Service Manual ZF Gearbox
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SERVICE MANUAL AND SPARE PARTS LIST M R E PA I R ZF 3 M (HBW 35) ZF 5 M (HBW 50) ZF 10 M (HBW 100) ZF 12 M (HBW 125) / HBW 10 ZF 15 M (HBW 150) ZF 15 MA (HBW 150 A) ZF 15 MIV (HBW 150 V) ZF 25 M (HBW 250) ZF 25 MA ZF 30 M Cod. 310.01.0052f A L U N A Manual and Spare Parts List ZF M line This ZF M manual has been prepared for all those who have to do with ZFHURTH Marine reversing gearbox units of the ZF M line, including models ZF 3 M, 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 aid for handling ZF M transmissions and will answer all questions that may arise in daily operation and in connection with the installation and repair of ZF M transmissions. This manual contains: - Technical description of the gearbox units and a number of important technical data; - Instructions for proper installation of the gearbox in the craft; - Explanatory notes on correct operation and maintenance; - Detailed description of all disassembly and reassembly procedures (with drawings); - Troubleshooting table with possible causes of trouble and the required remedial action; - Spare parts list with stock numbers of all sparte parts; - Explosion-View drawings showing each part with the reference numerals used in the text. No problems will be encountered in handling, installing and operating the ZF M gearbox if the instructions in this manual are followed. Should a repair be necessary, a qualified technician will have no difficulty in doing the repair work in accordance with the detailed instructions given on the following pages. In addition, ZF M Service Stations (distributors and dealers) are available for any repairs and for supplying the spare parts required. The manufacturer will always be glad to name the Service Station nearest to your location. All transmission units are covered by a worldwide guarantee given by the manufacturer. The manufacturer’s warranty will be subject to the condition that: - the instructions in this manual are strictly observed in handling the transmission. - no work is performed by persons not authorized by ZF-HURTH Marine. - no changes or alterations of any kind are made on the transmission. Failure to observe these points will invalide all and any warranty claims. Caution: never start doing any work on the transmission unless and until the engine and the propeller have come to a complete standstill. 3 Manual and Spare Parts List ZF M line Table of contents 1. 1.1 1.2 Description Brief description Technical data and main dimensions 1.2.1 ZF 3 M boat reversing gearbox unit 1.2.2 ZF 5 M boat reversing gearbox unit 1.2.3 ZF 10 M boat reversing gearbox unit 1.2.4 ZF 12 M boat reversing gearbox unit 1.2.5 ZF 15 M boat reversing gearbox unit 1.2.6 ZF 15 MA boat reversing gearbox unit 1.2.7 ZF 15 MIV boat reversing gearbox unit 1.2.8 ZF 25 M boat reversing gearbox unit 1.2.9 ZF 25 MA boat reversing gearbox unit 1.2.10 Accessories 1.2.11 Tools 1.2.12 Ident. No. 1.3 Gear casing 1.4 Gear set 1.5 Multiple-disc clutch and clutch operation 1.6 Shaft bearings 1.7 Shaft seals 1,8 Lubrication 1.9 Cooling unit 2. 2.1 2.2 2.3 2.4 2.5 2.9 2.10 2.11 Installation Delivery condition Transport Removal of preservative Painting the gearbox Connection of gearbox with engine Connection of gearbox with propeller Suspension of enginegearbox assembly in the boat Position of gearbox in the boat Operation of gearbox Cooling unit Engine-gearbox compartment 3. 3.1 3.2 3.3 3.4 3.5 3.6 3.7 Operation General information Initial operation Operating temperature Operation of gearbox Sailing or moving in tow Lay-up periods Preparation for re-use 2.6 2.7 2.8 4 4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 6. 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 Maintenance Transmission oil Oil quantity Oil level checks Oil change Checking the shift cable and linkage Cooling unit Automatic transmission fluiid List of recommended fluids Disassembly Removing the cooling unit Removing and disassembling the actuating lever cover plate Removing the bearing shields Separating the gearbox sections and removing the input and output shafts Removing the shifting fork Removing the intermediate gear Disassembling the input shaft Disassembling the output shaft Disassembling the quill shaft Reassembly General information Pre-assembling the intermediate gear shaft in the gearbox section without opening Pre-assembling the shifting fork in the gearbox section with opening Pre-assembling the actuating lever cover plate Pre-assembling the gears Measuring the pre-assembled gears to determine setting value «a» Pre-assembling the bearing shields Pre-assembling the actuating members Reassembling the input shaft Reassembling the output shaft Reassembling the quill shaft Final assembly of gearbox Measuring the gear sets of input shaft and output shaft Mounting the actuating lever cover plate Mounting the cooling unit 7. Procedure to adjust the shifting lever cover 8. Troubleshooting 9. Spare parts list 10. Drawings (Explosion view) Manual and Spare Parts List ZF M line 1. Description 1.1 Brief description ZF-HURTH Marine boat reversing gearbox units of the ZF M line are servo-automatically controlled helical gear transmissions developed for use in pleasure craft and commercial craft. The servooperated multiple-disc clutch requires only minimum effort for shifting, making the ZF M transmission suitable for single-lever remote control via a rod linkage or shift cable. In emergency situations the ZF M permits direct reversing at engine speed above idle rpm. The torque capacity of the clutch is exactly rated, preventing shock loads from exceeding a predetermined value to ensure maximum protection of the engine and thus providing the effect of a safety clutch. The transmission units are characterized by low weight and small overall dimensions. The gearbox castings are made of a high-strength, corrosion-resistant aluminium alloy, chromized for improved seawater resistance and optimum adhesion of paint. A choice of gear ratios, a high efficiency rating and low-noise operation are other prominent features of the ZF M gearbox units. The transmissions are immersion-lubricated. Maintenance is restricted to oil level checks (see «Maintenance», chapter 4). Transmission sizes are available for right-hand (RH) and left-hand (LH) rotation of the input shaft, the direction of rotation being specified as seen by an observer facing the input shaft. In gear lever positions A, the engine shaft and the propeller shaft rotate in opposite directions, in position B in the same direction (Fig. 1). On model ZF 15 MIV, the directions of rotation are the other way round (Fig. 2). Engine manufacturers should note that the direction of rotation refers to an observer facing the flywheel, so that lefthand rotation of the engine corresponds to right-hand rotation of the gearbox input shaft. The shafts are supported by heavy-duty taper roller bearings and the gearbox is designed to take the axial propeller thrust (for permissible values see «Technical data», item 1.2). Fig. 1 Fig. 2 5 Manual and Spare Parts List ZF M line 1.2.1 ZF 3 M Transmission power input Transmission input speed (rpm) Power diagram Based on engine power B to DIN 6270; shock factor K = 1.25 to applied, if engine has 1 cylinder K = 1.20 for 2 cylinders K = 1.15 for 3 cylinders ZF 3 M-2 R ZF 3 M-3 R Shifting position «A» Technical data 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) 6 Manual and Spare Parts List ZF M line Fig. 3 ZF 3 M 54 All dimensions in mm 7 Manual and Spare Parts List ZF M line 1.2.2 ZF 5 M Transmission power input Power diagram for Pleasure Craft Duty Based on engine power B to DIN 6270; shock factor K = 1.25 to applied, if engine has 1 cylinder K = 1.20 for 2 cylinders K = 1.15 for 3 cylinders MODEL RATIO «A» Pos POWER / RPM «B»Pos kW hp INPUT POWER CAPACITY kW hp 2800 rpm ZF 5 M 2.045 2.722 1.864 2.150 0.0066 0.0047 0.0088 0.0063 18 13 25 18 kW hp kW 3000 rpm 20 14 27 19 MAX hp WEIGHT BELL HSGS. RPM kg lb AND NOTES 5000 5000 8 18 B/W Max input power 20 kW 3600 rpm 20 17 27 23 «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. 8 Manual and Spare Parts List ZF M line Fig. 4 ZF 5 M 54 All dimensions in mm 9 Manual and Spare Parts List ZF M line 1.2.3 ZF 10 M 1,8 Transmission power input Transmission input speed (rpm) Power diagram for Pleasure Craft Duty Based on engine power B to DIN 6270; shock factor K = 1.25 to applied, if engine has 1 cylinder K = 1.20 for 2 cylinders K = 1.15 for 3 cylinders ** Max. 95 Nm (70 ft lb) admissible for main travelling direction with gear lever set to «B» MODEL RATIO «A» Pos POWER / RPM «B»Pos kW hp INPUT POWER CAPACITY kW hp 2800 rpm ZF 10 M 1.482 1.792 2.045 2.722 1.864 1.864 1.864 2.150 kW hp kW 3000 rpm MAX hp WEIGHT BELL HSGS. RPM kg lb AND NOTES 9.5 21 SAE 4, 5, B/W Max input power 38 kW. Ratio 1.482 «B» Pos. max torque 95 Nm. Ratio 1.792 «B» Pos. max torque 95 Nm. 3600 rpm 0.0109 0.0146 30 41 33 44 38 51 5000 0.0095 0.0068 0.0128 0.0091 27 19 36 26 29 20 38 27 34 25 46 33 5000 5000 «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. 10 Manual and Spare Parts List ZF M line Fig. 5 ZF 10 M 54 All dimensions in mm 11 Manual and Spare Parts List ZF M line 1.2.4 ZF 12 M Transmission power input Transmission input speed (rpm) Power diagram for pleasure craft Based on engine power B to DIN 6270; shock factor K = 1.25 to applied, if engine has fewer than 4 cylinders. MODEL RATIO «A» Pos POWER / RPM «B»Pos kW hp INPUT POWER CAPACITY kW hp 2800 rpm ZF 12 M 2.136 2.632 1.955 1.955 0.0131 0.0111 0.0176 0.0149 37 31 49 42 kW hp kW 3000 rpm 39 33 53 45 MAX hp WEIGHT BELL HSGS. RPM kg lb AND NOTES 5000 5000 13 29 SAE 4, 5, B/W Max input power 55 kW 3600 rpm 47 40 63 54 «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. 12 Manual and Spare Parts List ZF M line Fig. 6 ZF 12 M Model without mounting flange a) Clockwise rotation b) Oil dipstick and filter screw 17 mm c) M 8/12 deep, holes same on both sides d) Oil drain plug 17 mm width across flats e) Spline profile similar B 10 x 23 x 29 DIN 5464 f) Minimum lever travel All dimensions in mm Model with mounting flange 13 Manual and Spare Parts List ZF M line 1.2.5 ZF 15 M Transmission power input Transmission input speed (rpm) Power diagram for Pleasure Craft Duty Based on engine power B to DIN 6270; shock factor K = 1.25 to applied, if engine has 1 cylinder K = 1.20 for 2 cylinders K = 1.15 for 3 cylinders ** Max. 120 Nm (88.5 ft lb) admissible for main travelling direction with gear lever set to «B» MODEL RATIO «A» Pos POWER / RPM «B»Pos kW hp INPUT POWER CAPACITY kW hp 2800 rpm ZF 15 M 1.556 1.875 1.955 1.955 0.0152 0.0204 43 57 kW hp kW 3000 rpm 46 61 MAX hp WEIGHT BELL HSGS. RPM kg lb AND NOTES 5000 13 29 SAE 4, 5, B/W, Yanmar JH 3600 rpm 55 73 Max input power 55 kW. Ratio 1.556 «B» Pos. max torque 120 Nm. Ratio 1.875 «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. 14 Manual and Spare Parts List ZF M line Fig. 7 ZF 15 M All dimensions in mm 15 Manual and Spare Parts List ZF M line 1.2.6 ZF 15 MA Transmission power input Gearbox input speed (1/min) Power diagram for Pleasure Craft Duty Based on engine power B to DIN 6270; shock factor K = 1.25 to applied, if engine has 1 cylinder K = 1.20 for 2 cylinders K = 1.15 for 3 cylinders ** Max. 120 Nm (88.5 ft lb) admissible for main travelling direction with gear lever set to «B» MODEL RATIO «A» Pos POWER / RPM «B»Pos kW hp INPUT POWER CAPACITY kW hp 2800 rpm ZF 15 MA 8 degrees 1.875 2.136 2.632 1.955 1.955 1.955 0.0152 0.0131 0.0111 0.0204 0.0176 0.0149 43 37 31 57 49 42 kW hp kW 3000 rpm 46 39 33 61 53 45 MAX hp WEIGHT BELL HSGS. RPM kg lb AND NOTES 5000 5000 5000 13 29 SAE 4, 5, B/W, Yanmar JH 3600 rpm 55 47 40 73 63 54 Max input power 55 kW. Ratio 1.875 «B» Pos. max torque 120 Nm. Ratio 2.136 «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. 16 Manual and Spare Parts List ZF M line Fig. 8 ZF 15 MA Model without mounting flange a) Clockwise rotation b) Oil dipstick and filter screw 17 mm c) M 8/12 deep, holes same on both sides d) Oil drain plug 17 mm width across flats e) Spline profile similar B 10 x 23 x 29 DIN 5464 f) Minimum lever travel g) Support for control cable h) full profile All dimensions in mm Model with mounting flange 17 Manual and Spare Parts List ZF M line 1.2.7 ZF 15 MIV Transmission power input Transmission input speed (rpm) Power diagram for Pleasure Craft Duty Based on engine power B to DIN 6270; shock factor K = 1.25 to applied, if engine has 1 cylinder K = 1.20 for 2 cylinders K = 1.15 for 3 cylinders * Max. 120 Nm (88.5 ft lb) admissible for main travelling direction with gear lever set to «B». ** Max 45 kW for main travelling direction with gear lever set to «B». MODEL RATIO «A» Pos POWER / RPM «B»Pos kW hp INPUT POWER CAPACITY kW hp 2800 rpm ZF 15 MIV 8 degrees 2.134 2.718 2.995 2.224 2.224 2.224 0.0152 0.0111 0.0204 0.0149 43 31 57 42 kW hp kW 3000 rpm 46 33 61 45 MAX hp WEIGHT BELL HSGS. RPM kg lb AND NOTES 5000 5000 5000 20 44 SAE 4, 5, B/W, Yanmar JH 3600 rpm 55 40 73 54 Max input power 55 kW. 