ZF Marine Transmission - Operating Manual

Operating Instructions
ZF 7500, ZF 7549, ZF 7550

ZF 7500 NR, ZF 7549 NR,
ZF 7550 NR
ZF 7600, ZF 7650
ZF 7600 NR, ZF 7650 NR
ZF 7540, ZF W 7540
ZF 7540 NR, ZF W 7540 NR
ZF 7640, ZF 7641, ZF 7645, ZF 7646
ZF 7640 NR, ZF 7641 NR
ZF 7645 NR, ZF 7646 NR
ZF 7550 A, ZF 7550 NRA
ZF 7550 V, ZF 7550 NRV
ZF 7600 A, ZF 7650 A
ZF 7600 NRA, ZF 7650 NRA
ZF 7600 V, ZF 7650 V
ZF 7600 NRV, ZF 7650 NRV
ZF 7550 NR2H, ZF 7550 NR2
ZF 7550 NR2B
ZF 7600 NR2H, ZF 7600 NR2
ZF 7600 NR2B
ZF 7650 NR2H, ZF 7650 NR2
ZF 7650 NR2B
ZF W 7500, ZF W 7510
ZF W 7500 NR, ZF W 7510 NR
ZF 7561, ZF 7566
ZF 7561 NR, ZF 7566 NR
ZF 7661, ZF 7666
ZF 7661 NR, ZF 7666 NR
ZF W 7610, ZF W 7615
ZF W 7610 NR, ZF W 7615 NR
ZF 7549 C, ZF 7500 C, ZF 7850 C
ZF 7549 NRC, ZF 7500 NRC, ZF 7850 NRC
ZF Marine Transmission
ZF 7500/7600 Series
3084 758 101
Important note
General information
The following safety instructions appear in this manual.
NOTE:
Refers to special processes, techniques, data, use of auxiliary equipment etc.
CAUTION
This is used when incorrect, unprofessional working practices could damage the product
DANGER!
This is used when lack of care could lead to personal injury or death.
Subject to alterations in design
Copyright by ZF
These operating instructions are protected by copyright. Any reproduction and dissemination in whatever form also
in adapted, paraphrased or extracted form in particular as a reprint, photomechanical or electronic reproduction or
as a storage in data-processing equipment or data networks without approval by the holder of the copyright is prohibited and will be prosecuted under civil and criminal law
Edition:
2006-09
ZF Friedrichshafen AG
D-88038 Friedrichshafen,
Customer service
Telefon: (07541) 77-0
ZF 7500/7600 Series
Contents
Contents
Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1
1.1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
ZF-Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2
2.1
Monitoring values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Monitoring data for ZF 7550 NR2/NR2B/NR2H,
ZF 7650 NR2/NR2B/NR2H, ZF 7600 NR2/NR2B/NR2H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Summary of technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Direction of propeller rotation for forward drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5
Description of basic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.1
Power, speed, rotation direction, ratio, type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.2
General design (see end of section for differences in the NR series) . . . . . . . . . . . . . . . . . . . .14
5.3
Transmission views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.3.1
View of transmissions ZF 7500, ZF 7550, ZF 7549, ZF 7600, ZF 7650 . . . . . . . . . . . . . . . . . . .15
5.3.2
View of transmissions ZF 7500A, ZF 7550A, ZF 7600A, ZF 7650A . . . . . . . . . . . . . . . . . . . . .17
5.3.3
View of transmissions ZF 7500V, ZF 7550V, ZF 7600V, ZF 7650V . . . . . . . . . . . . . . . . . . . . .20
5.3.4
View of transmissions (left version) ZF 7550NR2H, ZF 7600 NR2H, ZF 7650 NR2H . . . . . . .22
5.3.5
View of transmissions (right version) ZF 7550 NR2H; ZF 7600 NR2H, ZF 7650 NR2H . . . . .24
5.3.6
View of transmissions ZF 7550 NR2B, ZF 7600 NR2B, ZF 7650 NR2B . . . . . . . . . . . . . . . . . .26
5.3.7
View of transmissions ZF 7550 NR2, ZF 7600 NR2, ZF 7650 NR2 . . . . . . . . . . . . . . . . . . . . . .28
5.3.8
View of transmissions ZF 7540, ZF 7541, ZF 7545,
ZF 7546, ZFW 7540, ZF 7640, ZF 7641, ZF 7645, ZF 7646 . . . . . . . . . . . . . . . . . . . . . . . . . . .30
5.3.9
View of transmissions ZFW 7500, ZFW 7510, ZF 7661,
ZF 7666, ZF 7561, ZF 7566, ZFW 7610, ZFW 7615 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
5.3.10 View of transmissions ZF 7549 C, ZF 7500 C, ZF 7850 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5.4
Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
5.5
Oil supply and transmission cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.6
Control unit and transmission actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.7
Checks and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.1
Permissible installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.2
Transmission attachments for transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.3
Transmission mounting on foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
6.3.1
Casting resin base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
6.4
Connection to the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6.4.1
Normal engine arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6.4.2
U/V-drive arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6.4.3
U/V-drive installation diagram when drive shaft is in W-arrangement . . . . . . . . . . . . . . . . . . . .47
6.5
Connection to propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6.6
Aligning the transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6.7
Connections for transmission cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
3
Contents
6.8
6.9
6.9.1
6.9.2
ZF 7500/7600 Series
Connection of monitoring devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission actuation devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical actuation of transmission (Not with NR2, NR2H, NR2B type transmissions) . . . .
Electrical actuation of transmission
(Not with NR2, NR2H, NR2B type transmissions. For these transmissions see section 6.9.3) .
Electrical actuation of NR2, NR2H, NR2B type transmissions . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum transmission monitoring facilities (for values, see section Monitoring values) . .
Additional transmission monitoring (for values, see section Monitoring values) . . . . . . . . . .
Necessary measures before operating the transmission for the first time . . . . . . . . . . . . . . . . . .
Oil fill, oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
51
52
7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1
Change-over procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1
Change-over from neutral to ahead or neutral to astern . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2
Change-over from ahead to astern with vessel moving at low speed
(not applicable for non-reversing transmissions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.3
Change-over from ahead to astern with vessel moving at higher speed
(not applicable for non-reversing transmissions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.4
Emergency change-over in case of danger (not applicable for non-reversing transmissions) . .
7.2
Operation with engine stationary and propeller trailing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1
Occasional trailing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2
Regular trailing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3
Operation with the manual mechanical actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.1
Mechanical emergency operation of mechanical transmission actuation . . . . . . . . . . . . . . . . . .
7.3.2
Mechanical emergency operation of the electrical transmission actuation
(except NR2, NR2H, NR2B type transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3
Mechanical emergency operation of the electrical transmission actuation
of NR2, NR2H, NR2B type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3.1 Mechanical emergency control for version with auxiliary screws . . . . . . . . . . . . . . . . . . . . . . .
7.3.3.2 Mechanical emergency control for version with push / pull slider . . . . . . . . . . . . . . . . . . . . . . .
7.4
Operation with emergency shift
(Come home screws, not with NR2, NR2B, NR2H transmissions) . . . . . . . . . . . . . . . . . . . . .
59
59
59
66
8
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2
Protection against corrosion, preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3
Maintenance work plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4
Special versions / Special scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.1
Special scope of supply - Transmissions with additional trailing oil pump (item 18) . . . . . . . .
8.5
Trouble shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6
ZF service stations, Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
68
69
70
71
71
71
75
6.9.3
6.10
6.10.1
6.10.2
6.11
6.11.1
6.11.2
54
55
56
56
57
58
58
58
59
59
59
59
59
60
61
61
61
63
63
64
Maintenance system job sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ZF 7500/7600 Series
Foreword
ZF 7500/7600 Operating Instructions

