ZF 2000 Om

Operating Instructions
ZF 2000; ZF 2050; ZF 2150

ZF 2000 NR; ZF 2050 NR; ZF 2150 NR
ZF 2000 A; ZF 2050 A; ZF 2150 A
ZF 2000 NRA; ZF 2050 NRA; ZF 2150 NRA
ZF 2000 V; ZF 2050 V; ZF 2150 V
ZF 2000 NRV; ZF 2050 NRV; ZF 2150 NRV
ZF Marine Transmission
ZF 2000 Series
3100 758 101
Safety Instructions ZF 2000 Series
The following safety instructions appear in this manual.

! ENVIRONMENTAL HAZARDS
NOTE Do not allow lubricants and cleaning agents to get into
Refers to special processes, techniques, data, use of the water, soil, groundwater or drainage systems.
auxiliary equipment etc.
Request safety data sheets for the appropriate
VORSICHT products from your relevant environmental
This is used when incorrect, unprofessional working protection agency and comply with the
practices could damage the product. requirements they contain.
Collect waste oil in a sufficiently large
container.
! DANGER Dispose of waste oil, contaminated filters,
This is used when lack of care could lead to personal
lubricants and cleaning agents in accordance
injury or death.
with environmental protection regulations.
Comply with the manufacturer’s instructions
when handling lubricants and cleaning agents.
Subject to alterations in design
Copyright by ZF
These operating instructions are protected by copyright. Any reproduction and dissemination in whatever form – also
in adapted, paraphrased or extracted form – in particular as a reprint, photomechanical or electronic reproduction or
as a storage in data-processing equipment or data networks without approval by the holder of the copyright is
prohibited and will be prosecuted under civil and criminal law.
Printed:
Edition: 04.02
3100 758 101
2
ZF 2000 Series
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Power, speed, rotation direction, ratio,
type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Transmission views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 ZF 2000 – transmission views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 ZF 2000 A – transmission views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 ZF 2000 V – ZF 2000 – transmission views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Monitoring data for ZF 2000 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Oil supply and transmission cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.1 Control unit and transmission actuation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1 Electrical transmission actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 Mechanical transmission actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7 Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1 Changeover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2 Operation with engine at a standstill and propeller driven by the current
(trailing operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.3 Special versions / special scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8 Operating when the actuation device is faulty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

8.1 Mechanical emergency operation of the electrical actuation valve . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.2 Mechanical emergency operation of the mechanical actuation valve . . . . . . . . . . . . . . . . . . . . . . . 22
9 Operation with emergency shift (“Come home screws”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10 Trolling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.1 Electrical trolling (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.2 ZF-AUTOTROLL (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11 Troubleshooting notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12 Spare parts orders and service centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3
ZF 2000 Series
13 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13.1 Application group P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13.2 Application group L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13.3 Application group M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13.4 Application group C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
14 Maintenance time schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

14.1 Regular maintenance jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
14.2 Additional one-off maintenance jobs on new or overhauled transmission
(also see maintenance jobs 12.1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
14.3 Anti-corrosion protection measures after long periods of downtime
(see “Corrosion-proofing” Appendix). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
15 Maintenance job schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

15.1 Maintenance level / maintenance jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
16 Tool kit for maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

16.1 Tool kit W1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1 Maintenance system job sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4
ZF 2000 Series Foreword
Operating Instructions
Foreword
ZF Marine Transmission
2000ARH 2000VLV
ZF 2000 A ZF 2000 V
The operating instructions apply to the standard version of the transmission. Variations are possible according to
special customer requirements and operating conditions. If the data contained in the operating instructions are
different to the data contained in the technical or commercial specifications, the data in the specifications shall apply.
Important!
Ensure that these operating instructions are always kept to hand. Carefully read the operating instructions. Pay
particular attention to the safety instructions.
Some of the illustrations contained in the operating instructions may differ from your installed transmission.
Furthermore, safety devices and covers may sometimes be omitted to enable clearer illustration.
5
Description ZF 2000 Series
1 Description Key
1.1 Power, speed, rotation direction, ratio, 1 Model
type plate 2 Serial no.
3 Parts list no.
ZF marine transmissions are designed and manufactured 4 Customer reference no.
according to the regulations of the various classification 5 Total ratio
societies. The input powers approved by the 6 Oil capacity
classification societies depend on the input speed, the 7 Mass (dry)
class of the craft and the different design regulations 8 Lubricant, see ZF List of Lubricants
currently in force. In most cases, the maximum torques TE-ML 04
approved by ZF are also fully accepted by the 9 Clutch oil pressure (nominal)
classification societies. 10 Max. power/speed ratio for intermittent operation
at very widely differing engine speeds
If requested, the classification society specified by the 11 Max. power/speed ratio for intermittent operation
customer can carry out a full test or factory acceptance at widely differing engine speeds
test (test stand). 12 Max. power/speed ratio for intermittent operation
at differing engine speeds
Normally, the input shaft rotates in a clockwise direction 13 Max. power/speed ratio for continuous operation
(looking at the transmission input flange). Transmissions at max. engine power
which are specially designed for anti-clockwise input
shaft rotation (looking at the transmission input flange)
have an arrow on the transmission input end to show the NOTE
rotation direction. For items 10 to 13, also refer to section 13
“Maintenance”.
The total ratio is stamped on the transmission type plate
which is located on the back of the transmission housing. Information under 1, 2, 3 and 5 must be quoted when
querying problems and ordering spare parts etc.
Data included on the type plate:
1.2 General
FRIEDRICHSHAFEN (See the end of this section for different features of the
- GERMANY -
“NR” series)
MODEL SERIAL NO.
1 2 The ZF 2000 Series transmissions are axially offset

PARTS LIST NO. REFERENCE NO.
3 4 reversing and step-up gears of 3-shaft design with a

RATIO TOTAL MAIN GEAR SPUR GEAR clutch on both the transmission input shaft and the
5 reversing shaft. The general design is the same for all
OIL CAPACITY (dm 3 ) MASS DRY (kg) CLUTCH OIL PRESSURE (bar)
6 7 9 transmissions. The main components subject to wear can

6
PLEASURE LIGHT 8 MEDIUM CONTINUOUS
be accessed through an aperture in the housing, even if
kW/RPM 10 11 12 13 the transmission is still installed.
OIL CHANGE: AFTER FIRST 50 HOURS OPERATION AND
8 EVERY 1000 HOURS OR 12 MONTHS, WHICHEVER OCCURS FIRST.
LUBRICANT SEE ZF LIST TE-ML04 SAE 30 OR 40
6
ZF 2000 Series Description
At the same time, the flow of oil to the operating clutch

220 mm for .. 2000
is increased, i.e. the heat generated during shifting is
quickly dissipated, which means that the clutches can
operate efficiently under extreme load. The heat
generated in trolling mode is also reliably dissipated,
even during continuous operation.
In the event of faults in the operating oil circuit, both

= Normal version
multi-disk clutches can be mechanically pressed
together by means of three bolts which are accessible
from the outside (only when the transmission is at a
standstill). This emergency control feature can be used to
engage “enginewise” propulsion or “counter-
280 mm for .. 2000 A enginewise” propulsion.
280 mm for .. 2000 V
An easily replaceable control unit – fitted with all the
valves, slides and control equipment for the operating
and lubricating oil circuits – is built onto the
10°
transmission housing.
= A-version
= V-version In the basic version of the transmission, the ZF 2000 /

ZF 2000A/V control unit is actuated electrically. If
required, can also be supplied with mechanical
actuation.
The cast transmission housings are extremely torsionally The electrical transmission actuation system can also be
rigid and made from a light metal alloy which is almost supplied with an electrical trolling valve or ZF-
totally resistant to salt water. The machined surfaces and Autotroll.
tapped holes required for attaching the transmission
mountings and the bell housing are included as standard. Differences in the NR Series:
In order to ensure long life and quiet operation, all The NR ... Series transmissions are step-up gears with
power-transmitting gearing is designed with high safety one clutch which can be arranged either on the input
levels in mind, case-hardened, ground and then specially shaft or on the reversing shaft.
treated.
Depending on the version, the output rotation direction
The shafts run in anti-friction bearings. A propeller can be the same as or opposite to the input rotation
thrust bearing is installed in the transmission to absorb direction. Otherwise, the design and the external
the propeller thrust. The reversing clutches arranged on dimensions are exactly the same as in the reversing
the input shaft and the reversing shaft are multi-disk transmission.
clutches with steel/sinter disks. They are operated by
means of oil pressure.
The high delivery rate of the oil pump ensures rapid

clutch response. The contact pressure of the clutch is
modulated during shifting to ensure smooth operation.
7
Transmission views ZF 2000 Series
2 Transmission views
2.1 ZF 2000 – transmission views
ZF marine transmissions ZF 2000, ZF 2000 NR, ZF 2050, ZF 2050 NR, ZF 2150, ZF 2150 NR
The add-ons, connections and pipes on your transmission may be different to those pictured here.
46
25
23
34
2000prh
18
2 21 5 53
28
2000pvl
20
8
ZF 2000 Series Transmission views
15 22 47 189 188
13
41
33
10
44 2000plh 26
11 20 12
Key:
1 Transmission mounting faces 25 Oil dipstick
2, 21 Measuring point for clutch oil pressure 26 Output
5 Measuring point for oil pressure upstream 28 Flange-mounting face for bell housing
of filter
33 Oil filter
8 Input
34 Emergency control
10 Engine-driven oil pump (counter-enginewise rotation)
11, 12, 41 Measuring points for oil temperature 44 Emergency control
(enginewise rotation)
13 Water connection flanges
46 Oil filler hole
15 Oil cooler
47 Inspection hole cover transmission housing
18 Position for trailing oil pump
53 Measuring point for oil temperature
20 Oil drain plug downstream of cooler
22 Measuring point for lubricating 188 Emergency actuation of the electrical
oil pressure control valve (enginewise rotation)
23 Transmission breather 189 Emergency actuation of the electrical
control valve (counter-enginewise rotation)
9
2.2 ZF 2000 A – transmission views