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. 18 Manual and Spare Parts List ZF M line Fig. 9 ZF 15 MIV 19 Manual and Spare Parts List ZF M line 1.2.8 ZF 25 M Transmission power input kW hp 90 120 80 100 70 60 80 50 70 60 40 50 30 40 30 20 15 1 2 3 4 5 6x103 Transmission input speed (rpm) Power diagram for Pleasure Craft Duty Based on engine power B to DIN 6270; shock factor K = 1.25 to applied, if engine has 1 cylinder K = 1.20 for 2 cylinders K = 1.15 for 3 cylinders ** Max. 230 Nm (170 ft lb) admissible for main travelling direction with gear lever set to «B» MODEL RATIO «A» Pos POWER / RPM «B»Pos kW hp INPUT POWER CAPACITY kW hp 2800 rpm ZF 25 M 1.880 2.273 2.737 2.095 2.095 2.722 0.0262 0.0216 0.0177 0.0351 0.0289 0.0237 73 60 50 98 81 66 kW hp kW 3000 rpm 79 65 53 MAX hp WEIGHT BELL HSGS. RPM kg lb AND NOTES 5000 5000 5000 18 40 SAE 4, 5, B/W, Yanmar JH 3600 rpm 105 80 87 78 71 64 107 104 85 Max input power 80 kW. Ratio 1.880 «B» Pos. max torque 230 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. 20 Manual and Spare Parts List ZF M line Fig. 10 ZF 25 M 21 Manual and Spare Parts List ZF M line 1.2.9 ZF 25 MA Transmission power input kW hp 90 120 80 100 70 60 80 50 70 60 40 50 30 40 30 20 15 1 2 3 4 5 6x103 Transmission input speed (rpm) Power diagram for Pleasure Craft Duty Based on engine power B to DIN 6270; shock factor K = 1.25 to applied, if engine has 1 cylinder K = 1.20 for 2 cylinders K = 1.15 for 3 cylinders ** Max. 169 Nm (125 ft lb) admissible for main travelling direction with gear lever set to «B» MODEL RATIO «A» Pos POWER / RPM «B»Pos kW hp INPUT POWER CAPACITY kW hp 2800 rpm ZF 25 MA 8 degrees 2.227 2.737 2.737 2.737 0.0215 0.0177 0.0288 0.0237 60 50 81 66 kW hp kW 3000 rpm 64 53 86 71 MAX hp WEIGHT BELL HSGS. RPM kg lb AND NOTES 5000 5000 18 40 SAE 4, 5, B/W, Yanmar JH 3600 rpm 77 64 104 85 Max input power 80 kW. Ratio 2.227 «B» Pos. max torque 169 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. 22 Manual and Spare Parts List ZF M line B Fig. 11 ZF 25 MA 75 23 Manual and Spare Parts List ZF M line 1.2.10 Accessories Resilient Coupling for ZF 3 M - ZF 5 M - ZF 10 M Ident-No. 254 750 - 3306 316 001 spline A 10 x 23 x 29 DIN 5464 max. torque 100 Nm max. axial misalignment 0.25 mm friction factor 4–10 Nm 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 spline A 10 x 23 x 29 DIN 5464 max. torque 200 Nm max. axial misalignment 0.25 mm friction factor 6–14 Nm Resilient Coupling for ZF 25 M - ZF 25 MA Ident-No. 256 526 - 3307 316 001 spline SAE 20/40 26 Z max. torque 200 Nm max. axial misalignment 0.25 mm friction factor 6–14 Nm 24 Manual and Spare Parts List ZF M line 1.2.10 Accessories Resilient Coupling for ZF 25 M / 25 MA Ident-No. 223 557 - 3307 316 003 spline SAE 20/40 26 Z max. torque 450 Nm Resilient Coupling PERKINS for ZF 25 M / 25 MA Ident-No. 288 238 - 3307 316 002 Bolt circle 142,6 spline SAE 20/40 26 Z max. torque 200 Nm 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 Bolt circle 142,6 spline A 10 x 23 x 29 DIN 5464 max. torque 200 Nm 25 Manual and Spare Parts List ZF M line 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) Bolt circle 235+0.1 Adapter flange ZF 15 MIV Ident-No. 345 965 - 3306 116 004 (kit) Bolt circle 235+0.1 Adapter flange ZF 25 M - ZF 25 MA Ident-No. 345 964 - 3307 116 001 (kit) Bolt circle 235+0.1 26 Manual and Spare Parts List ZF M line 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 107 001 377 755 - 0636 010 575 M8 x DIN 931-8.8 vcad (4x) tightening torque 14 Nm (when mounting on transmission) 442 372 - 0630 302 090 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 27 Manual and Spare Parts List ZF M line 1.2.12 Gearboxes and accessories Model prop. turns anti engine draw. no. Id. no. weight ZF 3 M 2,05:1 2,72:1 487926 487927 344544 254750 388817 459413 344544 254750 407345 407346 467329 344544 500013 326742 254750 254762 288240 407205 407206 344544 500013 326742 254762 288240 407208 407207 344544 500013 326742 254762 288240 407461 407462 344544 500013 326742 254762 288240 407377 439386 407378 345965 500015 326742 254762 288240 408089 408090 345964 326742 256526 288238 223557 345964 326742 256526 288238 223557 3302 002 001 3302 002 002 3306 116 001 3306 316 001 3303 002 001 3303 002 002 3306 116 001 3306 316 001 3304 002 003 3304 002 004 3304 002 010 3304 002 005 3306 116 001 3306 116 002 3306 107 001 3306 316 001 3306 316 003 3306 316 002 3305 002 001 3305 002 002 3306 116 001 3306 116 002 3306 107 001 3306 316 003 3306 316 002 3306 002 003 3306 002 004 3306 116 001 3306 116 002 3306 107 001 3306 316 003 3306 316 002 3306 001 004 3306 001 003 3306 001 005 3306 116 001 3306 116 002 3306 107 001 3306 316 003 3306 316 002 3306 003 001 3306 003 003 3306 003 002 3306 116 004 3306 116 003 3306 107 001 3306 316 003 3306 316 002 3307 002 001 3307 002 007 3307 002 002 3307 116 001 3315 116 001 3306 107 001 3307 316 001 3307 316 002 3307 316 003 3307 001 005 3307 001 006 3307 116 001 3315 116 001 3306 107 001 3307 316 001 3307 316 002 3307 316 003 8 kg 8 kg Housing adapter Kit Damper plate ZF 5 M Housing adapter Kit Damper plate ZF 10 M Housing adapter Kit Housing adapter Kit SAE 5 Oil cooler Kit Damper plate Damper plate Damper plate PERKINS ZF 12 M Housing adapter Kit Housing adapter Kit SAE 5 Oil cooler Kit Damper plate Damper plate PERKINS ZF 15 M Housing adapter Kit Housing adapter Kit SAE 5 Oil cooler Kit Damper plate Damper plate PERKINS ZF 15 MA Housing adapter Kit Housing adapter Kit SAE 5 Oil cooler Kit Damper plate Damper plate PERKINS ZF 15 MIV Housing adapter Kit Housing adapter Kit SAE 5 Oil cooler Kit Damper plate Damper plate PERKINS ZF 25 M Housing adapter Kit Housing adapter Kit SAE5 Oil cooler Kit Damper plate Damper plate PERKINS Damper plate ZF 25 MA Housing adapter Kit Housing adapter Kit SAE5 Oil cooler Kit Damper plate Damper plate PERKINS Damper plate 28 up to 100 Nm 2,05:1 2,72:1 up to 100 Nm 1,48:1 1,79:1 2,05:1 2,72:1 up to 100 Nm up to 200 Nm up to 200 Nm 2,14:1 2,63:1 up to 200 Nm up to 200 Nm 1,56:1 1,88:1 up to 200 Nm up to 200 Nm 2,0:1 2,14:1 2,5:1 up to 200 Nm up to 200 Nm 2,13:1 2,72:1 2,99:1 up to 200 Nm up to 200 Nm 1,88:1 2,27:1 2,74:1 up to 200 Nm up to 200 Nm up to 450 Nm 2,23:1 2,74:1 up to 200 Nm up to 200 Nm up to 450 Nm 8 kg 8 kg 9,5 kg 9,5 kg 9,5 kg 13 kg 13 kg 13 kg 13 kg 13 kg 13 kg 13 kg 20 kg 20 kg 20 kg 18 kg 18 kg 18 kg 18 kg 18 kg Manual and Spare Parts List ZF M line 1.3 Gear Casing The oil-tight gearbox housing is made of a corrosion-resistant aluminium alloy chromized for added protection from corrosion. The gear casing is divided in a vertical plane into two equal halves. Cooling fins ensure good heat dissipation and mechanical rigidity. The oil filter screw with dipstick and the oil drain plug are screwed into the gear casing. The filler screw is provided with a breather hole. The actuating lever, actuating cam and cover plate are a pre-assembled unit fitted laterally to the gearbox unit. Holes (see «Main dimensions» item 1.2 pos. c) are provided for bolting the transmission to a flywheel housing or an adapter flange. 1.4 Gear set The transmission is equipped with case hardened helical gears made of forged low-carbon alloy steel and case hardened spiral bevel gears (V drive). The drive shaft with the drive gears are an integral unit. 1.5 Multiple-disc clutch and clutch operation - power train The engine torque is applied to the input shaft (36) in the specified direction of rotation and, in shifting position A (see Main Dimensions item 1.2), via gear (44), the frictionally engaged clutch discs (51 and 52) to the external disc carrier (57) and from there via the guide sleeve (59) to the output shaft (66). In shifting position B, the torque is transmitted from the input shaft (36) via intermediate gear (26), gear (65), clutch discs (51 and 52) to the external disc carrier (57), the guide sleeve (59) and the output shaft (66). Function The transmission uses a positively driven, mechanically operated multipledisc clutch system mounted on the output shaft. The thrust force required for obtaining positive frictional engagement between the clutch discs is provided by a servoautomatic system. This essentially comprises a number of balls which, by the rotary movement of the external disc carrier, are urged against inclined surfaces provided in pockets between the guide sleeve and the external disc carrier and in this way exert axial pressure. The thrust force and, as a result, the transmittable friction torque are thus proportional to the input torque applied. Due to the cup springs (48) supporting the clutch disc stack and a limitation of the range of axial travel of the external disc carrier (57), the thrust force will not exceed a predetermined value. The actuating sleeve (60) is held in the middle position by spring-loaded pins. To initiate the shifting operation, the actuating sleeve (60) needs merely be displaced axially by the shifting fork until the arresting force has been overcome. Then the actuating sleeve (60) is moved automatically by the spring-loaded pins, while the external disc carrier which follows this movement, is rotated by frictional forces exerted by the clutch discs, and the shifting operation is completed servo-automatically as described above. The splined input shaft connecting the transmission with the engine is hardened as well. The driven shaft (propeller side) of the transmission, with the exception of the ZF15 MIV model, is fitted with an integrally forged coupling flange. The servo-automatic clutch system governs the direction of rotation of the input shaft, and ZF M transmission units are available for clockwise: (RH = right hand) or counterclockwise (LH = left hand) rotation. Fig. 11 Input 36 Output 66 Power flow in lever position 45 44 48 51 52 57 60 59 65 A B 29 Manual and Spare Parts List ZF M line 1.6 Shaft bearings Both the input and the output shafts are carried in amply dimensioned taper roller bearings. The propeller thrust can be absorbed by the bearings (for permissible values see «Technical data», item 1.2). The intermediate gear and the movable gears are carried in sturdy needle roller bearings. 1.7 Shaft seals External sealing of the input and output shafts is provided by radial sealing rings. The running surfaces on the shafts are casehardened. 1.8 Lubrication The transmissions are immersion-lubricated. The bearings are generously supplied with splash oil. 1.9 Cooling unit Transmissions intended for use at high ambient temperatures and for continuous operation at high power (especially when shifting position B is used for the main direction of movement of the craft), must be supplied with a cooling unit (see item 2.10). 2. Installation 2.1 Delivery condition Before leaving the factory, each transmission is subjected to a test run with the prescribed ATF oil. The residual oil remaining in the transmission after draining acts as a preservative and provides reliable protection against corrosion for at least 1 year if the units are properly stored. 2.5 Connecting the gearbox with engine 2.2 Transport If the flywheel housing of the engine is of suitable design, the gearbox unit should be directly bolted to the housing by means of the holes provided in the gearbox. Make certain to use bolts with the right appropriate length (see «Main dimensions», item 1.2) and thighten them to the correct torque, M8 =14 Nm (10 ft lb), M10 = 28 Nm (20 ft lb) using LOCTITE 242 or 262 Care should be taken when transporting the gearbox or the engine-gearbox assembly to prevent undue shocks and impacts. This applies particulary to the input and output shafts. 2.3 Removal of preservative Use a suitable solvent for removing the anticorrosive agent, but never use emery cloth or paper, because this could damage the sealing surface and void the warranty. It is advisable, especially after long periods of storage, to flush the transmission with the prescribed oil and remove residual oil. Fit a recommended damping plate between the engine and the transmission to compensate for minor alignment errors and protect the input shaft from external forces and loads. An adapter flange and a damper plate are available on request for each gearbox unit (see «Main dimensions», item 1.2.10). The radial and axial runout values shown in the drawing Fig. 12 should never be exceeded between the engine and transmission. 