Post on 01-Jan-2017
S E R V I C E M A N U A L A N D S P A R E P A R T S L I S TS E R V I C E M A N U A L A N D S P A R E P A R T S L I S T
Cod. 310.01.0052f
RE
PA
I RM A N U A L
ZF 3 M (HBW 35)ZF 5 M (HBW 50)ZF 10 M (HBW 100)ZF 12 M (HBW 125) / HBW 10ZF 15 M (HBW 150)ZF 15 MA (HBW 150 A)ZF 15 MIV (HBW 150 V)ZF 25 M (HBW 250)ZF 25 MAZF 30 M
Manual and Spare Parts List ZF M line
3
This ZF M manual has been preparedfor all those who have to do with ZF-HURTH Marine reversing gearbox unitsof the ZF M line, including models ZF 3M, ZF 5 M, ZF 10 M, ZF 12 M, ZF 15 M,ZF 15 MA, ZF 25 M, ZF 25 MA, ZF 30 M,ZF 15 MIV, in particular for- power plant suppliers- shipyards- craft owners
The ZF M manual is intended as an aidfor handling ZF M transmissions and willanswer all questions that may arise indaily operation and in connection with theinstallation and repair of ZF M transmis-sions.
This manual contains:
- Technical description of the gearboxunits and a number of important tech-nical data;
- Instructions for proper installation of thegearbox in the craft;
- Explanatory notes on correct operationand maintenance;
- Detailed description of all disassemblyand reassembly procedures (withdrawings);
- Troubleshooting table with possiblecauses of trouble and the required re-medial action;
- Spare parts list with stock numbers ofall sparte parts;
- Explosion-View drawings showingeach part with the reference numeralsused in the text.
No problems will be encountered in han-dling, installing and operating the ZF Mgearbox if the instructions in this manualare followed. Should a repair be neces-sary, a qualified technician will have nodifficulty in doing the repair work in ac-cordance with the detailed instructionsgiven on the following pages.
In addition, ZF M Service Stations (dis-tributors and dealers) are available forany repairs and for supplying the spareparts required. The manufacturer will al-ways be glad to name the Service Sta-tion nearest to your location.
All transmission units are covered by aworldwide guarantee given by the manu-facturer. The manufacturer’s warrantywill be subject to the condition that:- the instructions in this manual are
strictly observed in handling thetransmission.
- no work is performed by persons notauthorized by ZF-HURTH Marine.
- no changes or alterations of any kindare made on the transmission.
Failure to observe these points willinvalide all and any warranty claims.
Caution: never start doing any work onthe transmission unless and until theengine and the propeller have come toa complete standstill.
Manual and Spare Parts List ZF M line
4
Table of contents
1. Description1.1 Brief description1.2 Technical data and main
dimensions1.2.1 ZF 3 M boat reversing
gearbox unit1.2.2 ZF 5 M boat reversing
gearbox unit1.2.3 ZF 10 M boat reversing
gearbox unit1.2.4 ZF 12 M boat reversing
gearbox unit1.2.5 ZF 15 M boat reversing
gearbox unit1.2.6 ZF 15 MA boat reversing
gearbox unit1.2.7 ZF 15 MIV boat reversing
gearbox unit1.2.8 ZF 25 M boat reversing
gearbox unit1.2.9 ZF 25 MA boat reversing
gearbox unit1.2.10 Accessories1.2.11 Tools1.2.12 Ident. No.1.3 Gear casing1.4 Gear set1.5 Multiple-disc clutch and clutch
operation1.6 Shaft bearings1.7 Shaft seals1,8 Lubrication1.9 Cooling unit
2. Installation2.1 Delivery condition2.2 Transport2.3 Removal of preservative2.4 Painting the gearbox2.5 Connection of gearbox
with engine2.6 Connection of gearbox
with propeller2.7 Suspension of engine-
gearbox assembly in the boat2.8 Position of gearbox in
the boat2.9 Operation of gearbox2.10 Cooling unit2.11 Engine-gearbox compartment
3. Operation3.1 General information3.2 Initial operation3.3 Operating temperature3.4 Operation of gearbox3.5 Sailing or moving in tow3.6 Lay-up periods3.7 Preparation for re-use
4. Maintenance4.1 Transmission oil4.2 Oil quantity4.3 Oil level checks4.4 Oil change4.5 Checking the shift cable
and linkage4.6 Cooling unit4.7 Automatic transmission fluiid
List of recommended fluids
5. Disassembly5.1 Removing the cooling unit5.2 Removing and disassembling
the actuating lever cover plate5.3 Removing the bearing shields5.4 Separating the gearbox
sections and removing theinput and output shafts
5.5 Removing the shifting fork5.6 Removing the intermediate gear5.7 Disassembling the input shaft5.8 Disassembling the output shaft5.9 Disassembling the quill shaft
6. Reassembly6.1 General information6.2 Pre-assembling the intermediate
gear shaft in the gearbox sectionwithout opening
6.3 Pre-assembling the shifting forkin the gearbox section withopening
6.4 Pre-assembling the actuatinglever cover plate
6.5 Pre-assembling the gears6.6 Measuring the pre-assembled
gears to determine settingvalue «a»
6.7 Pre-assembling the bearingshields
6.8 Pre-assembling the actuatingmembers
6.9 Reassembling the input shaft6.10 Reassembling the output shaft6.11 Reassembling the quill shaft6.12 Final assembly of gearbox6.13 Measuring the gear sets of
input shaft and output shaft6.14 Mounting the actuating lever
cover plate6.15 Mounting the cooling unit
7. Procedure to adjust the shiftinglever cover
8. Troubleshooting
9. Spare parts list
10. Drawings (Explosion view)
Manual and Spare Parts List ZF M line
5
1. Description
1.1 Brief description
ZF-HURTH Marine boat reversing gear-box units of the ZF M line are servo-au-tomatically controlled helical gear trans-missions developed for use in pleasurecraft and commercial craft. The servo-operated multiple-disc clutchrequires only minimum effort for shifting,making the ZF M transmission suitablefor single-lever remote control via a rodlinkage or shift cable.
In emergency situations the ZF M per-mits direct reversing at engine speedabove idle rpm.
The torque capacity of the clutch is ex-actly rated, preventing shock loads fromexceeding a predetermined value to en-sure maximum protection of the engineand thus providing the effect of a safetyclutch.
The transmission units are characterizedby low weight and small overall dimen-sions. The gearbox castings are madeof a high-strength, corrosion-resistantaluminium alloy, chromized for improvedseawater resistance and optimumadhesion of paint.
A choice of gear ratios, a high efficiencyrating and low-noise operation are otherprominent features of the ZF M gearboxunits.
The transmissions are immersion-lubri-cated. Maintenance is restricted to oillevel checks (see «Maintenance», chap-ter 4).
The shafts are supported by heavy-dutytaper roller bearings and the gearbox isdesigned to take the axial propeller thrust(for permissible values see «Technicaldata», item 1.2).
Transmission sizes are available forright-hand (RH) and left-hand (LH)rotation of the input shaft, the directionof rotation being specified as seen by anobserver facing the input shaft.In gear lever positions A, the engine shaftand the propeller shaft rotate in oppo-site directions, in position B in the samedirection (Fig. 1).On model ZF 15 MIV, the directions ofrotation are the other way round (Fig. 2).
Engine manufacturers should note thatthe direction of rotation refers to an ob-server facing the flywheel, so that left-hand rotation of the engine correspondsto right-hand rotation of the gearbox in-put shaft.
Fig. 1
Fig. 2
Manual and Spare Parts List ZF M line
6
1.2.1 ZF 3 M
Power diagramBased on engine power B to DIN 6270;shock factorK = 1.25 to applied, if engine has 1 cylinderK = 1.20 for 2 cylindersK = 1.15 for 3 cylinders
Transmission input speed (rpm)
Transmission power input
Technical data ZF 3 M-2 R ZF 3 M-3 R
Shifting position «A» ratio 2.05:1 2.72:1
Shifting position «B» ratio 1.86:1 2.15:1
Input torque max. Nm (ft lb) 40 (29,5) 30 (22,1)
Power input max. kW (hp) 15 (20)
Input speed max. rpm 5000
Propeller thrust max. N (lb) 1000 (225)
Weight without fluid kg (lb) 8 (17.7)
Fluid quantity liter 0.3
Fluid grade Automatic-Transmission-Fluid (ATF)
Manual and Spare Parts List ZF M line
7
All dimensions in mm
Fig. 3 ZF 3 M
54
Manual and Spare Parts List ZF M line
8
1.2.2 ZF 5 M
Power diagram for Pleasure Craft DutyBased on engine power B to DIN 6270;shock factorK = 1.25 to applied, if engine has 1 cylinderK = 1.20 for 2 cylindersK = 1.15 for 3 cylinders
Transmission power input
ZF 5 M 2.045 1.864 0.0066 0.0088 18 25 20 27 20 27 5000 8 18 B/W2.722 2.150 0.0047 0.0063 13 18 14 19 17 23 5000 Max input power 15 kW
MODEL RATIO POWER / RPM INPUT POWER CAPACITY MAX WEIGHT BELL HSGS.
«A» Pos «B»Pos kW hp kW hp kW hp kW hp RPM kg lb AND NOTES
2800 rpm 3000 rpm 3600 rpm
«A» POS = continuous running position (normally AHEAD).«B» POS = reverse position.B/W = Borg Warner adaptor.Note = For all «M» (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine ÷ 1.25, 2 cylinder engine ÷ 1.20,3 cylinder engine ÷ 1.15.
Manual and Spare Parts List ZF M line
9
Fig. 4 ZF 5 M
All dimensions in mm
54
Manual and Spare Parts List ZF M line
10
** Max. 95 Nm (70 ft lb) admissible for main travelling direction with gearlever set to «B»
1.2.3 ZF 10 M
Power diagram for Pleasure Craft DutyBased on engine power B to DIN 6270;shock factorK = 1.25 to applied, if engine has 1 cylinderK = 1.20 for 2 cylindersK = 1.15 for 3 cylinders
Transmission input speed (rpm)
Transmission power input
1,8
MODEL RATIO POWER / RPM INPUT POWER CAPACITY MAX WEIGHT BELL HSGS.
«A» Pos «B»Pos kW hp kW hp kW hp kW hp RPM kg lb AND NOTES
2800 rpm 3000 rpm 3600 rpm
ZF 10 M 1.482 1.864 0.0109 0.0146 30 41 33 44 38 51 5000 9.5 21 SAE 4, 5, B/W1.792 1.864 Max input power 38 kW.2.045 1.864 0.0095 0.0128 27 36 29 38 34 46 5000 Ratio 1.482 «B» Pos.2.722 2.150 0.0068 0.0091 19 26 20 27 25 33 5000 max torque 95 Nm. Ratio
1.792 «B» Pos. maxtorque 95 Nm.
«A» POS = continuous running position (normally AHEAD).«B» POS = reverse position.B/W = Borg Warner adaptor.Note = For all «M» (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine ÷ 1.25, 2 cylinder engine ÷ 1.20,3 cylinder engine ÷ 1.15.
Manual and Spare Parts List ZF M line
11
Fig. 5 ZF 10 M
All dimensions in mm
54
Manual and Spare Parts List ZF M line
12
1.2.4 ZF 12 M
Power diagram for pleasure craftBased on engine power B to DIN 6270;shock factor K = 1.25 to applied,if engine has fewer than 4 cylinders.
Transmission input speed (rpm)
Transmission power input
ZF 12 M 2.136 1.955 0.0131 0.0176 37 49 39 53 47 63 5000 13 29 SAE 4, 5, B/W2.632 1.955 0.0111 0.0149 31 42 33 45 40 54 5000 Max input power 55 kW
MODEL RATIO POWER / RPM INPUT POWER CAPACITY MAX WEIGHT BELL HSGS.
«A» Pos «B»Pos kW hp kW hp kW hp kW hp RPM kg lb AND NOTES
2800 rpm 3000 rpm 3600 rpm
«A» POS = continuous running position (normally AHEAD).«B» POS = reverse position.B/W = Borg Warner adaptor.Note = For all «M» (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine ÷ 1.25, 2 cylinder engine ÷ 1.20,3 cylinder engine ÷ 1.15.
Manual and Spare Parts List ZF M line
13
Fig. 6 ZF 12 M
Model without mounting flange
a) Clockwise rotation b) Oil dipstick and filler screw 17 mm c) M 8/12 deep, holes same on both sides d) Oil drain plug 17 mm widthacross flats e) Spline profile similar B 10 x 23 x 29 DIN 5464 f) Minimum lever travel
Model with mounting flangeAll dimensions in mm
Manual and Spare Parts List ZF M line
14
** Max. 120 Nm (88.5 ft lb) admissible for main travelling directionwith gear lever set to «B»
1.2.5 ZF 15 M
Power diagram for Pleasure Craft DutyBased on engine power B to DIN 6270;shock factorK = 1.25 to applied, if engine has 1 cylinderK = 1.20 for 2 cylindersK = 1.15 for 3 cylinders
Transmission input speed (rpm)
Transmission power input
MODEL RATIO POWER / RPM INPUT POWER CAPACITY MAX WEIGHT BELL HSGS.
«A» Pos «B»Pos kW hp kW hp kW hp kW hp RPM kg lb AND NOTES
2800 rpm 3000 rpm 3600 rpm
ZF 15 M 1.556 1.955 0.0152 0.0204 43 57 46 61 55 73 5000 13 29 SAE 4, 5, B/W, Yanmar JH1.875 1.955 Max input power 55 kW.
Ratio 1.556 «B» Pos.max torque 120 Nm.Ratio 1.875 «B» Pos. max torque 120 Nm.
«A» POS = continuous running position (normally AHEAD).«B» POS = reverse position.B/W = Borg Warner adaptor.Note = For all «M» (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine ÷ 1.25, 2 cylinder engine ÷ 1.20,3 cylinder engine ÷ 1.15.
Manual and Spare Parts List ZF M line
15
Fig. 7 ZF 15 M
All dimensions in mm
Manual and Spare Parts List ZF M line
16
** Max. 120 Nm (88.5 ft lb) admissible for main travelling directionwith gear lever set to «B»
1.2.6 ZF 15 MA
Power diagram for Pleasure Craft DutyBased on engine power B to DIN 6270;shock factorK = 1.25 to applied, if engine has 1 cylinderK = 1.20 for 2 cylindersK = 1.15 for 3 cylinders
Gearbox input speed (1/min)
Transmission power input
MODEL RATIO POWER / RPM INPUT POWER CAPACITY MAX WEIGHT BELL HSGS.
«A» Pos «B»Pos kW hp kW hp kW hp kW hp RPM kg lb AND NOTES
2800 rpm 3000 rpm 3600 rpm
ZF 15 MA 1.875 1.955 0.0152 0.0204 43 57 46 61 55 73 5000 13 29 SAE 4, 5, B/W, Yanmar JH2.136 1.955 0.0131 0.0176 37 49 39 53 47 63 5000 Max input power 55 kW.
8 degrees 2.632 1.955 0.0111 0.0149 31 42 33 45 40 54 5000 Ratio 1.875 «B» Pos.max torque 120 Nm.Ratio 2.136 «B» Pos. max torque 120 Nm.
«A» POS = continuous running position (normally AHEAD).«B» POS = reverse position.B/W = Borg Warner adaptor.Note = For all «M» (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine ÷ 1.25, 2 cylinder engine ÷ 1.20,3 cylinder engine ÷ 1.15.
Manual and Spare Parts List ZF M line
17
Fig. 8 ZF 15 MA
Model without mounting flange
a) Clockwise rotation b) Oil dipstick and filler screw 17 mm c) M 8/12 deep, holes same on both sides d) Oil drain plug 17 mm width across flats e) Spline profilesimilar B 10 x 23 x 29 DIN 5464 f) Minimum lever travel g) Support for control cable h) full profile
Model with mounting flangeAll dimensions in mm
Manual and Spare Parts List ZF M line
18
* Max. 120 Nm (88.5 ft lb) admissible for main travelling direction withgear lever set to «B».
** Max 45 kW for main travelling direction with gear lever set to «B».
1.2.7 ZF 15 MIV
Power diagram for Pleasure Craft DutyBased on engine power B to DIN 6270;shock factorK = 1.25 to applied, if engine has 1 cylinderK = 1.20 for 2 cylindersK = 1.15 for 3 cylinders
Transmission power input
Transmission input speed (rpm)
MODEL RATIO POWER / RPM INPUT POWER CAPACITY MAX WEIGHT BELL HSGS.
«A» Pos «B»Pos kW hp kW hp kW hp kW hp RPM kg lb AND NOTES
2800 rpm 3000 rpm 3600 rpm
ZF 15 MIV 2.134 2.224 0.0152 0.0204 43 57 46 61 55 73 5000 20 44 SAE 4, 5, B/W, Yanmar JH2.718 2.224 0.0111 0.0149 31 42 33 45 40 54 5000 Max input power 55 kW.
8 degrees 2.995 2.224 5000 Ratio 2.134 «B» Pos.max torque 120 Nm.
«A» POS = continuous running position (normally AHEAD).«B» POS = reverse position.B/W = Borg Warner adaptor.Note = For all «M» (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine ÷ 1.25, 2 cylinder engine ÷ 1.20,3 cylinder engine ÷ 1.15.