ZF marine transmissions ZF 2000 A, ZF 2000 NRA, ZF 2050 A, ZF 2050 NRA, ZF 2150 A, ZF 2150 NRA
46
25
23
34
18
21 5 53
2000ARH
28
20 2000AVL
10
15 22 47 189 188
13
41
33
10
44
26
2000ALH
11 20 12
Key:
of filter 33 Oil filter
8 Input 34 Emergency control
13 Water connection flanges (enginewise rotation)
15 Oil cooler 46 Oil filler hole
18 Position for trailing oil pump 47 Inspection hole cover transmission housing
20 Oil drain plug 53 Measuring point for oil temperature

downstream of cooler
22 Measuring point for lubricating
oil pressure 188 Emergency actuation of the electrical
control valve (enginewise rotation)
23 Transmission breather
189 Emergency actuation of the electrical
11
2.3 ZF 2000 V – transmission views

ZF marine transmissions ZF 2000 V; ZF 2000 NRV; ZF 2050 V; ZF 2050 NRV; ZF 2150 V; ZF 2150 NRV.
46
25
23
34
3100VRV
18
21 5 53
3100VHL
20
12
15 22 47 189 188
13
8
33
1
26
10
3100VLV
11 20 12
Key:
of filter
33 Oil filter
8 Input
34 Emergency control
(enginewise rotation)
13 Water connection flanges
46 Oil filler hole
15 Oil cooler
47 Inspection hole cover transmission housing
18 Position for trailing oil pump
53 Measuring point for oil temperature
20 Oil drain plug
downstream of cooler
22 Measuring point for lubricating
oil pressure
control valve (enginewise rotation)
23 Transmission breather
13
14
3 Monitoring data for ZF 2000 Series
Monitoring data for ZF 2000 Series

Filter Clutch oil pressure Lubricating Oil temperature
contamination oil pressure
P, L, M-apps. C application P, L, M, C-apps.
Measuring point 1) 5 2, 21, 27 22 11, 12, 41
Operating mode “Neutral” 9) Position 9) Position 9) __________ Normal operation Trailing
Enginewise or Enginewise or “Neutral” operation 8)
counter- counter-engine-
enginewise wise rotation
rotation
Nominal value __________ PKN 7) __________ __________ __________ __________ __________
Nom. display min __________ PK = PKN – 1 bar 4) 3.5 bar 0.4 bar 30 °C 30 °C __________
value
max 21 bar PK = PKN + 2 bar 4) 6 bar 8 bar 90 °C 100 °C 75 °C 8) 11)
105 °C 8) 12)
Warning __________ PK = PKN – 3 bar __________ 0.25 bar ▼ 2) 95 °C ▲ 2) 105 °C ▲ 2) __________
▼ 2) 5) 6)
Minimum monitoring 14) Pressure switch Pressure gauge 0 to 25 bar __________ Thermometer 0 to 120 °C
Additional monitoring 14) Pressure gauge Pressure switch or6) Pressure switch Temperature switch 2) or temperature sensor 16)
0 to 40 bar 3) pressure sensor 16) or pressure 0 to 120 °C
0 to 25 bar gauge 0 to 6 bar
1) Refer to monitoring plan in installation manual for 8) For operation with engine at a standstill and ▲ Increasing
schematic arrangement; refer to installation drawing current-driven propeller (also refer to Section 7, ▼ Decreasing
or operating instructions or “Basic transmission page 22)
description” section in installation manual for PK = Clutch oil pressure
9) For normal operation without trolling
arrangement on transmission PKN = Nominal clutch oil pressure
10) Not listed in above table
2) For visual and audible warning PVF = Pressure upstream of filter
11) Without trailing pump
3) Use distributor
ZF 2000 Series
12) With trailing pump
4) At 60 °C to 80 °C oil temperature
13) Not listed in above table
5) With time delay 3 to 10 s (to be provided by shipyard)
14) Not within the standard ZF scope of supply
6) Warning must be rendered inoperational in
“Neutral” or “Trolling on” position 15) Not listed in above table
7) The nominal clutch pressure is specified in the 16) For remote display
binding, order-specific technical documents and also 17) Not listed in above table
stamped on the type plate.
ZF 2000 Series Functional description
4 Functional description
Transmission and power flow diagram ZF 2000, ZF 2050, ZF 2150

(ZF 2000 NR, ZF 2050 NR, ZF 2150 NR only have clutches D and E)
Gears are in
mesh
A = Input shaft
B = Reversing shaft
Power flow
C = Output shaft
Counter-enginewise
rotation D = Clutch for counter-
Enginewise rotation enginewise rotation
E = Clutch for enginewise rotation
Transmission and power flow diagram ZF 2150 A, ZF 2150 V

(ZF 2150 A NR, ZF 2150 V NR only have clutches D and E)
D D
A A
Gears are in Gears are in
B mesh B mesh
E
C C
Counter-enginewise A = Input shaft
A roatation A B = Reversing shaft
C C C = Output shaft
Enginewise D = Clutch for counter-
B A roatation A enginewise rotation
B
C C E = Clutch for enginewise rotation
The transmission and power flow diagram shows the The full amount of engine power can be transmitted in
power flow for “enginewise” output rotation (input and both output rotation directions. The ratio specified on the
output rotating in the same direction) and for “counter- type plate applies to both output rotation directions, i.e.
enginewise” output rotation (input and output rotating in identical transmission versions can be used in multi-
opposite directions). engine installations. This set-up requires fewer spare
parts and permits the use of standardized reconditioned
transmissions.
15
Oil supply and transmission cooling ZF 2000 Series
5 Oil supply and transmission cooling

The transmission housings are designed as oil reservoirs. electrically operated pilot valve. Electrical transmission
An oil pump is installed to supply oil for transmission actuation is the basic transmission version.
lubrication, transmission cooling and engagement of the
multi-disk clutch. This pump supplies oil to the pressure
oil circuit at a rate dependent on the speed of the
transmission input shaft. A high-output pump is used to
ensure ample oil for transmission lubrication and
cooling, even at low transmission input speeds.
The oil pump is driven by a driver off the transmission

intermediate shaft.
The transmissions are equipped with an oil cooler

manufactured from saltwater-resistant material for
cooling the transmission oil. After cooling, the oil passes
through an oil filter (slot-type filter) to the control unit
and then to the clutches and the transmission lubrication
points.
Connecting unions are provided as standard equipment

for monitoring transmission temperature, oil pressure
upstream of the filter, lubricating oil pressure and clutch
oil pressure. (Refer to section 2 “Transmission views”
for details of positions and designations.)
5.1 Control unit and transmission actuation

The control unit is a complete assembly located on the
transmission housing. It contains:
● The control slide valve for filling and ventilating the

transmission clutches
● The control valve for setting the clutch pressure
● The time switch for modulating the clutch pressure
The control slide valve is axially moved into the desired

position. This may be by mechanical or electrical means,
depending on the type of actuation. The oil flowing out
of the control unit is used for lubricating and cooling the
clutch disks, the meshing gears and the bearings.
With mechanical transmission actuation, the control

slide valve is moved in the control unit by oil pressure
via a mechanically operated pilot valve.
With electrical transmission actuation, the control slide

valve is moved in the control unit by oil pressure via an
16
ZF 2000 Series Actuation
6 Actuation
6.1 Electrical transmission actuation ! DANGER
With electrical transmission actuation, the control slide The transmission clutches are disengaged in “Neutral”
valve is moved in the control unit by oil pressure via an shift position. The propeller shaft can still keep turning.
electrically operated pilot valve. The pilot valve is If you require the propeller shaft to be stationary, then
mounted on the control unit. it is necessary to provide a propeller shaft brake or
another shaft interlock.
The pilot valve has two electromagnets. These are:
Enginewise: Only electromagnet “a” on the
transmission output end is energized.
• The electromagnet pointing towards the transmission
output (valve end “a”) which is responsible for the
Counter-enginewise: Only electromagnet “b” is
“enginewise” shift position (output shaft rotating in the
energized (opposite end to “a”).
same direction as the input).
• The opposite electromagnet (valve end “b”) which is CAUTION
responsible for the “counter-enginewise” shift position Both electromagnets “a” and “b” are not allowed to be
(output shaft rotating in the opposite direction to the energized at the same time.
input).
a b ! DANGER
The transmission automatically reverts to “Neutral” if
c there is a power failure. This may make it impossible
d to maneuver the craft.
If there is a malfunction in the electrical power supply,

the pilot valve can be locked against electromagnet “a”
and “b” as an emergency measure. This is done by using
a 3 mm Allen key to turn a threaded pin with a hexagon
socket (see section 8.1). Make sure you include a 3 mm
Allen key in your on-board toolkit and that it can be
accessed by the ship’s crew in case of an emergency.
a Electromagnet for “enginewise” shift position ! DANGER

When the emergency actuation is applied, the craft
b Electromagnet for “counter-enginewise” shift cannot be controlled using the selector lever. The
position emergency actuation must be deactivated in order to
c Pilot valve permit control using the electrical actuation device. To
do this, unscrew the threaded pins on both
d Control unit electromagnets of the pilot valve so they are flush with
The shift position can be selected as follows by the plane face. Before setting off, make sure that the
activating these electromagnets: emergency actuation of the pilot valve has not been
activated.
Neutral: No voltage at either of electromagnets “a” or
“b”
17
Actuation ZF 2000 Series
6.2 Mechanical transmission actuation

With mechanical transmission actuation, the control
slide valve is moved in the control unit by oil pressure
via a mechanically operated pilot valve. The pilot valve
is mounted on the control unit.
The pilot valve has a lever for actuation.
The shift position is selected by moving the lever. The

lever can be moved 32 degrees about its axis of rotation.
The pivoting range is limited by stops. The central
position between these stops corresponds to neutral.
Each shift position is detent and can be selected as
follows: (as seen looking onto the axis of rotation):
Neutral: The lever is in the detent central position.
! DANGER
The transmission clutches are disengaged in “Neutral”
shift position. The propeller shaft can still keep turning.
If you require the propeller shaft to be stationary, then
it is necessary to provide a propeller shaft brake or
another shaft interlock.
Enginewise: Pivot the lever from the central position

counter clockwise until it engages (Detent
position enginewise output rotation).
Counter-enginewise: Pivot the lever from the central

position clockwise until it engages (Detent
position counter-enginewise output
rotation).
The actuation force is about 25 N with a lever arm length

of 100 mm. To ensure reliable shifts, check the selector
travel distances achieved on the transmission at certain
intervals and after every repair or overhaul. Correct the
travel distances if necessary. Check also the clamping
screw at certain intervals and after every repair or
overhoul. Tightening torque 23 Nm.
18
ZF 2000 Series Normal operation
7 Normal operation 7.1.4 Emergency changeover in the event of danger