1
Foreword
1.1
ZF-Transmission
The description, operation and maintenance sections are applicable to the standard transmission version.
Variations are possible according to special customer requirements and operating conditions. If the data contained in
the operating instructions are different to the data contained in the technical or commercial specifications, the data in
the specifications shall apply.
Important!
Ensure that these operating instructions are always kept to hand. Carefully read the operating instructions. Pay particular attention to the safety instructions.
Some of the illustrations contained in the operating instructions may differ from your installed transmission. Furthermore, safety devices and covers may sometimes be omitted to enable clearer illustration.
Foreword
ZF 7500/7600 Series
Important Note:
1. The warranty conditions agreed with ZF apply for these transmissions. However, ZF can only honour warranty
claims if:
the transmission has been installed, monitored, operated and maintained in accordance with these operating instructions,
ZF-approved lubricants have been used,
the limit values specified on the transmission for the ratio of input power to input speed and for input speed are
respected according to the transmission application group.
2. The transmission manufacturer, as a supplier of one single component in the vessel drive system, cannot be held
responsible for vibrations or vibrational problems occurring in this system. Therefore, ZF will not accept liability
for transmission noise or damage to the transmission, flexible coupling or other parts of the drive unit caused by
such vibrations.
We therefore recommend that vibrations are recorded and calculated including, where appropriate, transmissioncomponents not subject to load.
PVF= PK + 8 bar
max
Pressure gauge
0 to 40 bar 3)
1 bar 4)
2) 5) 6)
__________
7 bar
3.5 bar
__________
Position 9)
Neutral
2)
8) For operation with engine at a standstill and

current-driven propeller (also refer to section 7.2)
2)
105 C
100 C
30 C
2)
__________
Thermometer 0 to 120 C
95 C
90 C
30 C
__________
__________
75 C 8) 11)
105 C 8) 12)
__________
__________
Trailing
operation 8)
P, L, M, Capplication
14) Not within the standard ZF scope of supply
13) Not included in table above
PVF = Pressure before filter
11) Without trailing pump

12) With trailing pump (not within the standard ZF
scope of supply)
PK = Clutch oil pressure

PKN = Nominal clutch oil pressure
Decreasing
Increasing
16) For remote display
9) For normal operation
C
application
Normal operation
11, 12, 41
P, L, Mapplication
Oil temperature
Pressure switch or
Temperature switch 2) or temperature sensor 16)
pressure gauge 0 to 6 bar 0 to 120 C
__________
0.25 bar
5 bar
0.4 bar
__________
__________
22
Lubricating oil
pressure
7) The nominal clutch pressure is specified in the

binding, order-specific technical documents and
also stamped on the type plate.
Pressure switch or
pressure sensor 16) 0 to 25 bar
6)
Pressure gauge 0 to 25 bar
PK = PKN 3 bar
PK = PKN + 2 bar 4)
PK = PKN
PKN 7)
6) Warning must be set to not functioning when in shift

position Neutral
5) Warning with time delay of between 3 to 10 s

(provided by shipyard)
4) At 60 C to 80 C oil temperature
3) Use distributor piece
2) For visual and acoustic warning
1) Refer to section 5.3 for arrangement of measuring

points on transmission
For further details, refer to section 2
Additional monitoring
Pressure switch
Minimum monitoring 14)
14)
31 bar
2) 5)
__________
min
__________
Warning
Nom. display
value
Nominal value
CounterPosition 9)
engine-wise
Counter-engine-wise
output rotation9) output rotation
Operating mode
2, 21, 27
Measuring point 1)
Clutch oil pressure
Monitoring data for ZF 7550 NR2/NR2B/NR2H, ZF 7650 NR2/NR2B/NR2H, ZF 7600 NR2/NR2B/NR2H
2.1
Filter
contamination
Monitoring values
2
ZF 7500/7600 Series
Monitoring values
PVF= PK + 6 bar
max
Pressure gauge
0 to 40 bar 3)
2) 5) 6)
__________
6 bar
3.5 bar
2)
8) For operation with engine at a standstill and

current-driven propeller (also refer to section 7.2)
2)
105 C
100 C
30 C
2)
__________
Thermometer 0 to 120 C
95 C
90 C
30 C
__________
__________
75 C 8) 11)
105 C 8) 12)
__________
__________
Trailing
operation 8)
P, L, M, Capplication
PKN = Nominal clutch oil pressure
11) Without trailing pump
19) For transmission with PKN = 17.5 bar

14) Not within the standard ZF scope of supply
18) For transmission with PKN = 16 bar
12) With trailing pump (not within the standard ZF

scope of supply)
PVF = Pressure before filter
PK = Clutch oil pressure
Decreasing
Increasing
16) For remote display
9) For normal operation
C
application
Normal operation
11, 12, 41
P, L, Mapplication
Oil temperature
Pressure switch or
Temperature switch 2) or temperature sensor 16)
pressure gauge 0 to 6 bar 0 to 120 C
__________
0.25 bar
4.5 bar
0.4 bar
__________
__________
22
Lubricating oil
pressure
7) The nominal clutch pressure is specified in the

binding, order-specific technical documents and
also stamped on the type plate.
Pressure switch or
pressure sensor 16) 0 to 25 bar
6)
Pressure gauge 0 to 25 bar
PK = PKN 3 bar
PK = PKN + 2 bar 4)
PK = PKN 1 bar
6) Warning must be set to not functioning when in shift

position Neutral
5) Warning with time delay of between 3 to 10 s

(provided by shipyard)
4) At 60 C to 80 C oil temperature
3) Use distributor piece
2) For visual and acoustic warning
1) Refer to section 5.3 for arrangement of measuring

points on transmission
For further details, refer to section
Pressure switch
14)
Minimum monitoring 14)
2) 5) 19)
24 bar
26 bar
Warning
2) 5) 18)
__________
min
PKN 7)
__________
Nominal value
Nom. display
value
__________
Position 9)
Enginewise or counterengine-wise rotation
Neutral 9)
Enginewise or
counter-enginewise rotation
Operating mode
4)
Position 9)
Neutral
2, 21, 27
Clutch oil pressure
Measuring point 1)
Filter
contamination
Monitoring data for ZF 7500/7600 Series without version NR2, NR2B, NR2H
Monitoring values
ZF 7500/7600 Series
ZF 7500/7600 Series
Summary of technical data
Direction of rotation, transmission input shaft

(standard version)
Identification mark
for the oil pump ratio
Design engine speed
Engine idling speed
approx. 1 650 to 2 300
>/= 415
approx. 1 100 to 1 650
>/= 275
Additional forces on transmission input in accordance with section 6.4 (Loads applicable to the face end
of input shaft)
in radial direction
max. 4 000 N
in axial direction
max. 1 500 N
Alignment accuracy of the propeller shaft (also refer in to section 6.5)
Transmission
Dimension A
Max permissible
according section 5.2 angle error x
[mm]
A = 340
A = 448
Max. shift
displacement y
Smallest permissible distance

L to first bearing depending
on propeller shaft diameter d
[mm]
[mm]
500 for d < 120
0.05
0.10
1 000 for d >/= 120
ZF 7500/7600
Series
800 for d < 150

A = 450
A = 600
0.1
0.15
1 200 for d 150 to 200

2 000 for d > 200
Permitted radial force on propeller shaft for centering on transmission output flange (refer to section 6.5) max.
1000 N
ZF 7500/7600 Series
Cooler data ZF 7500 Series without NR2/NR2B/NR2H type transmissions without ZF 7540, 7550 transmissions and ZF 7600 Series
Largest permitted cooling water flow rate
17 500 dm3/h
Smallest permitted cooling water flow rate
5 400 dm3/h
Loss of pressure between cooling water inlet/outlet
at
17 500 dm3/h
0.5 bar
Max. permitted water pressure at cooling water inlet
4 bar
Highest cooling water inlet temperature
40 C
Highest transmission ambient temperature
60 C
Cooler data ZF 7540, 7550 transmissions and ZF 7600 Series without ZF 7500 Series and NR2/NR2B/NR2H
type transmissions
17 500 dm3/h
5 400 dm3/h
at
17 500 dm3/h
0.5 bar
4 bar
Highest cooling water inlet temperature
32 C
Highest transmission ambient temperature
60 C
Cooler data NR2/NR2B/NR2H type transmissions