Manual and Spare Parts List ZF M line
19
Fig. 9 ZF 15 MIV
Manual and Spare Parts List ZF M line
20
** Max. 230 Nm (170 ft lb) admissible for main travelling direction with gear lever set to «B»
1.2.8 ZF 25 M
Power diagram for Pleasure Craft DutyBased on engine power B to DIN 6270;shock factorK = 1.25 to applied, if engine has 1 cylinderK = 1.20 for 2 cylindersK = 1.15 for 3 cylinders
Transmission input speed (rpm)
Transmission power inputkW
90
80
70
60
50
40
30
20
151 2 3 4 5 6x103
30
40
50
60
70
80
100
120
hp
MODEL RATIO POWER / RPM INPUT POWER CAPACITY MAX WEIGHT BELL HSGS.
«A» Pos «B»Pos kW hp kW hp kW hp kW hp RPM kg lb AND NOTES
2800 rpm 3000 rpm 3600 rpm
ZF 25 M 1.880 2.095 0.0262 0.0351 73 98 79 105 80 107 5000 18 40 SAE 4, 5, B/W, Yanmar JH2.273 2.095 0.0216 0.0289 60 81 65 87 78 104 5000 Max input power 80 kW.2.737 2.722 0.0177 0.0237 50 66 53 71 64 85 5000 Ratio 1.880 «B» Pos.
max torque 230 Nm.
«A» POS = continuous running position (normally AHEAD).«B» POS = reverse position.B/W = Borg Warner adaptor.Note = For all «M» (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine ÷ 1.25, 2 cylinder engine ÷ 1.20,3 cylinder engine ÷ 1.15.
Manual and Spare Parts List ZF M line
21
Fig. 10 ZF 25 M
Manual and Spare Parts List ZF M line
22
1.2.9 ZF 25 MA
** Max. 169 Nm (125 ft lb) admissible for main travelling direction with gear lever set to «B»
Power diagram for Pleasure Craft DutyBased on engine power B to DIN 6270;shock factorK = 1.25 to applied, if engine has 1 cylinderK = 1.20 for 2 cylindersK = 1.15 for 3 cylinders
Transmission input speed (rpm)
Transmission power inputkW
90
80
70
60
50
40
30
20
151 2 3 4 5 6x103
30
40
50
60
70
80
100
120
hp
MODEL RATIO POWER / RPM INPUT POWER CAPACITY MAX WEIGHT BELL HSGS.
«A» Pos «B»Pos kW hp kW hp kW hp kW hp RPM kg lb AND NOTES
2800 rpm 3000 rpm 3600 rpm
ZF 25 MA 2.227 2.737 0.0215 0.0288 60 81 64 86 77 104 5000 18 40 SAE 4, 5, B/W, Yanmar JH2.737 2.737 0.0177 0.0237 50 66 53 71 64 85 5000 Max input power 80 kW.
8 degrees Ratio 2.227 «B» Pos.max torque 169 Nm.
«A» POS = continuous running position (normally AHEAD).«B» POS = reverse position.B/W = Borg Warner adaptor.Note = For all «M» (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine ÷ 1.25, 2 cylinder engine ÷ 1.20,3 cylinder engine ÷ 1.15.
Manual and Spare Parts List ZF M line
23
Fig. 11 ZF 25 MA
a) Clockwise rotation b) Oil dipstick and filler screw 17 mm c) M 10/15 deep, holes same on both sides d) Oil drain plug 17 mm widthacross flats e) SAE 26 teeth - DP 20/40 - 30° - Flat Root - Class t6 - f) Minimum lever travel
B
75
Manual and Spare Parts List ZF M line
24
1.2.10 Accessories
Resilient Coupling for ZF 3 M - ZF 5 M - ZF 10 M Ident-No. 254 750 - 3306 316 001
Resilient Coupling for ZF 25 M - ZF 25 MA Ident-No. 256 526 - 3307 316 001
Resilient Coupling for ZF 10 M - ZF 12 M - ZF 15 M - ZF 15 MA - ZF 15 MIV Ident-No. 254 762 - 3306 316 003
splineA 10 x 23 x 29
DIN 5464
max. torque 100 Nmmax. axial misalignment 0.25 mm
friction factor 4–10 Nm
splineA 10 x 23 x 29
DIN 5464
max. torque 200 Nmmax. axial misalignment 0.25 mm
friction factor 6–14 Nm
splineSAE 20/40
26 Z
max. torque 200 Nmmax. axial misalignment 0.25 mm
friction factor 6–14 Nm
Manual and Spare Parts List ZF M line
25
1.2.10 Accessories
Resilient Coupling for ZF 25 M / 25 MA Ident-No. 223 557 - 3307 316 003
Resilient Coupling PERKINS for ZF 10 M - ZF 12 M - ZF 15 M - ZF 15 MA - ZF 15 MIV Ident-No. 288 240 - 3306 316 002
Resilient Coupling PERKINS for ZF 25 M / 25 MA Ident-No. 288 238 - 3307 316 002
splineSAE 20/40
26 Z
splineSAE 20/40
26 Z
Bolt circle 142,6
Bolt circle 142,6
splineA 10 x 23 x 29
DIN 5464
max. torque 450 Nm
max. torque 200 Nm
max. torque 200 Nm
Manual and Spare Parts List ZF M line
26
1.2.10 Accessories
Adapter flange for ZF 3 M - ZF 5 M - ZF 10 M - ZF 12 M - ZF 15 M - ZF 15 MA Ident-No. 344 544 - 3306 116 001 (kit)
Adapter flange ZF 25 M - ZF 25 MA Ident-No. 345 964 - 3307 116 001 (kit)
Adapter flange ZF 15 MIV Ident-No. 345 965 - 3306 116 004 (kit)
Bolt circle 235+0.1
Bolt circle 235+0.1
Bolt circle 235+0.1
Manual and Spare Parts List ZF M line
27
1.2.10 Accessories
Cooler for ZF 10 M - ZF 12 M - ZF 15M - ZF 15 MA - ZF 15 MIV - ZF 25 M - ZF 25 MA Ident-No. 326 742 - 3306 107 001
M8 x DIN 931-8.8 vcad (4x)tightening torque 14 Nm
(when mounting on transmission)
1.2.11 Tools
Tool to adjust the shifing lever cover on ZF 10 M - ZF 12 M - ZF 15M - ZF 15 MA - ZF 25 M - ZF 25 MA(See Service Bulletin No. 007/03)
BRACKET P/N 20.4039.02
EXTENSION SECTION P/N 20.4039.03
377 755 - 0636 010 575
442 372 - 0630 302 090
Manual and Spare Parts List ZF M line
28
Model prop. turns draw. no. Id. no. weightanti engine
ZF 3 M 2,05:1 487926 3302 002 001 8 kg2,72:1 487927 3302 002 002 8 kg
Housing adapter Kit 344544 3306 116 001Damper plate up to 100 Nm 254750 3306 316 001
ZF 5 M 2,05:1 388817 3303 002 001 8 kg2,72:1 459413 3303 002 002 8 kg
Housing adapter Kit 344544 3306 116 001Damper plate up to 100 Nm 254750 3306 316 001
ZF 10 M 1,48:1 407345 3304 002 003 9,5 kg1,79:1 407346 3304 002 004 9,5 kg2,05:1 - 3304 002 0102,72:1 467329 3304 002 005 9,5 kg
Housing adapter Kit 344544 3306 116 001Housing adapter Kit SAE 5 500013 3306 116 002Oil cooler Kit 326742 3306 107 001Damper plate up to 100 Nm 254750 3306 316 001Damper plate up to 200 Nm 254762 3306 316 003Damper plate PERKINS up to 200 Nm 288240 3306 316 002
ZF 12 M 2,14:1 407205 3305 002 001 13 kg2,63:1 407206 3305 002 002 13 kg
Housing adapter Kit 344544 3306 116 001Housing adapter Kit SAE 5 500013 3306 116 002Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 254762 3306 316 003Damper plate PERKINS up to 200 Nm 288240 3306 316 002
ZF 15 M 1,56:1 407208 3306 002 003 13 kg1,88:1 407207 3306 002 004 13 kg
Housing adapter Kit 344544 3306 116 001Housing adapter Kit SAE 5 500013 3306 116 002Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 254762 3306 316 003Damper plate PERKINS up to 200 Nm 288240 3306 316 002
ZF 15 MA 2,0:1 407461 3306 001 004 13 kg2,14:1 - 3306 001 003 13 kg2,5:1 407462 3306 001 005 13 kg
Housing adapter Kit 344544 3306 116 001Housing adapter Kit SAE 5 500013 3306 116 002Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 254762 3306 316 003Damper plate PERKINS up to 200 Nm 288240 3306 316 002
ZF 15 MIV 2,13:1 407377 3306 003 001 20 kg2,72:1 439386 3306 003 003 20 kg2,99:1 407378 3306 003 002 20 kg
Housing adapter Kit 345965 3306 116 004Housing adapter Kit SAE 5 500015 3306 116 003Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 254762 3306 316 003Damper plate PERKINS up to 200 Nm 288240 3306 316 002
ZF 25 M 1,88:1 408089 3307 002 001 18 kg2,27:1 - 3307 002 007 18 kg2,74:1 408090 3307 002 002 18 kg
Housing adapter Kit 345964 3307 116 001Housing adapter Kit SAE5 - 3315 116 001Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 256526 3307 316 001Damper plate PERKINS up to 200 Nm 288238 3307 316 002Damper plate up to 450 Nm 223557 3307 316 003
ZF 25 MA 2,23:1 - 3307 001 005 18 kg2,74:1 - 3307 001 006 18 kg
Housing adapter Kit 345964 3307 116 001Housing adapter Kit SAE5 - 3315 116 001Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 256526 3307 316 001Damper plate PERKINS up to 200 Nm 288238 3307 316 002Damper plate up to 450 Nm 223557 3307 316 003
1.2.12 Gearboxes and accessories
Manual and Spare Parts List ZF M line
29
1.3 Gear Casing
The oil-tight gearbox housing is made ofa corrosion-resistant aluminium alloychromized for added protection from cor-rosion. The gear casing is divided in avertical plane into two equal halves.Cooling fins ensure good heat dissipa-tion and mechanical rigidity.
The oil filter screw with dipstick and theoil drain plug are screwed into the gearcasing. The filler screw is provided witha breather hole.
The actuating lever, actuating cam andcover plate are a pre-assembled unit fit-ted laterally to the gearbox unit.
Holes (see «Main dimensions» item 1.2pos. c) are provided for bolting the trans-mission to a flywheel housing or anadapter flange.
1.4 Gear set
The transmission is equipped with casehardened helical gears made of forgedlow-carbon alloy steel and case hard-ened spiral bevel gears (V drive). Thedrive shaft with the drive gears are anintegral unit.
The splined input shaft connecting thetransmission with the engine is hardenedas well.
The driven shaft (propeller side) of thetransmission, with the exception of theZF15 MIV model, is fitted with an inte-grally forged coupling flange.
The servo-automatic clutch system gov-erns the direction of rotation of the inputshaft, and ZF M transmission units areavailable for clockwise:(RH = right hand) or counterclockwise(LH = left hand) rotation.
Fig. 11
45 44 48 51 52 57 60 59 65
36
66
Power flowin lever position
Output
AB
1.5 Multiple-disc clutch and clutch operation - power train
The engine torque is applied to the inputshaft (36) in the specified direction ofrotation and, in shifting position A (seeMain Dimensions item 1.2), via gear (44),the frictionally engaged clutch discs (51and 52) to the external disc carrier (57)and from there via the guide sleeve (59)to the output shaft (66).
In shifting position B, the torque is trans-mitted from the input shaft (36) via inter-mediate gear (26), gear (65), clutch discs(51 and 52) to the external disc carrier(57), the guide sleeve (59) and the out-put shaft (66).
Function
The transmission uses a positivelydriven, mechanically operatedmultipledisc clutch system mounted onthe output shaft.
The thrust force required for obtainingpositive frictional engagement betweenthe clutch discs is provided by a servo-automatic system.
This essentially comprises a number ofballs which, by the rotary movement ofthe external disc carrier, are urgedagainst inclined surfaces provided inpockets between the guide sleeve andthe external disc carrier and in this wayexert axial pressure. The thrust forceand, as a result, the transmittable fric-tion torque are thus proportional to theinput torque applied.Due to the cup springs (48) supportingthe clutch disc stack and a limitation ofthe range of axial travel of the externaldisc carrier (57), the thrust force will notexceed a predetermined value.
The actuating sleeve (60) is held in themiddle position by spring-loaded pins. Toinitiate the shifting operation, the actuat-ing sleeve (60) needs merely be dis-placed axially by the shifting fork until thearresting force has been overcome. Thenthe actuating sleeve (60) is moved auto-matically by the spring-loaded pins, whilethe external disc carrier which follows thismovement, is rotated by frictional forcesexerted by the clutch discs, and the shift-ing operation is completed servo-auto-matically as described above.
Input
Manual and Spare Parts List ZF M line
30
1.6 Shaft bearings
Both the input and the output shafts arecarried in amply dimensioned taper rollerbearings.
The propeller thrust can be absorbed bythe bearings (for permissible values see«Technical data», item 1.2).
The intermediate gear and the movablegears are carried in sturdy needle rollerbearings.
1.7 Shaft seals
External sealing of the input and outputshafts is provided by radial sealing rings.The running surfaces on the shafts arecasehardened.
1.8 Lubrication
The transmissions are immersion-lubri-cated. The bearings are generously sup-plied with splash oil.
1.9 Cooling unit
Transmissions intended for use at highambient temperatures and for continu-ous operation at high power (especiallywhen shifting position B is used for themain direction of movement of the craft),must be supplied with a cooling unit (seeitem 2.10).
2. Installation
2.1 Delivery condition
HURTH ZF M gearbox units leave thefactory in fully assembled condition. Forsafety reasons, the gearbox is not filledwith oil for shipment. The actuating le-ver is mounted on the actuating shaft.On request, the gearbox is delivered withthe cooling unit (see item 2.10) andflange (see item 1.2) fitted, as well asthe previous damper plate between en-gine and gearbox.The multi-spline shaft is provided with anoil film and protected by a plastic cap.The bright surfaces of the coupling flangeon the output side are coated with ananticorrosive agent for shipment andstorage. The casing is chromized andthus resistant to seawater.
Fig. 12
(0.1 mm = 0.004 inches)
Before leaving the factory, each trans-mission is subjected to a test run withthe prescribed ATF oil. The residual oilremaining in the transmission after drain-ing acts as a preservative and providesreliable protection against corrosion forat least 1 year if the units are properlystored.
2.2 Transport
Care should be taken when transportingthe gearbox or the engine-gearbox as-sembly to prevent undue shocks andimpacts. This applies particulary to theinput and output shafts.
2.3 Removal of preservative
Use a suitable solvent for removing theanticorrosive agent, but never use em-ery cloth or paper, because this coulddamage the sealing surface and void thewarranty.
It is advisable, especially after long peri-ods of storage, to flush the transmissionwith the prescribed oil and remove re-sidual oil.
2.4 Painting the gearbox
Always cover the running surfaces andsealing lips of the radial sealing rings onboth shafts before painting. Make cer-tain that the breather hole on the oil fillerscrew is not covered by paint. The iden-tification plates should remain clearly leg-ible.
2.5 Connecting the gearbox with engine
Fit a recommended damping plate be-tween the engine and the transmissionto compensate for minor alignment er-rors and protect the input shaft from ex-ternal forces and loads.
If the flywheel housing of the engine isof suitable design, the gearbox unitshould be directly bolted to the housingby means of the holes provided in thegearbox.Make certain to use bolts with the rightappropriate length (see «Main dimen-sions», item 1.2) and thighten them tothe correct torque, M8 =14 Nm (10 ft lb),M10 = 28 Nm (20 ft lb)using LOCTITE 242 or 262
An adapter flange and a damper plateare available on request for each gear-box unit (see «Main dimensions», item1.2.10).
The radial and axial runout values shownin the drawing Fig. 12 should never beexceeded between the engine and trans-mission.
The input shaft end is provided with amulti-spline or involute spline profile (see«Main dimensions», item 1.2).
Manual and Spare Parts List ZF M line
31
2.6 Connection of gearbox with propeller
We recommend a flexible connectionbetween the gearbox and the propellershaft, when the engine is flexiblymounted, in order to compensate forangular deflections. The installation of aspecial propeller thrust bearing is notrequired, since the propeller thrust willbe taken by the transmission bearing,provided the value specified under«Technical data», item 1.2, is not ex-ceeded. However, the output shaftshould be protected from additionalloads. Special care should be taken toprevent torsional vibration. When usinga universal joint shaft, make certain toobserve the manufacturer’s instructions.
2.7 Suspension of engine–gearbox assembly in the boat
Special care should be taken to protectthe gearbox from detrimental stressesand loads when the engine-transmissionassembly is not elastically suspended inthe boat or craft.
The gearbox should be conveniently ac-cessible for maintenance. If the oil drainplug of the gearbox is not accessible, theoil will have to be sucked off.
2.8 Position of gearboxin the boat
The inclination of the gearbox unit in thedirection of the shafts should not exceedan installation angle of 20 degrees (seeFig.13) and 15° for ZF 15 MIV.
2.9 Operation of gearbox
The gearbox is suitable for single leverremote control. Upon loosening the re-taining screw (7), the actuating lever (6)can be moved to any position requiredfor the control elements (cable or rod link-age). (Fig. 14).
IMPORTANTMake certain that the lever does not con-tact the actuating lever cover plate (9):the minimum distance between lever andcover must be 0.5 mm.