During normal operation, the transmission requires little In the event of an emergency, it is of course possible to
attention apart from monitoring of the transmission change from “Ahead” to “Astern”, even at high engine
temperature and transmission oil pressure gauges. speeds.
7.1 Changeover However, in this case also, we recommend waiting 1 to

2 seconds after selecting “Astern” before increasing the
In our experience, the changeover procedures described
engine speed.
below are optimum, i.e. they stop the craft in the shortest
possible time and offer the best possible protection for
During such maneuvers, please note that, in many cases
the transmission reversing clutches and, therefore, the
(depending on the type of craft etc.), the time needed to
entire propulsion system. We therefore strongly
bring the craft to a halt is not shortened at all or is only
recommend you follow the changeover procedures
shortened very slightly compared to the changeover
suggested here. Changes from “Neutral” to “Ahead” or
procedure described above. Therefore, in spite of the
“Astern” and vice versa must be performed quickly. The
considerably increased load on the propulsion system,
lever should never remain in the undefined ranges
the chances of avoiding a collision are not greatly
between these positions.
reduced in most cases.
7.1.1 Changeover from “Neutral” to “Ahead” or
7.2 Operation with engine at a standstill and
from “Neutral” to “Astern”
propeller driven by the current
Move the engine throttle control to idle position. Select (trailing operation)
the desired direction of travel and wait 1 to 2 seconds. 7.2.1 Occasional trailing operation
Then increase the engine speed to the desired operating
speed. The basic transmission version (without trailing oil
pump) allows occasional trailing operation.
7.1.2 Changeover from “Ahead” to “Astern” with
craft moving at low speed The transmission oil temperature must be monitored
(not for ZF...NR) (measuring points 11 and 12 are in the oil sump) and may
not exceed 75 °C. If the oil temperature is too high, the
Move the engine throttle control to idle position. Select
craft speed must be reduced. If required, the engine can
the opposite direction of travel to the one selected and
also be operated for a short period until the transmission
wait 1 to 2 seconds. Then increase the engine speed to
oil temperature falls to the required level as a result of
the desired operating speed.
coolant circulation (transmission in “Ahead” or
7.1.3 Changeover from “Ahead” to “Astern” with “Neutral” position). Trailing operation is permitted for
craft moving at high speed up to 15 hours in emergencies.
(not for ZF...NR)
7.2.2 Regular trailing operation
Move the engine throttle control to idle position. Leave
the transmission control lever in “Ahead” position – in If regular trailing operation is envisaged for periods of
order to utilize the engine braking effect on the propeller more than 5 hours uninterrupted, a trailing oil pump (see
– until the engine speed has dropped to approx. 1.2 x idle Section 7.3) must be installed. The oil temperature must
speed. Then select “Astern” and wait 1 to 2 seconds. be monitored and may not exceed 105 °C (the sump
Then increase the engine speed to the desired operating temperature is approximately the same as the clutch disk
speed. temperature). If the oil temperature is too high, the craft
speed must be reduced or coolant must be directed
through the transmission oil cooler. The coolant quantity
can either be obtained by means of a special valve in the
operative engine units or supplied by a separately driven
water pump. Given the dimensions, a coolant quantity
19
Normal operation ZF 2000 Series
equal to max. 25 % of the water quantity used during Maintenance notes

normal operation can be reckoned with. Maintenance jobs 101 and 102 must be carried out on a
daily basis, even in the case of operation with the engine
CAUTION at a standstill and the propeller rotating (see section 5)
If the transmission oil temperature exceeds 90 °C, ensure
that the transmission remains in “Neutral” after the
engine is started. Normal operation is only permitted
once the transmission oil temperature has fallen below
90 °C.
7.3 Special versions / special scope of supply

If a special version or special scope of supply requires
different operating and maintenance procedures which
are not described in the following sections, please refer
to the order-specific specifications for details.
7.3.1 Special scope of supply – transmission with

additional trailing oil pump (item 18)
This oil pump is fitted on the transmission housing in the 18
output shaft area. It is driven by the transmission output
shaft via a gear train. The oil pump always delivers oil to
the oil circuit in the same direction, irrespective of the
output rotation direction. When the engine is at a 18Trailing oil pump
standstill and the output shaft is turning, this oil pump
supplies lubricating oil to the transmission. This means
that it is permissible to operate the unit as long as is
required when the engine is at a standstill and the
propeller is rotating.
Operating notes
For operation with engine at a standstill and rotating
propeller shaft, the transmission actuator must be in
“Neutral” position.
Monitoring notes
There is no need to monitor the oil pressures when the
engine is at a standstill. The transmission oil temperature
must be monitored as specified in Section 3.
Furthermore, there is an additional measuring point (41)
for measuring the oil temperature (see section 2).
Only the transmission oil temperature can be measured

at measuring point (41) when the oil pump or trailing
pump is circulating oil.
20
ZF 2000 Series Operating when the actuation device is faulty
8 Operating when the actuation device is faulty 1. Switch off the engine.
The transmission can be mechanically operated by hand 2. Set the shift position on the pilot valve.
in the event of malfunctions in the actuation device.
8.1 Mechanical emergency operation of the ! DANGER

electrical actuation valve
Engine and transmission components can get very hot
Manual operation involves threaded pins with a 3 mm (danger of burns). Take appropriate safety precautions.
hexagon socket which are arranged on the ends of the
pilot valve. Neutral shift position
There are two positions for these threaded pins: Electromagnet “a”: Threaded pin screwed out (flush
with plane face)
Screwed out: Flush with the plane face
Electromagnet “b”: Threaded pin screwed out (flush
Screwed in: Screwed in by approx. 5 mm
with plane face)
In either case, resistance is encountered when the limit
position is reached.
189 d 188
Enginewise shift position
Electromagnet “a”: Threaded pin screwed in (approx. 5

mm in from plane face)
Electromagnet “b”: Threaded pin screwed out (flush
with plane face)
188 Position of the threaded pin for the

“enginewise” shift position (output shaft
rotating in the same direction as the input)
189 Position of the threaded pin for the
“counter-enginewise” shift position (output
shaft rotating in the opposite direction to
the input)
d Pilot valve
Manual actuation is to be performed in the following
sequence:
21
Operating when the actuation device is faulty ZF 2000 Series
Counter-enginewise shift position ! DANGER

When the emergency actuation is applied, the craft
Electromagnet “a”: Threaded pin screwed out (flush
cannot be controlled using the selector lever. The
with plane face)
emergency actuation must be deactivated in order to
Electromagnet “b”: Threaded pin screwed in (approx. 5 permit control using the electrical actuation device. To
mm in from plane face) do this, unscrew the threaded pins on both
electromagnets of the pilot valve so they are flush with
the plane face. Before setting off, make sure that the
emergency actuation of the pilot valve has not been
activated.
8.2 Mechanical emergency operation of the

mechanical actuation valve
Emergency actuation is performed using the lever of the
pilot valve. To do this, unhook the pull/push cable or
linkage of the remote mechanical actuation from the
pilot valve lever when the engine is stopped.
Mechanical emergency actuation is to be performed in

3. Start the engine and check the correct direction of the following sequence:
travel. Repeat points 1 to 3 to correct the direction of
travel. 1. Switch off the engine.
2. Make sure the pull/push cable or linkage for the
removed mechanical actuation is unhooked.
! DANGER 3. By hand, move the lever of the pilot valve to the
The clutch set using the pilot valve is always engaged required shift position until it engages.
when the engine is running. When the mechanical Neutral: The lever is engaged in the central position.
emergency actuation of the transmission has been
engaged, the transmission cannot be shifted to neutral Enginewise: Pivot the lever from the central position
or reversed using the selector lever. The helmsman towards the transmission output until it
must always be aware of this fact. Operation of the engages.
craft must be adapted to take account of this situation.
In port or when traveling on a narrow or busy Counter-enginewise: Pivot the lever from the central
waterway, stop the engine and have the craft towed. position towards the opposite end to the
transmission output until it engages.
To deactivate mechanical manual actuation, switch off
The actuation force is about 25 N with a lever arm length
the engine and screw out both threaded pins on the pilot
of 100 mm.
valve so they are flush with the plane face.
4. Use appropriate measures (e.g. wire, cord, etc.) to
secure the selector lever in the selected position.
5. Start the engine and check the correct direction of
travel. Repeat points 1 to 3 to correct the direction of
travel.
22
ZF 2000 Series Operating when the actuation device is faulty
! DANGER
The clutch set using the pilot valve is always engaged
when the engine is running. When the mechanical
emergency actuation of the transmission has been
engaged, the transmission cannot be shifted to neutral
or reversed using the selector lever. The person in
charge of the craft must always be aware of this fact.
Operation of the craft must be adapted to take account
of this situation. In port or when traveling on a narrow
or busy waterway, stop the engine and have the craft
towed.
To deactivate mechanical emergency actuation, switch

off the engine and hook the linkage for the remote
mechanical actuator onto the selector lever of the control
unit. Check the setting.
23
Operation with emergency shift (“Come home screws”) ZF 2000 Series
9 Operation with emergency shift (“Come home transmission is at operating temperature. In this case,
screws”) further travel is permitted without restriction..
If no power transmission is achieved in spite of the ➣ No oil pressure at measuring point 2. There is
measures described in section 8, there is a malfunction in enough oil in the transmission (oil level between
the transmission (e.g. failure of the transmission min. and max. on the dipstick). In this case, travel is
hydraulics). In such cases, the clutch disks on the shift possible at up to 50 % of maximum engine speed.
clutch can be pressed together mechanically using
CAUTION
clamping screws built into the transmission. There will not be any hydraulic lubrication of the
transmission. This may result in the transmission
There are three clamping screws for the enginewise
suffering more damage.
clutch and three for the counter-enginewise clutch. They
are accessible from the outside on the transmission
output end. The housing apertures are covered by screw Necessary tools
plugs.
a) Allen key 8 mm, to unscrew the screw plugs.
CAUTION b) Allen key 10 mm, minimum leg length 80 mm, to turn