12 000 dm3/h
3 900 dm3/h
at
12 000 dm3/h
1 bar
4 bar
Highest cooling water inlet temperature ZF 7550 NR2/NR2B/NR2H
40 C
Highest cooling water temperature ZF 7600, 7650 NR2/NR2B/NR2H
32 C
Highest gearbox ambient temperature
60 C
10
ZF 7500/7600 Series
Oil types
The relevant valid ZF list of lubricants TE-ML 04 for ZF marine gears is binding.
This list is available from any ZF After-Sales Service Point and on the internet under
www.zf.com.
Then choose Service, Technical Information, ZF List of Lubricants, List of Lubricants
(English) then under TE-ML 04 choose the PDF download.
Viscosity classes SAE 30 or SAE 40 at oil sump temperature < 80 C
Viscosity class SAE 40 at oil sump temperature > 80 C
Oil quantities
transmission ratio
ZF 7500, ZF 7549, ZF 7550, ZF 7600, ZF 7650
approx. 75 dm3
ZF 7550 A, ZF 7650 A, ZF 7550 V, ZF 7650 V
approx. 75 dm3
ZF 7550 NR2, ZF 7650 NR2
approx. 50 dm3
ZF 7550 NR2B, ZF 7650 NR2B
approx. 50 dm3
ZF 7550 NR2H, ZF 7650 NR2H
approx. 50 dm3
ZF 7540, ZF 7640, ZF 7641,

ZF 7645, ZF 7646, ZF W 7540
approx. 80 dm3
ZF 7661, ZF 7666, ZF W 7500, ZF W 7510

ZF 7561, ZF 7566, ZF W 7610, ZF W 7615
approx. 120 dm3
ZF 7549C, ZF 7500C, ZF 7850C
approx. 75 dm3
refer to transmission type plate
transmission weight depending on scope of supply, refer to transmission type plate
11
Direction of propeller rotation for forward drive
12
Direction of propeller rotation for forward drive
ZF 7500/7600 Series
ZF 7500/7600 Series
Description of basic transmission
5.1
Power, speed, rotation direction, ratio,

type plate
ZF marine transmissions are designed and manufactured

according to the regulations of the various classification
societies. The input powers approved by the classification societies depend on the input speed, the class of the
craft and the different design regulations currently in
force. In most cases, the maximum torques approved by
ZF are also fully accepted by the classification societies.
If requested, the classification society specified by the
customer can carry out a full test or factory acceptance
test (test stand).
Normally, the input shaft rotates in a clockwise direction
(looking at the transmission input flange). Transmissions
which are specially designed for anti-clockwise input
shaft rotation (looking at the transmission input flange)
have an arrow on the transmission input end to show the
rotation direction.
Key
1
2
3
4
5
6
7
8
9
10
11
12
13
Model
Serial no.
Parts list no.
Customer reference no.
Total ratio and code letter for oil pump ratio
Oil capacity
Mass (dry)
Lubricant, see ZF List of Lubricants
TE-ML 04
Clutch oil pressure (nominal)
Max. power/speed ratio for intermittent operation
at very widely differing engine speeds
at widely differing engine speeds
at differing engine speeds
Max. power/speed ratio for continuous operation
at max. engine power
NOTE
For items 10 to 13, also refer to section 8 Maintenance.
The total ratio is stamped on the transmission type plate

which is located on top of the transmission housing.
Information under 1, 2, 3 and 5 must be quoted when

querying problems and ordering spare parts etc.
Data included on the type plate:
The code letter stamped after the total ratio in box 5 signifies the following:
Letter
Rated engine speed for

continuous operation
Engine idle
speed
1650 to 2300
> 415
1100 to 1650
> 275
FRIEDRICHSHAFEN
- GERMANY SERIAL NO.
MODEL
1
PARTS LIST NO.
REFERENCE NO.
3
RATIO TOTAL
MAIN GEAR
SPUR GEAR
MASS DRY (kg)
CLUTCH OIL PRESSURE (bar)
OIL CAPACITY (dm 3 )
PLEASURE
kW/RPM
10
LIGHT
11
Oil pump ratio A is the standard version.
9
MEDIUM
CONTINUOUS
12
13
OIL CHANGE: AFTER FIRST 50 HOURS OPERATION AND

EVERY 1000 HOURS OR 12 MONTHS, WHICHEVER OCCURS FIRST.
LUBRICANT SEE ZF LIST TE-ML04 SAE 30 OR 40
13
5.2
General design (see end of section for differences in the NR series)

A= 0 mm
ZF 7549 C
ZF 7550 C
ZF 7850 C
A= 340 mm
ZF 7500
ZF 7550
ZF 7550 NR2H
ZF 7550 NR2
ZF 7550 NR2B
ZF 7600
ZF 7650
ZF 7650 NR2H
ZF 7650 NR2
ZF 7650 NR2B
ZF 7600 NR2H
ZF 7600 NR2
ZF 7600 NR2B
V-version
A
8
006779.4
A-version
A=600 mm
ZFW 7500
ZFW 7510
ZF 7561
ZF 7566
ZF 7661
ZF 7666
ZFW 7610
ZFW 7615
A=450 mm
ZF 7540
ZFW 7540
ZF 7640
ZF 7641
ZF 7645
ZF 7646
ZFW 7640
ZFW 7645
A=448 mm
ZF 7500A
ZF 7500V
ZF 7600A
ZF 7600 V
ZF 7650 A
ZF 7650 V
ZF 7500/7600 series transmissions are abaxial 3-shaft

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

600 mm are made of grey cast iron.The housing of the
transmissions with an offset A=450 mm can be either
grey cast iron or light alloy. Light alloy are ZF 7540; ZF
7640, ZF 7645. The machined faces and tapped holes for
attaching the transmission mountings are included as
standard. With transmissions with an offset A of 600
mm, the rigid supports are cast onto the transmission
housing and then machined.
In order to ensure long service life and quiet operation,
all power-transmitting gears are configured for high
safety levels, case-hardened, ground and then specially
treated. The shafts run in roller bearings. Propeller thrust
bearings are installed in the transmission (not
NR2/NR2H/NR2B type transmissions). The reversing
clutches arranged on the input and reversing shafts are of
multi-disc type with steel/sinter friction pairing.They are
pressed together by oil pressure.
The high pump discharge rate ensures that the clutches
respond rapidly when actuated. During the gearshift
process, the clutch contact pressure is modulated to ensure a smooth shift.
At the same time the engaged clutch is fed with an increased flow of oil so that the heat generated during the
gearshift process is rapidly dissipated, meaning the load
capacity of the clutches is higher.
In the event of a fault in the operating oil circuit, the two
multi-disc clutches can be pressed together mechanically
by means of 3 bolts accessible from the outside (only
when the transmission is at a standstill). This emergency
control method (not available with NR2, NR2H, NR2B
transmissions) permits either enginewise or counter-enginewise rotation of the output shaft.
For gearshifts, there is an easily interchangeable controlunit with all the necessary valves, slide valves and othercontrol modules for the operating and lubricating oil circuits mounted on the transmission casing. The control
unit is operated mechanically via a lever or electrical.
NR2, NR2H, NR2B type transmissions are intended for
electrical actuation only.
Differences in the NR Series:
ZF 7500/7600 series (except NR2, NR2H, NR2B)
The NR.... series transmissions are reduction gears with
one clutch, which can be arranged either on the input
shaft or the reversing shaft. The output shaft rotates in
either the opposite or the same direction as the input
shaft, depending on the transmission-version. Otherwise, the design and external dimensions are identical as
in the reversing transmission.
NR2 NR2H and NR2B type transmissions
NR2 NR2H and NR2B type transmissions have a specially designed 2-shaft arrangement with one clutch on
the input shaft. The output shaft rotats in the opposite direction of the input shaft. The external dimensions are
different to the dimensions of the reversing transmissions.
ZF 7500/7600 Series
5.3
Transmission views
5.3.1 View of transmission ZF 7500, ZF 7550, ZF 7549, ZF 7600, ZF 7650