2.4 Painting the gearbox Always cover the running surfaces and sealing lips of the radial sealing rings on both shafts before painting. Make certain that the breather hole on the oil filler screw is not covered by paint. The identification plates should remain clearly legible. The input shaft end is provided with a multi-spline or involute spline profile (see «Main dimensions», item 1.2). Fig. 12 HURTH ZF M gearbox units leave the factory in fully assembled condition. For safety reasons, the gearbox is not filled with oil for shipment. The actuating lever is mounted on the actuating shaft. On request, the gearbox is delivered with the cooling unit (see item 2.10) and flange (see item 1.2) fitted, as well as the previous damper plate between engine and gearbox. The multi-spline shaft is provided with an oil film and protected by a plastic cap. The bright surfaces of the coupling flange on the output side are coated with an anticorrosive agent for shipment and storage. The casing is chromized and thus resistant to seawater. (0.1 mm = 0.004 inches) 30 Manual and Spare Parts List ZF M line 2.6 Connection of gearbox with propeller 2.8 Position of gearbox in the boat We recommend a flexible connection between the gearbox and the propeller shaft, when the engine is flexibly mounted, in order to compensate for angular deflections. The installation of a special propeller thrust bearing is not required, since the propeller thrust will be taken by the transmission bearing, provided the value specified under «Technical data», item 1.2, is not exceeded. However, the output shaft should be protected from additional loads. Special care should be taken to prevent torsional vibration. When using a universal joint shaft, make certain to observe the manufacturer’s instructions. The inclination of the gearbox unit in the direction of the shafts should not exceed an installation angle of 20 degrees (see Fig.13) and 15° for ZF 15 MIV. 2.7 Suspension of engine–gearbox assembly in the boat Special care should be taken to protect the gearbox from detrimental stresses and loads when the engine-transmission assembly is not elastically suspended in the boat or craft. The gearbox should be conveniently accessible for maintenance. If the oil drain plug of the gearbox is not accessible, the oil will have to be sucked off. The shifting travel, as measured at the pivot point of the actuating lever, between the neutral position and end positions A and B must be at least 35 mm for the outer and 30 mm for the inner pivot point. A larger amount of lever travel is in no way detrimental. 2.9 Operation of gearbox The gearbox is suitable for single lever remote control. Upon loosening the retaining screw (7), the actuating lever (6) can be moved to any position required for the control elements (cable or rod linkage). (Fig. 14). IMPORTANT Make certain that the lever does not contact the actuating lever cover plate (9): the minimum distance between lever and cover must be 0.5 mm. The control cable should be perpendicular to the actuating lever in the neutral position of the lever. The zero position of the operating lever on the control console must coincide with the zero position of the actuating lever on the gearbox. IMPORTANT However, if the lever travel is shorter, proper gear engagement might beimpeded which, in turn, would mean premature wear, excessive heat generation and resulting damage. The position of the cover plate underneath the actuating lever is factory-adjusted to ensure equal lever travel from neutral position A and B. IMPORTANT If this cover is removed in exceptional cases, proceed as described under item 6.14 of this manual. When installing the gearbox, make certain that shifting is not impeded by restricted movability of the cable, by unsuitably positioned guide sheaves, too small bending radius, etc. Minimum shifting movement for actuating lever (6) Fig. 14 Clamping screw (7) to be tightened to torque of 20 Nm Do not remove cover plate (9) or loosen screws Fig. 13 Oil drain plug ➞ Oil dipstick and oil filler screw 17 mm width across flats ➞ 20° Min. distance of actuating lever 0.5 mm 31 Manual and Spare Parts List ZF M line 2.10 Cooling unit Fig. 15 The arrangement of the cooling unit for the ZF 10 M, ZF 12 M, ZF 15 M, ZF 15 MA, ZF 15 MIV, ZF 25 M and 25 MA (no cooling is required for ZF 3 M and 5 M) can be seen from Fig.15. The table below shows the maximum power output in continuous operation (lever position A and B) usable without cooling. When these values are exceeded, a cooling unit is required. The cooling unit should be connected to the fresh-water pressure line (external circuit) of the engine in accordance with Fig.16. The minimum volume of flow is 10 ltr/min. Retrofitting of the cooling unit involves no problems (see item 6.15). Max. engine power usable without cooling 2.11 Engine-gearbox compartment Lever position Care should be taken that the engine gearbox compartment is properly ventilated. ZF 3 M ZF 5 M ZF 10 M A no cooling no cooling B no cooling 25 kW 34 hp Fig. 16 32 ZF 12 M ZF 15 M ZF 15 MA 40 kW 54 hp 25 kW 34 hp ZF 15 MIV ZF 25 M ZF 25 MA 25 kW 34 hp 20 kW 34 hp 40 kW 54 hp always with cooling unit 10 liters/min 2.6 gal/min Manual and Spare Parts List ZF M line 3. Operation 3.1 General information All ZF M boat reversing gearbox units are test-run on a test stand at the factory prior to delivery. For safety reasons, the oil is drained before shipment. completition of the gear changing operation is servo-automatically controlled. Gear changing should be smooth, not too slow, and continuous (without interruption). Direct changes from forward to reverse are permissible, since the multiple-disc clutch permits gear changing at high rpm, including sudden reversing at top speeds in the event of danger. 4. Maintenance 3.5 Sailing or moving in tow ZF 3 M ZF 5 M ZF 10 M ZF 12 M ZF 15 M ZF 15 MA ZF 15 MIV ZF 25 M ZF 25 MA 3.2 Initial operation Fill the gearbox with oil (ATF), (see 4.7 or recommended fluids). The oil level should be up to the index mark on the dipstick (see fig. 17). To check the oil level, just insert the dipstick, do not screw in. Retighten the hex screw with the dipstick after the oil level check. Do not forget sealing ring. 3.3 Operating temperature Normal operating temperature of the transmission oil should be in the range of 50°C (122°F) to 80°C (176°F). Max. permissible ATF temperature of 100°C (212°F) may only be reached for a short time. Rotation of the propeller while the boat is sailing, being towed, or anchored in a river, as well as operation of the engine with the propeller stopped (for charging the battery), will have no detrimental effects on the gearbox. IMPORTANT When the boat is sailing (engine stopped), the gear lever must be in zero pos-ition. Never put the gear lever in the pos-ition corresponding to the direction of travel of the boat. 3.6 Lay-up periods Fig. 17 To ensure trouble-free operation of the clutch only use Automatic Transmission Fluid (ATF). 4.2 Oil quantity ZF 30 M 0.30 ltr 0.30 ltr 0,35 ltr 0.56 ltr 0.56 ltr 0.47 ltr 1.00 ltr 0.75 ltr 0.75 ltr 0.32 qts 0.32 qts 0.37 qts 0.59 qts 0.59 qts 0.50 qts 1.06 qts 0.79 qts 0.79 qts min. 0.90 ltr min. 0.95 qts max. 1.10 ltr max. 1.17 qts Use the index mark on the dipstick as a reference (see item 3.2) 4.3 Oil level checks Locking the propeller shaft by an additional brake is not required: use the gear lever position opposite your direction of travel for this purpose. 3.4 Operation of gearbox The zero position of the operating lever on the control console must coincide with the zero position of the actuating lever on the transmission. Shifting is initiated by a cable or rod linkage via the shifting lever and an actuating cam. The 4.1 Transmission oil If the transmission is not used for periods of more than 1 year it should be completely filled with oil of the same grade to prevent corrosion. Protect the input shaft and the output flange by means of an anticorrosive coating if required. 3.7 Preparation for re-use See item 2.3 Correct readings up to 20° inclination in direction of shafts (15° for ZF 15 MIV) Check the oil level in the gearbox about once a month. Correct oil level: index mark on dipstick (see item 3.2). Always use the same oil grade when topping up. Don’t overfill the gearbox. This will create higher operating temperatures. 4.4 Oil change Change the oil the first time after about 25 hours of operation, then at intervals of at least 1 year. 4.5 Checking the control cable linkage The control cable or rod linkage should be checked at shorter time intervals. Check the zero position of the operating lever (on the control console) and of the shifting lever (on the gearbox) on this occasion. The minimum lever travel from the neutral position to operating positions (0-A = 0-B) should be 35 mm (1.38 in) for the outer and 30 mm (1.18 in) for the inner pivot point. Make certain that these minimum values are safely reached. Check the cable for easy movability (see item 2.9). 4.6 Cooling If the transmission is equipped with a cooling unit, drain the cooling water before long periods of non-use when temperature is below freezing point. 33 Manual and Spare Parts List ZF M line 4.7 Automatic Transmission Fluid List of recommended fluids For ZF-HURTH ZF M Marine Transmissions Automatic Transmission Fluid (ATF) must to be used as lubricant. ADDINOL MINERALÖL GMBH, KRUMPA/D ADDINOL MINERALÖL GMBH, KRUMPA/D AGIP PETROLI SPA, ROM/I AGIP PETROLI SPA, ROM/I AGIP PETROLI SPA, ROM/I AGIP PETROLI SPA, ROM/I AGIP SCHMIERTECHNIK, WÜRZBURG/D AGIP SCHMIERTECHNIK, WÜRZBURG/D ARAL LUBRICANTS GMBH, BOCHUM/D ARAL LUBRICANTS GMBH, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D BLASER SWISSLUBE, HASLE-RÜEGSAU/CH BP OIL DEUTSCHLAND, HAMBURG/D BP OIL INTERNATIONAL, LONDON/GB BP OIL INTERNATIONAL, LONDON/GB BP OIL INTERNATIONAL, LONDON/GB BP OIL INTERNATIONAL, LONDON/GB BUCHER+CIE AG, LANGENTHAL/CH BUCHER+CIE AG, LANGENTHAL/CH CALPAM GMBH, ASCHAFFENBURG/D CALPAM GMBH, ASCHAFFENBURG/D CALTEX PETROLEUM CORP., LONDON/GB CALTEX PETROLEUM CORP., LONDON/GB CALTEX PETROLEUM CORP., LONDON/GB CALTEX PETROLEUM CORP., LONDON/GB CALTEX PETROLEUM CORP., LONDON/GB CASTROL LTD, SWINDON/GB CASTROL LTD, SWINDON/GB CASTROL LTD, SWINDON/GB CASTROL LTD, SWINDON/GB CASTROL LTD, SWINDON/GB CASTROL LTD, SWINDON/GB CEPSA, MADRID/E CHEVRON PRODUCTS CO., RICHMOND/USA CITGO PETROLEUM CORP., TULSA/USA C.J.DIEDERICHS SÖHNE, WUPPERTAL/D DE OLIEBRON B.V., ZWIJNDRECHT/NL DE OLIEBRON B.V., ZWIJNDRECHT/NL DEA MINERALÖL AG, HAMBURG/D DEA MINERALÖL AG, HAMBURG/D DEA MINERALÖL AG, HAMBURG/D DEUTSCHE SHELL AG, HAMBURG/D DUCKHAMS OIL, BROMLEY/GB ELF LUBRIFIANTS, PARIS/F ELF LUBRIFIANTS, PARIS/F ELF LUBRIFIANTS, PARIS/F ELF LUBRIFIANTS, PARIS/F ELF LUBRIFIANTS, PARIS/F ELF LUBRIFIANTS, PARIS/F ELLER-MONTAN-COMP., DUISBURG/D ENGEN PETROLEUM, CAPE TOWN/ZA ERTOIL SA, MADRID/E ESSO AG, HAMBURG/D ESSO AG, HAMBURG/D ESSO AG, HAMBURG/D FIAT LUBRIFICANTI, VILLASTELLONE/I FINA EUROPE SA, BRÜSSEL/B FUCHS LUBRICANTS (UK), DERBY/GB FUCHS LUBRICANTS (UK), DERBY/GB FUCHS MINERALÖLWERKE, MANNHEIM/D GINOUVES GEORGES SA, LA FARLEDE/F GULF OIL (GB) LTD, CHELTENHAM/GB GULF OIL (GB) LTD, CHELTENHAM/GB HANDELSMIJ NOVIOL B.V., NIJMEGEN/NL HOMBERG GMBH+CO KG, WUPPERTAL/D IGOL FRANCE, PARIS/F INA RAFINERIJA ZAGREB/CROATIA ITALIANA PETROLI, GENOVA/I JAPAN ENERGY CORP., TOKYO/JAPAN KÄPPLER K., STUTTGART/D KLÖCKNER ENERGIEHANDEL GMBH, KÖLN/D KROON OIL BV, ALMELO/NL KROON OIL BV, ALMELO/NL KUWAIT PETROLEUM, HOOGVLIET/NL KUWAIT PETROLEUM, HOOGVLIET/NL KUWAIT PETROLEUM, HOOGVLIET/NL 34 ADDINOL ATF D IID ADDINOL ATF D III AGIP ATF II D AGIP ATF D 309 AGIP ATF PLUS AGIP DEXRON III AUTOL GETRIEBEÖL ATF-D AUTOL GETRIEBEÖL ATF III D ARAL GETRIEBEÖL ATF 22 ARAL GETR.ÖL ATF 55 F-30589 AVIA FLUID ATF 86 BLASOL 229 FRONTOL UNIVERSAL-ATF 100 AUTRAN DX II AUTRAN MBX AUTRAN DX III (F-30370) AUTRAN DX III (F-30381) MOTOREX ATF SUPER D-22656 MOTOREX ATF DEXRON III MC PAMATIC FLUID 289 CALPAMATIC FLUID III F CALTEX ATF-HDA CALTEX ATF-HDM CALTEX TEXAMATIC 1278 CALTEX TEXAMATIC 7045 CALTEX TEXAMATIC 1205A CASTROL TQ-D (22765) CASTROL TQ DEXRON III F-30520 CASTROL TRANSMAX S (F-30319) CASTROL TRANSMAX T (F-30359) CASTROL TQ-D (21289) CASTROL ATF 21293 CEPSA ATF-70 CHEVRON ATF F-30108 CITGO ATF DEXRON III F-30167 CIDISOL-HYDR.-FLUID DEXRON IID ATF DMM ATF 289 DEAMATIC DEAFLUID 4011 DEAFLUID 3003 MAC ATF D-21666 UNIMATIC TRANSANTAR DF2 ANTAR 22329 ELFMATIC G2 22329 HUILE RENAULT DIESEL STARMATIC ELFMATIC G3 TRANSANTAR DF3 ELLMO-AUTOMATIK-FLUID 22233 ENGEN ATF 22D TRANSMISIONES AUTOMATICAS D2 ESSO ATF D (21611) ESSO ATF F-30320 ESSO ATF D (21065) TUTELA GI/A FINAMATIC II-D SILKTRAN MP-ATF SILKTRAN PSV ATF TITAN ATF 4000 YORK LT 785 UNIFLUID ATF 2 KENDALL ATF DEXRON IID HOMBERG-GETRIEBE-FLUID D IGOL ATF 420 INA-ATF SUPER TRANSMISSION FLUID DX JOMO ATF K SELECTOL FLUID GETR.ÖL IID 23 DEUTZ OEL ATF-D ATF DEXRON IID ALMIROL ATF Q8 AUTO 15 Q8 AUTO 14 (IID-21677) Q8 AUTO 14 (IID) KUWAIT PETROLEUM, HOOGVLIET/NL LEPRINCE+SIVEKE GMBH, HERFORD/D LIQUI MOLY / MEGUIN, ULM/D LIQUI MOLY / MEGUIN, ULM/D LUBRICATION ENGIN., FORT WORTH/USA MAURAN SA, ODARS/F MIN.ÖL-RAFFIN. DOLLBERGEN, UETZE/D MOBIL OIL, WEDEL/D MOBIL OIL, WEDEL/D MOBIL OIL, WEDEL/D MOBIL SEKIYU KABUS.KAISHA, TOKYO/J MOL HUNGARIAN OIL, KOMARON/H MORRIS LUBRICANTS, SHREWSBURY/GB NAFTEC, ALGIER/DZ NANHAI SUPERIOR LUB-OIL, CHINA NIS-RAFINERIJA NAFTE BEOGRAD/YU OEST G. MIN.