Only use the emergency shift if you do not have any the clamping screws
other possible way of returning to port. The emergency c) Ring/open-end wrench 10 mm, to turn key “b” or “d”.
shift may prevent hydraulic oil lubrication. This may d) Special key (Allen key, straight, 10 mm, length 95
result in the transmission suffering more damage. mm) for screwing in the clamping screws which
cannot be accessed using b). This key can be obtained
from ZF by quoting part no. 1X 56 186 369 or by
modifying a standard 10 mm Allen key to 95 mm
length.
.
34
44
Key:
Emergency actuation is to be performed in the following
34 Emergency shift, counter-enginewise sequence:
44 Emergency shift, enginewise
1. Switch off the engine.
Operation with emergency shift is permitted under the
following conditions:
➣ The oil pressure at measuring point 2 must be at least ! DANGER

3.5 bar when the engine is idling and the Remove the ignition key or take other precautions to
prevent the engine from being started inadvertently.
24
ZF 2000 Series Operation with emergency shift (“Come home screws”)
2. Disable the activation function for the pilot valve three clamping screws to approx. 35 Nm tightening
(section 6), e.g. by removing the plugs from the torque.
electrical transmission actuation device or by
unhooking the pull/push cable from the mechanical ! DANGER
transmission actuation device. Screw in the clamping screws evenly to prevent the
clutch piston from becoming tilted. If the clutch piston
CAUTION
Only one shift clutch is allowed to be engaged on a is tilted, the clutch will either be unable to transmit
transmission at any one time, otherwise there will be torque or only an inadequate amount of torque.
power transmission via both output directions of rotation
and the transmission will block. For this reason, the 6. Screw in the screw plugs to close the housing
normal transmission actuation device must be disabled apertures.
when operating with the emergency shift. The engine can be started and the craft got underway to
the next service center with the emergency shift engaged
3. Determine which clutch to engage. To do this, you like this.
need to know the direction of rotation of the engine
and the direction of rotation of the propeller when ! DANGER
traveling ahead. If the propeller turns in the same When the emergency shift feature of the transmission
direction as the engine when traveling ahead, engage has been engaged, the transmission cannot be shifted to
the clutch for enginewise rotation, no. 44. If the neutral or reversed using the selector lever. The person
propeller turns in the opposite direction to the engine in charge of the craft must always be aware of this fact.
when traveling ahead, engage the clutch for counter- Operation of the craft must be adapted to take account
enginewise rotation, no. 34. of this situation. In port or when traveling on a narrow
4. Unscrew and remove the screw plugs (use the 8 mm or busy waterway, stop the engine and have the craft
Allen screw). towed.
5. Slowly turn the engine using a barring gear on the

The emergency shift is deactivated in the following
engine end and shine a torch through the housing
sequence:
aperture made accessible by the removal of the screw
plug (use a mirror if this is awkward). Stop the
1. Switch off the engine.
rotation of the engine when one of the three Allen
screws (clamping screws) is in the center of the 2. Determine which clutch to engage.
aperture. You can turn the engine in either direction 3. Unscrew and remove the screw plugs (use the 8 mm
when doing this. The correct position must be reached Allen screw).
after turning through max. 120°. 4. Slowly turn the engine using a barring gear on the
Insert the 10 mm Allen key (tool b) or d), see above) into engine end and shine a torch through the housing
the socket of the clamping screw. Use a 10 mm aperture made accessible by the removal of the screw
ring/open-end wrench on the Allen key and turn all three plugs (use a mirror if this is awkward). Stop the
clamping screws clockwise, working in several passes, rotation of the engine when one of the three Allen
to screw them in by 8 – 10 mm (the break-loose torque screws (clamping screws) is in the center of the
may be up to 80 Nm at first). In one final pass, tighten all aperture. You can turn the engine in either direction
when doing this. The correct position must be reached
after turning through max. 120°.
Insert the 10 mm Allen key (tool b) or d), see above) into
the socket of the clamping screw. Use a 10 mm
ring/open-end wrench on the Allen key and unscrew all
three clamping screws counterclockwise, working in
25
Operation with emergency shift (“Come home screws”) ZF 2000 Series
several passes, by 8 – 10 mm. Bring the clamping screws

into contact with a tightening torque of 10 Nm.
5. Screw in the screw plugs to close the housing

aperture.
6. Restore the activation function for the pilot valve
(section 6), e.g. by connecting the plugs to the
electrical transmission actuation device or by hooking
in the pull/push cable on the mechanical transmission
actuation device.
! DANGER
Screw the clamping screws out evenly to prevent the
clutch piston from becoming tilted. If the clutch piston
is tilted, the clutch will either be unable to interrupt
torque transmission or only do so to an inadequate
amount.
26
ZF 2000 Series Trolling
10 Trolling • For engines with max. operating speed above

2000 rpm: 1000 rpm
Only for transmissions with a trolling valve installed and
activated (special equipment). The following trolling Max. permitted lubricating oil temperature: 90 °C
devices are available for the ZF 2000: Transmissions with electrical trolling have no protective
function to prevent the engine speed limit being
➣ - Electrical trolling exceeded in trolling mode. Stop trolling if the permitted
➣ - ZF AUTOTROLL values for engine speed or lubricating oil temperature are
exceeded.
Description of function
Trolling mode enables the propeller to turn more slowly ! DANGER

than in transmissions without trolling mode. As a result, Trolling involves maneuvering with the clutch
trolling is used for maneuvering the craft at low speed. slipping. The craft can be reversed and maneuvered in
port in trolling mode. However, you should bear in
In trolling mode, the propeller speed may be approx. 0.3 mind that with the propeller turning slowly in trolling
to 0.7 times the propeller speed in non-trolling mode. mode, the resulting propeller thrust may not be enough
to move the craft sufficiently. Sizeable craft with a
The propeller speed is reduced by allowing a defined deep draft and relatively low-powered engines either
amount of slip on the clutch disks. To achieve this, the cannot be maneuvered in trolling mode or can only be
clutch oil pressure is deliberately reduced in trolling moved extremely sluggishly. On the other hand,
mode until the disks start to slip. The clutch oil pressure lightweight sports craft with powerful engines and a
is the pressure with which the clutch disks are pressed predominantly shallow draft display excellent
together. responsiveness. As a result, we recommend testing the
The transmission oil circuit is designed to be able to reactions of the craft by maneuvering in trolling mode
dissipate the heat which builds up in the clutch due to on open water. If the results are unsatisfactory, the
friction. The trolling valve for setting the clutch oil person in charge of the craft or the responsible
pressure is located on the middle of the transmission certification officer should forbid the system from
control unit. being used in port. Switching off trolling at relatively
high engine speeds can result in the craft accelerating
10.1 Electrical trolling (special equipment)
suddenly. To avoid this, shift the transmission to
In trolling mode, the clutch oil pressure in the neutral before exiting trolling mode (except in an
transmission is set using an electrical control signal. The emergency). The transmission supplier is unable to
actuation device required for this does not form part of accept any responsibility for damage to property and
the transmission. Refer to the operating instructions injuries caused due to failure to observe these operating
supplied by the manufacturer for information about how regulations.
to operate the trolling actuator. The trolling device can
be used for moving ahead or astern without any time
limit, providing the permitted engine speed and
lubricating oil temperature values are not exceeded.
Max. permitted engine speed in trolling mode

• For engines with max. operating speed up to 2000 rpm:
0.5 x max. operating speed
27
Trolling ZF 2000 Series
10.2 ZF-AUTOTROLL (special equipment)

ZF-AUTOTROLL can be used in conjunction with
electrical transmission actuation. ZF AUTOTROLL is a
controlled trolling device. In trolling mode, the
transmission sets the propeller speed as specified by the
actuation device. The actuation device itself does not
form part of the transmission. Refer to the operating
instructions supplied by the manufacturer for
information about how to operate the trolling actuator.
We recommend consulting these operating instructions
on a regular basis.
The main identification characteristics to show that the

transmission is fitted with the ZF-AUTOTROLL system
are:
• The propeller speed set on the trolling selector lever is

automatically kept at a constant speed (governed).
• Maneuvering is simple, even with craft that have a
deep draft and relatively low-powered engines. This is
thanks to the changeover control sequence in which the
clutch pressure is briefly increased when changing
direction and the propeller speed is governed.
• The transmission cannot be operated incorrectly. The
clutch is engaged automatically whenever the
maximum permitted engine speed is exceeded in
trolling mode.
! DANGER
Automatic clutch engagement can result in the craft
accelerating suddenly. To avoid this, shift the
transmission to neutral before exiting trolling mode
(except in an emergency).
28
ZF 2000 Series Troubleshooting notes
11 Troubleshooting notes
Faults in the propulsion unit are often initially blamed on
transmission errors; however, in many cases, external
influences on the transmission are the cause of such
faults.
The following troubleshooting notes describe the main

faults which can occur, their causes and remedial action.
If you cannot remedy the fault using these notes, please

contact your nearest ZF service center. If you intend to
remedy transmission faults yourself or carry out repairs
yourself, we recommend that you order the workshop
manual and transmission spare parts list from our ZF
Service Station at the Friedrichshafen plant.
29
Troubleshooting notes ZF 2000 Series
Fault Possible cause Remedial action

Transmission oil • Insufficient water flow through cooler ➣ Increase water flow
temperature too high
• Sludge in oil cooler ➣ Clean oil cooler,
(measuring points 11*,
see maintenance job 169
12* and 41*)
Transmission oil • Excessive water flow through cooler ➣ Reduce water flow
temperature too low
Oil pressure upstream • Oil cooler dirty ➣ Clean oil side of oil cooler
of oil cooler and filter
too high (measuring
point 5*)
No operating oil • No oil in transmission ➣ Add oil
pressure (measuring
• Wrong rotation direction at ➣ Use special transmission version
points 2*, 21* and 27*)
transmission input
• Defective display unit ➣ Remedy fault
Operating oil pressure • Oil viscosity too low ➣ Use a prescribed oil grade
too low (measuring (see List of Lubricants)
points 2*, 21* and 27*)
• Defective oil pump ➣ Replace oil pump
• Pressure relief valve leaking ➣ Remedy fault
• Time switch for pressure modulation ➣ See “Clutch slipping” fault
defective
If the fault cannot be remedied, the transmission lubricating oil supply is also at risk.
Proceed at reduced engine speed only until repairs can be carried out.
Operating oil pressure • Oil viscosity too high ➣ Use a prescribed oil grade
too high (measuring (see List of Lubricants)
points 2*, 21* and 27*)
Drive interrupted • Mechanical transmission actuation: ➣ Adjust setting
between transmission Incorrect shift angle
input and transmission
• Electrical transmission actuation: ➣ Remedy electrical system fault
output; clutch not
Electrical system fault
transmitting torque
Test option:
Normal force applied when actuating
the transmission using the manual
control lever.
• No operating oil pressure ➣ See “No operating oil pressure” or
“Oil pressure too low”
* ee monitoring data, Section 3 as well as transmission views, Section 2.
30
ZF 2000 Series Troubleshooting notes
Fault Possible cause Remedial action