The add-ons, connections and pipes on your transmission may be different to those pictured here.
41
46
34
26
18
11
16
10
37
19
12
18
22
21
27
25
23
7
44
33
20
32
15
ZF 7500/7600 Series
Key:
1
Mounting faces for transmission(mounting

brackets not included in scope of supply for
basic version)
25
Oil dipstick
26
Output
2, 21, 27
Pressure measuring point for clutch oil
32
Oil chamber drain
Oil sludge drain plug for filter
33
Oil filter
Input
34
Emergency control
(counter-enginewise rotation)
10
Engine-driven oil pump
35
Coolant inlet
11, 12, 41
Oil temperature measuring points
36
Coolant outlet
15
Oil cooler
37
16
Pressure connection for stand-by pump
Inspection cover,
(on transmission housing)
18
Position for trailing oil pump
44
19
Suction side connection for standby pump
Emergency control
(enginewise rotation)
20
Oil drain plug
46
Oil fill hole
22
Pressure measuring point for lubricating

oil
105
Mechanical selector lever for manual actuation
23
Transmission breather
16
ZF 7500/7600 Series
5.3.2 View of transmissions ZF 7500A, ZF 7550A, ZF 7600A, ZF 7650A

The add-ons, connections and pipes on your transmission may be diffrent to those pictured here.
34
44
26
20
16
10
18
46
22
5
33
32
25
23
17
ZF 7500/7600 Series
18
8
35
36
19
27
21
18
20
ZF 7500/7600 Series
Key:
1

basic version)
2, 21, 27
Oil pressure measuring point upstream of oil

filter
Input
10
11, 12, 41 Oil temperature measuring points

15
Oil cooler
16
18
19
20
Oil drain plug
22
Pressure measuring point for lubricating oil
23
25
Oil dipstick
26
Output
32
Oil chamber drain
33
Oil filter
34
Emergency control
35
Coolant inlet
36
Coolant outlet
37
Inspection cover,
44
Emergency control
46
Oil fill hole
105
19
ZF 7500/7600 Series
5.3.3 View of transmissions ZF 7500V, ZF 7550V, ZF 7600V, ZF 7650V

37
105
22
5
33
7
32
23
25
12
26
15
11
46
35
36
44
20
20
18
ZF 7500/7600 Series
27 21 2
41
10
16
19
20
Key:
1

basic version)
25
Oil dipstick
26
Output
2, 21, 27
32
Oil chamber drain

filter
33
Oil filter
35
Coolant inlet
36
Coolant outlet
Input
37
10
Inspection cover,
44
Emergency control
46
Oil fill hole
105

15
Oil cooler
16
18
19
20
Oil drain plug
22
23
21
ZF 7500/7600 Series
5.3.4 View of transmissions (left version) ZF 7550NR2H, ZF 7600 NR2H, ZF 7650 NR2H
15
13
26
(11)
(20)
(12)
18
11
20 12 10
20
22
ZF 7500/7600 Series
21 27
23 25
46
37
22
33
7
32
Key:
1

basic version)
26
Output
32
Oil chamber drain
2, 21, 27
33
Oil filter

filter
37
Inspection cover,
46
Oil fill hole
Input
10
11, 12
13
Water connection flanges
15
Oil cooler
18
20
Oil drain plug
22
23
25
Oil dipstick
23
ZF 7500/7600 Series
5.3.5 View of transmissions (right version) ZF 7550 NR2H; ZF 7600 NR2H, ZF 7650 NR2H
15
13
26
10
11 20 12
18
(11)
(20)
(12)
20
24
ZF 7500/7600 Series
22 25
2 27
7 32
21
33
23
46
37
Key:
1

basic version)
26
Output
32
Oil chamber drain
2, 21, 27
33
Oil filter

filter
37
Inspection cover,
46
Oil fill hole
Input
10
11, 12
13
15
Oil cooler
18
20
Oil drain plug
22
23
25
Oil dipstick
25
ZF 7500/7600 Series
5.3.6 View of transmissions ZF 7550 NR2B, ZF 7600 NR2B, ZF 7650 NR2B

18
26
33
10
5
15
13
25
23
11
20
12
26
(11)
(20)
(12)
ZF 7500/7600 Series
15
21 27
22
46
37
8
20
Key:
1

basic version)
2, 21, 27

filter
Input
10
11, 12
13
15
Oil cooler
18
20
Oil drain plug
22
23
25
Oil dipstick
26
Output
33
Oil filter
37
Inspection cover,
46
Oil fill hole
27
ZF 7500/7600 Series
5.3.7 View of transmission ZF 7550 NR2, ZF 7600 NR2, ZF 7650 NR2

15
13
33
10
8
5
25
23
26
11 20 12
2
(11) (20) (12)
21 27
22
37
46
20
006779
28
ZF 7500/7600 Series
Key:
1

basic version)
22
23
2, 21, 27
25
Oil dipstick

filter
26
Output
33
Oil filter
Input
37
10
Inspection cover,
11, 12
46
Oil fill hole
13
15
Oil cooler
18
20
Oil drain plug
29
ZF 7500/7600 Series
5.3.8 View of transmissions ZF 7540, ZF 7541, ZF 7545, ZF 7546, ZFW 7540,

ZF 7640, ZF 7641, ZF 7645, ZF 7646
105
41 10
22
16
33
7
5
25
23
32
34
44
26
11 20
12
19
15
35
36
18
21 27
20
37
46
30
ZF 7500/7600 Series
Key:
1

basic version)
2, 21, 27

filter
Input
10

15
Oil cooler
16
18
19
20
Oil drain plug
22
23
25
Oil dipstick
26
Output
32
Oil chamber drain
33
Oil filter
34
Emergency control
35
Coolant inlet
36
Coolant outlet
37
Inspection cover,
44
Emergency control
46
Oil fill hole
105
31
ZF 7500/7600 Series
5.3.9 View of transmissions ZFW 7500, ZFW 7510, ZF 7661, ZF 7666,

ZF 7561, ZF 7566, ZFW 7610, ZFW 7615
Key:
1
Transmission mounting face (cast-on rigid

supports)
Input (Flange not part of basic equipment)
35
Coolant inlet
36
Coolant outlet
32
ZF 7500/7600 Series
25
23
Filter area (sludge drain)
25
Oil dipstick
11
Oil temperature measuring point
26
Output
12A
Temperature sensor(not part of basic version)
32
Oil chamber drain plug
33
Oil filter
19
Suction connection for stand-by pump
34
20
Oil drain plug
Emergency control (counter-enginewise rotation)
22
Pressure measuring point for lubricating

oil
41A
Thermometer(not part of basic version)
23
33
ZF 7500/7600 Series
2A
Pressure switch(not part of basic version)
27A
Pressure gauge (not part of basic version)
5A
Oil pressure measuring point upstream of

cooler and filter
37
Inspection cover (on transmission housing)
41A
Thermometer(not part of basic version)
10
44
Emergency control (enginewise rotation)
15
Oil cooler
46
Oil fill hole
16
105
23
25
Oil dipstick
34
ZF 7500/7600 Series
5.3.10View of transmissions ZF 7549 C, ZF 7500 C, ZF 7850 C