ÖLWERK, FREUDENSTADT/D OMEX PETROLEUM PTY, BELLEVUE/AUS OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A OPTIMOL ÖLWERKE, HAMBURG/D OSWALD KLUTH, BARGFELD-STEGEN/D PAKELO MOTOR OIL, SAN BONIFACIO/I PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PARS OIL CO., TEHRAN/IR PAZ LUBRICANTS&CHEMICALS, HAIFA/IL PENNZOIL PRODUCT COMP., HOUSTON/USA PETRO-CANADA, MISSISSAUGA/CDN PETROL OFISI A.S., BAKANLIKLAR/TR PETROLEX, KWIDZYN/PL PRINZ-SCHULTE, FRECHEN/D PRINZ-SCHULTE, FRECHEN/D REPSOL DISTRIBUCION SA, MADRID/E S.A.E.L, ALCOBENDAS/E SASOL OIL, RANDBURG/ZA SCHMIERSTOFFRAFFINERIE SALZBERGEN/D SHELL ASEOL AG, BERN/CH SHELL INTERNATIONAL, LONDON/GB SHELL INTERNATIONAL, LONDON/GB SLOVNAFT JS CO, BRATISLAVA/SLO SONOL ISRAEL LTD, HAIFA/IL SOPROGRASA SA, MADRID/E STATOIL STAVANGER/N STATOIL STAVANGER/N STL TECNOL, ESCALQUENS/F SUN OIL COMPANY, AARTSELAAR/B SUN OIL COMPANY, AARTSELAAR/B SUOMEN PETROOLI OY, HAMINA/SF SUOMEN PETROOLI OY, HAMINA/SF SVENSKA STATOIL AB, NYNÄSHAMN/S TAMOIL LUBES, GENEVA/CH TEXACO LUBRICANTS COMP., BEACON/USA TEXACO SERVICES LTD, BRÜSSEL/B TEXACO SERVICES LTD, BRÜSSEL/B TEXACO SERVICES LTD, BRÜSSEL/B TEXACO SERVICES LTD, BRÜSSEL/B TEXACO SERVICES LTD, BRÜSSEL/B TEXACO SERVICES LTD, BRÜSSEL/B TEXACO SERVICES LTD, BRÜSSEL/B TOTAL RAFFINAGE DISTR., PARIS/F TOTAL RAFFINAGE DISTR., PARIS/F TOTAL RAFFINAGE DISTR., PARIS/F TOTAL SOUTH AFRICA, JOHANNESBURG/ZA TURBOTANK BÖSCHE+BÖDEKER, BREMEN/D UFANEFTECHIM REFINERY, UFA/RUS UNIL DEUTSCHLAND GMBH, BREMEN/D VALVOLINE INC., LEXINGTON/USA VALVOLINE INTERNAT., DORDRECHT/NL VEBA OEL AG, GELSENKIRCHEN/D VEEDOL INTERNATIONAL, SWINDON/GB VEEDOL INTERNATIONAL, SWINDON/GB VEEDOL INTERNATIONAL, SWINDON/GB YACCO SA, ST PIERRE-LES-ELBEUF/F ZELLER+GMELIN GMBH&CO, EISLINGEN/D Q8 AUTO 14 (IID-21883) LEPRINXOL FLUID CN ATF IIE MEGOL ATF IID AUTOMATIC TRANSMISSION FLUID INTER OIL INTER MATIC ATF D2 PENNASOL FLUID-GETR.ÖL TYP PCN MOBIL ATF 220 D20104 / D21685 MOBIL ATF F-30107 MOBIL ATF 220 D21412 / D22187 MOBIL ATF 220Y (D-21412) CARRIER ATF LIQUIMATIC DII TASSILIA NANHAI ATF (D2) GALAX MATIC DAC ATF T 4011 OMEX ATF DEXRON II OMV ATF D II (D22427) OMV ATF III (F-30580) OPTIMOL ATF T 4011 UNIVERSAL ATF-D MULTIPURPOSE TRANSM. FLUID IID PANOLIN ATF MULTI 21996 PANOLIN ATF DEXRON III PARS ENTEGHAL-E AUTOMATIC OIL PAZBO EZF PENNZOIL ATF F-30110 DEXRON III/MERC.ATF (F-30395) PETROL OFISI ATF II VECO MATIC IID AERO-LINE ATF-2 AERO-LINE ATF-D REPSOL MATIC ATF GULF ATF DII D-22233 SASOL ATF DXII WINTERSHALL ATF D ASEOL ATF DB UNIVERSAL SHELL DONAX TA (D-21666) SHELL DONAX TG (F-30358) MADIT AUTOMATIC DEXRON 2 D SOPRAL 164 TRANSWAY DX III (F-30373) TRANSWAY DX II TECNOL TECMATIC D2 SUNAMATIC 149 SUNAMATIC 153 TEBOIL FLUID E (F-30301) TEBOIL FLUID D TRANSWAY DX III (F-30373) TAMOIL ATF II D ATF MERCON / DEXRON III TEXAMATIC 7045 TEXAMATIC 4261 TEXAMATIC 7080 TEXTRAN PSM TEXAMATIC 4011 TEXAMATIC 4291 TEXAMATIC 9226 TOTAL FLUIDE ATX TOTAL FLUIDE IID TOTAL FLUIDE AT 42 TOTAL FLUIDE ATD TURBO UNIV. ATF MERCON 4011 UFALUB ATF UNIL MATIC CN T 4011 VALVOLINE MULTI-PURPOSE ATF VALVOLINE ATF TYPE D MOVARA ATF-GETRIEBEÖL DIID VEEDOL ATF-M (22764) VEEDOL ATF DEXRON III F-30521 VEEDOL UNITRANS S PLUS YACCO ATF D DIVINOL FLUID 666 Manual and Spare Parts List ZF M line 5. Disassembly 5.3 Removing the bearing shields 5.5. Removing the shifting fork (15) Note: fold out illustration sheets 1 and 2 or (for ZF 15 MIV) sheets 3 and 4 (exploded views) for reference. 5.3.1 Remove hex head screw (5) from bearing shields (2) and (3), using 13 mm spanner (wrench), and take off spring washers (4). 5.5.1 Remove screw plug (17) (not necessary in ZF 3 M - 5 M since there is no plug but only a O-ring). 5.1 Removing the cooling unit (if present) Unscrew 4 hex head screws M8x50 and take off unit (see illustration under item 6.14.2). 5.3.2 Remove cover (3) and bearing shield (2) on input shaft (36) together with seals (28). 5.5.2 Pull actuating shaft (16) out of the hole in the half housing. 5.5.3 Remove shifting fork (15). 5.4 Separating the gearbox sections and removing the input and output shafts 5.6 Removing the intermediate gear (26) 5.2.1 Always set actuating lever to neutral position. 5.4.1 Remove hex nuts (22) from gearbox (1), using 13 mm spanner (wrench), take off spring washers (4) and remove screws (21). 5.6.1 Heat gearbox section with intermediate gear to a temperature of approx. 80°C (176 F); in ZF 3 M - 5 M only, first remove the retaining ring (23). 5.2.2 Remove hex nuts (22) from cover plate (9), using 13 mm spanner (wrench), and take off spring washers (4). 5.4.2 Separate the two halves of gearbox (1) by light hammer blows on the oil filler screw and oil drain plug (19 and 20). 5.6.2 Knock pin (24) out of its bearing by light hammer blows, using a driving pin of suitable size. 5.2.3 Remove cover plate assembly (12), lever (6) and actuating cam (11). 5.4.3 Remove shims (37, 38, 39, 40) from the input and output shafts and keep separately. For proper reassembly it is advisable to note down the thickness and location of each of the shims to obtain the correct bearing play. If none of the parts (2, 3, 32, 33, 36) on the input shaft and of the parts (2, 3, 34, 35, 43, 46, 47, 59) of the output shaft are replaced, the shims can be re-used in the same positions. When any of these parts are replaced, the dimensions of the gear set relative to the casing have to be measured anew and suitable shims have to be installed. 5.6.3 Remove intermediate gear (26), retaining plates (25) and roller cage (27). 5.2 Removing and disassembling the actuating lever cover plate 5.2.4 Remove screw (7) from lever (6). Pull off lever (6). Remove actuating cam (11) and needle bearing (70) only in models ZF 12 M - 15 M - 25 M - 30 M. Remove actuating cam sealing ring (8). 5.7 Disassembling the input shaft (36) 5.7.1 Remove outer bearing races (32). 5.7.2 In the event of bearing damage, cautiously drive inner races (33) off the input shaft (36) with a punch (away from gear). 35 Manual and Spare Parts List ZF M line 5.8 Disassembling the output shaft (66) 5.8.1 Mount support rail on a vice with the pins pointing upwards (not on ZF 15 MIV). 5.8.2 Place output shaft (66) vertically on the support rail with the flange side down. 5.8.3 Remove screw (41) spacer (42) and outer bearing race (34). Only in models ZF 3 M - 5 M remove also shims (68) and in model ZF 15 MA spacer (68). 5.8.4 Place side of gear (65) adjacent to shaft flange against a suitable support (a divided flange or two brackets of suitable section) and use pin of suitable size to press off the output shaft. Do not place the support neither against the gear's (65) teeth nor against the friction washer (43). But place it as shown on the drawing below. The parts removed from the upside of the shaft are not interchangeable with the parts removed from the flange side. Keep separately. 5.8.5 Remove keys (67) from the output shaft and keep in a separate place (1 key for ZF 3 M and 5 M, 2 keys for ZF 10 M, 12 M, 15 M, 15 MA, and 4 keys for ZF 25 M, 25 MA and ZF 30 M). Fig. 18 41 34 42 68 Fig. 19 65 65 36 43 Manual and Spare Parts List ZF M line 5.8.6 Put off shims (53, 54, 55, 56), spacer (47) and needle bearing (45) from the output shaft. 5.8.7 Attach divided flange to face side of bearing shield (2) and pull off thrust washer (43), inner race (46) and taper roller bearing (34, 35) with shield. On ZF 15 MIV only pull off taper roller bearing (34, 35). 5.8.9 Dismantling the gears Compress cup springs (48) (only one each side for ZF 3 M - 5 M) by means of dismantling tool. Remove circlip (50) and take off thrust plate (49). 5.8.10 Dismantling the actuating members. Detach springs (64), watching for balls (58). 5.8.11 Remove disc carrier (57). 5.8.8 Remove internal and external clutch discs from gears (44) and (65). 5.8.12 Place actuating sleeve (60) on a plane surface and press out guide sleeve (59). Watch for detent pins and springs jumping off the guide sleeve. It will be advisible to wrap a rag around the actuating sleeve (60) and the guide sleeve (59) to catch any parts that might jump off. Fig. 20 5.9 Disassembling the quill shaft (ZF 15 MIV). Note: see drawing page 38. 5.9.1 Remove grooved ring nut (83) by means of socket spanner and take off ring (34) with sealing ring (31). 5.9.2 Place divided flange against face side of bevel gear (80) and force bevel gear (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 of divided flange. Fig. 22 64 47 53 - 54 55 - 56 46 45 43 57 58 63 34 - 35 2 57 58 59 60 61 62 Fig. 21 50 49 48 44 - 65 37 Manual and Spare Parts List ZF M line 6. Reassembly Note: fold out illustration sheets 1 and 2 (exploded views) for reference. For ZF 15 MIV use illustration sheets 3 and 4. 6.1 General information The following points should be observed when reassembling the gearbox: - Clean all parts thoroughly, especially sealing surfaces, inspect for wear, damage and cracks, and replace if required. - Check shifting fork (15) for wear. The contact surfaces of this fork are provided with amolybdenum coating. Should this coating be worn away at any point, replace the shifting fork. Max wear on guiding surfaces 0.2 mm (0.008 in) on each side. - Thrust rings (43) require replacement if wear exceeds 0.25 mm (0.0098 in). - Internal discs (51) have a sintered metal coating of 0.3 mm (0.012 in) on each side. If the surface structure (after clean-ing) shows indications of wear, replace the discs. - Apply thin coat of oil to antifriction bearings before installation. Fig. 23 6.2 Assembling the intermediate gear shaft in gearbox section side cooler 6.2.1 Insert retaining plate (25). IMPORTANT: Note that the bevelled corners of retaining plates (25) have to be placed in different positions (see illustration on sheet 1). 6.2.2 Insert needle cage (27) into intermediate gear (26) and place complete assembly 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 gear shaft (24)* and drive it into gearbox section by knocking slightly on a drive pin. * on ZF 3 M - 5 M insert intermediate gear shaft with seeger 23 and Loctite 574. * on ZF 25 M - 25 MA and ZF 30 M, insert intermediate gear shaft (24) without O-ring (23) and close bore in gearbox section with sealing compound by pressing 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 knocking with a driver pin on the edge of the hole of the housing. Close the outsider hole in the housing by pressing in plug (23) with Loctite 574. Fig. 24 8 0.5 ±0.2 mm 6.3 Assembling the shifting fork in gearbox section side shifting cover 6.3.1 Insert shifting fork (15) into gearbox section (1) side the actuating lever in such a way that the long arm of the fork points downwards. 6.3.2 Insert shifting rod (16) through bores in gearbox and shifting fork. 6.3.3 Fit screw plug (17) to gearbox, making certain that the clearance between shifting rod (16) and screw plug (17) is min. 0.5 mm (0.02 in). Seal screw plug with Loctite 242 (ZF 3 M - 5 M only O-Ring). 6.3.4 Check shifting fork for easy movability. 6.4 Pre-assembling the actuating lever cover plate Use punch tool to press sealing ring (8) into cover plate (9). Spread antifriction bearing 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 and cover plate 0.5 mm (0.02 in). 6.4.3 Clamp actuating lever by means of retaining screw (7), using a 13 mm spanner (wrench). Screw in with torque of 20 Nm. Punch Tool 11 8 6 9 7 70 not for ZF 3 M - 5 M - 10 M 38 Manual and Spare Parts List ZF M line 6.5 Pre-assembling the gears (65) and (44) with cup springs (48) and clutch discs (51 and 52) 6.6 Measuring the pre-assembled gears (65) and (44) to determine setting value «a». IMPORTANT: If previously disassembled parts are used, make certain that only mating and associated parts are reassembled. If no parts had to be replaced, the previously disassembled shims (53, 54, 55, 56) can be re-used in their former arrangement and positions without any measuring operation. 6.5.1 Join two cup springs (48) (only one cup spring for ZF 3 M - 5 M) face to face (external diameters in contact) and place them on the centering collar of gears (65) and (44). If measuring is required, proceed as follows: 6.5.2 Place thrust ring (49) on cup springs. 6.6.1 Place pre-assembled gear (65), and subsequently gear (44) on thrust washer (43), (end face of hub downwards, see illustration). 6.5.3 Place circlip (50) on gear hub and use mounting tool and press to fit circlip into groove on hub. Don't press completely the cup springs and be sure that the tool presses at least on three points on the thrust washer (49). IMPORTANT: On ZF 3 M - 5 M - 10 M there is a step on the thrust washer (43). Put the side of the washer with the step against the gear. Be sure that the needle bearing inner race (46) is fitted into it. 6.5.4 Attach clutch discs (51 and 52), first internal disc (51), then alternatively external disc (52), internal disc (51), etc. Fig. 25 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 required, until prescribed seeting value «a» is obtained (see illustration). 