Drive between For possible causes and remedial action, see “Clutch not transmitting torque” fault.
transmission input and
transmission output
cannot be interrupted;
clutch does not
disengage
Clutch slips at high • Operating oil pressure too low ➣ See remedy for “Operating oil pressure
engine speed (measuring points 2*, 21* and 27*) too low (measuring points 2*, 21* and
27*)”. If the fault cannot be remedied on
board, proceed at reduced engine speed –
so that the clutch does not slip – until
repairs can be carried out. Avoid
changes in direction or only change
direction with the propeller almost at a
standstill and with engine idle speed as
low as possible.
Oil level sinks rapidly • Leaks on housing joints or oil lines, oil ➣ Correct mechanical fault
(as indicated on escaping past shaft seals
dipstick). See
• Oil cooler leaking into coolant system ➣ Remedy fault, replace oil cooler if
maintenance job 101
necessary
“Oil level check”
Oil level increases (see • Water entering the oil circuit from the ➣ Correct mechanical fault
maintenance job 101 cooling system
“Oil level check”)
Transmission is too • Torsional vibration resonance of ➣ Avoid critical speed range. Use more
loud in certain speed propulsion system in engine speed suitable flexible coupling (see
ranges range maintenance job 161)
Transmission too loud • Torsional vibration resonance of ➣ Increase engine idle speed range
in engine idle speed propulsion system in engine idle speed
range range
Engine stalls following • Engine idle speed too low ➣ Increase engine idle speed range
rapid change from
• Change in direction effected too ➣ Change direction as recommended in
“Ahead” to “Astern”
quickly or effected at excessive craft Section 7.1.3
speed
* ee monitoring data, Section 3 as well as transmission views, Section 2.
31
Spare parts orders and service centers ZF 2000 Series
12 Spare parts orders and service centers

If a transmission fault cannot be remedied using the troubleshooting notes in section 11, please contact your nearest
ZF service center.
A list of ZF service centers with the latest telephone and telefax numbers can be ordered from ZF Marine GmbH if
required.
Only use genuine ZF spares when carrying out repairs.
Always quote the following details when ordering or

inquiring about spare parts
• Model
• Transmission no.
• Parts list no.
• Total ratio
This information is stamped on the transmission type
plate.
In the case of transmissions with classification, note that

spare parts without classification are always supplied
under the indicated item numbers.
If a design with classification is required, the desired

type of test must be stated in addition to the item
number.
This is also necessary if the transmission parts list is

quoted when ordering and when requesting
reconditioned transmissions.
32
ZF 2000 Series Maintenance / ZF Duty Classification Definitions
13 Maintenance / ZF Duty Classification Definitions
13.1 Application group P 13.3 Application group M

● Engine data for transmission assignment: ● Engine data for transmission assignment:
Max. power for intermittent operation Max. power for intermittent operation
● Operating type: ● Operating type:

Intermittent operation at very widely differing engine Intermittent operation at differing engine speeds
speeds
● Annual operating hours: Up to approx. 3500
● Preferred hull type: Semi-planing, planing
● Preferred hull type: Planing
● Typical applications:
● Typical applications: Work boats, charter boats
Privately used leisure and pleasure craft
● Typical application examples:
● Typical application example: Crew boats, supply boats, fishing boats, coastguard
Privately used leisure and pleasure craft boats, passenger boats, ferries, yachts etc.
13.2 Application group L 13.4 Application group C

● Engine data for transmission assignment: ● Engine data for transmission assignment: Max.
Max. power for intermittent operation continuous power
● Operating type: ● Operating type: Continuous operation at max. engine

Intermittent operation at widely differing engine power
speeds
● Annual operating hours: Unlimited
● Preferred hull type: Displacement, semi-planing
● Preferred hull type: Semi-planing, planing
● Typical applications: Work boats
● Typical applications:
Navy vessels, authority vessels and similar craft,
Tug boats, pusher boats, supply boats, fishing boats,
private charter boats
passenger boats, cargo ships, ferries etc.
Fast boats, yachts, patrol boats, police boats, customs
boats, coastguard boats, pilot boats, fire service boats,
rescue boats, sport fishing boats etc.
33
Maintenance time schedule ZF 2000 Series
14 Maintenance time schedule
14.1 Regular maintenance jobs
Maintenance level Application groups Interval At least every

(operating hours)
A1 All Every day of operation 3 months

(also see K1, K2)
A2 All 500 6 months
A3 All 2000 2 years
A4 C and M ---------------- 5 years
L and P ---------------- 8 years
A5 All Each time the engine Transmission operating condition

undergoes a basic
overhaul
14.2 Additional one-off maintenance jobs on new or overhauled transmission

(also see maintenance jobs 12.1)
Maintenance level Operating hours At least every
Z1 50 to 100 12 months
14.3 Anti-corrosion protection measures after long periods of downtime

(see “Corrosion-proofing” Appendix)
Maintenance level Interval Downtime NOTE: See Appendix
K1 Every 10 to 20 days Up to 6 months

ZF Marine Transmissions
K2 Following operation 9 months Corrosion-proofing
(3070 755 101)
K3 Following operation Max. 36 months
34
ZF 2000 Series Maintenance job schedule
15 Maintenance job schedule

15.1 Maintenance level / maintenance jobs
Maintenance level Maintenance jobs Tools required
Regular One-off
A5 A4 A3 A2 A1 Z1
101 Check oil level None
103 Carry out visual check None
121 Clean outside of transmission None
122 Retighten all screw/bolt connections Ship’s tools
accessible from outside
123 Check control position settings None
124 Lubricate external moving parts None
141 Change oil Ship’s tools
142 Change oil filter Ship’s tools
161 Visually check flexible coupling None
162 Visually check flexible engine and None
transmission mounting
163 Visually check clutch disks Ship’s tools
164 Visually check gearing Ship’s tools
165 Check oil pump W1
166 Check control unit W1
167 Check actuating unit W1
168 Re-calibrate gauges ------
169 Clean oil cooler ------
172* Check injection line valve W1
173 Check input shaft seal None
174 Check output shaft seal None
200* Basic transmission overhaul W2
T1 + T1 + T1 -- -- T1
T2 + T2 Spare parts required
NB
* = See workshop manual for instructions T1, T2 = See spare parts list for part sets
NB = Spare parts as necessary W1 = See operating instructions for tool kit
W2 = See workshop manual for tool kit
35
Tool kit for maintenance ZF 2000 Series
16 Tool kit for maintenance
16.1 Tool kit W1

Tool kit W1 is made up of standard tools. Standard tools include, e.g.
General tools
Open-end wrenches up to size .................................................................................................................. 63 mm
Straight ring spanners up to size ............................................................................................................... 46 mm
Offset ring spanners up to size .................................................................................................................. 46 mm
Socket wrench set................................................................................................................................. 4 - 13 mm
Socket wrench set................................................................................................................................ 11 -32 mm
Socket wrench set................................................................................................................................ 22 -50 mm
Socket wrench set for hexagon socket head bolts................................................................................. 5 -22 mm
Pliers (straight) for circlips (inner rings) ........................................................................................... I 1 - 4 (no.)
Pliers (straight) for circlips (outer rings) ..........................................................................................A 1 - 4 (no.)
Screwdrivers .................................................................................................................................... up to 13 mm
Hammers (metal + plastic), punches
Testing and measuring equipment
Torque wrenches ............................................................................................................................. 10 - 350 Nm
Vernier caliper, depth gauge .............................................................................. Measuring range up to 300 mm
Feeler gauge ....................................................................................................... Measuring range 0.05 - 1.0 mm
Miscellaneous
Oil filter wrench
Tools for emergency transmission actuation
Allen key ..................................................................................................................................................... 3 mm
Allen key ..................................................................................................................................................... 8 mm
Allen key (ZF part no. 1 x 56 186 369, 95 mm long ................................................................................ 10 mm
Allen key, minimum leg length 80 mm .................................................................................................... 10 mm
36
ZF 2000 Series Maintenance system job sheets
1 Maintenance system job sheets