8
37
46
22
44
25
23
34
20
35
ZF 7500/7600 Series
33
21 27
32
41
2
10
16
15
35
36
26
11
19
12
20
26
Output
32
Oil chamber drain
33
Oil filter
34
Emergency control
35
Coolant inlet
36
Coolant outlet
37
Inspection cover,
44
Emergency control
46
Oil fill hole
Key:
1
Transmission mounting face (cast-on rigid

supports)
2, 21, 27

filter
Input
10

15
Oil cooler
16
18
19
20
Oil drain plug
22
23
25
Oil dipstick
36
ZF 7500/7600 Series
5.4
Functional description
Transmission and power flow diagram ZF 7500, ZF 7549, ZF 7550, ZF 7600, ZF 7650, ZF 7540, ZF 7640,
ZF 7641, ZF 7645, ZF 7646, ZF W 7540, ZF W 7500, ZF W 7510, ZF 7661, ZF 7666, ZF 7561, ZF 7566,
ZFW 7610, ZFW 7615
(for ZF 7500 NR, ZF 7549 NR, ZF 7550 NR, ZF 7600 NR, ZF7650 NR, ZF 7640 NR, ZF 7641 NR, ZF 7645
NR, ZF 7646 NR, ZF 7540 NR,ZF 7661 NR, ZF 7666 NR, ZF W 7540 NR, ZF W 7510 NR, ZF W 7500 NR,
ZF 7561 NR, ZF 7566 NR, ZFW 7610 NR, ZFW 7615 NR only have either clutch D or E)
D
A
Gears are in
mesh
B
C
E
C
A = Input shaft
A
Power flow during:

Counter-enginewise rotation
Enginewise rotation
B = Reversing shaft
C = Output shaft
D = Clutch for counter-enginewise rotation

E = Clutch for enginewise rotation
001 635
transmission and power flow diagram for ZF 7550A, ZF 7550V, ZF 7600 A, ZF 7600 V, ZF 7650 A, ZF 7650
V
(ZF 7550 NRA, ZF 7550 NRV, ZF 7600 NRA, ZF 7600 NRV, ZF 7650 NRA, ZF 7650 NRV only have either
clutch D or E)
V-version
A-version
D
D
A
Gears are
in mesh
Power flow
during:
counter-enginewise rotation
AA
CC
C
B
C
Gears are
in mesh
enginewise
rotation
A
A
B
A - Input shaft
B - Reverse shaft
C - Output shaft
D - Clutch for counterenginewise rotation
E - Clutch for engine
wise rotation
CC
001 645
37
ZF 7500/7600 Series
transmission and power flow diagram for ZF 7550NR2, ZF 7550NR2H, ZF 7550NR2B, ZF 7600 NR2, ZF
7600 NR2H, ZF 7600 NR2B, ZF 7650 NR2, ZF 7650 NR2H, ZF 7650 NR2B
D
A
A
C
Power flow in
counter- enginewise
rotation
001 635_1
A - Input shaft
C - Output shaft
D - Clutch
transmission and power flow diagram for ZF 7549C, ZF 7500C, ZF 7850C

(ZF 7549 NRC, ZF 7500 NRC, ZF 7850 NRC, only have clutches E or F)
F
B
C
Gears are
in mesh
D A
B
A - Input shaft
B - Reverse shaft
C - Clutch shaft
F - Clutch for counterenginewise rotation
E - Clutch for engine
wise rotation
008 143_1
E
D
C
B
A
engine-wise rotation
B
D
38
Power flow in:

counter- enginewise rotation
ZF 7500/7600 Series
ZF 7500/7600 Series (except NR2, NR2H, NR2B)

The transmission and powerflow diagram shows the
flow of power for enginewise rotation (output shaft rotating in same direction as input shaft) and for counterenginewise rotation (output shaft rotating in opposite
direction to input shaft).
Full engine power can be transmitted in both directions
of rotation. The ratio indicated on the type plate applies
for both rotation directions of the output shaft. Identical
transmissions can therefore be used for multi-engine installations. This requires fewer spare parts and permits
the use of standardized exchange units.
NR2, NR2H, NR2B type transmissions
Connecting unions are included as standard for monitoring transmission temperature, oil pressure upstream of
the filter, lubricating oil pressure and clutch oil pressure.
For locations and descriptions, see section 5.3.
5.6
Control unit and transmission actuation
The control unit is a complete module fitted on the transmission housing. It comprises:
a spool valve for charging and draining the clutch
packs
a control valve for the clutch pressure level
a time switch for modulating the clutch pressure
The transmission and powerflow diagram shows the

flow of power for counter-enginewise rotation (output
shaft rotating in opposite direction to input shaft) only
since these transmissions have a specially designed 2shaft arrangement.
The spool valve is moved axially into the respective shift

position. Depending on the actuation system, the valve is
moved mechanically, or hydraulically. The oil flowing
out from the control unit is used to lubricate and cool the
clutch discs, meshing gears and bearing locations.
5.5
If the transmission is mechanically actuated (not NR2,

NR2H, NR2B), the spool valve is moved via the selector
lever located on top of the control unit. A dial shows the
current shift positionengaged. The basic transmission
version is mechanically actuated (not NR2, NR2H,
NR2B).
Oil supply and transmission cooling
The transmission housings are designed as oil reservoirs.

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

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

they are tested on test rigs/benches. During this test, every function, oil pressures, temperature and noise level are
checked thoroughly. During the test run, the inside of the
transmission is flushed with oil to preserve it. The trans-
39
mission can then be stored in a dry place for up to 12

months without the need for further special measures.
Any necessary preservation of the outside of the transmission depends on storage conditions and should be undertaken by the customer. Preservation measures for
long storage periods must be specified when ordering.
40
ZF 7500/7600 Series
ZF 7500/7600 Series
Installation
When planning what powerpack to use, care must be taken to ensure sufficient free space for removing the oil
cooler, oil filter, oil pump, clutch packs and discs and for
withdrawing the dipstick. (The dimensions required for
these procedures are specified on the transmission installation drawings). It is possible to remove clutch packs
and discs whilst the transmission is still installed.
The oil drain plugs must also be easily accessible. If
there is not enough space available to place a pan under
the oil drain openings for collecting the oil during oilchanges, it is advisable to permanently fit a suction pipe
on the transmission in place of the oil drain plug.The oil
must then be removed by suction during oil changes.
CAUTION
The screw
connections listed below are to be provided
C
i
by the customer and must be rated in acc. with the operating loads supplied:
suspension brackets to transmission (provided this

does not fall within ZF scope of supply);
suspension brackets to foundation;
flexible coupling to engine or transmission;
propeller shaft to transmission
The safety equipment required for rotating components

must be in place, e.g.:
protective covers for output flange, flexible coupling and/or engine flywheel and drive shaft,
Installation
6.1
Permissible installation position
The installation documents specified in the transmission

supply contract shall apply.
6.2
Transmission attachments for transportation
The lifting tackle for transportation should only be attached to the lugs provided.
On transmissions without attached mounting brackets,
lifting eyes are screwed onto the pads intended for taking
up the suspension brackets during delivery. These retaining lugs are only used for transporting the transmission.
They must not be used to transport the engine and transmission unit in the flange-mounted-on-the-engine version. Afterwards, these lifting eyes must be removed so
that the suspension brackets can be attached.
On transmissions where the mounting brackets have
already been fitted, the lifting tackle should be attached
to the eyes of the mounting brackets. On the mounting
brackets supplied by ZF, the corresponding outer bracing ribs have been provided with eyes. If the mounting
brackets are manufactured by the shipyard or by the engine manufacturer, suitable means of attachment must be
provided.
Under no circumstances may the lifting gear be attached
in other places, particularly not to the input shaft, the output shaft, the covers, the oil pumps or the pipes.
protective covers and guard equipment for universal joint shafts.
41
Installation
6.3
ZF 7500/7600 Series
Transmission mounting on foundation
There are machined pads and mounting threads on the