6.6.4 Shims are available in thicknesses of 0.4 - 0.5 - 0.6 and 0.7 mm. (0.016 - 0.020 - 0.024 and 0.028 in) Setting value «a» Type ZF 3 M ZF 5 M ZF 10 M HBW 10 ZF 12 M ZF 15 M ZF 15 MA ZF 15 MIV ZF 25 M / 25 MA ZF 30 M Old versions (4+3 external clutch discs) HBW 10 (versions from 01 to 08) HBW 150 (versions from 09 to 14) HBW 150 V (versions from 01 to 07) mm 8.0±0.1 inches 0.315±0.004 13.0±0.1 0.512±0.004 12.4±0.1 0.488±0.004 16.2±0.1 19.75±0.1 0.638±0.004 0.778±0.004 13.2±0.1 0.520±0.004 Fig. 26 53 - 54 55 - 56 50 49 50 49 48 48 44 - 65 45 Thrust washer (43) bronze side upwards 44 - 65 46 47 39 Manual and Spare Parts List ZF M line 6.7 Pre-assembling the bearing shields (2) for the input and output shafts 6.8.4 Press guide sleeve (59) into actuating sleeve (60) up to midway position (noticeable click). Use a driver tool to press sealing rings (30 - input and 31 - output) into shield (2). 6.8 Pre-assembling the clutch members 6.8.5 Insert balls (58) into ball pockets of guide sleeve, attach disc carrier (57), turn upside down then fit balls in opposite face side and attach second disc carrier (57). 6.8.1 Fit driving pins (63), springs (61) and detent pins (62) to guide sleeve (59). 6.8.6 Attach springs (64) with closed part of spring windings pointing outwards. 6.9 Reassembling the input shaft Preheat inner races (33) of taper roller bearings to a temperature of 100° C (212F) and, using tubular or punch tool, press races on input shaft (36) on both sides. IMPORTANT: Repress after cooling down, so that no gap is left. 6.8.2 Place actuating sleeve (60) on plane press surface. 6.8.3 Place guide sleeve (59) on top of actuating sleeve (60) with the three driving pins (63) in alignment with the three grooves in the actuating sleeve. Watch for correct position of detent pins (62) relative to angular pockets of sleeve. Fig. 27 Fig. 29 Punch tool Fig. 30 Punch tool Tubular tool 31 - 32 2 33 33 36 Fig. 28 36 64 58 63 57 40 58 59 60 61 62 Manual and Spare Parts List ZF M line 6.10 Reassembling the output shaft 6.10.1 Place pre-assembled bearing shield (item 6.7) with seal (28) on output shaft (66) (not applicable to ZF 15 MIV). 6.10.2 Attach outer race (34) of taper roller bearing. 6.10.3 Pre-heat inner race (35) of taper roller 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). IMPORTANT: Repress after cooling down, so that no gap is left. 6.10.4 Fit thrust ring (43) in such a way that sintered surface (brown colour) faces gear. 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). 6.10.5 Use tubular tool to press on inner race (46) of needle bearing for gear (65). 6.10.9 Press pre-assembled actuating members (see item 6.8) on output shaft (66). 6.10.6 Attach needle cages (45) and completely pre-assembled gear (65) with clutch discs (51 and 52). IMPORTANT: Align keys radially relative to guide sleeve (59). Fig. 31 Fig. 32 Punch tool 46 42 41 44 35 66 46 65 43 35 66 34 28 2 41 Manual and Spare Parts List ZF M line 6.10.10 Attach shims (53,54,55, 56) to gear (44). 6.10.16 Screw on bolt (41), (supplied with Loctite) and tighten to torque: 6.10.11 Attach spacer (47) to gear (44). ZF 3 M - 5 M ZF 10 M ZF 12 M - 15 M ZF 15 MA - 15 MIV ZF 25 M - 25 MA ZF 30 M 6.10.12 Use tubular tool to press on inner 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 engagement with actuating member. 6.10.14 Attach thrust ring (43) in such a way that sintered surface (brown colour) faces gear. 6.10.15 Pre-heat inner race (35) of taper roller bearing to a temperature of approx. 100°C (212 F) and press it on shaft. IMPORTANT: Repress after cooling down, so that no gap is left. 50 Nm 60 Nm 100 Nm 100 Nm 120 Nm 120 Nm 37 ft lb 44 ft lb 74 ft lb 74 ft lb 89 ft lb 89 ft lb 6.10.17 (ZF 3 M, ZF 5 M only) attach shims (68) to end shaft (66). The gap has to be 0.2 ± 0.05 mm (0.0079±0.0019 in). 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). 6.10.18 (ZF 15 MA only) attach spacer (68). 6.11.7 Second bearing: Press on inner race (74). Fit outer race (75). 6.10.19 Check gears (44) and (65) for free movability in an axial direction. 6.11.8 Push on clip (73) together with O-ring (85). 6.10.20 Attach outer race (34) of taper roller bearing. 6.11.9 Tighten grooved ring nut (83) to a torque of 95 Nm (70 lbft), using a socket spanner, and then secure by pressing rim into groove in shaft. 6.11 Reassembling the quill shaft ZF 15 MIV 6.11.1 Fit radial sealing ring (31) and clip (84) together with O-ring (86). 6.11.10 Fit radial sealing ring (31) and cup (84) together with O-Ring (86). Fig. 33 Fig. 35 0.2 ± 0.05 mm 41 42 35 82 31 84 68 86 Fig. 34 41 74 81 75 76 80 75 76 84 74 86 42 85 31 73 83 Manual and Spare Parts List ZF M line 6.12 Final assembly of gearbox 6.12.1 Place pre-assembled gearbox section (1) - (with intermediate gear) on side wall. 6.12.2 Place pre-assembled output shaft (66) in lower part of gearbox with flange side towards intermediate gear side (on ZF 15 MIV, bevel gear towards intermediate 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-assembled quill shaft (73) in lower part of gearbox (watching to correct engagement of marked teeth). Add shims 78 on quill shaft: 1.2 mm on side input shaft and 2.2 mm on side output flange. Add shims (70) on clutch shaft 2 x 0.1 mm on side output flange. 6.12.5 (ZF 15 MIV only) Check backlash 0.08 to 0.13 mm (0.003 to 0.005 in). Between teeth of bevel gears using a dial indicator in contact with tooth surface. Fig. 36 To correct backlash: Replace shim 78 side output flange with a thicker one to decrease backlash and vice-versa. If the correction is not enough to reach the correct backlash, modify shimming (70) on clutch shaft side output flange and 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 inserting shims (78) side input shaft. 6.12.6 Seal with LOCTITE 574 surface of pre-assembled gearbox section (1) (with shifting fork) and place upper section on lower section of gearbox. 6.12.7 Insert screws (21) preferably in the middle, and screw in low-tight to secure the two gearbox sections together. 6.12.9 Fit bearing shield (2) with gasket (28) to output shaft (66) by means of spring washers (4) and screws (5), using a 13 mm spanner (wrench). Tighten to torque of 14 Nm (10 ft lb). 6.12.10 Slide pre-assembled bearing shield (2) with gasket (28) over input shaft and secure by means of springer washer (4) and screws (5), using a 13 mm 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) on output and input shafts to eliminate bearing play, simultaneously rotating the shafts. 6.13.2 Determine dimension «b» by means of depth gauge (see illustration). 6.12.8 Use a plastic hammer to align the two gearbox section (1) by tapping them gently into position. Cover centering depth with seal (28) Side shifting cover 43 Manual and Spare Parts List ZF M line 6.13.3 Measure dimension «c» on cover (3) with gasket (28) installed, using a depth gauge (see illustration). The difference between the two dimensions indicates the distance to be filled up with shims (37, 38, 39, 40). Shims are available in thicknesses of 0.1 - 0.15-02.-03. and 0.5 mm. On ZF 15 MIV, a hole is provided on the output side of the housing to permit this measuring operation: move shaft via gear (65) by means of a lever through opening in gearbox (see illustration next page). Fig. 37 b Cover centering depth with gasket (28) Distance from gear set c Compensate for difference by inserting shims (37, 38, 39, 40) Compensate for difference by inserting shims (70, 71, 72) Compensate for difference by inserting shims (37, 38, 39, 40) Distance from gear set c Cover centering depth with gasket (28) b ct orre To c lash k bac ➤ 44 ➤ ➤ ➤ ct orre To c play l axia sate pen nce m (78) o C fere g shims f i d for sertin by in Manual and Spare Parts List ZF M line 6.13.4 Insert the required number of shims into the bearing bores of the gearbox to obtain an axial clearance of the output and input shafts of 0.05 ± 0.02 mm. Fig. 38 If no parts had to be replaced (see item 5.4.4), the previously disassembled shims (37, 38, 39, 40) can be re-used in the previous arrangement and positions. It will be advisable, however, to check the bearing clearance and correct it if required. 6.13.5 Mount the previously measured covers (3) on the output and input shafts by means of spring washers (4) and screws (5), using a 13 mm spanner (wrench). Tighten to torque of 14 Nm (10 ft lb). 6.13.6 Place spring washers (4) underneath all screws (21) and tighten screws to a torque of 22 Nm (16 ft lb), using a 13 mm spanner (wrench). 6.13.7 Tap output and input shafts lightly in an axial direction while rotating the shafts, to ensure freedom of movement. Fig. 39 6.13.8 Axial clearance of input and output shafts: 0.05 ± 0.02 mm, measured by means of dial indicator in contact with end face of shaft (see illustration). 6.13.9 Measure axial clearence of quill shaft (on ZF 15 MIV), also with dial indicator 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 45 Manual and Spare Parts List ZF M line 6.14 Mounting the actuating lever cover plate 6.14.1 Place gasket (29) or Loctite 574 on pre-assembled cover plate and fit it to gearbox. Watch for proper engagement of actuating cam and shifting fork. The cover plate can be mounted when the shifting fork is in the middle (=neutral) position. It is important to adjust the actuating lever to exactly midway position in neutral. Screw the cover plate in place in this position. The lever travel from 0 to A and from 0 to B should be equal. After a lever travel of 28 to 31 mm (1.10 to 1.22 in) the transmission should be in gear. If the lever travel from «0» to «A» and from «0» to «B» is not equal adjust cover position by light hammer blows on the cover up to reach the equal travels. Fit spring washer (4) and screw nuts (22). Tighten to a torque of 20 Nm (15 ft lb). If studs (69) need to be replaced, fit them with Loctite 270 on the housing. Fig. 40 46 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 operation. 6.14.3 Fit oil drain plug (20) with sealing ring (18) and oil dipstick (19) with sealing 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 side opposite the cover plate (9). By means of 4 screws M8x65 and washers (available on kit pag. 23 item 1.2.10). Manual and Spare Parts List ZF M line 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 fork to the neutral position. 1 B) Apply Loctite 574 (or alternatively 518) on the cover surface and position it with the lever in neutral (see picture 2). Only for ZF 25 M, 25 MA: Push towards the bottom (see picture 3). 2 C) Lightly tighten the four nuts. D) Adjust the cover roughly in the middle. ZF 25 M, ZF 25 MA 3 E) Fit the adjusting bracket p/n 20.4039.02 using only one nut lightly tighten: the cover 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 position apply on the adjusting bracket the suitable extension section P/N 20.4039.03 (see picture 5). F) Move the lever toward the detent A without engaging the clutch and mark the position; repeat the same for the detent B. If the shifting lever has two holes refer to the inner hole (see picture 6 and 7). 5 6 4 7 47 Manual and Spare Parts List ZF M line G) Engage the clutch, turn back the lever to the engaging point and mark the position; repeat the same procedure for the other clutch (see picture 8 and 9). 8 9 H) Consider the centre line between the internal marks and measure the distance from 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 marks must be 24 mm. The maximum difference between the two measurements must be less than 3 mm. 10 A must always be < 24 mm B must always be < 24 mm A – B < 3 mm EX.: A = 20 mm, B = 24 mm A – B = 4 mm > 3 mm NOT ALLOWED A = 21 mm, B = 23 mm A – B = 2 mm < 3 mm OK A If the above conditions are not reached, move the cover toward the opposite direction where the measurement is largest by light hammer taps and repeat the marking operation. If it is not possible to adjust the cover to maximum 24 mm, the gearbox needs to be exchanged. 11 B I) After the correct adjusting measurement is reached tighten the four nuts with 22 Nm (16 lb.ft) torque. 6) Connect the shifting cable to the inner hole (if two holes) of the lever. Adjust the neutral position of the cable by the middle of the play of the lever in neutral. The control cable should be perpendicular to the actuating lever in neutral position of the lever. 