The control cable should be perpendicu-lar to the actuating lever in the neutralposition of the lever.The zero position of the operating leveron the control console must coincide withthe zero position of the actuating leveron the gearbox.
The shifting travel, as measured at thepivot point of the actuating lever, be-tween the neutral position and end posi-tions A and B must be at least 35 mm forthe outer and 30 mm for the inner pivotpoint.A larger amount of lever travel is in noway detrimental.
IMPORTANTHowever, if the lever travel is shorter,proper gear engagement mightbeimpeded which, in turn, would meanpremature wear, excessive heat genera-tion and resulting damage.
The position of the cover plate under-neath the actuating lever is factory-ad-justed to ensure equal lever travel fromneutral position A and B.
IMPORTANTIf this cover is removed in exceptionalcases, proceed as described under item6.14 of this manual.
When installing the gearbox, make cer-tain that shifting is not impeded by re-stricted movability of the cable, by un-suitably positioned guide sheaves, toosmall bending radius, etc.
Fig. 13
20°
➞
➞
Clamping screw (7) tobe tightened to torqueof 20 Nm
Minimum shifting movementfor actuating lever (6)
Do not remove coverplate (9) or loosen screws
Oil drain plugOil dipstick and oil filler screw17 mm width across flats
Min. distance ofactuating lever 0.5 mm
Fig. 14
Manual and Spare Parts List ZF M line
32
2.10 Cooling unit
The arrangement of the cooling unit forthe ZF 10 M, ZF 12 M, ZF 15 M, ZF 15MA, ZF 15 MIV, ZF 25 M and 25 MA (nocooling is required for ZF 3 M and 5 M)can be seen from Fig.15.
The table below shows the maximumpower output in continuous operation (le-ver position A and B) usable without cool-ing. When these values are exceeded,a cooling unit is required.
The cooling unit should be connected tothe fresh-water pressure line (externalcircuit) of the engine in accordance withFig.16. The minimum volume of flow is10 ltr/min. Retrofitting of the cooling unitinvolves no problems (see item 6.15).
2.11 Engine-gearbox compartment
Care should be taken that the enginegearbox compartment is properly venti-lated.
Fig. 15
10 liters/min2.6 gal/min
Fig. 16
Max. engine power usable without cooling
Lever position ZF 3 M ZF 10 M ZF 12 M ZF 15 MIV ZF 25 MZF 5 M ZF 15 M ZF 25 MA
ZF 15 MA A no cooling no cooling 40 kW 25 kW 40 kW
54 hp 34 hp 54 hp B no cooling 25 kW 25 kW 20 kW always with
34 hp 34 hp 34 hp cooling unit
Manual and Spare Parts List ZF M line
33
Correct readings up to 20°inclination in direction of shafts(15° for ZF 15 MIV)
3. Operation
3.1 General information
All ZF M boat reversing gearbox unitsare test-run on a test stand at the fac-tory prior to delivery.
For safety reasons, the oil is drainedbefore shipment.
3.2 Initial operation
Fill the gearbox with oil (ATF), (see 4.7or recommended fluids). The oil levelshould be up to the index mark on thedipstick (see fig. 17).
To check the oil level, just insert the dip-stick, do not screw in. Retighten the hexscrew with the dipstick after the oil levelcheck. Do not forget sealing ring.
3.3 Operating temperature
Normal operating temperature of thetransmission oil should be in the rangeof 50°C (122°F) to 80°C (176°F). Max.permissible ATF temperature of 100°C(212°F) may only be reached for a shorttime.
3.4 Operation of gearbox
The zero position of the operating leveron the control console must coincide withthe zero position of the actuating leveron the transmission. Shifting is initiatedby a cable or rod linkage via the shiftinglever and an actuating cam. The
completition of the gear changing opera-tion is servo-automatically controlled.Gear changing should be smooth, not tooslow, and continuous (without interrup-tion). Direct changes from forward to re-verse are permissible, since the multi-ple-disc clutch permits gear changing athigh rpm, including sudden reversing attop speeds in the event of danger.
3.5 Sailing or moving in tow
Rotation of the propeller while the boatis sailing, being towed, or anchored in ariver, as well as operation of the enginewith the propeller stopped (for chargingthe battery), will have no detrimental ef-fects on the gearbox.
IMPORTANTWhen the boat is sailing (enginestopped), the gear lever must be in zeropos-ition. Never put the gear lever in thepos-ition corresponding to the directionof travel of the boat.
Locking the propeller shaft by an addit-ional brake is not required: use the gearlever position opposite your direction oftravel for this purpose.
3.6 Lay-up periods
If the transmission is not used for peri-ods of more than 1 year it should be com-pletely filled with oil of the same gradeto prevent corrosion. Protect the inputshaft and the output flange by means ofan anticorrosive coating if required.
3.7 Preparation for re-useSee item 2.3
4. Maintenance
4.1 Transmission oil
To ensure trouble-free operation of theclutch only use Automatic TransmissionFluid (ATF).
4.2 Oil quantity
ZF 3 M 0.30 ltr 0.32 qtsZF 5 M 0.30 ltr 0.32 qtsZF 10 M 0,35 ltr 0.37 qtsZF 12 M 0.56 ltr 0.59 qtsZF 15 M 0.56 ltr 0.59 qtsZF 15 MA 0.47 ltr 0.50 qtsZF 15 MIV 1.00 ltr 1.06 qtsZF 25 M 0.75 ltr 0.79 qtsZF 25 MA 0.75 ltr 0.79 qts
min. 0.90 ltr min. 0.95 qtsZF 30 Mmax. 1.10 ltr max. 1.17 qts
Use the index mark on the dipstick as areference (see item 3.2)
4.3 Oil level checks
Check the oil level in the gearbox aboutonce a month. Correct oil level: indexmark on dipstick (see item 3.2). Alwaysuse the same oil grade when topping up.Don’t overfill the gearbox. This will cre-ate higher operating temperatures.
4.4 Oil change
Change the oil the first time after about25 hours of operation, then at intervalsof at least 1 year.
4.5 Checking the control cable linkage
The control cable or rod linkage should bechecked at shorter time intervals. Checkthe zero position of the operating lever (onthe control console) and of the shifting le-ver (on the gearbox) on this occasion. Theminimum lever travel from the neutral po-sition to operating positions (0-A = 0-B)should be 35 mm (1.38 in) for the outerand 30 mm (1.18 in) for the inner pivotpoint. Make certain that these minimumvalues are safely reached. Check the ca-ble for easy movability (see item 2.9).
4.6 Cooling
If the transmission is equipped with acooling unit, drain the cooling waterbefore long periods of non-use whentemperature is below freezing point.
Fig. 17
Manual and Spare Parts List ZF M line
34
4.7 Automatic Transmission FluidList of recommended fluidsFor ZF-HURTH ZF M Marine Transmissions Automatic Transmission Fluid (ATF) must to be used as lubricant.
ADDINOL MINERALÖL GMBH, KRUMPA/D ADDINOL ATF D IIDADDINOL MINERALÖL GMBH, KRUMPA/D ADDINOL ATF D IIIAGIP PETROLI SPA, ROM/I AGIP ATF II DAGIP PETROLI SPA, ROM/I AGIP ATF D 309AGIP PETROLI SPA, ROM/I AGIP ATF PLUSAGIP PETROLI SPA, ROM/I AGIP DEXRON IIIAGIP SCHMIERTECHNIK, WÜRZBURG/D AUTOL GETRIEBEÖL ATF-DAGIP SCHMIERTECHNIK, WÜRZBURG/D AUTOL GETRIEBEÖL ATF III DARAL LUBRICANTS GMBH, BOCHUM/D ARAL GETRIEBEÖL ATF 22ARAL LUBRICANTS GMBH, BOCHUM/D ARAL GETR.ÖL ATF 55 F-30589AVIA MINERALÖL-AG, MÜNCHEN/D AVIA FLUID ATF 86BLASER SWISSLUBE, HASLE-RÜEGSAU/CH BLASOL 229BP OIL DEUTSCHLAND, HAMBURG/D FRONTOL UNIVERSAL-ATF 100BP OIL INTERNATIONAL, LONDON/GB AUTRAN DX IIBP OIL INTERNATIONAL, LONDON/GB AUTRAN MBXBP OIL INTERNATIONAL, LONDON/GB AUTRAN DX III (F-30370)BP OIL INTERNATIONAL, LONDON/GB AUTRAN DX III (F-30381)BUCHER+CIE AG, LANGENTHAL/CH MOTOREX ATF SUPER D-22656BUCHER+CIE AG, LANGENTHAL/CH MOTOREX ATF DEXRON III MCCALPAM GMBH, ASCHAFFENBURG/D PAMATIC FLUID 289CALPAM GMBH, ASCHAFFENBURG/D CALPAMATIC FLUID III FCALTEX PETROLEUM CORP., LONDON/GB CALTEX ATF-HDACALTEX PETROLEUM CORP., LONDON/GB CALTEX ATF-HDMCALTEX PETROLEUM CORP., LONDON/GB CALTEX TEXAMATIC 1278CALTEX PETROLEUM CORP., LONDON/GB CALTEX TEXAMATIC 7045CALTEX PETROLEUM CORP., LONDON/GB CALTEX TEXAMATIC 1205ACASTROL LTD, SWINDON/GB CASTROL TQ-D (22765)CASTROL LTD, SWINDON/GB CASTROL TQ DEXRON III F-30520CASTROL LTD, SWINDON/GB CASTROL TRANSMAX S (F-30319)CASTROL LTD, SWINDON/GB CASTROL TRANSMAX T (F-30359)CASTROL LTD, SWINDON/GB CASTROL TQ-D (21289)CASTROL LTD, SWINDON/GB CASTROL ATF 21293CEPSA, MADRID/E CEPSA ATF-70CHEVRON PRODUCTS CO., RICHMOND/USA CHEVRON ATF F-30108CITGO PETROLEUM CORP., TULSA/USA CITGO ATF DEXRON III F-30167C.J.DIEDERICHS SÖHNE, WUPPERTAL/D CIDISOL-HYDR.-FLUID DEXRON IIDDE OLIEBRON B.V., ZWIJNDRECHT/NL ATF DMMDE OLIEBRON B.V., ZWIJNDRECHT/NL ATF 289DEA MINERALÖL AG, HAMBURG/D DEAMATICDEA MINERALÖL AG, HAMBURG/D DEAFLUID 4011DEA MINERALÖL AG, HAMBURG/D DEAFLUID 3003DEUTSCHE SHELL AG, HAMBURG/D MAC ATF D-21666DUCKHAMS OIL, BROMLEY/GB UNIMATICELF LUBRIFIANTS, PARIS/F TRANSANTAR DF2ELF LUBRIFIANTS, PARIS/F ANTAR 22329ELF LUBRIFIANTS, PARIS/F ELFMATIC G2 22329ELF LUBRIFIANTS, PARIS/F HUILE RENAULT DIESEL STARMATICELF LUBRIFIANTS, PARIS/F ELFMATIC G3ELF LUBRIFIANTS, PARIS/F TRANSANTAR DF3ELLER-MONTAN-COMP., DUISBURG/D ELLMO-AUTOMATIK-FLUID 22233ENGEN PETROLEUM, CAPE TOWN/ZA ENGEN ATF 22DERTOIL SA, MADRID/E TRANSMISIONES AUTOMATICAS D2ESSO AG, HAMBURG/D ESSO ATF D (21611)ESSO AG, HAMBURG/D ESSO ATF F-30320ESSO AG, HAMBURG/D ESSO ATF D (21065)FIAT LUBRIFICANTI, VILLASTELLONE/I TUTELA GI/AFINA EUROPE SA, BRÜSSEL/B FINAMATIC II-DFUCHS LUBRICANTS (UK), DERBY/GB SILKTRAN MP-ATFFUCHS LUBRICANTS (UK), DERBY/GB SILKTRAN PSV ATFFUCHS MINERALÖLWERKE, MANNHEIM/D TITAN ATF 4000GINOUVES GEORGES SA, LA FARLEDE/F YORK LT 785GULF OIL (GB) LTD, CHELTENHAM/GB UNIFLUIDGULF OIL (GB) LTD, CHELTENHAM/GB ATF 2HANDELSMIJ NOVIOL B.V., NIJMEGEN/NL KENDALL ATF DEXRON IIDHOMBERG GMBH+CO KG, WUPPERTAL/D HOMBERG-GETRIEBE-FLUID DIGOL FRANCE, PARIS/F IGOL ATF 420INA RAFINERIJA ZAGREB/CROATIA INA-ATF SUPERITALIANA PETROLI, GENOVA/I TRANSMISSION FLUID DXJAPAN ENERGY CORP., TOKYO/JAPAN JOMO ATF KKÄPPLER K., STUTTGART/D SELECTOL FLUID GETR.ÖL IID 23KLÖCKNER ENERGIEHANDEL GMBH, KÖLN/D DEUTZ OEL ATF-DKROON OIL BV, ALMELO/NL ATF DEXRON IIDKROON OIL BV, ALMELO/NL ALMIROL ATFKUWAIT PETROLEUM, HOOGVLIET/NL Q8 AUTO 15KUWAIT PETROLEUM, HOOGVLIET/NL Q8 AUTO 14 (IID-21677)KUWAIT PETROLEUM, HOOGVLIET/NL Q8 AUTO 14 (IID)
KUWAIT PETROLEUM, HOOGVLIET/NL Q8 AUTO 14 (IID-21883)LEPRINCE+SIVEKE GMBH, HERFORD/D LEPRINXOL FLUID CNLIQUI MOLY / MEGUIN, ULM/D ATF IIELIQUI MOLY / MEGUIN, ULM/D MEGOL ATF IIDLUBRICATION ENGIN., FORT WORTH/USA AUTOMATIC TRANSMISSION FLUIDMAURAN SA, ODARS/F INTER OIL INTER MATIC ATF D2MIN.ÖL-RAFFIN. DOLLBERGEN, UETZE/D PENNASOL FLUID-GETR.ÖL TYP PCNMOBIL OIL, WEDEL/D MOBIL ATF 220 D20104 / D21685MOBIL OIL, WEDEL/D MOBIL ATF F-30107MOBIL OIL, WEDEL/D MOBIL ATF 220 D21412 / D22187MOBIL SEKIYU KABUS.KAISHA, TOKYO/J MOBIL ATF 220Y (D-21412)MOL HUNGARIAN OIL, KOMARON/H CARRIER ATFMORRIS LUBRICANTS, SHREWSBURY/GB LIQUIMATIC DIINAFTEC, ALGIER/DZ TASSILIANANHAI SUPERIOR LUB-OIL, CHINA NANHAI ATF (D2)NIS-RAFINERIJA NAFTE BEOGRAD/YU GALAX MATIC DACOEST G. MIN.ÖLWERK, FREUDENSTADT/D ATF T 4011OMEX PETROLEUM PTY, BELLEVUE/AUS OMEX ATF DEXRON IIOMV AG, SCHWECHAT/A OMV ATF D II (D22427)OMV AG, SCHWECHAT/A OMV ATF III (F-30580)OPTIMOL ÖLWERKE, HAMBURG/D OPTIMOL ATF T 4011OSWALD KLUTH, BARGFELD-STEGEN/D UNIVERSAL ATF-DPAKELO MOTOR OIL, SAN BONIFACIO/I MULTIPURPOSE TRANSM. FLUID IIDPANOLIN AG, MADETSWIL/CH PANOLIN ATF MULTI 21996PANOLIN AG, MADETSWIL/CH PANOLIN ATF DEXRON IIIPARS OIL CO., TEHRAN/IR PARS ENTEGHAL-E AUTOMATIC OILPAZ LUBRICANTS&CHEMICALS, HAIFA/IL PAZBO EZFPENNZOIL PRODUCT COMP., HOUSTON/USA PENNZOIL ATF F-30110PETRO-CANADA, MISSISSAUGA/CDN DEXRON III/MERC.ATF (F-30395)PETROL OFISI A.S., BAKANLIKLAR/TR PETROL OFISI ATF IIPETROLEX, KWIDZYN/PL VECO MATIC IIDPRINZ-SCHULTE, FRECHEN/D AERO-LINE ATF-2PRINZ-SCHULTE, FRECHEN/D AERO-LINE ATF-DREPSOL DISTRIBUCION SA, MADRID/E REPSOL MATIC ATFS.A.E.L, ALCOBENDAS/E GULF ATF DII D-22233SASOL OIL, RANDBURG/ZA SASOL ATF DXIISCHMIERSTOFFRAFFINERIE SALZBERGEN/D WINTERSHALL ATF DSHELL ASEOL AG, BERN/CH ASEOL ATF DB UNIVERSALSHELL INTERNATIONAL, LONDON/GB SHELL DONAX TA (D-21666)SHELL INTERNATIONAL, LONDON/GB SHELL DONAX TG (F-30358)SLOVNAFT JS CO, BRATISLAVA/SLO MADIT AUTOMATICSONOL ISRAEL LTD, HAIFA/IL DEXRON 2 DSOPROGRASA SA, MADRID/E SOPRAL 164STATOIL STAVANGER/N TRANSWAY DX III (F-30373)STATOIL STAVANGER/N TRANSWAY DX IISTL TECNOL, ESCALQUENS/F TECNOL TECMATIC D2SUN OIL COMPANY, AARTSELAAR/B SUNAMATIC 149SUN OIL COMPANY, AARTSELAAR/B SUNAMATIC 153SUOMEN PETROOLI OY, HAMINA/SF TEBOIL FLUID E (F-30301)SUOMEN PETROOLI OY, HAMINA/SF TEBOIL FLUID DSVENSKA STATOIL AB, NYNÄSHAMN/S TRANSWAY DX III (F-30373)TAMOIL LUBES, GENEVA/CH TAMOIL ATF II DTEXACO LUBRICANTS COMP., BEACON/USA ATF MERCON / DEXRON IIITEXACO SERVICES LTD, BRÜSSEL/B TEXAMATIC 7045TEXACO SERVICES LTD, BRÜSSEL/B TEXAMATIC 4261TEXACO SERVICES LTD, BRÜSSEL/B TEXAMATIC 7080TEXACO SERVICES LTD, BRÜSSEL/B TEXTRAN PSMTEXACO SERVICES LTD, BRÜSSEL/B TEXAMATIC 4011TEXACO SERVICES LTD, BRÜSSEL/B TEXAMATIC 4291TEXACO SERVICES LTD, BRÜSSEL/B TEXAMATIC 9226TOTAL RAFFINAGE DISTR., PARIS/F TOTAL FLUIDE ATXTOTAL RAFFINAGE DISTR., PARIS/F TOTAL FLUIDE IIDTOTAL RAFFINAGE DISTR., PARIS/F TOTAL FLUIDE AT 42TOTAL SOUTH AFRICA, JOHANNESBURG/ZA TOTAL FLUIDE ATDTURBOTANK BÖSCHE+BÖDEKER, BREMEN/D TURBO UNIV. ATF MERCON 4011UFANEFTECHIM REFINERY, UFA/RUS UFALUB ATFUNIL DEUTSCHLAND GMBH, BREMEN/D UNIL MATIC CN T 4011VALVOLINE INC., LEXINGTON/USA VALVOLINE MULTI-PURPOSE ATFVALVOLINE INTERNAT., DORDRECHT/NL VALVOLINE ATF TYPE DVEBA OEL AG, GELSENKIRCHEN/D MOVARA ATF-GETRIEBEÖL DIIDVEEDOL INTERNATIONAL, SWINDON/GB VEEDOL ATF-M (22764)VEEDOL INTERNATIONAL, SWINDON/GB VEEDOL ATF DEXRON III F-30521VEEDOL INTERNATIONAL, SWINDON/GB VEEDOL UNITRANS S PLUSYACCO SA, ST PIERRE-LES-ELBEUF/F YACCO ATF DZELLER+GMELIN GMBH&CO, EISLINGEN/D DIVINOL FLUID 666
Manual and Spare Parts List ZF M line
35
5. Disassembly
Note: fold out illustration sheets 1 and 2or (for ZF 15 MIV) sheets 3 and 4 (ex-ploded views) for reference.