Page
101 Check oil level .................................................................................................................................................38
103 Carry out visual check......................................................................................................................................40
121 Clean outside of transmission ..........................................................................................................................42
122 Retighten all screw/bolt connections accessible from outside.........................................................................44
123 Check control position settings ........................................................................................................................46
124) Lubricate external moving parts ......................................................................................................................48
141 Change oil ........................................................................................................................................................50
142 Change oil filter ..............................................................................................................................................52
161 Visually check flexible coupling......................................................................................................................54
162 Visually check flexible engine and transmission mounting (if fitted) .............................................................56
163 Visually check clutch disks..............................................................................................................................58
164 Visually check gearing.....................................................................................................................................60
165 Check oil pump ................................................................................................................................................62
166 Check control unit............................................................................................................................................66
167 Check actuation device (mechanical, electrical)..............................................................................................68
168 Re-calibrate gauge............................................................................................................................................72
169 Clean oil cooler ................................................................................................................................................74
173 Check input shaft seal ......................................................................................................................................78
174 Check output shaft seal ....................................................................................................................................80
37
MAINTENANCE SYSTEM JOB SHEET
Transmission type: ZF 2000 Series
Maintenance Maintenance level If possible, to be Time required in
job no. performed in conjunction minutes
with maintenance job no.
101 A1 ---------- 10
Description of
maintenance 101 Check oil level
work
Only withdraw the oil dipstick when the engine is at a standstill, otherwise risk of burns due to
hot oil spraying out.
Safety measures
Only top up the oil when the engine is at a standstill, otherwise risk of burns due to hot oil
spraying out.
Tools ------------------------------
Parts ------------------------------
Material Non-fraying cloth
Test equipment ------------------------------
Procedure see next page
Location: Date: Page: 1 of: 2
38
During initial fill, following repairs and after cleaning
the oil filter, make sure that some of the oil remains in the
oil cooler, in the oil lines and in the filter chamber rather
than flowing back into the transmission housing. You
should therefore recheck the oil level after a short period
of operation.
2000ARH
The correct oil level is between the upper and lower

marks on the oil dipstick.
max.
min.
004 666
To add oil, unscrew the oil filler plug and top up the oil.
2000ARH
39
103 A1 121 10
Description of
maintenance 103 Carry out visual check
work
Always keep your distance when visually checking rotating parts, otherwise risk of getting
Safety measures
caught in the rotating part
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
Test equipment ------------------------------
40
Check for leaks at the points the input shaft and output
shaft protrude from the transmission housing as well as
at the oil line ports, monitoring equipment ports and
coolant ports (visual check).
2000PLH
ZF 2150
2000ALH
ZF 2150 A
2000VHL
ZF 2150 V
.
41
121 A2 103 30
Description of
maintenance 121 Clean outside of transmission
work
Only use cleaning products that meet the requirements of the regulations for the prevention of
Safety measures
accidents.
Tools Ship’s tools
Parts Cleaning products
Material ------------------------------
Test equipment ------------------------------
42
Clean the outside of the transmission using cleaning
products to make the visual check easier – see 103.
Important: Do not allow cleaning products to come into

contact with rubber parts, hose lines and shaft seals.
2000PLH
ZF 2150
2000ALH3
ZF 2150
2000VLV
ZF 2150 V
43
122 Z1 ---------- 20
Description of
maintenance 122 Retighten all screw/bolt connections accessible from outside.
work
Safety measures Only retighten the connections when the transmission is at a standstill.
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
Test equipment ------------------------------
44
Retighten all accessible screw/bolt connections.
Pay particular attention to the following connections:
● Engine to flexible coupling
● Flywheel housing to bell housing
● Mounting bracket to transmission
● Mounting bracket to foundation.
Also check the ports/connections “to” and “from” the oil
cooler as well as the monitoring equipment
ports/connections. Retighten them as necessary.
You should retighten the bolts to the specified torque

when the transmission is cold (approx. 20 °C).
2000PLH
ZF 2150
2000AHLH3
ZF 2150 A
2000VLV
ZF 2150 V
45
123 A2 ---------- 15
Description of
maintenance 123 Check control position settings
work
Block the engine starting device,

Safety measures
otherwise risk of the craft moving off.
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
Test equipment ------------------------------
46
Only required in the case of the “mechanical
transmission actuation” version.
Loosen the mechanical connection between the

transmission control lever and the transmission linkage
or pull-push cable.
Select “Neutral” on controls and move the transmission
control lever to “Neutral” detent position.
Holes on the transmission control lever and shift linkage
or on the yoke end of the pull-push cable must be
aligned.
Select “Ahead” on controls and move the transmission
control lever as far as the “enginewise” or “counter-
enginewise” detent position. Hole in the transmission
control lever must be aligned with the hole in the linkage
or on the yoke end.
Check the “Astern” position in the same way. The

positions indicated must be safely and reliably
obtainable. Adjust the mechanism on the transmission
linkage if necessary.
47
124 A2 ---------- 15
Description of
124 Lubricate external moving parts
maintenance
(Only required in the case of the “mechanical transmission actuation” version).
work
Safety measures ------------------------------
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
Test equipment ------------------------------
Lightly lubricate the moving parts of the mechanical transmission actuator (yoke end on
Procedure transmission control lever, linkage connections and connection to controls) with lithium
saponified grease.
48
49
141 A3 142 / 163 / 164 30
Description of
maintenance 141 Change oil
work
Block the engine starting device.

Change the oil at an oil temperature of max. 40 – 50 °C, otherwise risk of burns.
Collect used oil in a suitably large oil container, otherwise risk of environmental pollution.
Safety measures Oil capacity: ZF 2000/ 2050/2150 approx. 21 dm3
ZF 2000A/ 2050A/2150A approx. 21 dm3
ZF 2000V/ 2050V/2150V approx. 21 dm3
Parts New gasket/sealing rings
Oil grade:
Approved oils as per applicable “ZF List of Lubricants TE-EL 04 for ZF Marine
Material
Transmissions”. The currently applicable list of lubricants is supplied with the transmission.
It can be ordered from any ZF service center.
Test equipment ------------------------------
50
If possible, perform this job in conjunction with
maintenance job 142.
Withdraw the oil dipstick, unscrew the oil drain plug and
drain the oil.
Remove the oil by suction if the transmission is fitted

with an oil suction device.
After fitting a new seal, screw in and tighten the oil drain
plug.
Close the oil suction device if one is fitted.
2000PLH
ZF 2150
To add oil, unscrew the oil filler plug or take off the
inspection hole cover.
Add fresh oil.
Oil capacity:
ZF 2000/ 2050/2150 approx. 21 dm3
ZF 2000A/ 2050A/2150A approx. 21 dm3
ZF 2000V/ 2050V/2150V approx. 21 dm3
Then fit a new seal on the oil filler plug (or a new gasket
on the inspection hole cover) and re-insert the oil filler
plug (or re-attach the inspection hole cover).
Finally, check the oil level - see maintenance job 101.
2000PLH
Using the oil dipstick is the only way to obtain an
accurate reading.
51
142 A3 141 / 163 / 164 30
Description of
maintenance 142 Change oil filter.
work
Caution: Do not fit a new oil filter immediately after stopping the engine. To be on the
safe side, wait 30 minutes after stopping the engine before changing the filter.
If you don´t follow these instructions hot oil steps suddenly under pressure
between sealing and oil filter! There is combustion Danger
Safety measures
Block the engine starting device. Collect used oil in a suitably large oil container,
otherwise risk of environmental pollution.
Escaping oil quantity: Approx. 1 dm3
Gasket
Parts
Caution: Operating Pressure 24 bar
Oil grade:
Approved oils as per applicable “ZF List of Lubricants TE-EL 04 for ZF Marine
Material
Transmissions”. The currently applicable list of lubricants is supplied with the transmission. It
can be ordered from any ZF service center.
Test equipment ------------------------------
52
maintenance jobs 141, 163 and 164..
CAUTION
Do not fit a new oil filter immediately after stopping the
engine. To be on the safe side, wait 30 minutes after
stopping the engine before changing the filter. If you
don´t follow these instructions hot oil steps suddenly
under pressure between sealing and oil filter! There is
combustion danger!
ZF 2150 A
Use an oil filter wrench to remove the filter cartridge.

Use a container to collect the oil which drains out.
Fit the filter cartridge in accordance with the

manufacturer’s instructions.
Fit a new seal – screw on the filter until it makes contact.

Tighten by hand. Check for leaks.
ZF 2150 V
53
161 A4 ---------- 30
Description of
maintenance 161 Visually check flexible coupling
work
Safety measures Block the engine starting device.
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
Test equipment ------------------------------
54
Check that the rims of the flexible coupling are in perfect
condition. To do this, slowly turn over the engine and
check the rubber parts by looking through the inspection
hole in the bell housing.
004 681
Check the rubber parts for signs of cracking,

embrittlement and overheating.
004 682
Check the markings (if there are any) for distortion.
004 683
55
162 A4 ---------- 15
Description of
maintenance 162 Visually check flexible engine and transmission mounting (if fitted)
work
Safety measures ------------------------------
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
Test equipment ------------------------------
Check that the rubber-metal mountings on the engine and transmission are in perfect condition.
Procedure
The rubber parts must not show any signs of cracking, embrittlement or other damage.
56
57
163 A4 141 / 142 / 164 15
Description of
maintenance 163 Visually check clutch disks
work

Safety measures Remove all parts which could fall into the transmission once the inspection hole cover has been
opened (mechanics should empty their breast pockets).
Parts ------------------------------
Material ------------------------------
Test equipment ------------------------------
58
It is advisable for this job to be performed when
changing the oil – see maintenance job 141.
Remove the inspection hole cover.
Check the multi-disk clutch. The outer disk carrier must

not show any signs of overheating.
59
164 A4 141 / 142 / 163 15
Description of
maintenance 164 Visually check gearing
work

Safety measures Remove all parts which could fall into the transmission once the inspection hole cover has been
opened (mechanics should empty their breast pockets).
Parts ------------------------------
Material ------------------------------
Test equipment ------------------------------
60
It is advisable for this job to be performed when
changing the oil – see maintenance job 141.
Remove the inspection hole cover.
Check the teeth of the gears on the input shaft, the

reversing shaft and the output shaft. The tooth flanks
must not show any signs of pitting or similar wear.
61
165 A4 ---------- 180
Description of 165 Check oil pump

maintenance Engine-driven pump (primary pump)
work Trailing pump (secondary pump) not fitted in basic transmission
Safety measures Block the engine starting device if you intend to remove the oil pump.
Tools Tool kit WI
Parts ------------------------------
Material Set of seals and gaskets
Test equipment ------------------------------
62
Engine-driven pump (primary pump)
NOTE
The oil pump is a complete part and is not generally
dismantled. However, checking or cleaning work may
require the pump to be dismantled. Pay particular
attention to inspecting the dismantled pump for scoring,
mounting play and impeller/pinion end play.
Removing and dismantling

