304 006 28740162 Stop pin 3 3306 304 033 187840

63 Guide pin 3 3306 304 008 19527164 Torsion spring 3 3306 304 024 20679865 Gear z5=43 1 3306 304 018 40723566 Intermediate shaft z6=29 1 3306 303 005 38841167 Cotter 2 3306 304 007 18784168 Tapered roller bearing 1 0635 370 053 -70 Shim 0.1 mm 2 0630 004 260 28083971 Shim 0.3 mm 1 0630 004 259 28084072 Shim 0.5 mm 1 0630 004 258 28084172 Nut (actuating lever) 1 0637 006 157 45578573 Ring 1 3306 304 054 34469074 Tapered roller bearing 2 0635 501 936 -76 Spacer ring 2 3306 304 009 32711578 Shim 1.3 mm 2 3306 304 042 34546978 Shim 1.4 mm 2 3306 304 043 34547078 Shim 1.5 mm 2 3306 304 044 34467378 Shim 1.6 mm 2 3306 304 045 34467478 Shim 1.7 mm 2 3306 304 046 34467578 Shim 1.8 mm 2 3306 304 047 34467678 Shim 1.9 mm 2 3306 304 048 34467778 Shim 2.0 mm 2 3306 304 049 34467878 Shim 2.1 mm 2 3306 304 050 34467978 Shim 2.2 mm 2 3306 304 051 344680

78 Shim 2.3 mm 2 3306 304 052 34468178 Shim 2.4 mm 2 3306 304 053 34468280 Gear z =33 1 3306 304 039 38841081 Key 1 0631 501 182 10533482 Output shaft 1 3306 304 041 34467083 Ring nut 1 3306 304 010 19541384 Ring 2 3306 304 040 34464485 0-Ring 1 0634 306 072 10559086 0-Ring 2 0634 303 690 29161887 Needle bearing 2 0635 303 056 26862088 Stud 4 0636 610 232 39633089 Plug 4 0636 301 039 33880590 Name Plate 1 3306 301 005 -91 Oil name plate 1 3304 301 016 387428

* Up to letter E production date (see name plate description pag.46)

ItemNo

Part name Number per gearboxPart No Old p/n

ZF 15 MIV


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59

SEAL KITSZF M SPARE PARTS KITS

ZF 3M - ZF 5M KIT P/N 3303 199 001 ID/N 500426PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverO-Ring 1 0634 306 179 105524 Shift fork shaftSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 4 3304 301 015 288739 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 830 280135 Input shaftSealing ring 1 0634 300 371 105153 Output shaft

ZF 10 M KIT P/N 3304 199 003 ID/N 500427PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverO-Ring 1 0634 306 011 105679 Intermediate shaft

Sealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 4 3304 301 015 288739 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 830 280135 Input shaftSealing ring 1 0634 300 371 105153 Output shaft

HBW 10 - ZF 12 M - ZF 15 M - ZF 15 MA KIT P/N 3306 199 001 ID/N 500428PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverO-Ring 1 0634 303 118 105530 Intermediate shaftSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 4 3306 301 014 254715 CoverGasket 1 3306 301 015 254716 Shifting cover

Sealing ring 1 0634 301 833 215875 Input shaftSealing ring 1 0634 300 466 105159 Output shaft

ZF 15 MIV KIT P/N 3306 199 004 ID/N 500429PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 2 3306 301 014 254715 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 833 215875 Input shaftSealing ring 2 0634 300 146 401647 Output shaftO-Ring 1 0634 306 072 105590 Output shaftO-Ring 2 0634 303 690 291618 Output shaft

ZF 25 M - ZF 25 MA KIT P/N 3307 199 001 ID/N 500430 (EXCL. VERS. 22; 23)PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 4 3307 301 011 274251 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 832 284260 Input shaftSealing ring 1 0634 300 466 105159 Output shaft

ZF 30 M KIT P/N 3320 199 001PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 - Shift coverSealing ring 2 3306 301 016 - Drain plug/oil dipstickGasket 4 3307 301 011 - CoverSealing ring 1 0634 311 025 - Input shaftSealing ring 1 0634 311 026 - Output shaft


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60

SEAL + CLUTCH PACK KITS

HBW 10 - ZF 12 M - ZF 15 M - ZF 15 MA KIT P/N 3306 199 007 ID/N 500438PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverO-Ring 1 0634 303 118 105530 Intermediate shaft

reparaturanleitung u ersatzteilliste zf3m bis zf30m mechanisch

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