5.1 Removing the cooling unit(if present)
Unscrew 4 hex head screws M8x50 andtake off unit (see illustration under item6.14.2).
5.2 Removing and disassembling theactuating lever cover plate
5.2.1 Always set actuating lever to neu-tral position.
5.2.2 Remove hex nuts (22) from coverplate (9), using 13 mm spanner (wrench),and take off spring washers (4).
5.2.3 Remove cover plate assembly (12),lever (6) and actuating cam (11).
5.2.4 Remove screw (7) from lever (6).Pull off lever (6). Remove actuating cam(11) and needle bearing (70) only inmodels ZF 12 M - 15 M - 25 M - 30 M.Remove actuating cam sealing ring (8).
5.3 Removing the bearing shields
5.3.1 Remove hex head screw (5) frombearing shields (2) and (3), using 13 mmspanner (wrench), and take off springwashers (4).
5.3.2 Remove cover (3) and bearingshield (2) on input shaft (36) together withseals (28).
5.4 Separating the gearbox sections andremoving the input and output shafts
5.4.1 Remove hex nuts (22) from gear-box (1), using 13 mm spanner (wrench),take off spring washers (4) and removescrews (21).
5.4.2 Separate the two halves of gear-box (1) by light hammer blows on the oilfiller screw and oil drain plug (19 and 20).
5.4.3 Remove shims (37, 38, 39, 40)from the input and output shafts and keepseparately. For proper reassembly it isadvisable to note down the thickness andlocation of each of the shims to obtainthe correct bearing play.If none of the parts (2, 3, 32, 33, 36) onthe input shaft and of the parts (2, 3, 34,35, 43, 46, 47, 59) of the output shaftare replaced, the shims can be re-usedin the same positions. When any of theseparts are replaced, the dimensions of thegear set relative to the casing have tobe measured anew and suitable shimshave to be installed.
5.5. Removing the shifting fork (15)
5.5.1 Remove screw plug (17) (not nec-essary in ZF 3 M - 5 M since there is noplug but only a O-ring).
5.5.2 Pull actuating shaft (16) out of thehole in the half housing.
5.5.3 Remove shifting fork (15).
5.6 Removing the intermediate gear (26)
5.6.1 Heat gearbox section with interme-diate gear to a temperature of approx.80°C (176 F); in ZF 3 M - 5 M only, firstremove the retaining ring (23).
5.6.2 Knock pin (24) out of its bearing bylight hammer blows, using a driving pinof suitable size.
5.6.3 Remove intermediate gear (26),retaining plates (25) and roller cage (27).
5.7 Disassembling the input shaft (36)
5.7.1 Remove outer bearing races (32).
5.7.2 In the event of bearing damage,cautiously drive inner races (33) off theinput shaft (36) with a punch (away fromgear).
Manual and Spare Parts List ZF M line
36
5.8 Disassembling the outputshaft (66)
5.8.1 Mount support rail on a vice withthe pins pointing upwards (not on ZF 15MIV).
5.8.2 Place output shaft (66) verticallyon the support rail with the flange sidedown.
5.8.3 Remove screw (41) spacer (42)and outer bearing race (34).Only in models ZF 3 M - 5 M removealso shims (68) and in model ZF 15 MAspacer (68).
42
5.8.4 Place side of gear (65) adjacent toshaft flange against a suitable support(a divided flange or two brackets of suit-able section) and use pin of suitable sizeto press off the output shaft.Do not place the support neither againstthe gear's (65) teeth nor against the fric-tion washer (43). But place it as shownon the drawing below.
The parts removed from the upside ofthe shaft are not interchangeable with theparts removed from the flange side. Keepseparately.
5.8.5 Remove keys (67) from the outputshaft and keep in a separate place (1key for ZF 3 M and 5 M, 2 keys for ZF 10M, 12 M, 15 M, 15 MA, and 4 keys forZF 25 M, 25 MA and ZF 30 M).
Fig. 18
Fig. 19
41
34 68
65
6543
Manual and Spare Parts List ZF M line
37
5.8.6 Put off shims (53, 54, 55, 56),spacer (47) and needle bearing (45) fromthe output shaft.
5.8.7 Attach divided flange to face sideof bearing shield (2) and pull off thrustwasher (43), inner race (46) and taperroller bearing (34, 35) with shield. On ZF15 MIV only pull off taper roller bearing(34, 35).
5.8.8 Remove internal and externalclutch discs from gears (44) and (65).
5.8.9 Dismantling the gearsCompress cup springs (48) (only oneeach side for ZF 3 M - 5 M) by means ofdismantling tool. Remove circlip (50) andtake off thrust plate (49).
5.8.10 Dismantling the actuating mem-bers.Detach springs (64), watching for balls (58).
5.8.11 Remove disc carrier (57).
5.8.12 Place actuating sleeve (60) on aplane surface and press out guide sleeve(59). Watch for detent pins and springsjumping off the guide sleeve. It will beadvisible to wrap a rag around the actu-ating sleeve (60) and the guide sleeve(59) to catch any parts that might jumpoff.
5.9 Disassembling the quill shaft (ZF 15MIV).
Note: see drawing page 38.
5.9.1 Remove grooved ring nut (83) bymeans of socket spanner and take offring (34) with sealing ring (31).
5.9.2 Place divided flange against faceside of bevel gear (80) and force bevelgear (80) spacer ring (76) and bearing(74) off quill shaft.
5.9.3 Remove key (81) and spacer ring (76).
5.9.4 Force off bearing (74) by means ofdivided flange.
Fig. 20
47
46
43
44 - 65
49
50
53 - 5455 - 56
45
34 - 35
2
Fig. 21
Fig. 22
64
575863
626160595857
48
Manual and Spare Parts List ZF M line
38
6. Reassembly
Note: fold out illustration sheets 1 and 2(exploded views) for reference. For ZF15 MIV use illustration sheets 3 and 4.
6.1 General information
The following points should be observedwhen reassembling the gearbox:
- Clean all parts thoroughly, especiallysealing surfaces, inspect for wear,damage and cracks, and replace if re-quired.
- Check shifting fork (15) for wear. Thecontact surfaces of this fork are pro-vided with amolybdenum coating.Should this coating be worn away atany point, replace the shifting fork. Maxwear on guiding surfaces 0.2 mm(0.008 in) on each side.
- Thrust rings (43) require replacementif wear exceeds 0.25 mm (0.0098 in).
- Internal discs (51) have a sinteredmetal coating of 0.3 mm (0.012 in) oneach side. If the surface structure (af-ter clean-ing) shows indications ofwear, replace the discs.
- Apply thin coat of oil to antifriction bear-ings before installation.
0.5 ±0.2 mm
not for ZF 3 M - 5 M - 10 M
6.2 Assembling the intermediategear shaft in gearbox section
side cooler
6.2.1 Insert retaining plate (25).
IMPORTANT:Note that the bevelled corners of retain-ing plates (25) have to be placed in differ-ent positions (see illustration on sheet 1).
6.2.2 Insert needle cage (27) into inter-mediate gear (26) and place completeassembly with retaining plate (25).
6.2.3 Insert second retaining plate (25).Not for ZF 3 M - 5 M.
6.2.4 Fit O-ring (23) to intermediate gearshaft (24)* and drive it into gearboxsection by knocking slightly on a drivepin.
* on ZF 3 M - 5 M insert intermediate gearshaft with seeger 23 and Loctite 574.
* on ZF 25 M - 25 MA and ZF 30 M, in-sert intermediate gear shaft (24) with-out O-ring (23) and close bore in gear-box section with sealing compound bypressing in a plug (23) with Loctite 574.(see illustration on sheet 1).
* on ZF 15 MIV insert intermediate shaft(24) and stop it in its place by knock-ing with a driver pin on the edge of thehole of the housing. Close the outsiderhole in the housing by pressing in plug(23) with Loctite 574.
6.3 Assembling the shifting fork ingearbox section side shifting cover
6.3.1 Insert shifting fork (15) into gear-box section (1) side the actuating leverin such a way that the long arm of thefork points downwards.
6.3.2 Insert shifting rod (16) throughbores in gearbox and shifting fork.
6.3.3 Fit screw plug (17) to gearbox,making certain that the clearance be-tween shifting rod (16) and screw plug(17) is min. 0.5 mm (0.02 in).Seal screw plug with Loctite 242 (ZF 3M - 5 M only O-Ring).
6.3.4 Check shifting fork for easymovability.
6.4 Pre-assembling the actuatinglever cover plate
Use punch tool to press sealing ring (8)into cover plate (9). Spread antifrictionbearing grease between sealing lips.
6.4.1 Insert actuating cam assembly (11)into cover plate (9).
6.4.2 Fit actuating lever (6).
IMPORTANT:Clearance between actuating lever andcover plate 0.5 mm (0.02 in).
6.4.3 Clamp actuating lever by meansof retaining screw (7), using a 13 mmspanner (wrench). Screw in with torqueof 20 Nm.
Fig. 23
8 11
70
6
7
Punch ToolFig. 24
8
9
Manual and Spare Parts List ZF M line
39
6.5 Pre-assembling the gears (65) and(44) with cup springs (48) and clutchdiscs (51 and 52)
IMPORTANT:If previously disassembled parts areused, make certain that only mating andassociated parts are reassembled.
6.5.1 Join two cup springs (48) (only onecup spring for ZF 3 M - 5 M) face to face(external diameters in contact) and placethem on the centering collar of gears (65)and (44).
6.5.2 Place thrust ring (49) on cupsprings.
6.5.3 Place circlip (50) on gear hub anduse mounting tool and press to fit circlipinto groove on hub. Don't presscompletely the cup springs and be surethat the tool presses at least on threepoints on the thrust washer (49).
6.5.4 Attach clutch discs (51 and 52), firstinternal disc (51), then alternatively ex-ternal disc (52), internal disc (51), etc.
6.6 Measuring the pre-assembledgears (65) and (44) to determinesetting value «a».
If no parts had to be replaced, the previ-ously disassembled shims (53, 54, 55,56) can be re-used in their former ar-rangement and positions without anymeasuring operation.
If measuring is required, proceed as fol-lows:
6.6.1 Place pre-assembled gear (65),and subsequently gear (44) on thrustwasher (43), (end face of hub down-wards, see illustration).
IMPORTANT:On ZF 3 M - 5 M - 10 M there is a stepon the thrust washer (43). Put the sideof the washer with the step against thegear. Be sure that the needle bearinginner race (46) is fitted into it.
6.6.2 Insert needle cage (45), inner race(46) and spacer (47) into bore of gear.
6.6.3 Fit shims (53, 54, 55, 56), as re-quired, until prescribed seeting value «a»is obtained (see illustration).
6.6.4 Shims are available in thicknessesof 0.4 - 0.5 - 0.6 and 0.7 mm.(0.016 - 0.020 - 0.024 and 0.028 in)
Setting value «a»
Type mm inchesZF 3 M 8.0±0.1 0.315±0.004ZF 5 MZF 10 M 13.0±0.1 0.512±0.004HBW 10ZF 12 MZF 15 M 12.4±0.1 0.488±0.004ZF 15 MAZF 15 MIVZF 25 M / 25 MA 16.2±0.1 0.638±0.004ZF 30 M 19.75±0.1 0.778±0.004Old versions(4+3 externalclutch discs)HBW 10(versionsfrom 01 to 08) 13.2±0.1 0.520±0.004HBW 150(versionsfrom 09 to 14)HBW 150 V(versionsfrom 01 to 07)
Fig. 25
50
49
44 - 65
48
Fig. 26
Thrust washer (43)bronze sideupwards
53 - 5455 - 56
50
49
44 - 65
48
4546
47
Manual and Spare Parts List ZF M line
40
6.7 Pre-assembling the bearingshields (2) for the input and outputshafts
Use a driver tool to press sealing rings(30 - input and 31 - output) into shield (2).
6.8 Pre-assembling the clutchmembers
6.8.1 Fit driving pins (63), springs (61)and detent pins (62) to guide sleeve (59).
6.8.2 Place actuating sleeve (60) onplane press surface.
6.8.3 Place guide sleeve (59) on top ofactuating sleeve (60) with the three driv-ing pins (63) in alignment with the threegrooves in the actuating sleeve. Watchfor correct position of detent pins (62)relative to angular pockets of sleeve.
6.8.4 Press guide sleeve (59) into actu-ating sleeve (60) up to midway position(noticeable click).
6.8.5 Insert balls (58) into ball pocketsof guide sleeve, attach disc carrier (57),turn upside down then fit balls in oppo-site face side and attach second disccarrier (57).
6.8.6 Attach springs (64) with closed partof spring windings pointing outwards.
6.9 Reassembling the input shaft
Preheat inner races (33) of taper rollerbearings to a temperature of 100° C(212F) and, using tubular or punch tool,press races on input shaft (36) on bothsides.
IMPORTANT:Repress after cooling down, so that nogap is left.
Fig. 27
31 - 32
Punch tool
2
Fig. 28
64
58
63
626160595857
Tubular tool
33
36
36
33
Punch tool
Fig. 29 Fig. 30
Manual and Spare Parts List ZF M line
41
6.10 Reassembling the output shaft
6.10.1 Place pre-assembled bearingshield (item 6.7) with seal (28) on outputshaft (66) (not applicable to ZF 15 MIV).
6.10.2 Attach outer race (34) of taperroller bearing.
6.10.3 Pre-heat inner race (35) of taperroller bearing to a temperature of approx.100°C (212 F) and press on output shaft(66) in hot condition.On ZF 15 MIV press complete bearing(68) on shaft (66).
IMPORTANT:Repress after cooling down, so that nogap is left.
6.10.4 Fit thrust ring (43) in such a waythat sintered surface (brown colour)faces gear.
6.10.5 Use tubular tool to press on innerrace (46) of needle bearing for gear (65).
6.10.6 Attach needle cages (45) andcompletely pre-assembled gear (65) withclutch discs (51 and 52).
6.10.7 Fit spacer (47) and shims (53, 54,55, 56) to gear (65).
6.10.8 Fit keys (67) to shaft (1 for ZF 3 M,5 M, 2 keys for 10 M, 12 M, 15 M, 15 MA,4 for ZF 25 M - 25 MA and ZF 30 M).
6.10.9 Press pre-assembled actuatingmembers (see item 6.8) on output shaft(66).
IMPORTANT:Align keys radially relative to guidesleeve (59).
Fig. 31
4241
35
66
Fig. 32
Punch tool
66
46
43
28
2
34
35
65
44
46
Manual and Spare Parts List ZF M line
42
6.10.10 Attach shims (53,54,55, 56) togear (44).
6.10.11 Attach spacer (47) to gear (44).
6.10.12 Use tubular tool to press on in-ner race (46) of needle bearing for gear(44).
6.10.13 Attach pre-assembled gear (44)with needle cage (45) and clutch discs(51 and 52).
Align external discs for proper engage-ment with actuating member.