7) Make sure that the way of the control cable is enough long to move the inner hole of the lever at least 30 mm. 48 Manual and Spare Parts List ZF M line 8. Troubelshooting Possible Troubles and Remedies Kind of trouble Noticeable effect Delay of gear Propeller will start rotating engagement with several seconds delay or only after increase in engine speed. Possible cause Remedy Detach shift cable and operate gearbox by hand to find whether malfunctions is caused by gear box or cable. If caused by transmission: Lever travel 0-A not equal to lever travel 0-B. Adjust cover plate (9) until lever is exactly in midway position. Travel 0-A = 0-B = 35 mm/30 mm 1.37 in/1.18 in Insufficient clearence between actuating lever and cover plate (9). Adjust to min. clearance of 0.5 mm (0.02 in). If caused by shift cable: Transmission Excessive effort required fails to move in to move actuating lever. gear Boat fails to Increased operating attain top temperature. speed specified Oil leakage Oil leakage visible on transmission unit. Shift cable fails to move lever through required min. travel 0-A=0-B = 35 mm/30 mm (1.37 in/1.18 in). Insufficient clearance between actuating lever and cover plate (9). Check total travel of shift cable. If too short, adjust accordingly. Detach shift cable and operate lever by hand. If lever jams, adjust clearance to 0.5 mm (0.02 in). Guide sheaves for shift cable unsuitably positioned: radius too small. Use of wrong oil. Check and adjust accordingly. Boat operated without cooling unit. Install cooling unit. Transmission operating in upper limit range. Corrosion effects in area of radial sealing ring and shaft; damaged radial sealing rings. Improper installation of seal. Use suitable ZF M transmission unit. Check and correct oil level. Remove and dismantle transmission remachine shafts, replace radial sealing rings Misalignment of output flanges. Check alignment to be within 0.08 mm (0.003 in) radially. Use ATF oil and check oil level. 49 Manual and Spare Parts List ZF M line 9. Spare Parts List Preface The spare parts list is only valid for the type and versions of transmission, as shown below. 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 relative Spare 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: 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; 006 ZF 30 M versions 001; 002 Name Plate The name plate is mounted to the transmission Transmission ratio Shifting position «A» Transmission type Transmission version ratio and serial number MODEL SER. N. P/N. Transmission part number 50 i ZF 10 M XXXXX XXXXX L A= 1,79 i B= 1,86 3304 002 004 Transmission ratio Shifting position «B» Actuating lever* Actuating lever 6 6 1 1 16 46 42 40 38 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3304 201 004 3304 201 003 3304 201 003 3304 201 004 3304 201 003 3304 201 003 3304 201 003 Part No 0630 302 090 3306 308 001 500635 3306 308 001 947.23.006.01 195062 947.23.006.01 0636 015 289 215870 0636 015 289 0630 302 090 442372 3304 301 013 288730 3304 301 013 3304 301 011 288787 3304 301 011 Old p/n 3306 201 003 206447 Part No HBW 10/ZF 12 M/15 M 500635 3306 308 001 500635 195062 947.23.006.01 195062 215870 0636 015 289 215870 442372 0630 302 090 442372 288730 3306 301 011 206452 288787 3306 301 010 206450 288768 3306 301 010 206450 465642 288079 288079 465642 - 288079 288079 Old p/n ZF 10 M 3304 301 012 288768 3304 301 012 3303 201 002 387532 3303 201 001 325952 3303 201 002 387532 3303 201 002 387532 3303 201 001 325952 3303 201 001 325952 3303 201 001 325952 Number ZF 3 M - ZF 5 M per gearbox Part No Old p/n * Up to letter «E» production date (see name plate description pag.50) Spring washer Hex head screw (cover) 4 Spring washer 4 5 Spring washer Spring washer 4 Cover 3A 4 Cover Cover 3 3 Bearing shield input Bearing shield output 2 2 Housing assy ZF 30 M - 2.7R «001» Housing assy ZF 30 M - 2.15R «002» 1 Housing assy ZF 25 MA - 2.74R «006» 1 1 Housing assy HBW 250 - 3,5R «13» Housing assy ZF 25 MA - 2.23R «005» 1 1 Housing assy ZF 25 M - 2.27R «007» Housing assy ZF 25 M - 2.74R «002» & «23» 1 1 Housing assy HBW 250 - 1,5R «16» Housing assy HBW 250 - 3L «19» 1 Housing assy ZF 25 M - 1.88R «001» & «22» Housing assy HBW 250 - 2L «20» 1 1 Housing assy ZF 15 MA 1 1 Housing assy HBW 100 - 2,5R «21» Housing assy HBW 10 / ZF 12 M / ZF 15 M 1 1 Housing assy HBW 100 - 3R «16» Housing assy HBW 100 - 2L «17» 1 1 Housing assy ZF 10 M - 2.05R «010» Housing assy ZF 10 M - 2.72R «005» 1 Housing assy ZF 10 M - 1.79R «004» 1 1 Housing assy ZF 3 M - 2.72R «002» Housing assy ZF 10 M - 1.48R «003» 1 1 Housing assy ZF 5 M - 2.72R «002» Housing assy ZF 3 M - 2.05R «001» 1 1 Housing assy HBW 50 - 2R «12» Housing assy HBW 50 - 3R «10» 1 Housing assy ZF 5 M - 2.05R «001» 1 1 Housing assy HBW 50 - 2L «11» 1 Item No Part name Old p/n Old p/n - 3307 201 004 345519 3307 201 004 345519 3307 201 003 3307 201 003 345517 3307 201 003 345517 3307 201 004 345519 3307 201 003 345517 Part No ZF 25 M 3307 201 001 3307 201 001 Part No 0630 302 090 442372 3307 301 009 274219 0630 302 090 3307 301 003 3307 301 009 3306 308 001 500635 3306 308 001 500635 3306 308 001 947.23.006.01 195062 947.23.006.01 195062 0636 015 289 215870 0636 015 289 215870 0636 015 289 0630 302 090 442372 3306 301 008 407475 3306 301 011 206452 3306 301 010 206450 3307 301 008 274248 3307 301 008 3320 201 001 3320 201 001 Part No 0630 302 090 3307 301 009 500635 3306 308 001 215870 0636 015 289 442372 - 274219 274248 3307 301 008 - - - - - - - - Old p/n ZF 30 M 274248 3307 301 008 - - Old p/n ZF 25 MA 3306 301 010 206450 3307 301 008 274248 3307 301 008 3306 201 001 407465 Part No ZF 15 MA Manual and Spare Parts List ZF M line 51 52 1 O-ring (Seeger ZF 3 M - ZF 5 M / Plug ZF 25 M - ZF 30 M) 23 Radial sealing ring, output (only vers. «22-23») Tapered roller bearing, input shaft 31 32 2 1 1 1 1 1 4 0636 015 299 199807 0636 015 299 Part No 0637 006 157 0636 010 376 3304 303 003 0635 501 943 - 0635 501 943 0634 300 371 105153 0634 300 371 0634 301 830 280135 0634 301 830 3306 301 015 254716 3306 301 015 3304 301 015 288739 3304 301 015 0635 300 526 106589 0635 300 530 3303 303 001 325961 3304 303 001 3304 303 003 288743 3303 303 002 325962 3304 303 002 0630 501 012 104807 0634 306 011 0637 006 157 455785 0636 010 376 215869 3306 301 013 228566 3306 301 013 3304 201 006 288729 3304 201 006 3306 301 016 326578 3306 301 016 0634 306 179 105524 0636 301 041 3303 308 001 325963 3306 308 004 3304 208 001 326000 3304 208 001 3303 108 001 326208 3304 108 002 3304 199 006 304332 3304 199 006 0631 329 032 104559 0631 329 032 3304 308 001 206448 3304 308 001 0634 502 009 106864 0634 502 009 Part No Old p/n HBW 10/ZF 12 M/15 M 3306 303 001 254730 - 0635 501 597 - 105153 0634 300 466 105159 280135 0634 301 833 215875 254716 3306 301 015 254716 288739 3306 301 014 254715 280128 3306 303 007 215878 - 288743 3306 303 003 206473 288741 3306 303 002 206470 105679 0634 303 118 105530 455785 0637 006 157 455785 215869 0636 010 376 215869 228566 3306 301 013 228566 288729 3306 201 005 206929 326578 3306 301 016 326578 442373 0636 301 041 442373 206484 3306 308 004 206484 326000 3306 208 001 223563 248459 3306 108 002 407210 304332 3306 199 008 407211 104559 0631 329 032 104559 206448 3306 308 002 388242 106864 0634 502 009 106864 442377 0636 101 727 442377 199807 0636 015 299 199807 Old p/n ZF 10 M 0636 101 727 442377 0636 101 727 * Up to letter «E» production date (see name plate description pag.50) Radial sealing ring, input (only vers. «22-23») Radial sealing ring, output (No HBW 250 «22-23») 30 31 Gasket cover plate (or LOCTITE 574) Radial sealing ring, input (No HBW 250 «22-23») Gasket cover 29 2 Cage 27 28 30 1 Cage 27 2 1 Retaining plate Intermediate gear 25 1 1 1 17 12 14 12 11 10 2 1 12 8 10 9 1 1 2 1 1 1 1 1 1 26 Intermediate gear shaft Hex nut 22 Retaining plate Hex nut 22 24 Hex nut 22 25 Hex nut Hex nut 22 Hex nut 22 22 Hex head screw Hex head screw 21A Hex head screw 21 21B Hex head screw Hex head screw 21 21 Oil drain plug Hex head screw 20 21 Sealing ring Oil dipstick/breather assy 18 Plug (O-ring for ZF 3 M - ZF 5 M) 17 19 Shifting fork assy Actuating shaft 15 16 Actuating cam assy Shift cover assembly 11 12 Cover plate Spring dowel pin 9 10 1 Radial sealing ring for shift cover 8 1 1 Hex head screw (actuating lever)* Hex head screw (actuating lever) 7 Number ZF 3 M - ZF 5 M per gearbox Part No Old p/n 7 Item No Part name Old p/n Part No Old p/n ZF 25 M Part No 0637 006 157 455785 0636 010 563 279058 0637 006 157 0636 010 548 0636 010 564 0635 501 597 - 0635 370 042 167210 0635 370 042 0634 311 026 501152 0634 300 466 105159 0634 300 466 105159 0634 300 466 0634 311 025 501151 0634 301 833 215875 0634 301 832 284260 0634 301 832 3306 301 015 254716 3306 301 015 254716 3306 301 015 3306 301 014 254715 3307 301 011 274251 3307 301 011 3306 303 007 215878 3307 303 004 222273 3307 303 004 3306 303 001 254730 3307 303 003 274226 3307 303 003 3306 303 003 206473 3307 303 002 288702 3307 303 002 3306 303 002 206470 3307 303 001 274225 3307 303 001 0634 303 118 105530 0630 361 039 285375 0630 361 039 0637 006 157 455785 0636 010 375 337982 0636 010 376 215869 3306 301 013 228566 3306 301 013 228566 3306 301 013 3306 201 002 408451 3307 201 005 274217 3307 201 005 3306 301 016 326578 3306 301 016 326578 3306 301 016 0636 301 041 442373 0636 301 041 442373 0636 301 041 3306 308 004 206484 3307 301 012 288673 3307 301 012 3306 208 001 223563 3307 208 001 327374 3307 208 001 3306 108 002 407210 3306 108 002 407210 3306 108 002 3306 199 008 407211 3306 199 008 407211 3306 199 008 0631 329 032 104559 0631 329 032 104559 0631 329 032 3306 308 002 388242 3306 308 002 388242 3306 308 002 0634 502 009 106864 0634 502 009 106864 0634 502 009 Part No 0637 006 157 0636 010 563 0635 300 114 167210 0635 370 042 105159 0634 311 026 284260 0634 311 025 254716 3306 301 015 274251 3307 301 011 222273 274226 3320 303 002 288702 3320 303 003 274225 3320 303 001 285375 0630 361 039 455785 500924 - 228566 3306 301 013 274217 3307 201 005 326578 3306 301 016 442373 0636 301 041 288673 3307 301 012 327374 3307 208 001 407210 3306 108 002 407211 3306 199 008 104559 0631 329 032 388242 3306 308 002 106864 0634 502 009 - - - - - - - - - - - - - - - - - - - - - - - - Old p/n ZF 30 M 442377 0636 101 727 Old p/n ZF 25 MA 0636 101 727 442377 0636 101 727 442377 0636 101 727 0636 015 299 199807 0636 015 299 199807 Part No ZF 15 MA Manual and Spare Parts List ZF M line Shim 0.1 mm Shim 0.15 mm Shim 0.30 mm (Shim 0.20 mm for ZF 25 M / 30 M) 37 38 39 Input shaft ZF 30 M 2.7R «001» Z1/Z3=23/22 Input shaft ZF 30 M 2.15R «002» Z1/Z3=27/22 36 Input shaft ZF 25 MA 2.74R «006» Z1/Z3=19/19 36 36 Input shaft HBW 250 - 3,5R «13» z = 16/18 Input shaft ZF 25 MA 2.23R «005» Z1/Z3=22/19 36 36 Input shaft ZF 25 M - 2.27R «007» Z1/Z3=22/21 Input shaft ZF 25 M - 2.74R «002» & «23» Z1/Z3=19/18 36 36 Input shaft HBW 250 - 1,5R «16» z = 28/21 Input shaft ZF 25 M - 1.88R «001» & «22» Z1/Z3=25/21 36 36 Input shaft HBW 250 - 2L «20» z = 21/25 Input shaft HBW 250 - 3L «19» z = 18/19 Input shaft ZF 15 MA - 2.63R «005» Z1/Z3=19/22 36 36 Input shaft ZF 15 MA 2.14R «003» Z=22/22 36 36 Input shaft HBW 150 - 3R «22» z = 18/22 Input shaft ZF 15 MA - 2R «004» Z1/Z3=24/22 36 36 Input shaft ZF 15 M - 1.88R «004» Z1/Z3=24/22 Input shaft HBW 150 - 2,4R «20» z = 18/22 36 36 Input shaft ZF 12 M - 2.63R «002» Z1/Z3=19/22 Input shaft ZF 15 M - 1.56R «003» Z1/Z3=27/22 36 Input shaft HBW 10 / ZF 12 M - 2.14R «001» Z1/Z3=22/22 36 36 Input shaft HBW 100 - 2,5R «21» z = 19/20 Input shaft HBW 10 - 2L «21» z = 22/22 36 36 Input shaft HBW 100 - 3R «16» z = 18/22 Input shaft HBW 100 - 2L «17» z = 24/22 36 36 Input shaft ZF 10 M - 2.05R «010» Z1/Z3=22/22 Input shaft ZF 10 M - 2.72R «005» Z1/Z3=18/20 36 36 Input shaft ZF 10 M - 1.48R «003» Z1/Z3=27/22 Input shaft ZF 10 M - 1.79R «004» Z1/Z3=24/22 36 36 Input shaft ZF 3 M - 2.05R «001» Z1/Z3=22/22 Input shaft ZF 3 M - 2.72R «002» Z1/Z3=18/20 36 36 Input shaft HBW 50 3R 10 Z=18/20 Input shaft ZF 5 M - 2.72R «002» Z1/Z3=18/20 36 36 Input shaft ZF 5 M -2.05R «001» Z1/Z3=22/22 Input shaft HBW 50 2R 12 Z=22/22 36 Input shaft HBW 50 - 2L «11» z = 22/22 36 36 Tapered roller bearing, output shaft 34 Item No Part name 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 - 3304 302 007 947.62.001.08 947.62.001.06 3304 302 006 3304 302 018 3304 302 005 3304 302 004 0635 501 943 Part No 3304 302 014 288734 3304 302 014 3304 302 012 288732 3304 302 012 - Old p/n 3306 302 010 468211 3306 302 009 439197 3306 302 008 325811 3306 302 006 304088 3306 302 007 313952 3306 302 005 206460 3306 302 005 206460 0635 501 597 Part No HBW 10/ZF 12 M/15 M 288734 3306 302 014 206477 288732 3306 302 012 206475 288731 3306 302 011 206474 470902 327229 304074 465465 - 305605 304059 - Old p/n ZF 10 M 3304 302 011 288731 3304 302 011 3303 302 002 458163 3303 302 001 326900 3303 302 002 458163 947.72.001.07 387535 947.72.001.03 325970 3303 302 001 326900 947.72.001.03 325970 0635 501 943 Number ZF 3 M - ZF 5 M per gearbox Part No Old p/n - Old p/n - - Old p/n 947.52.001.09 439199 3307 302 003 288967 3307 302 005 501485 3307 302 004 325809 947.52.001.04 304081 947.52.001.06 344588 947.52.001.08 387684 0635 370 051 Part No ZF 25 M 3307 302 002 3307 302 001 0635 370 051 Part No 3306 302 014 206477 3307 302 008 274254 3307 302 008 3306 