side of the transmission housing for attaching the
mounting brackets. If the mounting brackets are
manufactured at the shipyard, care must be taken to
ensure that the vertical distance between the
transmission output shaft and the foundation support
surface of the mounting bracket is correct. This distance
x must be within the following range:
x < (0,6 A) and > (-0,2 A)
A low foundation rigidity can cause resonance and then

lead to high levels of load on transmission components.
As a result, these components will fail prematurely.
If the propeller thrust is taken up by the transmission
(propeller thrust bearings for ahead and astern thrust are
installed in the transmission), the bearing elements must
also be appropriate for taking up the propeller thrust.
When operating a flexible transmission mounting and
rigidly connected propeller shaft, the alignment must
not be permanently distorted in operation.
If you have any queries, do not hesitate to contact us.
To align the transmission on the foundation (see
connection to propeller shaft), very strong supports
must be used. Individual supports - only around the
individual foundation bolts - are not permissible. The
mounting brackets supplied by ZF are provided with
aligning screws. These screws must be removed again
after the supports have been placed in position.
We recommend the use of fitted bolts to secure the
mounting brackets to the foundation. If through bolts
are used, solid stops should be fitted, at least in the
direction ahead propeller thrust.
The size of the mounting bolts (No., diameter, grade)
depends on the operating loads, and is to be specified by
the shipyard.Care should be taken to ensure that the
transmission mounting takes up not only the propeller
thrust and the weight, but also the reaction forces of the
input torque and ratio-dependent output torque.
+
X
Support surface
A +
X
Support surface
007691
The surfaces of the mounting bracket on the same side

as the transmission must be machined flat.
If required, dowels can be used at points specified in the
transmission installation drawing.
The transmission can be installed separately in the
foundation or, (in versions where it is flange-mounted to
the engine) it can be installed either rigidly or flexibly
together with the engine.
During mounting, the transmission must not be braced
to the foundation, i.e. all mounting brackets lie equally
flat on the foundation.
When selecting bearing elements for a flexible
transmission mounting, care must be taken to ensure
that the natural frequency of the flexibly installed
42
transmission does not coincide with the excitation

frequency of the engine unit or the propeller. The
foundation rigidity must also be taken into
consideration when calculating the natural frequency.
ZF 7500/7600 Series
Installation
6.3.1 Casting resin base

The support surface of the ZF mounting bracket
(flexible and rigid) has been designed for direct
mounting on a rigid surface (e.g. foundation frame). If
the transmission is to be mounted onto casting resin, it
may be necessary to enlarge the support surface using
an adapter plate supplied by the ship yard. The space
between the foundation frame and the adapter plate is
cast. In such instances, the adapter plate should be
designed in a way that makes it possible to remove and
install the transmission without destroying the casting
resin base. In addition to this, rigid pads should be fitted
for transmitting the propeller thrust to the foundation.
Once the casting resin has hardened, the transmission
should only be supported by the casting resin and not by
the alignment screws or any other alignment aids. When
aligning the transmission, the way in which the casting
resin reacted to shrink fitting during hardening should
be taken into consideration.
We recommend that plans for the design of any
mountings made of casting resin are made in
conjunction with the casting resin suppliers and/or a
certified specialist company. A specialist company is
able to provide advice at an early stage and is able to
create the calculations and drawings required for
approval from a classification society and to submit
these for approval.
43
Installation
6.4
Connection to the engine
ZF 7500/7600 Series
6.4.1 Normal engine arrangement
If rigid connection between engine and transmission is

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

the engine manufacturer with the aid of a torsional
vibration calculation. The transmission data necessary
for this calculation can be taken from our Data for
torsional vibration calculation sheet.
If a flexible coupling is supplied by ZF according to the
selection of the engine manufacturer or as stipulated by
the shipyard, ZF can in no way be held responsible for
the suitability or durability of the flexible coupling.
Assembly and disassembly of the clutch hub or the
input flange, i.e. the part of the flexible coupling on the
input side facing the transmission side must be carried
out according to the workshop manual of this
transmission series.
007693.2
The transmission can be installed separately or

flange-mounted on the engine. If the transmission is
installed separately, the foundation mounting will either
be rigid or flexible. Normally, the engine is mounted
flexibly. The torsionally flexible input connection must
also be capable of absorbing misalignments of the
engine axis relative to the transmission axis.
The elasticity of the engine mounting as well as the
alignment accuracy of engine to transmission must
(related to the transmission) be selected so that the axial
and radial forces bearing on the transmission due to the
retroactive forces of the flexible coupling do not exceed
the permissible limit (see summary of technical
data).
If the transmission is installed flange-mounted on the
engine, the bell housing connects the transmission to
the engine. In this instance, the two units are properly
centred. The flexible connection then no longer has to
absorb any additional forces caused by shaft
misalignment.
44
ZF 7500/7600 Series
Installation
6.4.2 U/V-drive arrangement
U-drive arrangement
006779.2
These forces and bending moments are absorbed at the

transmission end by the transmission input shaft,
transmission housing and mounting bracket; at the
engine end by the flexible coupling, crankshaft and
engine housing. The torsionally flexible coupling must
therefore be fitted with additional suspension elements
between the primary and secondary side. If the flexible
coupling or the engine crankshaft cannot absorb forces
and bending moments generated by the drive shaft, an
additional bearing must be installed between the drive
shaft and the flexible coupling. This bearing can be
supported by a flange on the engine. Alternatively, an
intermediate shaft can be installed and mounted in the
foundation.
The forces and bending moments generated by the drive
shaft occur periodically at double the engine speed of
rotation. The maximum value for additional load on the
transmission input shaft (refer to section 3) must not be
exceeded. The mounting bracket for the engine and/or
intermediate shaft, transmission and foundation should
have its dimensions calculated to ensure that
unacceptable levels of distortion cannot occur. If they
do occur, this would lead to noise and vibration. If
necessary, the foundation must be strengthened.
V-drive arrangement
006779.3
transmissiones with input and output flanges at the same

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

output, engine speed, size of the joint angle and the
lifetime required for the drive shaft. The drive shaft
manufacturer usually recommends a shaft size by
studying the actual operating conditions which the
vessel is likely to encounter. To ensure that the drive
shaft operates at the optimum kinematics, the joint
angles must be the same at both ends and the joint forks
must be mounted on the same plane. It should be
ensured the joint angles are as small as possible. In
transmissiones with parallel input and output shafts (Udrives), not more than max. 7 8. The output shaft in
V-drive transmissiones is already tilted by 8, i.e. the
drive shaft angle can be reduced to the minimum value
required for the joint bearing of the drive shaft. We
recommend to use the advantage of the tilted output
shaft and do not exceed a joint angle of max. 3. You
should try to use a drive shaft centre part with a
dynamic rotating mass as small as possible.
45
Installation
ZF 7500/7600 Series
DANGER!
Fit a safety device to all parts of the drive
shaft at which the rotating shaft presents a
possible danger to people and material. The
user and/or operator should comply with all
relevant safety precautions. It is essential
that the appropriate safety equiment (e. g.
retaining bracket, stable guard grill) is fitted to prevent parts of the drive shaft being
thrust out of the unit.
The drive shaft manufacturers technical documents
contain more detailed information about drive shafts.
The drive shaft can be arranged in two ways
W-arrangement with 1 = 2
004_971.1
To check the joint angles when aligning the engine , two

alignment shafts of equal lenght can be installed in
place of the drive shaft. The engine will be properly
aligned (and joint angles of equal size) when the ends of
the two alignment shafts meet (see installation
diagram).
Z-arrangement with 1 = 2
1
004_971.2
To check the joint angles when aligning a leaser based

aligning device can be used. The engine will be properly
aligned (and joint angles of equal size) when the engine
crank shaft and the transmission input shaft are in
parallel.
46
ZF 7500/7600 Series
Installation
6.4.3 U/V-drive installation diagram when drive shaft is in W-arrangement
004 971
Engine
Self-centering torsionally flexible connection.