6.10.14 Attach thrust ring (43) in such away that sintered surface (brown colour)faces gear.
6.10.15 Pre-heat inner race (35) of ta-per roller bearing to a temperature ofapprox. 100°C (212 F) and press it onshaft.
IMPORTANT:Repress after cooling down, so that nogap is left.
0.2
± 0.
05 m
m
6.10.16 Screw on bolt (41), (supplied withLoctite) and tighten to torque:
ZF 3 M - 5 M 50 Nm 37 ft lbZF 10 M 60 Nm 44 ft lbZF 12 M - 15 M 100 Nm 74 ft lbZF 15 MA - 15 MIV 100 Nm 74 ft lbZF 25 M - 25 MA 120 Nm 89 ft lbZF 30 M 120 Nm 89 ft lb
6.10.17 (ZF 3 M, ZF 5 M only) attachshims (68) to end shaft (66). The gap hasto be 0.2 ± 0.05 mm (0.0079±0.0019 in).
6.10.18 (ZF 15 MA only) attach spacer (68).
6.10.19 Check gears (44) and (65) forfree movability in an axial direction.
6.10.20 Attach outer race (34) of taperroller bearing.
6.11 Reassembling the quill shaftZF 15 MIV
6.11.1 Fit radial sealing ring (31) and clip(84) together with O-ring (86).
6.11.2 First bearing:Press on bearing inner race (74).Fit bearing outer race (75).
6.11.3 Fit spacer ring (76).
6.11.4 Fit key (81).
6.11.5 Press on gear (80).
6.11.6 Fit second spacer ring (76).
6.11.7 Second bearing:Press on inner race (74).Fit outer race (75).
6.11.8 Push on clip (73) together withO-ring (85).
6.11.9 Tighten grooved ring nut (83) to atorque of 95 Nm (70 lbft), using a socketspanner, and then secure by pressing riminto groove in shaft.
6.11.10 Fit radial sealing ring (31) andcup (84) together with O-Ring (86).
Fig. 33
Fig. 34
Fig. 35
41
82
81
75
74
85
73 83
31
86
84
76
80
76
75
74
86
84
31
41
42
35
68
Manual and Spare Parts List ZF M line
43
6.12 Final assembly of gearbox
6.12.1 Place pre-assembled gearboxsection (1) - (with intermediate gear) -on side wall.
6.12.2 Place pre-assembled output shaft(66) in lower part of gearbox with flangeside towards intermediate gear side (onZF 15 MIV, bevel gear towards interme-diate gear side).
6.12.3 Place pre-assembled input shaft(36) in upper part of gearbox.
6.12.4 (ZF 15 MIV only) Place pre-as-sembled quill shaft (73) in lower part ofgearbox (watching to correct engage-ment of marked teeth).Add shims 78 on quill shaft:1.2 mm on side input shaft and 2.2 mmon side output flange.Add shims (70) on clutch shaft 2 x 0.1mm on side output flange.
6.12.5 (ZF 15 MIV only) Check backlash0.08 to 0.13 mm (0.003 to 0.005 in). Be-tween teeth of bevel gears using a dialindicator in contact with tooth surface.
Side shifting cover
Fig. 36
To correct backlash:Replace shim 78 side output flange witha thicker one to decrease backlash andvice-versa.If the correction is not enough to reachthe correct backlash, modify shimming(70) on clutch shaft side output flangeand repeat procedure.
To correct axial play (quill shaft):Check axial play 0.05 ± 0.02 mm(0.002 ± 0.0008 in).Compensate for difference by insertingshims (78) side input shaft.
6.12.6 Seal with LOCTITE 574 surfaceof pre-assembled gearbox section (1)(with shifting fork) and place uppersection on lower section of gearbox.
6.12.7 Insert screws (21) preferably inthe middle, and screw in low-tight to se-cure the two gearbox sections together.
6.12.8 Use a plastic hammer to align thetwo gearbox section (1) by tapping themgently into position.
6.12.9 Fit bearing shield (2) with gasket(28) to output shaft (66) by means ofspring washers (4) and screws (5), us-ing a 13 mm spanner (wrench).Tighten to torque of 14 Nm (10 ft lb).
6.12.10 Slide pre-assembled bearingshield (2) with gasket (28) over inputshaft and secure by means of springerwasher (4) and screws (5), using a 13mm spanner (wrench).Tighten to torque of 14 Nm (10 ft lb).
6.13 Measuring the gears sets of input shaft and output shaft
(see illustration)
6.13.1 Tap outer races (32) and (34) onoutput and input shafts to eliminate bear-ing play, simultaneously rotating theshafts.
6.13.2 Determine dimension «b» bymeans of depth gauge (see illustration).
Cover centering depthwith seal (28)
Manual and Spare Parts List ZF M line
44
6.13.3 Measure dimension «c» on cover(3) with gasket (28) installed, using adepth gauge (see illustration). The dif-ference between the two dimensions in-dicates the distance to be filled up withshims (37, 38, 39, 40). Shims are avail-able in thicknesses of 0.1 - 0.15-02.-03.and 0.5 mm.
On ZF 15 MIV, a hole is provided on theoutput side of the housing to permit thismeasuring operation: move shaft viagear (65) by means of a lever throughopening in gearbox (see illustration nextpage).
Cover centeringdepth with gasket (28)
Distance from gear set
Compensate for differenceby inserting shims (37, 38, 39, 40)
Compensatefor differenceby inserting shims(70, 71, 72)
To correct
axial play
To correct
backlash
Compensate
for difference
by inserting shims (78)
Fig. 37
➤
➤
➤
➤
b
c
b
c Cover centering depthwith gasket (28)
Distance from gear set
Compensate for differenceby inserting shims
(37, 38, 39, 40)
Manual and Spare Parts List ZF M line
45
6.13.4 Insert the required number ofshims into the bearing bores of the gear-box to obtain an axial clearance of theoutput and input shafts of 0.05 ± 0.02mm.
If no parts had to be replaced (see item5.4.4), the previously disassembledshims (37, 38, 39, 40) can be re-used inthe previous arrangement and positions.It will be advisable, however, to checkthe bearing clearance and correct it ifrequired.
6.13.5 Mount the previously measuredcovers (3) on the output and input shaftsby means of spring washers (4) andscrews (5), using a 13 mm spanner(wrench). Tighten to torque of 14 Nm (10ft lb).
6.13.6 Place spring washers (4) under-neath all screws (21) and tighten screwsto a torque of 22 Nm (16 ft lb), using a13 mm spanner (wrench).
6.13.7 Tap output and input shafts lightlyin an axial direction while rotating theshafts, to ensure freedom of movement.
6.13.8 Axial clearance of input and out-put shafts: 0.05 ± 0.02 mm, measuredby means of dial indicator in contact withend face of shaft (see illustration).
6.13.9 Measure axial clearence of quillshaft (on ZF 15 MIV), also with dial indi-cator in contact with end face of the shaft(see illustration).Permissible clearance: 0.05 ± 0.02 mm.
0.05 ± 0.02 mm0.002 ± 0.0008 in
Fig. 38
Fig. 39
Manual and Spare Parts List ZF M line
46
6.14 Mounting the actuating levercover plate
6.14.1 Place gasket (29) or Loctite 574on pre-assembled cover plate and fit itto gearbox. Watch for proper engage-ment of actuating cam and shifting fork.The cover plate can be mounted whenthe shifting fork is in the middle (=neu-tral) position. It is important to adjust theactuating lever to exactly midway posi-tion in neutral.Screw the cover plate in place in thisposition.The lever travel from 0 to A and from 0to B should be equal. After a lever travelof 28 to 31 mm (1.10 to 1.22 in) the trans-mission should be in gear.If the lever travel from «0» to «A» andfrom «0» to «B» is not equal adjust coverposition by light hammer blows on thecover up to reach the equal travels. Fitspring washer (4) and screw nuts (22).Tighten to a torque of 20 Nm (15 ft lb).If studs (69) need to be replaced, fit themwith Loctite 270 on the housing.
6.14.2 Fit spring washers (4) and screws(5), using a 13 mm spanner (wrench).Tighten to a torque of 14 Nm (10 ft lb).Check actuating lever for proper opera-tion.
6.14.3 Fit oil drain plug (20) with sealingring (18) and oil dipstick (19) with seal-ing ring (18).Tighten to a torque of 20 Nm (15 ft lb).
6.15 Mounting the cooling unit(if provided)
6.15.1 Attach the cooling unit on the sideopposite the cover plate (9). By meansof 4 screws M8x65 and washers (avail-able on kit pag. 23 item 1.2.10).
Fig. 40
Manual and Spare Parts List ZF M line
47
7. Procedure to adjust the shifting lever cover
New bracket p/n 20.4039.02 to adjust the shifting lever cover (see picture 1).
A) Before mounting the cover clean the mating surfaces and adjust the shifting forkto the neutral position.
B) Apply Loctite 574 (or alternatively 518) on the cover surface and position it withthe lever in neutral (see picture 2).Only for ZF 25 M, 25 MA: Push towards the bottom (see picture 3).
C) Lightly tighten the four nuts.
D) Adjust the cover roughly in the middle.
E) Fit the adjusting bracket p/n 20.4039.02 using only one nut lightly tighten: thecover must be free to move with light hammer taps (see picture 4).
If the shifting lever in neutral has been rotated from the original vertical positionapply on the adjusting bracket the suitable extension section P/N 20.4039.03 (seepicture 5).
F) Move the lever toward the detent A without engaging the clutch and mark theposition; repeat the same for the detent B. If the shifting lever has two holesrefer to the inner hole (see picture 6 and 7).
3ZF 25 M, ZF 25 MA
2
11
4
765
Manual and Spare Parts List ZF M line
48
G) Engage the clutch, turn back the lever to the engaging point and mark the posi-tion; repeat the same procedure for the other clutch (see picture 8 and 9).
H) Consider the centre line between the internal marks and measure the distancefrom this line and the centre of the external marks (see picture 10 and 11).
The maximum allowed distance between the centre line and the external marksmust be 24 mm.The maximum difference between the two measurements must be less than 3 mm.
A must always be < 24 mmB must always be < 24 mmA – B < 3 mm
EX.:A = 20 mm, B = 24 mmA – B = 4 mm > 3 mm NOT ALLOWEDA = 21 mm, B = 23 mmA – B = 2 mm < 3 mm OK
If the above conditions are not reached, move the cover toward the opposite direc-tion where the measurement is largest by light hammer taps and repeat the markingoperation.If it is not possible to adjust the cover to maximum 24 mm, the gearbox needs to beexchanged.
I) After the correct adjusting measurement is reached tighten the four nuts with 22Nm (16 lb.ft) torque.
6) Connect the shifting cable to the inner hole (if two holes) of the lever. Ad-just the neutral position of the cable by the middle of the play of the leverin neutral.The control cable should be perpendicular to the actuating lever in neutralposition of the lever.
7) Make sure that the way of the control cable is enough long to move the innerhole of the lever at least 30 mm.
8
9
10
A
11
B
Manual and Spare Parts List ZF M line
49
8. Troubelshooting
Possible Troubles and Remedies
Kind of trouble Noticeable effect Possible cause RemedyDelay of gear Propeller will start rotating Detach shift cable and operateengagement with several seconds delay gearbox by hand to find whether
or only after increase in malfunctions is caused by gearengine speed. box or cable.
If caused by transmission:
Lever travel 0-A not equal to Adjust cover plate (9) until lever islever travel 0-B. exactly in midway position. Travel
0-A = 0-B = 35 mm/30 mm 1.37 in/1.18 in
Insufficient clearence between Adjust to min. clearanceactuating lever and cover plate (9). of 0.5 mm (0.02 in).
If caused by shift cable:
Shift cable fails to move lever Check total travel of shift cable.through required min. If too short, adjust accordingly.travel 0-A=0-B= 35 mm/30 mm (1.37 in/1.18 in).
Transmission Excessive effort required Insufficient clearance between Detach shift cable and operatefails to move in to move actuating lever. actuating lever and cover plate (9). lever by hand. If lever jams, adjustgear clearance to 0.5 mm (0.02 in).
Guide sheaves for shift cable Check and adjust accordingly.unsuitably positioned: radiustoo small.
Boat fails to Increased operating Use of wrong oil. Use ATF oil and check oil level.attain top temperature.speed specified Boat operated without cooling unit. Install cooling unit.
Transmission operating in upper Use suitable ZF M transmissionlimit range. unit.
Oil leakage Oil leakage visible on Corrosion effects in area of radial Check and correct oil level.transmission unit. sealing ring and shaft; damaged Remove and dismantle transmission
radial sealing rings. remachine shafts, replace radialImproper installation of seal. sealing rings
Misalignment of output flanges. Check alignment to be within0.08 mm (0.003 in) radially.
Manual and Spare Parts List ZF M line
50
9. Spare Parts List
PrefaceThe spare parts list is only valid for the type and versions of transmission, as shownbelow.You will find the transmission type and version on your transmission name plate.If the type and version indicated differs from that printed in this Manual, the relativeSpare Parts List should be ordered from ZF -HURTH Marine.The indicated dimensions and standards are as such not enough for ordering parts.
When ordering parts, please state:
- transmission type- serial number- item no. part name, ident no. and quantity of parts required.
The spare parts list is referring to the following versions:
Name Plate
The name plate is mounted to the transmission
Transmission type
Transmission version ratioand serial number
Transmission part number
Transmission ratioShifting position «B»
MODEL
SER. N.
P/N.
ZF 10 M
XXXXX
3304 002 004
Production date everyyear a new progressive
letter is assigned
ZF 3 M versions 001; 002 HBW 35 versions 25; 26;
ZF 5 M versions 001; 002 HBW 50 versions 09; 10; 11; 12; 14
ZF 10 M versions 003; 004; 005; 010 HBW 100 versions 14; 15; 16; 17; 20; 21
ZF 12 M versions 001; 002 HBW 125/HBW 10 versions 15; 16
ZF 15 M versions 003; 004 HBW 150 versions 18, 17; 20; 22
ZF 15 MA versions 003; 004; 005 HBW 150 A versions 01; 02
ZF 15 MIV versions 001; 002; 003 HBW 150 V versions 08; 09; 10; 11
ZF 25 M versions 001; 002; 007 HBW 250 versions 13; 16; 17; 18; 19; 20; 22; 23
ZF 25 MA versions 005; 006
ZF 30 M versions 001; 002
iA= 1,79
iB= 1,86LXXXXX
Transmission ratioShifting position «A»
Manual and Spare Parts List ZF M line
51
1Ho
usin
g as
sy H
BW 5
0 - 2
L «1
1»1
3303
201
001
3259
52
1Ho
usin
g as
sy Z
F 5
M -
2.05
R «0
01»
133
03 2
01 0
0132
5952
1Ho
usin
g as
sy H
BW 5
0 - 2
R «1
2»1
3303
201
001
3259
52
1Ho
usin
g as
sy H
BW 5
0 - 3
R «1
0»1
3303
201
002
3875
32
1Ho
usin
g as
sy Z
F 5
M -
2.72
R «0
02»
133
03 2
01 0
0238
7532
1Ho
usin
g as
sy Z
F 3
M -
2.05
R «0
01»
133
03 2
01 0
0132
5952
1Ho
usin
g as
sy Z
F 3
M -
2.72
R «0
02»
133
03 2
01 0
0238
7532
1Ho
usin
g as
sy Z
F 10
M -
1.48
R «0
03»
133
04 2
01 0
0328
8079
1Ho
usin
g as
sy Z
F 10
M -
1.79
R «0
04»
133
04 2
01 0
0328
8079
1Ho
usin
g as
sy Z
F 10
M -
2.05
R «0
10»
133
04 2
01 0
03-
1Ho
usin
g as
sy Z
F 10
M -
2.72
R «0
05»
133
04 2
01 0
0446
5642
1Ho
usin
g as
sy H
BW 1
00 -
3R «
16»
133
04 2
01 0
0328
8079
1Ho
usin
g as
sy H
BW 1
00 -
2L «
17»
133
04 2
01 0
0328
8079
1Ho
usin
g as
sy H
BW 1
00 -
2,5R
«21
»1
3304
201
004
4656
42
1Ho
usin
g as
sy H
BW 1
0 / Z
F 12
M /
ZF 1
5 M
133
06 2
01 0
0320
6447
1Ho
usin
g as
sy Z
F 15
MA
133
06 2
01 0
0140
7465
1Ho
usin
g as
sy H
BW 2
50 -
2L «
20»
133
07 2
01 0
0334
5517
1Ho
usin
g as
sy H
BW 2
50 -
3L «
19»
133
07 2
01 0
0434
5519
1Ho
usin
g as
sy H
BW 2
50 -
1,5R
«16
»1
3307
201
003
3455
17
1Ho
usin
g as
sy Z
F 25
M -
1.88
R «0
01»
& «
22»
133
07 2
01 0
0334
5517
1Ho
usin
g as
sy Z
F 25
M -
2.27
R «0
07»
133
07 2
01 0
03-
1Ho
usin
g as
sy Z
F 25
M -
2.74
R «0
02»
& «
23»
133
07 2
01 0
0434
5519
1Ho
usin
g as
sy H
BW 2
50 -
3,5R
«13
»1
3307
201
004
3455
19
1Ho
usin
g as
sy Z
F 25
MA
- 2.2
3R «
005»
3307
201
001
-
1Ho
usin
g as
sy Z
F 25
MA
- 2.7
4R «
006»
3307
201
001
-
1Ho
usin
g as
sy Z
F 30
M -
2.7R
«00
1»33
20 2
01 0
01-
1Ho
usin
g as
sy Z
F 30
M -
2.15
R «0
02»
3320
201
001
-
2Be
arin
g sh
ield
inpu
t1
3304
301
012
2887
6833
04 3
01 0
1228
8768
3306
301
010
2064
5033
06 3
01 0
1020
6450
3307
301
008
2742
4833
07 3
01 0
0827
4248
3307
301
008
-
2Be
arin
g sh
ield
out
put
133
04 3
01 0
1128
8787
3304
301
011
2887
8733
06 3
01 0
1020
6450
3306
301
010
2064
5033
07 3
01 0
0827
4248
3307
301
008
2742
4833
07 3
01 0
08-
3Co
ver
133
06 3
01 0
1120
6452
3307
301
009
2742
19
3Co
ver
233
04 3
01 0
1328
8730
3304
301
013
2887
3033
06 3
01 0
1120
6452
3307
301
009
2742
1933
07 3
01 0
09-
3ACo
ver
133
06 3
01 0
0840
7475
3307
301
003
-
4Sp
ring
was
her
3806
30 3
02 0
9044
2372
0630
302
090
4423
72
4Sp
ring
was
her
4006
30 3
02 0
9044
2372
0630
302
090
4423
7206
30 3
02 0
9044
2372
4Sp
ring
was
her
4206
30 3
02 0
9044
2372
4Sp
ring
was
her
4606
30 3
02 0
90-
5He
x he
ad s
crew
(cov
er)
1606
36 0
15 2
8921
5870
0636
015
289
2158
7006
36 0
15 2
8921
5870
0636
015
289
2158
7006
36 0
15 2
8921
5870
0636
015
289
2158
7006
36 0
15 2
89-
6Ac
tuat
ing
leve
r*1
947.