302 012 206475 3307 302 007 274253 3307 302 007 3320 302 002 3320 302 001 0635 370 051 Part No 274254 3307 302 008 274253 3307 302 007 - - - - - - Old p/n ZF 30 M 274252 3307 302 006 - - - Old p/n ZF 25 MA 3306 302 011 206474 3307 302 006 274252 3307 302 006 3306 302 003 407482 3306 302 001 3306 302 002 407468 0635 501 597 Part No ZF 15 MA Manual and Spare Parts List ZF M line 53 54 Forward gear HBW 250 - 3,5R «13» z = 56 Forward gear ZF 25 MA - 2.23R «005» Z2=49 Forward gear ZF 25 MA - 2.74R «006» Z2=52 Forward gear ZF 30 M - 2.7R «001» Z2=62 Forward gear ZF 30 M - 2.15R «002» Z2=58 44 44 44 44 44 Forward gear ZF 25 M - 2.27R «007» Z2=50 Forward gear ZF 25 M - 2.74R «002» & «23» Z2=52 44 44 Forward gear HBW 250 - 1,5R «16» z = 43 Forward gear ZF 25 M - 1.88R «001» & «22» Z2=47 44 44 Forward gear HBW 250 - 2L «20» z = 47 Forward gear HBW 250 - 3L «19» z = 52 Forward gear ZF 15 MA - 2.63R «005» Z2=50 44 44 Forward gear ZF 15 MA 2.14R «003» Z=47 44 44 Forward gear HBW 150 - 3R «22» z = 51 Forward gear ZF 15 MA - 1.88R «004» Z2=45 44 44 Forward gear ZF 15 M - 1.88R «004» Z2=45 Forward gear HBW 150 - 2,4R «20» z = 43 44 44 Forward gear ZF 12 M - 2.63R «002» Z2=50 Forward gear ZF 15 M - 1.56R «003» Z2=42 44 44 Forward gear HBW 10 - 2L «21» z = 47 Forward gear HBW 10 / ZF 12 M -2.14R «001» Z2=47 44 44 Forward gear HBW 100 - 2L «17» z = 43 Forward gear HBW 100 - 2,5R «21» z = 48 44 44 Forward gear ZF 10 M - 2.72R «005» Z2=49 Forward gear HBW 100 - 3R «16» z = 49 Forward gear ZF 10 M - 2.05R «010» Z2=45 44 44 Forward gear ZF 10 M - 1.79R «004» Z2=43 44 44 Forward gear ZF 3 M - 2.72R «002» Z2=49 Forward gear ZF 10 M - 1.48R «003» Z2=40 44 44 Forward gear HBW 50 - 3R «10» z = 49 Forward gear ZF 3 M - 2.05R «001» Z2=45 44 44 Forward gear ZF 5 M - 2.72R «002» Z2=49 Forward gear HBW 50 - 2R «12» z = 45 44 44 Forward gear HBW 50 - 2L «11» z = 45 Forward gear ZF 5 M - 2.05R «001» Z2=45 44 44 Spacer Thrust washer 42 Screw 41 43 Shim 0.50 mm 40 Item No Part name 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 Part No 3303 304 002 325976 3303 304 001 325971 3303 304 002 325976 3303 304 001 325971 3303 304 002 325971 3303 304 001 325971 3303 304 001 325971 3304 304 009 3304 304 008 3304 304 006 3304 304 006 3304 304 039 3304 304 008 3304 304 007 3304 304 019 288748 3304 304 019 3303 304 007 325960 3304 304 026 3303 304 014 320681 3304 304 038 Part No Old p/n HBW 10/ZF 12 M/15 M 470903 305607 287455 287455 - 305607 304060 3306 304 017 468212 3306 304 016 439198 3306 304 014 407220 3306 304 015 407221 3306 304 013 407219 3306 304 012 407218 3306 304 012 407218 288748 3306 304 029 344787 439611 3306 304 028 407281 450870 3306 304 057 420280 288735 3306 302 015 228540 Old p/n ZF 10 M 3304 302 015 288735 3304 302 015 Number ZF 3 M - ZF 5 M per gearbox Part No Old p/n Old p/n Part No Old p/n ZF 25 M Part No 3306 304 005 407483 3306 304 001 3306 304 003 407469 - 947.52.003.04 439200 3307 304 010 288971 3307 304 008 3307 304 007 305813 947.52.002.03 304083 3307 304 010 288971 3307 304 007 305813 3307 304 003 3307 304 001 3306 304 029 344787 3307 304 020 327395 3307 304 020 3306 304 028 407281 3306 304 028 407281 3306 304 028 3306 304 057 420280 3306 304 057 420280 3306 304 057 Part No - - 3320 304 007 3320 304 004 327395 3307 304 020 407281 3306 304 028 420280 3306 304 057 - - - - - - Old p/n ZF 30 M 274255 3307 302 009 Old p/n ZF 25 MA 3306 302 015 228540 3307 302 009 274255 3307 302 009 Part No ZF 15 MA Manual and Spare Parts List ZF M line Reverse gear HBW 50 - 3R «10» z = 43 Reverse gear ZF 5 M - 2.72R «002» Z5=43 Reverse gear ZF 3 M - 2.05R «001» Z5=41 Reverse gear ZF 3 M - 2.72R «002» Z5=43 65 65 65 65 Reverse gear ZF 5 M - 2.05R «001» Z5=41 Reverse gear HBW 50 - 2R «12» z = 41 65 65 Spring Reverse gear HBW 50 - 2L «11» z = 41 64 Driving pin 63 65 Compression spring (actuating members) Detent pin 61 Actuating sleeve 60 62 Ball Guide sleeve 58 59 Shim 0.7 mm Disc carrier Shim 0.6 mm 55 56 Shim 0.5 mm 54 57 External clutch disc Shim 0.4 mm 52 External clutch disc (old version) 52 53 External clutch disc External clutch disc 52 External clutch disc 52 52 Internal clutch disc Internal clutch disc 51 Internal clutch disc (old versions) 51 51 Internal clutch disc Half ring 50 Internal clutch disc Circlip 50 51 Thrust ring/end disc 49 51 Cup spring Cup spring 48 48 Needle bearing inner race Spacer 46 47 Needle cage Needle bearing inner race 45 46 Needle cage 45 Item No Part name 1 1 1 1 1 1 1 3 3 3 3 1 1 6 2 2 2 2 2 10 6 8 6 4 12 10 8 8 4 4 2 2 4 2 2 4 2 4 2 Part No 3304 304 018 3304 304 021 3304 304 040 3303 304 009 387539 3303 304 003 325966 3303 304 009 387539 3303 304 009 387539 3303 304 003 325966 3303 304 003 325966 3303 304 003 325966 3306 304 024 206798 3306 304 024 3304 304 025 288767 3304 304 025 3304 304 024 288766 3304 304 024 3304 304 023 287525 3304 304 023 3304 304 027 326063 3304 304 027 3303 304 010 438961 3304 304 015 0635 460 061 280133 0635 460 061 3303 304 008 325967 3304 304 016 3304 304 035 288763 3304 304 035 3304 304 034 288762 3304 304 034 3304 304 033 288761 3304 304 033 3304 304 032 288760 3304 304 032 3304 304 021 288758 3304 304 040 0630 503 040 320677 0630 513 059 3303 304 006 325959 3304 304 014 3303 304 005 325958 3303 304 011 326026 3304 304 017 3303 304 012 326060 3304 304 022 Part No Old p/n HBW 10/ZF 12 M/15 M 947.22.024.01 187872 3306 304 031 407230 947.42.017.01 288912 3306 304 027 407231 3306 304 011 326830 206798 3306 304 024 206798 288767 3306 304 008 195271 288766 3306 304 033 187840 287525 3306 304 006 287401 326063 3306 304 023 206817 438960 3306 304 022 439603 280133 0635 460 015 106700 288713 3306 304 032 407233 288763 3306 304 038 195717 288762 3306 304 037 195716 288761 3306 304 036 195715 288760 3306 304 035 195714 288758 280131 288755 3306 304 030 407139 305537 3306 304 026 387391 288756 3306 304 025 250992 288759 3306 304 021 251524 280132 0635 300 148 201187 Old p/n ZF 10 M 0635 300 411 320678 3304 304 037 Number ZF 3 M - ZF 5 M per gearbox Part No Old p/n Old p/n Part No Old p/n ZF 25 M Part No 3307 304 021 3307 304 021 3306 304 024 206798 3306 304 024 206798 3306 304 024 3306 304 008 195271 3306 304 008 195271 3306 304 008 3306 304 033 187840 3306 304 033 187840 3306 304 033 3306 304 006 287401 3306 304 006 287401 3306 304 006 3306 304 023 206817 3307 304 016 408093 3307 304 016 3306 304 022 439603 3307 304 015 274247 3307 304 015 0635 460 015 106700 0635 460 019 106732 0635 460 019 3306 304 032 407233 3307 304 017 326486 3307 304 017 3306 304 038 195717 3306 304 038 195717 3306 304 038 3306 304 037 195716 3306 304 037 195716 3306 304 037 3306 304 036 195715 3306 304 036 195715 3306 304 036 3306 304 035 195714 3306 304 035 195714 3306 304 035 3306 304 031 407230 3307 304 005 206026 3307 304 005 3306 304 027 407231 3306 304 011 326830 0630 502 031 277055 0630 502 031 3306 304 030 407139 3307 304 014 274271 3307 304 014 3306 304 026 387391 3307 304 019 305536 3307 304 019 3306 304 025 250992 3307 304 018 274242 3307 304 018 3306 304 021 251524 3306 304 021 251524 3306 304 021 3306 304 021 0635 300 148 Part No 3307 304 005 206798 3306 304 024 195271 3306 304 008 187840 3306 304 033 287401 3306 304 006 408093 3307 304 016 274247 3320 304 010 106732 0635 460 019 326486 3320 304 003 195717 3306 304 038 195716 3306 304 037 195715 3306 304 036 195714 3306 304 035 206026 3307 304 021 277055 0630 502 031 274271 3307 304 014 305536 3307 304 019 - - - - - - - - - - - - - - - - - - - Old p/n ZF 30 M 274242 3320 304 006 251524 201187 Old p/n ZF 25 MA 0635 300 148 201187 0635 300 148 201187 0635 300 148 Part No ZF 15 MA Manual and Spare Parts List ZF M line 55 56 Shim 1.0 mm 68d Nut (actuating lever) Spacer ZF 15 MA - ZF 25 MA Name plate Oil name plate 72 73 74 75 Stud Shim 0.5 mm 68c Needle bearing for shift cover Shim 0.2 mm 68b 69 Shim 0.1 mm 68a 70 Key Key 67 67 Output shaft Key 66 67 Reverse gear ZF 30 M - 2.7R «001» Z5=58 Reverse gear ZF 30 M - 2.15R «002» Z5=58 65 Reverse gear ZF 25 MA - 2.74R «006» Z5=52 65 65 Reverse gear HBW 250 - 3,5R «13» z = 49 Reverse gear ZF 25 MA - 2.23R «005» Z5=52 65 65 Reverse gear ZF 25 M - 2.27R «007» Z5=44 Reverse gear ZF 25 M - 2.74R «002» & «23» Z5=49 65 65 Reverse gear HBW 250 - 1,5R «16» z = 44 Reverse gear ZF 25 M - 1.88R «001» & «22» Z5=44 65 Reverse gear HBW 250 - 3L «19» z = 49 65 65 Reverse gear ZF 15 MA Z5=43 Reverse gear HBW 250 - 2L «20» z = 44 65 Reverse gear HBW 10 / ZF 12 M / ZF 15 M Z5=43 65 65 Reverse gear HBW 100 2L «17» z = 41 Reverse gear HBW 100 - 2,5R «21» z = 43 65 65 Reverse gear ZF 10 M - 2.72R «005» Z5=43 Reverse gear HBW 100 - 3R «16» z = 41 65 65 Reverse gear ZF 10 M - 1.79R «004» Z5=41 Reverse gear ZF 10 M- 2.05R «010» Z5=41 65 65 Reverse gear ZF 10 M - 1.48R «003» Z5=41 65 Item No Part name 1 1 1 1 2 4 1 1 1 1 4 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3304 304 012 3304 304 011 3304 304 011 3304 304 012 3304 304 011 3304 304 011 3304 304 011 Part No - 0631 501 634 3304 301 016 3306 301 005 - 3304 301 016 3306 301 005 0637 006 157 455785 0637 006 157 0636 610 232 396330 0636 610 232 0630 004 180 337662 0630 004 179 337664 0630 000 257 337665 0630 004 177 0631 501 634 280130 Old p/n 3306 304 018 407235 Part No HBW 10/ZF 12 M/15 M - - 3304 301 016 3306 301 005 - - 455785 0637 006 157 455785 0635 303 056 268620 396330 0636 610 232 396330 280130 3306 304 007 187841 439448 3306 304 019 407280 465466 288084 288084 465466 288084 288084 288084 Old p/n ZF 10 M 3303 304 004 325957 3304 304 013 Number ZF 3 M - ZF 5 M per gearbox Part No Old p/n Old p/n Old p/n 3307 304 006 288969 3307 304 006 288969 3307 304 009 274240 3307 304 009 274240 3307 304 009 274240 3307 304 006 288969 3307 304 009 274240 Part No ZF 25 M 3307 304 002 3307 304 002 Part No 3307 304 004 206121 3307 304 004 3304 301 016 3306 301 005 - - 3306 301 007 407474 3304 301 016 3306 301 005 - - 3304 301 016 3306 301 005 3307 301 004 0637 006 157 455785 0637 006 157 455785 0637 006 157 0635 303 056 268620 0635 303 056 268620 0635 303 056 0636 610 232 396330 0636 610 232 396330 0636 610 232 3306 304 007 187841 3320 304 005 3320 304 005 Part No - - - 3304 301 016 3306 301 005 455785 0637 006 157 268620 0635 303 056 396330 0636 610 232 206121 3307 304 004 - - - - - - - - - Old p/n ZF 30 M 408092 3320 304 011 - - Old p/n ZF 25 MA 3306 304 019 407280 3307 304 011 408092 3307 304 011 3306 304 004 407480 Part No ZF 15 MA Manual and Spare Parts List ZF M line Manual and Spare Parts List ZF M line Item No 1 2 3 4 5 6 6 7 7 8 9 10 11 12 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 36 36 36 36 37 38 39 40 41 42 43 44 44 44 44 45 46 47 48 Part name Housing assy Cover Cover Spring washer Hex screw Actuating lever * Actuating lever Hex. head screw * Hex. head screw (actuating lever) Shaft seal ring Cover Dowel pin Actuating cam assembly Shift cover assembly Shift fork Shift rod Plug Sealing ring Dipstick Oil drain plug Hex screw Hex nut Plug Intermediate shaft Disc Intermediate gear Needle bearing Gasket Gasket cover plate (or LOCTITE 574) Shaft seal, input Seal ring Tapered roller bearing Tapered roller bearing Input shaft HBW 150 V - 1.8R «08» z = 27/22 Input shaft ZF 15 MIV - 2.13R «001» z1/z3 = 24/22 Input shaft ZF 15 MIV - 2.72R «003» z1/z3 = 18/22 Input shaft ZF 15 MIV - 2.99R «002» z1/z3 = 19/22 Shim 0.10 mm Shim 0.15 mm Shim 0.50 mm Shim 1.00 mm Hex head screw Spacer Thrust ring Gear HBW 150V - 1,8R «08» z = 42 Gear ZF 15 MIV - 2.13R «001» z2 = 45 Gear ZF 15 MIV - 2.72R «003» z2 = 43 Gear ZF 15 MIV - 2.99R «002» z2 = 50 Needle bearing Needle bearing Spacer Spring Number per gearbox 1 1 1 39 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 14 15 1 1 2 1 1 2 1 1 2 2 1 1 1 1 1 2 2 2 2 1 1 2 1 1 1 1 2 2 2 4 ZF 15 MIV Part No 3306 201 004 3306 301 010 3306 301 023 0630 302 090 0636 015 289 947.23.006.01 3306 308 001 0636 015 299 0636 101 727 0634 502 009 3306 308 002 0631 329 032 3306 199 008 3306 108 002 3306 208 001 3307 301 012 0636 301 041 3306 301 016 3306 201 006 3306 301 013 0636 010 376 0637 006 157 0630 361 101 3306 303 006 3307 303 002 3306 303 001 3306 303 007 3306 301 014 3306 301 015 0634 301 833 0634 300 146 0635 501 597 0635 370 050 3306 302 006 3306 302 008 3306 302 009 3306 302 007 3306 302 011 3306 302 012 3306 302 015 3306 302 016 3306 304 057 3306 303 004 3306 304 029 3306 304 015 3306 304 014 3306 304 016 3306 304 013 0635 300 148 3306 304 021 3306 304 025 3306 304 026 Old p/n 344768 206450 326369 442372 215870 195062 500635 199807 442377 106864 388242 104559 407211 407210 223563 288673 442373 326578 345480 228566 215869 455785 322382 468772 288702 254730 215878 254715 254716 215875 401647 304088 325811 439197 313952 206474 206475 228540 228539 420280 326257 344787 407221 407220 439198 407219 201187 251524 250992 387391 * Up to letter «E» production date (see name plate description pag.46) 57 Manual and Spare Parts List ZF M line Item No 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 70 71 72 72 73 74 76 78 78 78 78 78 78 78 