Specified according to engine output and torsional vibration calculation.
Marine transmission with input and output at the

same end
Installation to help in the correct alignment of the

engine and transmission, i.e. to achieve equal
joint angles 1 = 2. Install two alignment shafts
in place of the drive shaft. The shafts must be of
equal length. Align the two units so that the ends
of the shafts meet and that the center line of the
shafts belong to the same plane. Finally, remove
the alignment shafts and install the drive shaft.
Variable length drive shaft

Selected in accordance with manufacturers recommendations. Comply with installation regulations (1 = 2, joint forks mounted in the same
plane).
Propeller shaft
47
Installation
6.5
Connection to propeller shaft
The dimensions of the connection depend on the

operating loads and must be specified by the shipyard.
The transmission output flange is designed to ensure that
the maximum permissible transmission torque is
transmitted by means of friction contact. For this
purpose the following bolts must be used for all bolt
holes.
ZF 7549, ZF 7500, ZF 7549C, ZF 7500C, ZF 7850C
M22x1.5Quality 10.9min. tensile strenght 1000 N/mm
ZF 7550 /A/V/NR2/NR2H/NR2B
M24x1.5Quality 10.9 min. tensile strenght 1000 N/mm
ZF 7541, ZF 7545, ZF 7546; ZF 7540, ZFW 7540,
ZF 7640, ZF 7641, ZF 7645, ZF 7646,
ZFW 7500, ZFW 7510, ZF 7661; ZF 7666,
ZFW 7610, ZFW 7615
M30x2 Quality 10.9 min. tensile strenght 1000 N/mm
If fit bolts are used, the bores of the propeller-shaft
flange and transmission output flange (material strength
750 to 900 N/mm2) may be opened out together by
drilling and reaming.
ZF 7500/7600 Series
6.6
Aligning the transmission
If the transmission mounting is relatively flexible, the

connection between the transmission output flange and
the propeller shaft must normally be capable of
absorbing relative movements (e.g. joint coupling or
flexible coupling). This does not apply if the propeller
shaft is also extremly flexible.
If the propeller shaft is connected rigidly to the
transmission output flange, the transmission must be
aligned with the propeller shaft. To do this, the vessel
must be fully fitted-out and afloat. If necessary, the
alignment procedure must be repeated before the vessel
goes into service.
Shafts with only one propeller-shaft bearing (Fig. A)
It must be possible to move the propeller shaft axially
and radially so that the propeller-shaft flange can be
inserted into the transmission output flange centre. The
transmission must be aligned so that the permissible
angle error x, based on measuring radius r, does not
exceed the value specified in the summary of technical
data section 3 value y is disregarded.
See Summary of technical data
48
ZF 7500/7600 Series
Installation
Shafts with two or more propeller-shaft bearings

(Fig. B)
It must be possible to move the propeller shaft axially so
that the propeller-shaft flange can be fitted in the centre
of the transmission output flange. The transmission
must be aligned so that the permissible errors x (based
on measuring radius r) and y do not exceed the values
stated in the table.
Both errors x and y may be present at the same time. If
the shaft is very thin and the distance L is very great, it
may not be possible to measure the value y. If the
propeller shaft can be installed in the centre of the
transmission output flange, with a maximum radial force
not exceeding the value specified in the summary of
technical data section 3, the y value can be
disregarded. If this is the case, the alignment
instructions for shafts with only one propeller-shaft
bearing apply.
NOTE
The values given for x and y only apply when the
distance L between the propeller-shaft flange and the last
shaft bearing is large enough in relation to the shaft
diameter d.
49
Installation
6.7
Connections for transmission cooling
(Data applies only to coolers fitted as standard at ZF)

The volume of heat generated in the transmission is
partly radiated from the housing surface and partly
dissipated through the oil cooler. The oil cooler included
in the basic transmission version is mounted on the
housing. All the necessary oil lines are securely attached
and ready for use.
The coolant inlet and outlet connections are located on
the side of the cooler and blanked off during shipment.
The blanking-off flanges can be used as welding flanges
when installing the coolant pipe. The positions of the
coolant inlet and outlet connections are shown on the
relevant transmission installation drawing.
The direction of water flow must be maintained, i.e.
water inlet and outlet must not be interchanged.
For permissible water flow rate and pressure loss
between coolant inlet and outlet, refer to technical data.
The specified water pressure at the coolant inlet must not
be exceeded. The cooler is designed to ensure adequate
heat dissipation at a transmission ambient temperature of
60C and a water inlet temperature as specified in
section 3 - even at full transmission load and maximum
engine speed.
ZF 7500/7600 Series
The correct transmission temperature is obtained by

adjusting the coolant flow rate.
A replaceable orifice, valve or similar must be included
in the circuit for this purpose. For this reason, the
transmission oil cooler water circuit should be connected
in parallel to the engine coolant circuit.
The max. permissible temperature increase for the
coolant in the transmission oil cooler is 3C and is of no
significance to the engine oil circuit. The stated
maximum coolant flow rate through the transmission oil
cooler must not be exceeded since this may lead to
cavitation in the cooler. Similarly, the minimum flow rate
must always be maintained, otherwise sludge may form
in the cooler after only a relatively short period of
operation
The pipes and shut-off valves for the sea water circuit
must be made from copper or material containing
copper for operation in seawater or brackish water.
Galvanized steel pipes must not be used due to the risk
of the zinc coating partly eroding as a result of galvanic
processes and rust debris being deposited on the webs
and flanged pipes in the cooler.
Within a short period of time, this would lead to the
cooler being damaged by pitting corrosion.
The water pipes must to be connected to the cooler in
such a way that stresses and recoil forces caused by
thermal expansion are avoided. If routing of the water
pipes makes this impossible, flexible connections must
be fitted, arranged as close as possible to the cooler.
50
ZF 7500/7600 Series
6.8
Installation
Connection of monitoring devices
The minimum monitoring facilities specified in the

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

available as required.
The mechanical actuator is fitted as standard. with the
ZF 7500/7600 Series except NR2, NR2H, NR2B
transmissions. With NR2, NR2H, NR2B transmissions
there is electrical actaution only. The actuation
mechanism must be designed so that a gear change can
only occur when the engine throttle control lever is in
idling position.
This can best be obtained with single lever control
whereby engine throttle control and transmission control
are interlocked. When using dual lever control, a
locking device should be incorporated in the
transmission actuation system so that a gearchange can
only be carried out when the engine throttle control lever
is in idling position.
A cutout device for the the transmission actuator should
also be provided for single lever control, so that the
engine can be run at high speed for inspection or
warming-up purposes without the need to actuate the
transmission.
51
Installation
ZF 7500/7600 Series
6.9.1 Mechanical actuation of transmission

(Not with NR2, NR2H, NR2B type transmissions)
In mechanically actuated transmissions, the spool valve
in the control unit is moved in an axial direction by means
of the control shaft rotary motion.
Key to drawings
103 Selector position for counterenginewise rotation
104 Selector position for enginewise
rotation
105 Selector lever for mechanical
actuation
137
105
121 Selector limit stop