23.0
06.0
119
5062
947.
23.0
06.0
119
5062
947.
23.0
06.0
119
5062
947.
23.0
06.0
119
5062
947.
23.0
06.0
119
5062
6Ac
tuat
ing
leve
r1
3306
308
001
5006
3533
06 3
08 0
0150
0635
3306
308
001
5006
3533
06 3
08 0
0150
0635
3306
308
001
5006
3533
06 3
08 0
0150
0635
3306
308
001
-
* Up
to le
tter «
E» p
rodu
ctio
n da
te (s
ee n
ame
plat
e de
scrip
tion
pag.
50)
ZF 3
M -
ZF 5
MZF
10
MHB
W 10
/ZF 12
M/15
MZF
15
MA
ZF 2
5 M
ZF 2
5 M
AZF
30
M
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
n
Item
NoPa
rt na
me
Num
ber
per
gear
box
Manual and Spare Parts List ZF M line
52
ZF 3
M -
ZF 5
MZF
10
MHB
W 10
/ZF 12
M/15
MZF
15
MA
ZF 2
5 M
ZF 2
5 M
AZF
30
M
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
n
Item
NoPa
rt na
me
Num
ber
per
gear
box
7He
x he
ad s
crew
(act
uatin
g le
ver)
*1
0636
015
299
1998
0706
36 0
15 2
9919
9807
0636
015
299
1998
0706
36 0
15 2
9919
9807
0636
015
299
1998
07
7He
x he
ad s
crew
(act
uatin
g le
ver)
106
36 1
01 7
2744
2377
0636
101
727
4423
7706
36 1
01 7
2744
2377
0636
101
727
4423
7706
36 1
01 7
2744
2377
0636
101
727
4423
7706
36 1
01 7
27-
8Ra
dial
sea
ling
ring
for s
hift
cove
r1
0634
502
009
1068
6406
34 5
02 0
0910
6864
0634
502
009
1068
6406
34 5
02 0
0910
6864
0634
502
009
1068
6406
34 5
02 0
0910
6864
0634
502
009
-
9Co
ver p
late
133
04 3
08 0
0120
6448
3304
308
001
206
448
3306
308
002
3882
4233
06 3
08 0
0238
8242
3306
308
002
3882
4233
06 3
08 0
0238
8242
3306
308
002
-
10Sp
ring
dow
el p
in1
0631
329
032
1045
5906
31 3
29 0
3210
4559
0631
329
032
1045
5906
31 3
29 0
3210
4559
0631
329
032
1045
5906
31 3
29 0
3210
4559
0631
329
032
-
11Ac
tuat
ing
cam
ass
y1
3304
199
006
3043
3233
04 1
99 0
0630
4332
3306
199
008
4072
1133
06 1
99 0
0840
7211
3306
199
008
4072
1133
06 1
99 0
0840
7211
3306
199
008
-
12Sh
ift c
over
ass
embl
y1
3303
108
001
3262
0833
04 1
08 0
0224
8459
3306
108
002
4072
1033
06 1
08 0
0240
7210
3306
108
002
4072
1033
06 1
08 0
0240
7210
3306
108
002
-
15Sh
iftin
g fo
rk a
ssy
133
04 2
08 0
0132
6000
3304
208
001
3260
0033
06 2
08 0
0122
3563
3306
208
001
2235
6333
07 2
08 0
0132
7374
3307
208
001
3273
7433
07 2
08 0
01-
16Ac
tuat
ing
shaf
t1
3303
308
001
3259
6333
06 3
08 0
0420
6484
3306
308
004
2064
8433
06 3
08 0
0420
6484
3307
301
012
2886
7333
07 3
01 0
1228
8673
3 307
301
012
-
17Pl
ug (O
-rin
g fo
r ZF
3 M
- ZF
5 M
)1
0634
306
179
1055
2406
36 3
01 0
4144
2373
0636
301
041
4423
7306
36 3
01 0
4144
2373
0636
301
041
4423
7306
36 3
01 0
4144
2373
0636
301
041
-
18Se
alin
g rin
g2
3306
301
016
3265
7833
06 3
01 0
1632
6578
3306
301
016
3265
7833
06 3
01 0
1632
6578
3306
301
016
3265
7833
06 3
01 0
1632
6578
3306
301
016
-
19Oi
l dip
stic
k/br
eath
er a
ssy
133
04 2
01 0
0628
8729
3304
201
006
2887
2933
06 2
01 0
0520
6929
3306
201
002
4084
5133
07 2
01 0
0527
4217
3307
201
005
2742
1733
07 2
01 0
05-
20Oi
l dra
in p
lug
133
06 3
01 0
1322
8566
3306
301
013
2285
6633
06 3
01 0
1322
8566
3306
301
013
2285
6633
06 3
01 0
1322
8566
3306
301
013
2285
6633
06 3
01 0
13-
21He
x he
ad s
crew
906
36 0
10 3
7621
5869
0636
010
376
2158
69
21He
x he
ad s
crew
1006
36 0
10 3
7621
5869
0636
010
376
2158
6906
36 0
10 5
6327
9058
21He
x he
ad s
crew
806
36 0
10 5
64-
21He
x he
ad s
crew
1206
36 0
10 5
63-
21A
Hex
head
scr
ew1
0636
010
375
3379
82
21B
Hex
head
scr
ew2
0636
010
548
5009
24
22He
x nu
t10
0637
006
157
4557
85
22He
x nu
t11
0637
006
157
4557
85
22He
x nu
t12
0637
006
157
4557
8506
37 0
06 1
5745
5785
22He
x nu
t14
0637
006
157
4557
85
22He
x nu
t12
0637
006
157
4557
85
22He
x nu
t17
0637
006
157
-
23O-
ring
(See
ger Z
F 3 M
- ZF
5 M
/ Pl
ug Z
F 25
M -
ZF 3
0 M
)1
0630
501
012
1048
0706
34 3
06 0
1110
5679
0634
303
118
1055
3006
34 3
03 1
1810
5530
0630
361
039
2853
7506
30 3
61 0
3928
5375
0630
361
039
-
24In
term
edia
te g
ear s
haft
133
03 3
03 0
0232
5962
3304
303
002
2887
4133
06 3
03 0
0220
6470
3306
303
002
2064
7033
07 3
03 0
0127
4225
3307
303
001
2742
2533
20 3
03 0
01-
25Re
tain
ing
plat
e1
3304
303
003
2887
43
25Re
tain
ing
plat
e2
3304
303
003
2887
4333
06 3
03 0
0320
6473
3306
303
003
2064
7333
07 3
03 0
0228
8702
3307
303
002
2887
0233
20 3
03 0
03-
26In
term
edia
te g
ear
133
03 3
03 0
0132
5961
3304
303
001
-33
06 3
03 0
0125
4730
3306
303
001
2547
3033
07 3
03 0
0327
4226
3307
303
003
2742
2633
20 3
03 0
02-
27Ca
ge1
0635
300
526
1065
8906
35 3
00 5
3028
0128
3306
303
007
2158
7833
06 3
03 0
0721
5878
3307
303
004
2222
7333
07 3
03 0
0422
2273
27Ca
ge2
0635
300
114
-
28Ga
sket
cov
er4
3304
301
015
2887
3933
04 3
01 0
1528
8739
3306
301
014
2547
1533
06 3
01 0
1425
4715
3307
301
011
2742
5133
07 3
01 0
1127
4251
3307
301
011
-
29Ga
sket
cov
er p
late
(or L
OCTI
TE 5
74)
133
06 3
01 0
1525
4716
3306
301
015
2547
1633
06 3
01 0
1525
4716
3306
301
015
2547
1633
06 3
01 0
1525
4716
3306
301
015
2547
1633
06 3
01 0
15-
30Ra
dial
sea
ling
ring,
inpu
t (No
HBW
250
«22
-23»
)1
0634
301
830
2801
3506
34 3
01 8
3028
0135
0634
301
833
2158
7506
34 3
01 8
3321
5875
0634
301
832
2842
6006
34 3
01 8
3228
4260
0634
311
025
-
30Ra
dial
sea
ling
ring,
inpu
t (on
ly v
ers.
«22
-23»
)1
0634
311
025
5011
51
31Ra
dial
sea
ling
ring,
out
put (
No H
BW 2
50 «
22-2
3»)
106
34 3
00 3
7110
5153
0634
300
371
1051
5306
34 3
00 4
6610
5159
0634
300
466
1051
5906
34 3
00 4
6610
5159
0634
300
466
1051
5906
34 3
11 0
26-
31Ra
dial
sea
ling
ring,
out
put (
only
ver
s. «
22-2
3»)
106
34 3
11 0
2650
1152
32Ta
pere
d ro
ller b
earin
g, in
put s
haft
206
35 5
01 9
43-
0635
501
943
-06
35 5
01 5
97-
0635
501
597
-06
35 3
70 0
4216
7210
0635
370
042
1672
1006
35 3
70 0
42-
* Up
to le
tter «
E» p
rodu
ctio
n da
te (s
ee n
ame
plat
e de
scrip
tion
pag.
50)
Manual and Spare Parts List ZF M line
53
ZF 3
M -
ZF 5
MZF
10
MHB
W 10
/ZF 12
M/15
MZF
15
MA
ZF 2
5 M
ZF 2
5 M
AZF
30
M
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
n
Item
NoPa
rt na
me
Num
ber
per
gear
box
34Ta
pere
d ro
ller b
earin
g, o
utpu
t sha
ft2
0635
501
943
-06
35 5
01 9
43-
0635
501
597
-06
35 5
01 5
97-
0635
370
051
-06
35 3
70 0
51-
0635
370
051
-
36In
put s
haft
HBW
50
- 2L
«11»
z =
22/
221
947.
72.0
01.0
332
5970
36In
put s
haft
ZF 5
M -2
.05R
«00
1» Z
1/Z3
=22/
221
3303
302
001
3269
00
36In
put s
haft
HBW
50
2R 1
2 Z=
22/2
21
947.
72.0
01.0
332
5970
36In
put s
haft
HBW
50
3R 1
0 Z=
18/2
01
947.
72.0
01.0
738
7535
36In
put s
haft
ZF 5
M -
2.72
R «0
02»
Z1/Z
3=18
/20
133
03 3
02 0
0245
8163
36In
put s
haft
ZF 3
M -
2.05
R «0
01»
Z1/Z
3=22
/22
133
03 3
02 0
0132
6900
36In
put s
haft
ZF 3
M -
2.72
R «0
02»
Z1/Z
3=18
/20
133
03 3
02 0
0245
8163
36In
put s
haft
ZF 1
0 M
- 1.
48R
«003
» Z1
/Z3=
27/2
21
3304
302
004
3040
59
36In
put s
haft
ZF 1
0 M
- 1.
79R
«004
» Z1
/Z3=
24/2
21
3304
302
005
3056
05
36In
put s
haft
ZF 1
0 M
- 2.
05R
«010
» Z1
/Z3=
22/2
21
3304
302
018
-
36In
put s
haft
ZF 1
0 M
- 2.
72R
«005
» Z1
/Z3=
18/2
01
3304
302
006
4654
65
36In
put s
haft
HBW
100
- 3R
«16
» z
= 18
/22
194
7.62
.001
.06
3040
74
36In
put s
haft
HBW
100
- 2L
«17
» z
= 24
/22
194
7.62
.001
.08
3272
29
36In
put s
haft
HBW
100
- 2,
5R «
21»
z =
19/2
01
3304
302
007
4709
02
36In
put s
haft
HBW
10
- 2L
«21»
z =
22/
221
3306
302
005
2064
60
36In
put s
haft
HBW
10
/ ZF 1
2 M
- 2.
14R
«001
» Z1
/Z3=
22/2
21
3306
302
005
2064
60
36In
put s
haft
ZF 1
2 M
- 2.
63R
«002
» Z1
/Z3=
19/2
21
3306
302
007
3139
52
36In
put s
haft
ZF 1
5 M
- 1.
56R
«003
» Z1
/Z3=
27/2
21
3306
302
006
3040
88
36In
put s
haft
ZF 1
5 M
- 1.
88R
«004
» Z1
/Z3=
24/2
21
3306
302
008
3258
11
36In
put s
haft
HBW
150
- 2,
4R «
20»
z =
18/2
21
3306
302
009
4391
97
36In
put s
haft
HBW
150
- 3R
«22
» z
= 18
/22
133
06 3
02 0
1046
8211
36In
put s
haft
ZF
15 M
A - 2
R «0
04»
Z1/Z
3=24
/22
133
06 3
02 0
0240
7468
36In
put s
haft
ZF 1
5 M
A 2.
14R
«003
» Z=
22/2
21
3306
302
001
-
36In
put s
haft
ZF
15 M
A - 2
.63R
«00
5» Z
1/Z3
=19/
221
3306
302
003
4074
82
36In
put s
haft
HBW
250
- 2L
«20
» z
= 21
/25
194
7.52
.001
.08
3876
84
36In
put s
haft
HBW
250
- 3L
«19
» z
= 18
/19
194
7.52
.001
.06
3445
88
36In
put s
haft
HBW
250
- 1,
5R «
16»
z =
28/2
11
947.
52.0
01.0
430
4081
36In
put s
haft
ZF 2
5 M
- 1.
88R
«001
» &
«22
» Z1
/Z3=
25/2
11
3307
302
004
3258
09
36In
put s
haft
ZF
25 M
- 2.
27R
«007
» Z1
/Z3=
22/2
11
3307
302
005
5014
85
36In
put s
haft
ZF 2
5 M
- 2.
74R
«002
» &
«23
» Z1
/Z3=
19/1
81
3307
302
003
2889
67
36In
put s
haft
HBW
250
- 3,
5R «
13»
z =
16/1
81
947.
52.0
01.0
943
9199
36In
put s
haft
ZF 2
5 M
A 2.
23R
«005
» Z1
/Z3=
22/1
933
07 3
02 0
01-
36In
put s
haft
ZF 2
5 M
A 2.