78 78 78 78 78 80 81 82 83 84 85 86 87 88 89 90 91 Part name Disc Ring half Internal clutch disc External clutch disc Shim 0.4 mm Shim 0.5 mm Shim 0.6 mm Shim 0.7 mm Disc carrier Ball Guide sleeve Change selector Pressure spring Stop pin Guide pin Torsion spring Gear z5= 43 Intermediate shaft z6=29 Cotter Tapered roller bearing Shim 0.1 mm Shim 0.3 mm Shim 0.5 mm Nut (actuating lever) Ring Tapered roller bearing Spacer ring Shim 1.3 mm Shim 1.4 mm Shim 1.5 mm Shim 1.6 mm Shim 1.7 mm Shim 1.8 mm Shim 1.9 mm Shim 2.0 mm Shim 2.1 mm Shim 2.2 mm Shim 2.3 mm Shim 2.4 mm Gear z = 33 Key Output shaft Ring nut Ring 0-Ring 0-Ring Needle bearing Stud Plug Name Plate Oil name plate * Up to letter «E» production date (see name plate description pag.46) 58 Number per gearbox 2 4 8 8 2 2 2 2 2 6 1 1 3 3 3 3 1 1 2 1 2 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 2 1 2 2 4 4 1 1 ZF 15 MIV Part No Old p/n 3306 304 030 3306 304 011 3306 304 027 3306 304 031 3306 304 035 3306 304 036 3306 304 037 3306 304 038 3306 304 032 0635 460 015 3306 304 022 3306 304 023 3306 304 006 3306 304 033 3306 304 008 3306 304 024 3306 304 018 3306 303 005 3306 304 007 0635 370 053 0630 004 260 0630 004 259 0630 004 258 0637 006 157 3306 304 054 0635 501 936 3306 304 009 3306 304 042 3306 304 043 3306 304 044 3306 304 045 3306 304 046 3306 304 047 3306 304 048 3306 304 049 3306 304 050 3306 304 051 3306 304 052 3306 304 053 3306 304 039 0631 501 182 3306 304 041 3306 304 010 3306 304 040 0634 306 072 0634 303 690 0635 303 056 0636 610 232 0636 301 039 3306 301 005 3304 301 016 407139 326830 407231 407230 195714 195715 195716 195717 407233 106700 439603 206817 287401 187840 195271 206798 407235 388411 187841 280839 280840 280841 455785 344690 327115 345469 345470 344673 344674 344675 344676 344677 344678 344679 344680 344681 344682 388410 105334 344670 195413 344644 105590 291618 268620 396330 338805 387428 Manual and Spare Parts List ZF M line ZF M SPARE PARTS KITS SEAL KITS ZF 3M - ZF 5M PART NAME Sealing ring O-Ring Sealing ring Gasket Gasket Sealing ring Sealing ring ZF 10 M PART NAME Sealing ring O-Ring Sealing ring Gasket Gasket Sealing ring Sealing ring KIT P/N 3303 199 001 Q.TY 1 1 2 4 1 1 1 P/N 0634 502 009 0634 306 179 3306 301 016 3304 301 015 3306 301 015 0634 301 830 0634 300 371 KIT P/N 3304 199 003 Q.TY 1 1 2 4 1 1 1 P/N 0634 502 009 0634 306 011 3306 301 016 3304 301 015 3306 301 015 0634 301 830 0634 300 371 HBW 10 - ZF 12 M - ZF 15 M - ZF 15 MA PART NAME Sealing ring O-Ring Sealing ring Gasket Gasket Sealing ring Sealing ring ZF 15 MIV PART NAME Sealing ring Sealing ring Gasket Gasket Sealing ring Sealing ring O-Ring O-Ring ZF 25 M - ZF 25 MA PART NAME Sealing ring Sealing ring Gasket Gasket Sealing ring Sealing ring ZF 30 M PART NAME Sealing ring Sealing ring Gasket Sealing ring Sealing ring Q.TY 1 1 2 4 1 1 1 P/N 0634 502 009 3306 301 016 3306 301 014 3306 301 015 0634 301 833 0634 300 146 0634 306 072 0634 303 690 KIT P/N 3307 199 001 Q.TY 1 2 4 1 1 1 POSITION Shift cover Shift fork shaft Drain plug/oil dipstick Cover Shifting cover Input shaft Output shaft ID/N 500427 ID/N 106864 105679 326578 288739 254716 280135 105153 POSITION Shift cover Intermediate shaft Drain plug/oil dipstick Cover Shifting cover Input shaft Output shaft KIT P/N 3306 199 001 P/N 0634 502 009 0634 303 118 3306 301 016 3306 301 014 3306 301 015 0634 301 833 0634 300 466 KIT P/N 3306 199 004 Q.TY 1 2 2 1 1 2 1 2 ID/N 500426 ID/N 106864 105524 326578 288739 254716 280135 105153 P/N 0634 502 009 3306 301 016 3307 301 011 3306 301 015 0634 301 832 0634 300 466 ID/N 106864 105530 326578 254715 254716 215875 105159 ID/N 500428 POSITION Shift cover Intermediate shaft Drain plug/oil dipstick Cover Shifting cover Input shaft Output shaft ID/N 500429 ID/N 106864 326578 254715 254716 215875 401647 105590 291618 POSITION Shift cover Drain plug/oil dipstick Cover Shifting cover Input shaft Output shaft Output shaft Output shaft ID/N 500430 (EXCL. VERS. 22; 23) ID/N 106864 326578 274251 254716 284260 105159 POSITION Shift cover Drain plug/oil dipstick Cover Shifting cover Input shaft Output shaft ID/N - POSITION Shift cover Drain plug/oil dipstick Cover Input shaft Output shaft KIT P/N 3320 199 001 Q.TY 1 2 4 1 1 P/N 0634 502 009 3306 301 016 3307 301 011 0634 311 025 0634 311 026 59 Manual and Spare Parts List ZF M line SEAL + CLUTCH PACK KITS ZF 3 M - ZF 5 M PART NAME Sealing ring O-Ring Sealing ring Gasket Gasket Sealing ring Sealing ring Thrust washer Inner clutch disc Outer clutch disc Spring Key Shim 0.15 mm Shim 0.2 mm Shim 0.30 mm Shim 0.1 mm Shim 0.15 mm Shim 0.30 mm ZF 10 M PART NAME Sealing ring O-Ring Sealing ring Gasket Gasket Sealing ring Sealing ring Thrust washer Inner clutch disc Outer clutch disc Spring Key Shim 0.1 mm Shim 0.15 mm Shim 0.30 mm Shim 0.1 mm Shim 0.15 mm Shim 0.30 mm KIT P/N 3303 199 002 Q.TY 1 1 2 4 1 1 1 2 4 4 3 1 2 2 2 2 2 2 P/N 0634 502 009 0634 306 179 3306 301 016 3304 301 015 3306 301 015 0634 301 830 0634 300 371 3304 304 019 3304 304 040 3304 304 021 3306 304 024 0631 501 634 3304 304 029 3304 304 030 3304 304 031 3304 302 011 3304 302 012 3304 302 014 KIT P/N 3304 199 004 Q.TY 1 1 2 4 1 1 1 2 8 6 3 2 2 2 2 2 2 2 P/N 0634 502 009 0634 306 011 3306 301 016 3304 301 015 3306 301 015 0634 301 830 0634 300 371 3304 304 019 3304 304 040 3304 304 021 3306 304 024 0631 501 634 3304 304 029 3304 304 030 3304 304 031 3304 302 011 3304 302 012 3304 302 014 HBW 10 - ZF 12 M - ZF 15 M - ZF 15 MA PART NAME Sealing ring O-Ring Sealing ring Gasket Gasket Sealing ring Sealing ring Thrust washer Inner clutch disc Outer clutch disc Spring Key Shim 0.3 mm Shim 0.4 mm Shim 0.1 mm Shim 0.15 mm Shim 0.30 mm 60 Q.TY 1 1 2 4 1 1 1 2 8 8 3 2 2 2 2 2 2 ID/N 500436 ID/N 106864 105524 326578 288739 254716 280135 105153 288748 288758 206798 280130 500016 288975 288974 288731 288732 288734 POSITION Shift cover Shift fork shaft Drain plug/oil dipstick Cover Shifting cover Input shaft Output shaft Bearing/gear Clutch pack Clutch pack Disc carrier Output shaft Clutch pack Clutch pack Clutch pack Input + output shaft Input + output shaft Input + output shaft ID/N 500437 ID/N 106864 105679 326578 288739 254716 280135 105153 288748 288758 206798 280130 500016 288975 288974 288731 288732 288734 POSITION Shift cover Intermediate shaft Drain plug/oil dipstick Cover Shifting cover Input shaft Output shaft Bearing/gear Clutch pack Clutch pack Disc carrier Output shaft Clutch pack Clutch pack Clutch pack Input + output shaft Input + output shaft Input + output shaft KIT P/N 3306 199 007 P/N 0634 502 009 0634 303 118 3306 301 016 3306 301 014 3306 301 015 0634 301 833 0634 300 466 3306 304 029 3306 304 027 3306 304 031 3306 304 024 3306 304 007 3306 304 034 3306 304 035 3304 302 011 3304 302 012 3304 302 014 ID/N 106864 105530 326578 254715 254716 215875 105159 344787 407231 407230 206798 187841 500254 195714 288731 288732 288734 ID/N 500438 POSITION Shift cover Intermediate shaft Drain plug/oil dipstick Cover Shifting cover Input shaft Output shaft Bearing/gear Clutch pack Clutch pack Disc carrier output shaft Clutch pack Clutch pack Input + output shaft Input + output shaft Input + output shaft Manual and Spare Parts List ZF M line SEAL + CLUTCH PACK KITS ZF 15 MIV KIT P/N 3306 199 005 PART NAME Sealing ring Sealing ring Gasket Gasket Sealing ring Sealing ring O-Ring O-Ring Thrust washer Inner clutch disc Outer clutch disc Spring Key Shim 0.3 mm Shim 0.4 mm Shim 0.1 mm Shim 0.15 mm Shim 0.30 mm ZF 25 M - ZF 25 MA PART NAME Sealing ring Sealing ring Gasket Gasket Sealing ring Sealing ring Thrust washer Inner clutch disc Outer clutch disc Spring Key Shim 0.3 mm Shim 0.4 mm Shim 0.1 mm Shim 0.15 mm Shim 0.20 mm ZF 30 M Q.TY 1 2 2 1 1 2 1 2 2 8 8 3 2 2 2 2 2 2 ID/N 500439 P/N 0634 502 009 3306 301 016 3306 301 014 3306 301 015 0634 301 833 0634 300 146 0634 306 072 0634 303 690 3306 304 029 3306 304 027 3306 304 031 3306 304 024 3306 304 007 3306 304 034 3306 304 035 3306 302 011 3306 302 012 3306 302 014 KIT P/N 3307 199 002 Q.TY 1 2 4 1 1 1 2 10 8 3 4 2 2 2 2 2 ID/N 106864 326578 254715 254716 215875 401647 105590 291618 344787 407231 407230 206798 187841 500254 195714 206474 206475 206477 POSITION Shift cover Drain plug/oil dipstick Cover Shifting cover Input shaft Output shaft Output shaft Output shaft Bearing/gear Clutch pack Clutch pack Disc carrier Intermediate shaft Clutch pack Clutch pack Input + intermediate shaft Input + intermediate shaft Input + intermediate shaft ID/N 500440 (EXCL. VERS. 22; 23) P/N 0634 502 009 3306 301 016 3307 301 011 3306 301 015 0634 301 832 0634 300 466 3307 304 020 3307 304 021 3307 304 005 3306 304 024 3307 304 004 3306 304 034 3306 304 035 3307 302 006 3307 302 007 3307 302 008 ID/N 106864 326578 274251 254716 284260 105159 327395 206026 206798 206121 500254 195714 274252 274253 274254 POSITION Shift cover Drain plug/oil dipstick Cover Shifting cover Input shaft Output shaft Bearing/gear Clutch pack Clutch pack Disc carrier Output shaft Clutch pack Clutch pack Input + output shaft Input + output shaft Input + output shaft P/N 0634 502 009 3306 301 016 3307 301 011 0634 311 025 0634 311 026 3307 304 020 3307 304 021 3307 304 005 3306 304 024 3307 304 004 3306 304 034 3306 304 035 3307 302 006 3307 302 007 3307 302 008 ID/N - POSITION Shift cover Drain plug/oil dipstick Cover Input shaft Output shaft Bearing/gear Clutch pack Clutch pack Disc carrier Output shaft Clutch pack Clutch pack Input + output shaft Input + output shaft Input + output shaft KIT P/N 3320 199 003 PART NAME Sealing ring Sealing ring Gasket Sealing ring Sealing ring Thrust washer Inner clutch disc Outer clutch disc Spring Key Shim 0.3 mm Shim 0.4 mm Shim 0.1 mm Shim 0.15 mm Shim 0.20 mm Q.TY 1 2 4 1 1 2 12 10 3 4 2 2 2 2 2 61 Manual and Spare Parts List ZF M line BEARING KITS (ALL VERSIONS) ZF 3 M - ZF 5 M KIT 501220 P/N 3303 199 003 PART NUMBER 0635 501 943 0635 300 526 0635 300 411 3303 304 012 3304 302 011 ZF 10 M DESCRIPTION Tapered roller bearing Cage Needle cage Needle bearing inner race Shim 0.10 mm KIT 501221 DESCRIPTION Tapered roller bearing Cage Needle cage Needle bearing inner race Shim 0.10 mm KIT 501222 PART NUMBER 0635 501 597 0635 300 148 3306 304 021 3306 303 007 0635 303 056 3306 302 011 ZF 15 MIV 62 DESCRIPTION Tapered roller bearing Tapered roller bearing Tapered roller bearing Cage Tapered roller bearing Needle cage Needle bearing inner race Needle bearing Shim 0.10 mm Shim 0.10 mm KIT 501224 LOCATION Input + Output shaft Reverse gear Reverse gear Intermediate shaft Shift cover Input + Output shaft Q.TY 4 2 2 1 2 4 LOCATION Input shaft Clutch shaft Clutch shaft Intermediate shaft Output shaft Reverse gear Reverse gear Shift cover Clutch shaft Input + Output shaft Q.TY 2 1 1 1 2 2 2 1 2 4 LOCATION Input shaft Output shaft Reverse gear Reverse gear Intermediate shaft Shift cover Input + Output shaft Q.TY 2 2 2 2 1 2 4 LOCATION Input shaft Output shaft Reverse gear Reverse gear Intermediate shaft Shift cover Input + Output shaft Q.TY 2 2 4 4 2 2 4 P/N 3307 199 003 PART NUMBER 0635 370 042 0635 370 051 0635 300 148 3306 304 021 3307 303 004 0635 303 056 3307 302 006 DESCRIPTION Tapered roller bearing Tapered roller bearing Needle cage Needle bearing inner race Cage Needle bearing Shim 0.10 mm PART NUMBER 0635 370 042 0635 370 051 0635 300 148 3306 304 021 0635 300 114 0635 303 056 3307 302 006 DESCRIPTION Tapered roller bearing Tapered roller bearing Needle cage Needle bearing inner race Cage Needle bearing Shim 0.10 mm ZF 30 M Q.TY 4 1 2 2 4 P/N 3306 199 006 PART NUMBER 0635 501 597 0635 370 050 0635 370 053 3306 303 007 0635 501 936 0635 300 148 3306 304 021 0635 303 056 0630 004 260 3306 302 011 ZF 25 M - ZF 25 MA LOCATION Input + Output shaft Intermediate shaft Reverse gear Reverse gear Input + Output shaft P/N 3306 199 003 DESCRIPTION Tapered roller bearing Needle cage Needle bearing inner race Cage Needle bearing Shim 0.10 mm KIT 501223 Q.TY 4 1 2 2 4 P/N 3304 199 005 PART NUMBER 0635 501 943 0635 300 530 3304 304 037 3304 304 022 3304 302 011 HBW 10 - ZF 12 M - ZF 15 M LOCATION Input + Output shaft Intermediate shaft Reverse gear Reverse gear Input + Output shaft P/N 3320 199 002 Manual and Spare Parts List ZF M line 10. Drawings (Explosion view) ZF 3M, ZF 5M, ZF 10M, ZF 12M, ZF 15M, ZF 15MA, ZF 25M, ZF 25MA, ZF 30M, 63 Manual and Spare Parts List ZF M line 68a 68b 68d 68c ZF 3M, ZF 5M, ZF 10M, ZF 12M, ZF 15M, ZF 15MA, ZF 25M, ZF 25MA, ZF 30M, 64 Manual and Spare Parts List ZF M line ZF 15 MIV 65 Manual and Spare Parts List ZF M line ZF 15 MIV 66 Manual and Spare Parts List ZF M line ZF 15 MIV 66 www.miniato.it ZF-HURTH MARINE
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File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.3 Linearized : Yes Create Date : 2003:11:28 15:51:50 Producer : Acrobat Distiller 4.0 for Macintosh Modify Date : 2004:05:19 07:51:30+02:00 Page Count : 69EXIF Metadata provided by EXIF.tools