– Remove the suction and pressure pipes.
– Collect the O-rings.
– Remove the pump by unscrewing the fixing nuts.
Collect the O-rings.
– Mark the position of the pump parts.
– Remove the bolts from the pump cover and dismantle
2000PLH
the pump.
ZF 2150
1 Oil seal
2 Fixing plate
1 2
3 4 5 9 3 Cylindrical pin
6
7 4 Bearing bridge
8 5 Housing
6 Seal element
7 Support ring
8 Rubber pressure zone seal
9 Pump cover
10 Hexagon bolt
11 Gear set (shaft)
10 9
Assembling
NOTE
- Carefully clean the components.
- Check the components.
- Apply a thin coat of oil on moving parts.
– Tighten the fixing bolts diagonally across to the

following torque value:
– For bolt strength 8.8 - 75 + 10 Nm
– For bolt strength 10.9 - 90 + 10 Nm
– Insert the seals and support rings as shown in the
enlarged parts drawing.
– Install the bearing bridge so the axial pressure zone is
pointing towards the high-pressure end (see
illustration).
– Lightly oil all parts before assembling them.
– Press the oil seals into the fixing plate from the end of
the centering collar to the base.
– Install the complete pump.
63
– Insert the O-ring and mount the pump.
– Tighten the fixing nuts.
– Install the suction line and pressure line.
Trailing pump (secondary pump)

NOTE
The oil pump is a complete part and is not generally
dismantled. However, checking or cleaning work may
require the pump to be dismantled.
When checking the pump, pay particular attention to
ensuring that the endplay is within the wear limit (max.
0,11 mm). The pump components should be checked for
scoring.
– Clean the parts carefully. Do not use any lint cloths

for cleaning. Lightly coat the moving parts with
service oil.
Removing and dismantling
– Remove the pipes as necessary.
– Unscrew the fixing screws and bolts from the oil
pump.
– Lift off the oil pump (use a lever to help you if
necessary).
– Unclip the retaining ring.
– Pull off the drive gear. 1 Reversing House
– Catch the Woodruff key.
2 Inner rotor
– Remove the fixing bolts from the pump cover and
take off the cover. 3 Outher rotor
4 Ball
5 Compression Spring
6 Woodruff key
Assembling
7 Cylindrical Bolt
– - Carefully clean the components
– - Check the components. A End play = max. 0,11 mm
– - Apply a thin coat of oil on the moving parts.
– Insert the pump components into the pump housing.

– Install the 3 springs fullfilled with greace. Fit the 3
balls and install the reversing house.
– Replace and securely bolt on the cover.
– Insert the fitted key (3) into the pump shaft.
– Heat the drive pinion (4) to approx. 85 °C and slide it
onto the pump shaft.
– Clip the retaining ring (5) into the annular groove in
the pump shaft.
64
65
166 A4 ---------- 120
Description of
maintenance 166 Check control unit
work
Tools Tool kit WI
Parts Gaskets
Material ------------------------------
Test equipment ------------------------------
66
1 2
3
9
10
11 12
13 15
14
4
9 16
17
18
8 19
5 6
7
20
22
23 21
37
38 24
37 36
39 35 26
34 25
40
33
32
31 27
28
30
29
1 Socket head bolt 15 Socket head bolt 28 Control piston

2 Socket head bolt 16 Screw plug 29 Screw plug
3 Cover 17 Cover 30 Screw plug
4 Seal 18 Seal 31 Control piston
5 Control housing 19 Hexagon bolt 32 Snap ring
6 Slotted plug 20 Cover 33 Compression spring
7 Ball 21 Seal 34 Bush
8 Orifice 22 Piston 35 Compression spring
9 Switch 23 Spacer bush 36 Washer
10 Washer 24 Screw plug 37 Compression spring
11 Compression spring 25 Seal 38 Control piston
12 Detent pin 26 Compression spring 39 Bush
13 Washer 27 Snap ring 40 Screw plug
14 Circlip
Check control unit:

NOTE
If possible, replace the control unit in its entirety rather than dismantling it. If the control unit has to be dismantled
for cleaning purposes or in order to replace compression springs, it does not need to be reset afterwards. However,
the transmission must undergo a pressure test.
67
167 A4 ---------- 180
Description of
maintenance 167 Check actuation device (mechanical, pneumatic, electrical)
work
Tools Tool kit WI
Parts see part kits T1 and T2
Material Cleaning products
Test equipment ------------------------------
68
A
Mechanical actuation device
Checking the actuation device, mechanical

Removing
- Unscrew the fixing bolts and remove the actuation device (A).
- Check the actuation device (A) can move freely.
69
A
Actuation device, electrical
Checking the actuation device, electrical

Removing
The electrical actuation unit is supplied as a complete unit and cannot be dismantled.
If the actuation unit does not function, it must be replaced as a complete unit.
70
71
168 A4 ---------- ----------
Description of
maintenance 168 Re-calibrate gauge
work
Safety measures ------------------------------
Tools Tool kit
Parts ------------------------------
Material ------------------------------
Test equipment ------------------------------
72
Check that the oil pressure and oil temperature gauges
display the correct values.
Option 1:
Connect calibrated gauges in parallel and compare the
displayed values. The error (difference) must not be
more than 10 % in the operating range concerned.
Option 2:
Remove the gauges and have them re-calibrated or use
replacement gauges.
73
169 A4 ---------- 60
Description of
maintenance 169 Clean oil cooler
work
Safety measures ------------------------------
Tools Tool kit WI
Parts ------------------------------
Material Set of seals and gaskets
Test equipment ------------------------------
74
General information 2. If coolers cleaned in this way are kept in storage as
Extract from manufacturer’s specifications: spare parts, i.e. not immediately reinstalled nor
flushed with transmission oil, they must be flushed
Clean the heat exchangers at regular intervals to ensure
with a preserving agent.
consistent performance. The level of contamination will
depend on the application location; therefore, you should Cleaning the water end
keep track of the operating hours and determine the Check the contamination before cleaning the water end.
cleaning interval yourself. If a greasy coating of lime is present, the water end must
be degreased before cleaning.
Heat exchanger disassembly procedure Flushing with water and anti-liming agent removes the
1. Mark the position of the attached flanges in relation lime; a 10 to 15% solution of hydrochloric acid may also
to each other. be used. An inhibitor additive must be added to this
solution to prevent it from reacting with the metal
2. Remove the pipes as necessary.
surfaces.
3. Unscrew the fixing nuts on the oil cooler and remove
the oil cooler. After cleaning, thoroughly flush the water end with clean
4. Unscrew the fixing bolts from the cooler. Remove the water. Then fill the oil end with the same oil that is to be
cover and water connection housing. Collect the O- used in subsequent operation. Then drain the oil.
rings.
5. Pull the pipe bundle out of the cooler housing. Collect Cleaning will be much more effective and cleaning time
the O-rings and bush. shorter if circulation is in the opposite direction to
circulation during normal operation, both at the oil end
and at the water end.
Cleaning the oil side
1. Flush the coolers using a suitable cleaning product.
Flush against the normal oil flow direction to loosen
any dirt – in particular debris from multi-disk
clutches and band brakes – deposited on the oil cooler
blades. This dirt will be flushed out by the cleaning
product. Place a suitable filter in the main flow so that
the flushed out impurities can be separated from the
cleaning product. You should continue cleaning until
inspection reveals that the cleaning product flowing
out is as pure as the cleaning product flowing in.
75
Assembling the heat exchanger
1. Insert the O-ring into the cooler housing.
2. Thread the pipe bundle into the cooler housing.
3. Turn the cooler and insert the O-ring and bush.
4. Install the cover and water connection housing with
O-ring. (See marking for position.)
Checking
After assembly, check the oil end and the water end. The
pressure indicated on the drawing or the type plate (oil
and water end) must not be exceeded.
76
77
173 A4 121 15
Description of
173 Check input shaft seal
maintenance
(in conjunction with maintenance job 121 if possible)
work
Safety measures ------------------------------
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
Test equipment ------------------------------
78
Check the input shaft seal for leaks. Collect any escaping
oil.
Check the oil level at suitable intervals and top up the oil
as necessary.
Replace the input shaft seal as soon as possible.
ZF 2150
ZF 2150 V
79
174 A4 121 15
Description of
174 Check output shaft seal
maintenance
(in conjunction with maintenance job 121 if possible)
work
Safety measures ------------------------------
Tools ------------------------------
Parts ------------------------------
Material ------------------------------
Test equipment ------------------------------
80
Check the output shaft seal for leaks. Collect any
escaping oil.
Check the oil level at suitable intervals and top up the oil
as necessary.
Replace the output shaft seal as soon as possible.
ZF 2150
81
Sealers
(extract from the manufacturer’s instructions for use)
The manufacturer’s instructions for use are always binding
HYLOMAR Grease
Universal seal SQ 32 M-Special, for use on housing and See List of Lubricants
cover mating faces).
Permanent plastic universal seal SQ 32M Special (CFC-

free), MARSTON, Ölchemie GmbH, 53909 Zülpich, Cleaners (for removing grease from tapered surfaces for
Germany, tel. (022 52) 2566 and 2725. oil press fits). Acetone, spirits (caution: Highly
inflammable) or standard cleaners that do not leave a
Instructions for use greasy residue.
Degrease the mating faces (Hylomar Cleaner) before use
and then apply HYLOMAR on both sides. Wait for the
sealant to dry (approx. 10 minutes) before commencing
assembly. Retighten the bolts after 10-15 minutes. If the Glycerin for oil press fits in Series ZF 600 through ZF
faces are planed flat, sealer only needs to be applied on 1950. Oil or glycerin can be used for fitting in the case of
one side. other transmission types.
We recommend you use HYLOMAR CLEANER to

remove old gasket residues, oil and grease.
Temperature resistant from -50 °C to +250 °C.
Loctite: No. 640

No. 275
Loctite Deutschland GmbH, Munich

Loctite Europa GmbH, Vienna
Instructions for use

Clean the parts. Apply enough of the product to fill the
gap. Join the parts together and let the product harden.
Dyken Read DX-296 for tooth flank contact pattern

acceptance in the case of transmissions subject to
classification society acceptance.
Dyken-Read DX-296/8 oz, Helling,

Sandorkai 1, 21107 Hamburg, tel. (040) 376010,
telex 213611 + 2165082, fax (040) 37601100
Made in Germany.
Subject to technical change without notice!
82
ZF Marine Transmissions
Corrosion-proofing
● Guidelines for corrosion-proofing of marine transmissions during storage at