74R
«006
» Z1
/Z3=
19/1
933
07 3
02 0
02-
36In
put s
haft
ZF 3
0 M
2.7
R «0
01»
Z1/Z
3=23
/22
3320
302
001
-
36In
put s
haft
ZF 3
0 M
2.1
5R «
002»
Z1/
Z3=2
7/22
3320
302
002
-
37Sh
im 0
.1 m
m2
3304
302
011
2887
3133
04 3
02 0
1128
8731
3306
302
011
2064
7433
06 3
02 0
1120
6474
3307
302
006
2742
5233
07 3
02 0
0627
4252
3307
302
006
-
38Sh
im 0
.15
mm
233
04 3
02 0
1228
8732
3304
302
012
2887
3233
06 3
02 0
1220
6475
3306
302
012
2064
7533
07 3
02 0
0727
4253
3307
302
007
2742
5333
07 3
02 0
07-
39Sh
im 0
.30
mm
233
04 3
02 0
1428
8734
3304
302
014
2887
3433
06 3
02 0
1420
6477
3306
302
014
2064
7733
07 3
02 0
0827
4254
3307
302
008
2742
5433
07 3
02 0
08-
Manual and Spare Parts List ZF M line
54
ZF 3
M -
ZF 5
MZF
10
MHB
W 10
/ZF 12
M/15
MZF
15
MA
ZF 2
5 M
ZF 2
5 M
AZF
30
M
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
n
Item
NoPa
rt na
me
Num
ber
per
gear
box
40Sh
im 0
.50
mm
233
04 3
02 0
1528
8735
3304
302
015
2887
3533
06 3
02 0
1522
8540
3306
302
015
2285
4033
07 3
02 0
0927
4255
3307
302
009
2742
5533
07 3
02 0
09-
41Sc
rew
133
03 3
04 0
1432
0681
3304
304
038
4508
7033
06 3
04 0
5742
0280
3306
304
057
4202
8033
06 3
04 0
5742
0280
3306
304
057
4202
8033
06 3
04 0
57-
42Sp
acer
133
03 3
04 0
0732
5960
3304
304
026
4396
1133
06 3
04 0
2840
7281
3306
304
028
4072
8133
06 3
04 0
2840
7281
3306
304
028
4072
8133
06 3
04 0
28-
43Th
rust
was
her
233
04 3
04 0
1928
8748
3304
304
019
2887
4833
06 3
04 0
2934
4787
3306
304
029
3447
8733
07 3
04 0
2032
7395
3307
304
020
3273
9533
07 3
04 0
20-
44Fo
rwar
d ge
ar H
BW 5
0 - 2
L «1
1» z
= 4
51
3303
304
001
3259
71
44Fo
rwar
d ge
ar Z
F 5
M -
2.05
R «0
01»
Z2=4
51
3303
304
001
3259
71
44Fo
rwar
d ge
ar Z
F 5
M -
2.72
R «0
02»
Z2=4
91
3303
304
002
3259
71
44Fo
rwar
d ge
ar H
BW 5
0 - 2
R «1
2» z
= 4
51
3303
304
001
3259
71
44Fo
rwar
d ge
ar H
BW 5
0 - 3
R «1
0» z
= 4
91
3303
304
002
3259
76
44Fo
rwar
d ge
ar Z
F 3
M -
2.05
R «0
01»
Z2=4
51
3303
304
001
3259
71
44Fo
rwar
d ge
ar Z
F 3
M -
2.72
R «0
02»
Z2=4
91
3303
304
002
3259
76
44Fo
rwar
d ge
ar Z
F 10
M -
1.48
R «0
03»
Z2=4
01
3304
304
007
3040
60
44Fo
rwar
d ge
ar Z
F 10
M -
1.79
R «0
04»
Z2=4
31
3304
304
008
3056
07
44Fo
rwar
d ge
ar Z
F 10
M -
2.05
R «0
10»
Z2=4
51
3304
304
039
-
44Fo
rwar
d ge
ar Z
F 10
M -
2.72
R «0
05»
Z2=4
91
3304
304
006
2874
55
44Fo
rwar
d ge
ar H
BW 1
00 -
3R «
16»
z =
491
3304
304
006
2874
55
44Fo
rwar
d ge
ar H
BW 1
00 -
2L «
17»
z =
431
3304
304
008
3056
07
44Fo
rwar
d ge
ar H
BW 1
00 -
2,5R
«21
» z
= 48
133
04 3
04 0
0947
0903
44Fo
rwar
d ge
ar H
BW 1
0 - 2
L «2
1» z
= 4
71
3306
304
012
4072
18
44Fo
rwar
d ge
ar H
BW 1
0 / Z
F 12
M -2
.14R
«00
1» Z
2=47
133
06 3
04 0
1240
7218
44Fo
rwar
d ge
ar Z
F 12
M -
2.63
R «0
02»
Z2=5
01
3306
304
013
4072
19
44Fo
rwar
d ge
ar Z
F 15
M -
1.56
R «0
03»
Z2=4
21
3306
304
015
4072
21
44Fo
rwar
d ge
ar Z
F 15
M -
1.88
R «0
04»
Z2=4
51
3306
304
014
4072
20
44Fo
rwar
d ge
ar H
BW 1
50 -
2,4R
«20
» z
= 43
133
06 3
04 0
1643
9198
44Fo
rwar
d ge
ar H
BW 1
50 -
3R «
22»
z =
511
3306
304
017
4682
12
44Fo
rwar
d ge
ar Z
F 15
MA
- 1.8
8R «
004»
Z2=
451
3306
304
003
4074
69
44Fo
rwar
d ge
ar Z
F 15
MA
2.14
R «0
03»
Z=47
133
06 3
04 0
01-
44Fo
rwar
d ge
ar Z
F 15
MA
- 2.6
3R «
005»
Z2=
501
3306
304
005
4074
83
44Fo
rwar
d ge
ar H
BW 2
50 -
2L «
20»
z =
471
3307
304
007
3058
13
44Fo
rwar
d ge
ar H
BW 2
50 -
3L «
19»
z =
521
3307
304
010
2889
71
44Fo
rwar
d ge
ar H
BW 2
50 -
1,5R
«16
» z
= 43
194
7.52
.002
.03
3040
83
44Fo
rwar
d ge
ar Z
F 25
M -
1.88
R «0
01»
& «
22»
Z2=4
71
3307
304
007
3058
13
44Fo
rwar
d ge
ar Z
F 25
M -
2.27
R «0
07»
Z2=5
01
3307
304
008
-
44Fo
rwar
d ge
ar Z
F 25
M -
2.74
R «0
02»
& «
23»
Z2=5
21
3307
304
010
2889
71
44Fo
rwar
d ge
ar H
BW 2
50 -
3,5R
«13
» z
= 56
194
7.52
.003
.04
4392
00
44Fo
rwar
d ge
ar Z
F 25
MA
- 2.2
3R «
005»
Z2=
491
3307
304
001
-
44Fo
rwar
d ge
ar Z
F 25
MA
- 2.7
4R «
006»
Z2=
521
3307
304
003
-
44Fo
rwar
d ge
ar Z
F 30
M -
2.7R
«00
1» Z
2=62
133
20 3
04 0
04-
44Fo
rwar
d ge
ar Z
F 30
M -
2.15
R «0
02»
Z2=5
81
3320
304
007
-
Manual and Spare Parts List ZF M line
55
45Ne
edle
cag
e2
0635
300
411
3206
7833
04 3
04 0
3728
0132
0635
300
148
2011
8706
35 3
00 1
4820
1187
0635
300
148
2011
8706
35 3
00 1
4820
1187
45Ne
edle
cag
e4
0635
300
148
-
46Ne
edle
bea
ring
inne
r rac
e2
3303
304
012
3260
6033
04 3
04 0
2228
8759
3306
304
021
2515
2433
06 3
04 0
2125
1524
3306
304
021
2515
2433
06 3
04 0
2125
1524
46Ne
edle
bea
ring
inne
r rac
e4
3306
304
021
-
47Sp
acer
233
03 3
04 0
1132
6026
3304
304
017
2887
5633
06 3
04 0
2525
0992
3306
304
025
2509
9233
07 3
04 0
1827
4242
3307
304
018
2742
4233
20 3
04 0
06-
48Cu
p sp
ring
233
03 3
04 0
0532
5958
48Cu
p sp
ring
433
04 3
04 0
1830
5537
3306
304
026
3873
9133
06 3
04 0
2638
7391
3307
304
019
3055
3633
07 3
04 0
1930
5536
3307
304
019
-
49Th
rust
ring
/end
dis
c2
3303
304
006
3259
5933
04 3
04 0
1428
8755
3306
304
030
4071
3933
06 3
04 0
3040
7139
3307
304
014
2742
7133
07 3
04 0
1427
4271
3307
304
014
-
50Ci
rclip
206
30 5
03 0
4032
0677
0630
513
059
2801
3106
30 5
02 0
3127
7055
0630
502
031
2770
5506
30 5
02 0
31-
50Ha
lf rin
g4
3306
304
011
3268
3033
06 3
04 0
1132
6830
51In
tern
al c
lutc
h di
sc4
3304
304
040
51In
tern
al c
lutc
h di
sc8
3304
304
040
3306
304
027
4072
3133
06 3
04 0
2740
7231
51In
tern
al c
lutc
h di
sc (o
ld v
ersi
ons)
894
7.42
.017
.01
2889
12
51In
tern
al c
lutc
h di
sc10
3307
304
021
3307
304
021
51In
tern
al c
lutc
h di
sc12
3307
304
021
52Ex
tern
al c
lutc
h di
sc4
3304
304
021
2887
58
52Ex
tern
al c
lutc
h di
sc6
3304
304
021
2887
58
52Ex
tern
al c
lutc
h di
sc8
3306
304
031
4072
3033
06 3
04 0
3140
7230
3307
304
005
2060
2633
07 3
04 0
0520
6026
52Ex
tern
al c
lutc
h di
sc (o
ld v
ersi
on)
694
7.22
.024
.01
1878
72
52Ex
tern
al c
lutc
h di
sc10
3307
304
005
-
53Sh
im 0
.4 m
m2
3304
304
032
2887
6033
04 3
04 0
3228
8760
3306
304
035
1957
1433
06 3
04 0
3519
5714
3306
304
035
1957
1433
06 3
04 0
3519
5714
3306
304
035
-
54Sh
im 0
.5 m
m2
3304
304
033
2887
6133
04 3
04 0
3328
8761
3306
304
036
1957
1533
06 3
04 0
3619
5715
3306
304
036
1957
1533
06 3
04 0
3619
5715
3306
304
036
-
55Sh
im 0
.6 m
m2
3304
304
034
2887
6233
04 3
04 0
3428
8762
3306
304
037
1957
1633
06 3
04 0
3719
5716
3306
304
037
1957
1633
06 3
04 0
3719
5716
3306
304
037
-
56Sh
im 0
.7 m
m2
3304
304
035
2887
6333
04 3
04 0
3528
8763
3306
304
038
1957
1733
06 3
04 0
3819
5717
3306
304
038
1957
1733
06 3
04 0
3819
5717
3306
304
038
-
57Di
sc c
arrie
r2
3303
304
008
3259
6733
04 3
04 0
1628
8713
3306
304
032
4072
3333
06 3
04 0
3240
7233
3307
304
017
3264
8633
07 3
04 0
1732
6486
3320
304
003
-
58Ba
ll6
0635
460
061
2801
3306
35 4
60 0
6128
0133
0635
460
015
1067
0006
35 4
60 0
1510
6700
0635
460
019
1067
3206
35 4
60 0
1910
6732
0635
460
019
-
59Gu
ide
slee
ve1
3303
304
010
4389
6133
04 3
04 0
1543
8960
3306
304
022
4396
0333
06 3
04 0
2243
9603
3307
304
015
2742
4733
07 3
04 0
1527
4247
3320
304
010
-
60Ac
tuat
ing
slee
ve1
3304
304
027
3260
6333
04 3
04 0
2732
6063
3306
304
023
2068
1733
06 3
04 0
2320
6817
3307
304
016
4080
9333
07 3
04 0
1640
8093
3307
304
016
-
61Co
mpr
essi
on s
prin
g (a
ctua
ting
mem
bers
)3
3304
304
023
2875
2533
04 3
04 0
2328
7525
3306
304
006
2874
0133
06 3
04 0
0628
7401
3306
304
006
2874
0133
06 3
04 0
0628
7401
3306
304
006
-
62De
tent
pin
333
04 3
04 0
2428
8766
3304
304
024
2887
6633
06 3
04 0
3318
7840
3306
304
033
1878
4033
06 3
04 0
3318
7840
3306
304
033
1878
4033
06 3
04 0
33-
63Dr
ivin
g pi
n3
3304
304
025
2887
6733
04 3
04 0
2528
8767
3306
304
008
1952
7133
06 3
04 0
0819
5271
3306
304
008
1952
7133
06 3
04 0
0819
5271
3306
304
008
-
64Sp
ring
333
06 3
04 0
2420
6798
3306
304
024
2067
9833
06 3
04 0
2420
6798
3306
304
024
2067
9833
06 3
04 0
2420
6798
3306
304
024
2067
9833
06 3
04 0
24-
65Re
vers
e ge
ar H
BW 5
0 - 2
L «1
1» z
= 4
11
3303
304
003
3259
66
65Re
vers
e ge
ar Z
F 5
M -
2.05
R «0
01»
Z5=4
11
3303
304
003
3259
66
65Re
vers
e ge
ar H
BW 5
0 - 2
R «1
2» z
= 4
11
3303
304
003
3259
66
65Re
vers
e ge
ar H
BW 5
0 - 3
R «1
0» z
= 4
31
3303
304
009
3875
39
65Re
vers
e ge
ar Z
F 5
M -
2.72
R «0
02»
Z5=4
31
3303
304
009
3875
39
65Re
vers
e ge
ar Z
F 3
M -
2.05
R «0
01»
Z5=4
11
3303
304
003
3259
66
65Re
vers
e ge
ar Z
F 3
M -
2.72
R «0
02»
Z5=4
31
3303
304
009
3875
39
ZF 3
M -
ZF 5
MZF
10
MHB
W 10
/ZF 12
M/15
MZF
15
MA
ZF 2
5 M
ZF 2
5 M
AZF
30
M
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
n
Item
NoPa
rt na
me
Num
ber
per
gear
box
Manual and Spare Parts List ZF M line
56
65Re
vers
e ge
ar Z
F 10
M -
1.48
R «0
03»
Z5=4
11
3304
304
011
2880
84
65Re
vers
e ge
ar Z
F 10
M -
1.79
R «0
04»
Z5=4
11
3304
304
011
2880
84
65Re
vers
e ge
ar Z
F 10
M- 2
.05R
«01
0» Z
5=41
133
04 3
04 0
1128
8084
65Re
vers
e ge
ar Z
F 10
M -
2.72
R «0
05»
Z5=4
31
3304
304
012
4654
66
65Re
vers
e ge
ar H
BW 1
00 -
3R «
16»
z =
411
3304
304
011
2880
84
65Re
vers
e ge
ar H
BW 1
00 2
L «1
7» z
= 4
11
3304
304
011
2880
84
65Re
vers
e ge
ar H
BW 1
00 -
2,5R
«21
» z
= 43
133
04 3
04 0
1246
5466
65Re
vers
e ge
ar H
BW 1
0 / Z
F 12
M /
ZF 1
5 M
Z5=
431
3306
304
018
4072
35
65Re
vers
e ge
ar Z
F 15
MA
Z5=
431
3306
304
004
4074
80
65Re
vers
e ge
ar H
BW 2
50 -
2L «
20»
z =
441
3307
304
009
2742
40
65Re
vers
e ge
ar H
BW 2
50 -
3L «
19»
z =
491
3307
304
006
2889
69
65Re
vers
e ge
ar H
BW 2
50 -
1,5R
«16
» z
= 44
133
07 3
04 0
0927
4240
65Re
vers
e ge
ar Z
F 25
M -
1.88
R «0
01»
& «
22»
Z5=4
41
3307
304
009
2742
40
65Re
vers
e ge
ar Z
F 25
M -
2.27
R «0
07»
Z5=4
41
3307
304
009
2742
40
65Re
vers
e ge
ar Z
F 25
M -
2.74
R «0
02»
& «
23»
Z5=4
91
3307
304
006
2889
69
65Re
vers
e ge
ar H
BW 2
50 -
3,5R
«13
» z
= 49
133
07 3
04 0
0628
8969
65Re
vers
e ge
ar Z
F 25
MA
- 2.2
3R «
005»
Z5=
521
3307
304
002
-
65Re
vers
e ge
ar Z
F 25
MA
- 2.7
4R «
006»
Z5=
521
3307
304
002
-
65Re
vers
e ge
ar Z
F 30
M -
2.7R
«00
1» Z
5=58
133
20 3
04 0
05-
65Re
vers
e ge
ar Z
F 30
M -
2.15
R «0
02»
Z5=5
81
3320
304
005
-
66Ou
tput
sha
ft1
3303
304
004
3259
5733
04 3
04 0
1343
9448
3306
304
019
4072
8033
06 3
04 0
1940
7280
3307
304
011
4080
9233
07 3
04 0
1140
8092
3320
304
011
-
67Ke
y1
0631
501
634
2801
3006
31 5
01 6
3428
0130
67Ke
y2
3306
304
007
1878
4133
06 3
04 0
0718
7841
67Ke
y4
3307
304
004
2061
2133
07 3
04 0
0420
6121
3307
304
004
-
68a
Shim
0.1
mm
106
30 0
04 1
77-
68b
Shim
0.2
mm
106
30 0
00 2
5733
7665
68c
Shim
0.5
mm
106
30 0
04 1
7933
7664
68d
Shim
1.0
mm
106
30 0
04 1
8033
7662
69St
ud4
0636
610
232
3963
3006
36 6
10 2
3239
6330
0636
610
232
3963
3006
36 6
10 2
3239
6330
0636
610
232
3963
3006
36 6
10 2
3239
6330
0636
610
232
-
70Ne
edle
bea
ring
for s
hift
cove
r2
0635
303
056
2686
2006
35 3
03 0
56 2
6862
006
35 3
03 0
5626
8620
0635
303
056
2686
2006
35 3
03 0
56-
72Nu
t (ac
tuat
ing
leve
r)1
0637
006
157
4557
8506
37 0
06 1
5745
5785
0637
006
157
4557
8506
37 0
06 1
5745
5785
0637
006
157
4557
8506
37 0
06 1
5745
5785
0637
006
157
-
73Sp
acer
ZF
15 M
A - Z
F 25
MA
133
06 3
01 0
0740
7474
3307
301
004
-
74Na
me
plat
e1
3306
301
005
-33
06 3
01 0
05-
3306
301
005
-33
06 3
01 0
05-
3306
301
005
-33
06 3
01 0
05-
3306
301
005
-
75Oi
l nam
e pl
ate
133
04 3
01 0
16-
3304
301
016
-33
04 3
01 0
16-
3304
301
016
-33
04 3
01 0
16-
3304
301
016
-33
04 3
01 0
16-
ZF 3
M -
ZF 5
MZF
10
MHB
W 10
/ZF 12
M/15
MZF
15
MA
ZF 2
5 M
ZF 2
5 M
AZF
30
M
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
nPa
rt No
Old
p/n
Part
NoOl
d p/
nPa
rt na
me
Num
ber
per
gear
box
Item
No
Manual and Spare Parts List ZF M line
57
1 Housing assy 1 3306 201 004 3447682 Cover 1 3306 301 010 2064503 Cover 1 3306 301 023 3263694 Spring washer 39 0630 302 090 4423725 Hex screw 8 0636 015 289 2158706 Actuating lever * 1 947.23.006.01 1950626 Actuating lever 1 3306 308 001 5006357 Hex. head screw * 1 0636 015 299 1998077 Hex. head screw (actuating lever) 1 0636 101 727 4423778 Shaft seal ring 1 0634 502 009 1068649 Cover 1 3306 308 002 388242