ZF agencies and intermediaries.
● Anti-corrosion protection and corrosion-proofing for ZF transmissions installed in
marine craft.
Guidelines for marine transmissions:
Anti-corrosion protection, packing types, storage conditions and storage periods
Extract from: F 43258/RT 3332
Level Storage period Ex works anti-corrosion protection Packing type Storage conditions
I Max. 12 months Internal corrosion-proofing: Transmission cov- Remove packing materials immediately
before first op- Corrosion inhibiting oil to ered with poly- after receipt and check external corro-
eration MIL-L-21260 or TL 9150-0037, thene sack in wet- sion-proofing. If protective film is dam-
C-640 strength, glued aged, touch up or completely recoat with
External corrosion-proofing: plywood case. suitable corrosion inhibitor. Store in en-
- Bright metal parts with corrosion in- closed area at steady temperature and at
hibitor to MIL-C-16173D grade 4, low relative humidity.
K 19, or TL 8030-015, grade 4. Protect from dirt and damp between in-
- Housing stallation until first operation.
a) Finished by ZF using single-com-
ponent synthetic resin lacquer,
shade RAL 7001.
b) Wash priming by ZF, client must
apply either 1 or 2-component
lacquer as soon as packing mate-
rials have been removed. Then, if
unit is to go into interim storage
for longer than 12 months, repack
as described in level II.
II Max. 36 months Internal corrosion-proofing: Packed in drying Do not open packing on receipt! Check
before installa- Corrosion inhibiting oil to agent by specialist for damage. Check reading on humidity
tion + max. 12 MIL-L-21260 or TL 9150-0037, outside company gauge. Store in enclosed area at steady
months be- C-640 in accordance with temperature and at low relative humidi-
tween installa- External corrosion-proofing: TL 8100-001, ty.
tion and first - Bright metal parts with corrosion in- packing grade A. Protect from dirt and damp between in-
operation hibitor to MIL-C-16173D grade 4, Quantity of drying stallation and first operation.
K 19, or TL 8030-015, grade 4. agent calculated
- Finish on housing: Single-compo- acc. to DIN 55474
nent synthetic resin lacquer, shade or TL 8100-004.
RAL 7001. Packing shall con-
tain a humidity
All apertures in housing must be se- gauge which can
curely sealed. be read from out-
side.
III More than 36 As II As II As II
months before In addition, after 36 months of storage,
installation + check humidity inside packing every 4
max. 12 months months by reading humidity gauge. If
between instal- humidity is too high, call in specialist
lation and first outside company to replace drying agent
operation and barrier cover and to check external
corrosion-proofing.
Separate “Anti-corrosion protection and corrosion-proofing” guidelines apply to the period between first operation and entry into regular
operation and to downtime. See “Description, Installation, Operation and Maintenance” publication.
1. Guideline for corrosion-proofing of marine transmissions during storage at
ZF agencies and intermediaries
CAUTION
The corrosion-proofing measures described below must be carried out by ZF-authorized personnel. Otherwise, war-
ranty claims shall be deemed null and void.
Series transmissions supplied by ZF have anti-corrosion Renewing corrosion-proofing:

protection according to level I of “Guidelines for marine Remove the inspection hole cover and inspect the inter-
transmissions: Anti-corrosion protection, packing type, nal components of the transmission. While rotating the
storage conditions and storage periods” F 43258/ input and output shafts, spray the internal components of
RT 3332-289. the transmission with corrosion inhibiting oil. Renew
corrosion-proofing on bright external steel parts.
The storage conditions stipulated in these guidelines ap-
ply: Store in enclosed area at steady temperature and low Measures to be taken before supplying stored trans-
relative humidity. missions:
Renew corrosion-proofing and drain corrosion inhibiting
Renew corrosion-proofing after 12 months at the latest.
oil before delivery of the stored transmission. Inform
The transmissions may then be stored for a further 12
customer that marine transmissions purchased through
months. If transmissions then need to be stored for a fur-
ZF agencies offer anti-corrosion protection for a maxi-
ther period, renew corrosion-proofing every 6 months.
mum of 12 months.
Corrosion-proofing procedure:
– Fill the transmission with corrosion inhibiting oil, up
to the upper mark on the oil dipstick. Use corrosion
inhibiting oil C 642 or C 644 to MIL- L-21260.
– Remove the inspection hole cover.
– While rotating the input and output shafts, spray the
internal components of the transmission with corro-
sion inhibiting oil.
– Replace the inspection hole cover.
– Repeat corrosion-proofing on bright external steel
parts.
2. Anti-corrosion protection and corrosion-proofing of ZF transmissions in-
stalled in marine craft
If an installed marine transmission is not to be operated Renewing corrosion-proofing:

for a long period, the anti-corrosion protection measures Remove the inspection hole cover and inspect the inter-
required depend heavily on temperature fluctuations, hu- nal components of the transmission. While rotating the
midity and the salt content in the engine room air. For input and output shafts (if possible), spray the internal
this reason, the recommended periods should only be re- components of the transmission with corrosion inhibitor.
garded as guidelines. In case of doubt, transmission anti- Renew corrosion- proofing on bright external steel parts.
corrosion protection should be the same as that of the en-
gine. Operating after K 1 corrosion-proofing:
Start the engine and let it run for approx. 5 minutes to al-
No anti-corrosion protection measures are necessary if low any condensation inside the transmission to mix
transmission downtime is due to be less than 3 months. with the corrosion inhibitor. Drain the corrosion inhibi-
tor and fill the transmission with the prescribed oil grade.
If transmission downtime is due to be longer than 3
See maintenance job 141.
months, corrosion-proofing should take place immedi-
ately after the craft is taken out of operation if possible, K 2 long-time corrosion-proofing:
but within 3 months at the latest. K1 or K2 corrosion-
– Drain the transmission oil as soon as possible after
proofing applies, depending on individual requirements.
operation but after 3 months at the latest. Then fill
When initially corrosion-proofing the transmission,
with corrosion inhibiting oil, up to at least the lower
flush the cooler with fresh water and drain. Do not seal
mark on the oil dipstick. See maintenance jobs for de-
the drainage opening. If draining is not possible, flush
tails. Use corrosion inhibiting oil C 642 or C 644 to
with fresh water and fill with 20% anti-freeze solution.
MIL- L-21260.
– Immediately afterwards, select “enginewise” or
K 1 corrosion-proofing
“counter-enginewise” position and let the engine run
– Pot life: 12 months.
for 5 to 10 minutes at increased idle speed (max. 50%
– Then renew corrosion-proofing every 6 months.
nominal operating speed). Then stop the engine.
K 2 long-time corrosion-proofing – Fill the transmission with corrosion inhibiting oil, up
– Pot life: 36 months. to the maximum level.
– Repeat every 36 months. – Spray or brush bright external steel parts with corro-
sion inhibitor.
K 1 corrosion-proofing:
– Grease protruding shaft sections.
– After operation, drain the transmission oil and fill
with corrosion inhibiting oil, up to upper mark on the Operating after K 2 long-time corrosion-proofing:
oil dipstick. See maintenance jobs for details. Use Drain the corrosion inhibiting oil until the normal oil lev-
corrosion inhibiting oil C 642 or C 644 to el is reached. Then let the engine run for approx. 5 min-
MIL- L-21260. utes.
– Immediately afterwards, select “enginewise” or Then drain the remaining corrosion inhibiting oil and fill
“counter-enginewise” position and let the engine run the transmission with the prescribed oil grade. See main-
for 5 to 10 minutes at increased idle speed (max. 50 % tenance job 141.
nominal operating speed). Then stop the engine.
– Spray or brush bright external steel parts with corro-
sion inhibitor.
– Grease protruding shaft sections.
Subject to technical change without notice.
Publication no. 3070 755 101-8.92e Printed in Germany/Imprimé en Allemagne

ZF 2000 Om

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ZF 2000 Om

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Operating Instructions

ZF 2000; ZF 2050; ZF 2150

The following safety instructions appear in this manual.

Subject to alterations in design

3100 758 101

3 Monitoring data for ZF 2000 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5 Oil supply and transmission cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

8 Operating when the actuation device is faulty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

9 Operation with emergency shift (“Come home screws”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

12 Spare parts orders and service centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

14 Maintenance time schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

15 Maintenance job schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

16 Tool kit for maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1 Maintenance system job sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

1 2 The ZF 2000 Series transmissions are axially offset

3 4 reversing and step-up gears of 3-shaft design with a

6 7 9 transmissions. The main components subject to wear can

At the same time, the flow of oil to the operating clutch

In the event of faults in the operating oil circuit, both

= V-version In the basic version of the transmission, the ZF 2000 /

The high delivery rate of the oil pump ensures rapid

2.2 ZF 2000 A – transmission views

15 Oil cooler 46 Oil filler hole

20 Oil drain plug 53 Measuring point for oil temperature

2.3 ZF 2000 V – transmission views

3 Monitoring data for ZF 2000 Series

Monitoring data for ZF 2000 Series

Transmission and power flow diagram ZF 2000, ZF 2050, ZF 2150

Transmission and power flow diagram ZF 2150 A, ZF 2150 V

5 Oil supply and transmission cooling

The oil pump is driven by a driver off the transmission

The transmissions are equipped with an oil cooler

Connecting unions are provided as standard equipment

5.1 Control unit and transmission actuation

● The control slide valve for filling and ventilating the

● The control valve for setting the clutch pressure

● The time switch for modulating the clutch pressure

The control slide valve is axially moved into the desired

With mechanical transmission actuation, the control

With electrical transmission actuation, the control slide

If there is a malfunction in the electrical power supply,

a Electromagnet for “enginewise” shift position ! DANGER

6.2 Mechanical transmission actuation

The pilot valve has a lever for actuation.

The shift position is selected by moving the lever. The

Neutral: The lever is in the detent central position.

Enginewise: Pivot the lever from the central position

Counter-enginewise: Pivot the lever from the central

The actuation force is about 25 N with a lever arm length

7 Normal operation 7.1.4 Emergency changeover in the event of danger

7.1 Changeover However, in this case also, we recommend waiting 1 to

equal to max. 25 % of the water quantity used during Maintenance notes

7.3 Special versions / special scope of supply

7.3.1 Special scope of supply – transmission with

Only the transmission oil temperature can be measured

8.1 Mechanical emergency operation of the ! DANGER

Enginewise shift position

Electromagnet “a”: Threaded pin screwed in (approx. 5

188 Position of the threaded pin for the

Counter-enginewise shift position ! DANGER

8.2 Mechanical emergency operation of the

Mechanical emergency actuation is to be performed in

To deactivate mechanical emergency actuation, switch