10 Dowel pin 1 0631 329 032 10455911 Actuating cam assembly 1 3306 199 008 40721112 Shift cover assembly 1 3306 108 002 40721015 Shift fork 1 3306 208 001 22356316 Shift rod 1 3307 301 012 28867317 Plug 1 0636 301 041 44237318 Sealing ring 1 3306 301 016 32657819 Dipstick 1 3306 201 006 34548020 Oil drain plug 1 3306 301 013 22856621 Hex screw 14 0636 010 376 21586922 Hex nut 15 0637 006 157 45578523 Plug 1 0630 361 101 32238224 Intermediate shaft 1 3306 303 006 46877225 Disc 2 3307 303 002 28870226 Intermediate gear 1 3306 303 001 25473027 Needle bearing 1 3306 303 007 21587828 Gasket 2 3306 301 014 25471529 Gasket cover plate (or LOCTITE 574) 1 3306 301 015 25471630 Shaft seal, input 1 0634 301 833 21587531 Seal ring 2 0634 300 146 40164732 Tapered roller bearing 2 0635 501 597 -34 Tapered roller bearing 1 0635 370 050 -36 Input shaft HBW 150 V - 1.8R «08» z = 27/22 1 3306 302 006 30408836 Input shaft ZF 15 MIV - 2.13R «001» z1/z3 = 24/22 1 3306 302 008 32581136 Input shaft ZF 15 MIV - 2.72R «003» z1/z3 = 18/22 1 3306 302 009 43919736 Input shaft ZF 15 MIV - 2.99R «002» z1/z3 = 19/22 1 3306 302 007 31395237 Shim 0.10 mm 2 3306 302 011 20647438 Shim 0.15 mm 2 3306 302 012 20647539 Shim 0.50 mm 2 3306 302 015 22854040 Shim 1.00 mm 2 3306 302 016 22853941 Hex head screw 1 3306 304 057 42028042 Spacer 1 3306 303 004 32625743 Thrust ring 2 3306 304 029 34478744 Gear HBW 150V - 1,8R «08» z = 42 1 3306 304 015 40722144 Gear ZF 15 MIV - 2.13R «001» z2 = 45 1 3306 304 014 40722044 Gear ZF 15 MIV - 2.72R «003» z2 = 43 1 3306 304 016 43919844 Gear ZF 15 MIV - 2.99R «002» z2 = 50 1 3306 304 013 40721945 Needle bearing 2 0635 300 148 20118746 Needle bearing 2 3306 304 021 25152447 Spacer 2 3306 304 025 25099248 Spring 4 3306 304 026 387391
* Up to letter «E» production date (see name plate description pag.46)
ItemNo
Part name Number per gearboxPart No Old p/n
ZF 15 MIV
Manual and Spare Parts List ZF M line
58
49 Disc 2 3306 304 030 40713950 Ring half 4 3306 304 011 32683051 Internal clutch disc 8 3306 304 027 40723152 External clutch disc 8 3306 304 031 40723053 Shim 0.4 mm 2 3306 304 035 19571454 Shim 0.5 mm 2 3306 304 036 19571555 Shim 0.6 mm 2 3306 304 037 19571656 Shim 0.7 mm 2 3306 304 038 19571757 Disc carrier 2 3306 304 032 40723358 Ball 6 0635 460 015 10670059 Guide sleeve 1 3306 304 022 43960360 Change selector 1 3306 304 023 20681761 Pressure spring 3 3306 304 006 28740162 Stop pin 3 3306 304 033 18784063 Guide pin 3 3306 304 008 19527164 Torsion spring 3 3306 304 024 20679865 Gear z5= 43 1 3306 304 018 40723566 Intermediate shaft z6=29 1 3306 303 005 38841167 Cotter 2 3306 304 007 18784168 Tapered roller bearing 1 0635 370 053 -70 Shim 0.1 mm 2 0630 004 260 28083971 Shim 0.3 mm 1 0630 004 259 28084072 Shim 0.5 mm 1 0630 004 258 28084172 Nut (actuating lever) 1 0637 006 157 45578573 Ring 1 3306 304 054 34469074 Tapered roller bearing 2 0635 501 936 -76 Spacer ring 2 3306 304 009 32711578 Shim 1.3 mm 2 3306 304 042 34546978 Shim 1.4 mm 2 3306 304 043 34547078 Shim 1.5 mm 2 3306 304 044 34467378 Shim 1.6 mm 2 3306 304 045 34467478 Shim 1.7 mm 2 3306 304 046 34467578 Shim 1.8 mm 2 3306 304 047 34467678 Shim 1.9 mm 2 3306 304 048 34467778 Shim 2.0 mm 2 3306 304 049 34467878 Shim 2.1 mm 2 3306 304 050 34467978 Shim 2.2 mm 2 3306 304 051 34468078 Shim 2.3 mm 2 3306 304 052 34468178 Shim 2.4 mm 2 3306 304 053 34468280 Gear z = 33 1 3306 304 039 38841081 Key 1 0631 501 182 10533482 Output shaft 1 3306 304 041 34467083 Ring nut 1 3306 304 010 19541384 Ring 2 3306 304 040 34464485 0-Ring 1 0634 306 072 10559086 0-Ring 2 0634 303 690 29161887 Needle bearing 2 0635 303 056 26862088 Stud 4 0636 610 232 39633089 Plug 4 0636 301 039 33880590 Name Plate 1 3306 301 005 -91 Oil name plate 1 3304 301 016 387428
* Up to letter «E» production date (see name plate description pag.46)
ItemNo
Part name Number per gearboxPart No Old p/n
ZF 15 MIV
Manual and Spare Parts List ZF M line
59
SEAL KITSZF M SPARE PARTS KITS
ZF 3M - ZF 5M KIT P/N 3303 199 001 ID/N 500426PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverO-Ring 1 0634 306 179 105524 Shift fork shaftSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 4 3304 301 015 288739 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 830 280135 Input shaftSealing ring 1 0634 300 371 105153 Output shaft
ZF 10 M KIT P/N 3304 199 003 ID/N 500427PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverO-Ring 1 0634 306 011 105679 Intermediate shaftSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 4 3304 301 015 288739 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 830 280135 Input shaftSealing ring 1 0634 300 371 105153 Output shaft
HBW 10 - ZF 12 M - ZF 15 M - ZF 15 MA KIT P/N 3306 199 001 ID/N 500428PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverO-Ring 1 0634 303 118 105530 Intermediate shaftSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 4 3306 301 014 254715 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 833 215875 Input shaftSealing ring 1 0634 300 466 105159 Output shaft
ZF 15 MIV KIT P/N 3306 199 004 ID/N 500429PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 2 3306 301 014 254715 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 833 215875 Input shaftSealing ring 2 0634 300 146 401647 Output shaftO-Ring 1 0634 306 072 105590 Output shaftO-Ring 2 0634 303 690 291618 Output shaft
ZF 25 M - ZF 25 MA KIT P/N 3307 199 001 ID/N 500430 (EXCL. VERS. 22; 23)PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 4 3307 301 011 274251 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 832 284260 Input shaftSealing ring 1 0634 300 466 105159 Output shaft
ZF 30 M KIT P/N 3320 199 001PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 - Shift coverSealing ring 2 3306 301 016 - Drain plug/oil dipstickGasket 4 3307 301 011 - CoverSealing ring 1 0634 311 025 - Input shaftSealing ring 1 0634 311 026 - Output shaft
Manual and Spare Parts List ZF M line
60
SEAL + CLUTCH PACK KITS
HBW 10 - ZF 12 M - ZF 15 M - ZF 15 MA KIT P/N 3306 199 007 ID/N 500438PART NAME Q.TY P/N ID/N POSITION
Sealing ring 1 0634 502 009 106864 Shift cover
O-Ring 1 0634 303 118 105530 Intermediate shaft
Sealing ring 2 3306 301 016 326578 Drain plug/oil dipstick
Gasket 4 3306 301 014 254715 Cover
Gasket 1 3306 301 015 254716 Shifting cover
Sealing ring 1 0634 301 833 215875 Input shaft
Sealing ring 1 0634 300 466 105159 Output shaft
Thrust washer 2 3306 304 029 344787 Bearing/gear
Inner clutch disc 8 3306 304 027 407231 Clutch pack
Outer clutch disc 8 3306 304 031 407230 Clutch pack
Shim 0.4 mm 2 3306 304 035 195714 Clutch pack
Shim 0.5 mm 2 3306 304 036 195715 Clutch pack
Spring 3 3306 304 024 206798 Disc carrier
ZF 10 M KIT P/N 3304 199 004 ID/N 500437PART NAME Q.TY P/N ID/N POSITION
Sealing ring 1 0634 502 009 106864 Shift cover
O-Ring 1 0634 306 011 105679 Intermediate shaft
Sealing ring 2 3306 301 016 326578 Drain plug/oil dipstick
Gasket 4 3304 301 015 288739 Cover
Gasket 1 3306 301 015 254716 Shifting cover
Sealing ring 1 0634 301 830 280135 Input shaft
Sealing ring 1 0634 300 371 105153 Output shaft
Thrust washer 2 3304 304 019 288748 Bearing/gear
Inner clutch disc 8 3304 304 040 - Clutch pack
Outer clutch disc 6 3304 304 021 288758 Clutch pack
Shim 0.4 mm 2 3304 304 032 288760 Clutch pack
Shim 0.5 mm 2 3304 304 033 288761 Clutch pack
Spring 3 3306 304 024 206798 Disc carrier
ZF 3 M - ZF 5 M KIT P/N 3303 199 002 ID/N 500436PART NAME Q.TY P/N ID/N POSITION
Sealing ring 1 0634 502 009 106864 Shift cover
O-Ring 1 0634 306 179 105524 Shift fork shaft
Sealing ring 2 3306 301 016 326578 Drain plug/oil dipstick
Gasket 4 3304 301 015 288739 Cover
Gasket 1 3306 301 015 254716 Shifting cover
Sealing ring 1 0634 301 830 280135 Input shaft
Sealing ring 1 0634 300 371 105153 Output shaft
Thrust washer 2 3304 304 019 288748 Bearing/gear
Inner clutch disc 4 3304 304 040 - Clutch pack
Outer clutch disc 4 3304 304 021 288758 Clutch pack
Shim 0.4 mm 2 3304 304 032 288760 Clutch pack
Shim 0.5 mm 2 3304 304 033 288761 Clutch pack
Spring 3 3306 304 024 206798 Disc carrier
Manual and Spare Parts List ZF M line
61
ZF 15 MIV KIT P/N 3306 199 005 ID/N 500439PART NAME Q.TY P/N ID/N POSITION
Sealing ring 1 0634 502 009 106864 Shift cover
Sealing ring 2 3306 301 016 326578 Drain plug/oil dipstick
Gasket 2 3306 301 014 254715 Cover
Gasket 1 3306 301 015 254716 Shifting cover
Sealing ring 1 0634 301 833 215875 Input shaft
Sealing ring 2 0634 300 146 401647 Output shaft
O-Ring 1 0634 306 072 105590 Output shaft
O-Ring 2 0634 303 690 291618 Output shaft
Thrust washer 2 3306 304 029 344787 Bearing/gear
Inner clutch disc 8 3306 304 027 407231 Clutch pack
Outer clutch disc 8 3306 304 031 407230 Clutch pack
Shim 0.4 mm 2 3306 304 035 195714 Clutch pack
Shim 0.5 mm 2 3306 304 036 195715 Clutch pack
Spring 3 3306 304 024 206798 Disc carrier
SEAL + CLUTCH PACK KITS
ZF 25 M - ZF 25 MA KIT P/N 3307 199 002 ID/N 500440 (EXCL. VERS. 22; 23)PART NAME Q.TY P/N ID/N POSITION
Sealing ring 1 0634 502 009 106864 Shift cover
Sealing ring 2 3306 301 016 326578 Drain plug/oil dipstick
Gasket 4 3307 301 011 274251 Cover
Gasket 1 3306 301 015 254716 Shifting cover
Sealing ring 1 0634 301 832 284260 Input shaft
Sealing ring 1 0634 300 466 105159 Output shaft
Thrust washer 2 3307 304 020 327395 Bearing/gear
Inner clutch disc 10 3307 304 021 - Clutch pack
Outer clutch disc 8 3307 304 005 206026 Clutch pack
Shim 0.4 mm 2 3306 304 035 195714 Clutch pack
Shim 0.5 mm 2 3306 304 036 195715 Clutch pack
Spring 3 3306 304 024 206798 Disc carrier
ZF 30 M KIT P/N 3320 199 003PART NAME Q.TY P/N ID/N POSITION
Sealing ring 1 0634 502 009 - Shift cover
Sealing ring 2 3306 301 016 - Drain plug/oil dipstick
Gasket 4 3307 301 011 - Cover
Sealing ring 1 0634 311 025 - Input shaft
Sealing ring 1 0634 311 026 - Output shaft
Thrust washer 2 3307 304 020 - Bearing/gear
Inner clutch disc 12 3307 304 013 - Clutch pack
Outer clutch disc 10 3307 304 005 - Clutch pack
Shim 0.4 mm 2 3306 304 035 - Clutch pack
Shim 0.5 mm 2 3306 304 036 - Clutch pack
Spring 3 3306 304 024 - Disc carrier
Manual and Spare Parts List ZF M line
62
BEARING KITS (ALL VERSIONS)
ZF 25 M - ZF 25 MA KIT 501224 P/N 3307 199 003PART NUMBER DESCRIPTION LOCATION Q.TY0635 370 042 Tapered roller bearing Input shaft 20635 370 051 Tapered roller bearing Output shaft 20635 300 148 Needle cage Reverse gear 23306 304 021 Needle bearing inner race Reverse gear 23307 303 004 Cage Intermediate shaft 10635 303 056 Needle bearing Shift cover 23307 302 006 Shim 0.10 mm Input + Output shaft 4
ZF 10 M KIT 501221 P/N 3304 199 005PART NUMBER DESCRIPTION LOCATION Q.TY0635 501 943 Tapered roller bearing Input + Output shaft 40635 300 530 Cage Intermediate shaft 13304 304 037 Needle cage Reverse gear 23304 304 022 Needle bearing inner race Reverse gear 23304 302 011 Shim 0.10 mm Input + Output shaft 4
ZF 3 M - ZF 5 M KIT 501220 P/N 3303 199 003PART NUMBER DESCRIPTION LOCATION Q.TY0635 501 943 Tapered roller bearing Input + Output shaft 40635 300 526 Cage Intermediate shaft 10635 300 411 Needle cage Reverse gear 23303 304 012 Needle bearing inner race Reverse gear 23304 302 011 Shim 0.10 mm Input + Output shaft 4
HBW 10 - ZF 12 M - ZF 15 M KIT 501222 P/N 3306 199 003PART NUMBER DESCRIPTION LOCATION Q.TY0635 501 597 Tapered roller bearing Input + Output shaft 40635 300 148 Needle cage Reverse gear 23306 304 021 Needle bearing inner race Reverse gear 23306 303 007 Cage Intermediate shaft 10635 303 056 Needle bearing Shift cover 23306 302 011 Shim 0.10 mm Input + Output shaft 4
ZF 15 MIV KIT 501223 P/N 3306 199 006PART NUMBER DESCRIPTION LOCATION Q.TY0635 501 597 Tapered roller bearing Input shaft 20635 370 050 Tapered roller bearing Clutch shaft 10635 370 053 Tapered roller bearing Clutch shaft 13306 303 007 Cage Intermediate shaft 10635 501 936 Tapered roller bearing Output shaft 20635 300 148 Needle cage Reverse gear 23306 304 021 Needle bearing inner race Reverse gear 20635 303 056 Needle bearing Shift cover 10630 004 260 Shim 0.10 mm Clutch shaft 23306 302 011 Shim 0.10 mm Input + Output shaft 4
ZF 30 M P/N 3307 199 002PART NUMBER DESCRIPTION LOCATION Q.TY0635 370 042 Tapered roller bearing Input shaft 20635 370 051 Tapered roller bearing Output shaft 20635 300 148 Needle cage Reverse gear 43306 304 021 Needle bearing inner race Reverse gear 40635 300 114 Cage Intermediate shaft 20635 303 056 Needle bearing Shift cover 23307 302 006 Shim 0.10 mm Input + Output shaft 4
Manual and Spare Parts List ZF M line
63
10. Drawings (Explosion view)
Manual and Spare Parts List ZF M line
64
68a
68b
68c68
d
Manual and Spare Parts List ZF M line
65
Manual and Spare Parts List ZF M line
66
ZF-HURTH MARINE
ww
w.m
inia
to.it