122 Undefined selector position
(pass through this area quickly)
123 Safe neutral area
124 Neutral detent setting
137 Switch for interrupting warning
signal (special scope of supply)
The lever is situated on top of the control unit. The
selector lever should be at an angle of approx. 90 to the
shift linkage when in neutral position. After removing
the lateral clamping screw on the selector shaft, the
selector lever can be rotated by approx. 11 on the
selector shaft. The control positions are shown on the
quadrant situated on the control unit and the marks on
the graduated circle on the selector shaft. The exact shift
angles of the individual control positions required for
establishing the required stroke and linkage connection
can be seen on the sketch Mechanical transmission
actuator.
The linkage connection bore on the selector lever
depends on the stroke of the shift mechanism. Select a
distance between the bore and the selector lever pivot
point which ensures that the specified shift angle (see
drawing) can be reliably attained.
Information about the mechanical emergency
operation of the mechanical transmission actuation
is given in section 7.3.1.
DANGER!
Mechanical transmission actuator
52
The transmission clutches are disengaged in Neutral

shift position. The propeller shaft can still keep turning.
If you require the propeller shaft to be stationary, then it
is necessary to provide a propeller shaft brake or another
shaft interlock.
ZF 7500/7600 Series
Installation
The bore may be between 45 and 95 mm away from the

selector lever pivot point. If necessary, the existing hole
(105 mm away) may be used.
The relationship between shift travel, bore spacing and
shift force is shown in the following table
Shift travel of
selector unit
Distance ofconnecting hole

from pivot point
Shift force
required
Neutral ahead
Neutral astern
H [mm]
30
40
r [mm]
F [N]
approx. 47
approx. 62
56
42
50
approx. 78
34
60
approx. 93
28
After the selector device has been adjusted, the selector

lever must be firmly fixed to the selector shaft using a
clamping screw. The shift angles must then be checked
as shown in the Figure. Special care must be taken that
the undefined ranges between
- neutral position and operating position for
enginewise rotation or
- neutral position and operating position for counterenginewise rotation
are passed through quickly.
Operations within the undefined ranges may damage the
reversing clutches. For this reason, shift movements in
the transmission must be checked at regular intervals and
following all repairs/overhauls, and adjusted if
necessary.
If the distance between the actuator and transmission
selector lever is too large, it is difficult to maintain the
specified control position by mechanical means. In such
cases we recommend the use of the electrical
transmission actuator.
53
Installation
6.9.2 Electrical actuation of transmission

(Not with NR2, NR2H, NR2B type transmissions. For these transmissions see section 6.9.3)
ZF 7500/7600 Series
respective shift position. If there is a failure in the

power supply, the transmission can be actuated
manually by using the selector lever.
NOTE
The basic version of this reversing transmission
shifts back to neutral automatically if the power
supply fails.
A special version is also available: shift position
retained during power failure for water jet or variable
pitch propeller applications with non reversing
transmissions). In accordance with customer wishes or
some classification society requirements, reversing
transmissions can also be supplied as this special
version. Before initial operation, check which version is
choosen by the vessel manufacturer.
Information about the mechanical emergency
operation of the electrical transmission actuation is
given in section 7.3.2.
DANGER!
The transmission clutches are disengaged in Neutral
shift position. The propeller shaft can still keep turning.
If you require the propeller shaft to be stationary, then it
is necessary to provide a propeller shaft brake or another
shaft interlock.
101 Electrical actuator

106 Electrical connection
140 Actuating pin for Item 141
141 Valve for mechanical auxiliary
operation
142 Setting for electrical operation
143 Setting for mechanical auxiliary
operation
In the case of electrical transmission actuation, the
spool valve is moved axially by means of oil pressure.
The required data for electrical connections and
soldering procedure for the plug element are shown in
the documentation supplied with the equipment.
If the transmission is electrically actuated, the manual
selector lever is moved simultaneously into the
54
ZF 7500/7600 Series
Installation
6.9.3 Electrical actuation of NR2, NR2H, NR2B type

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

carried out by push/pull slider
101
Version where the manual mechanical actuation is

carried out by screws.
101
101 electric actuation device

NOTE
In case of a power failure the shifting position prior to
the power failure remains unchanged.
For description of operation with manual mechanical actuation see section Operation.
106
006 626

106 electrical connections (plug connection included
in ZF scope of supply)
NOTE
In case of a power failure the shifting position prior to
the power failure remains unchanged.
For description of operation with manual mechanical actuation see section Operation.
55
Installation
ZF 7500/7600 Series
6.10 Transmission monitoring

5
41
21
27
22
12
11
The monitoring facilities stated in section 6.10.1 are essential for checking operating reliability of the transmission and must always be installed. In addition, the transmission is provided with measuring points for additional
monitoring equipment (see section 6.10.1).
6.10.1Minimum transmission monitoring facilities
(for values, see section Monitoring values)
Pressure reading upstream of oil cooler and filter (measuring point 5).
This measuring point is intended as a means of monitoring the oil filter. Any rise in pressure indicates that the
filter is becoming increasingly blocked.
A pressure-sensing switch must be used for monitoring.
It should be set to change over when pressure rises above
the preset value, and transmit a warning signal.
Clutch oil pressure (measuring point 2)
Depending on the transmission version and its inputtorque, the clutch oil pressure setting will vary. The
nominal clutch oil pressure is confirmed in the technical
documentation which is included with each order, and is
also stamped on the transmission type plate (see
section 5).
The clutch oil pressure indication applies to both the enginewise and counter-enginewise shift positions. In Neutral, the oil pressure at this measuring point drops to a
56
006 791
value given in the section Monitoring values, depending on input speed and oil temperature. To monitor
clutch oil pressure, a pressure gauge must be used.
If clutch oil pressure is in accordance with the specified
values and the conditions stated above apply, transmission lubrication will be assured. For this reason, separate
monitoring of lubricating oil pressure (measuring point
22) is unnecessary.
Oil temperature (measuring point 12)
A thermometer must be used to monitor transmission oil
temperature. The volume of water flowing through the
transmission oil cooler must be regulated until the transmission oil temperature remains within the recommended normal range during normal operation. The maximum
transmission oil temperature must not be exceeded during continuous operation.
ZF 7500/7600 Series
6.10.2Additional transmission monitoring (for values, see section Monitoring values)

Additional measuring points are provided on the transmission if a higher level of transmission function monitoring is desired. The relevant values are the same as
those at the measuring points for the minimum monitoring facility.
Installation
Oil temperature (measuring point 11)

An additional temperature sensor can be connected to
measuring point 11 for a remote thermometer or a temperature warning switch. The temperature switch must
be set to the warning value specified for the transmission
version in question.
Measuring point 41
Pressure reading upstream of oil filter (measuring point

5). If monitoring is to take place by means of a pressure
gauge and a warning device, a T-union can be attached
at measuring point 5 for simultaneous connection of a
pressure gauge and pressure-sensing switch. It is also
possible to use a pressure sensor with built-in switch
contact for an alarm device if a remote reading instrument is needed.
This measuring point can be used in transmission versions equipped with a trailing oil pump.
CAUTION
Measuring
point 41 is not located in the oil sump. It can
C i
only be used for monitoring oil temperature if the oil is
being circulated (engine running or rotating propellershaft with fitted trailing pump).
Clutch oil pressure (measuring points 21 and 27)

Measuring points 21 and 27 can be used to connect additional pressure-sensing switches in conjunction with a
warning device or pressure gauge.
When monitoring is via a pressure-sensing switch, this
must be adjusted so that the alarm signal is transmitted,
if pressure drops below the warning limit. In neutral
transmission setting, oil pressure will drop below the trip
value for the pressure-sensing switch, i.e. alarm goes off
in neutral even if oil pressure is normal. To prevent this
happening, the warning device should be deactivated
when the transmission is in Neutral e.g. by means of a
switch controlled by the transmission actuator (ZF special scope of supply). To prevent the alarm from tripping
in the period between operation of the control unit and
build-up to full clutch oil pressure (approx. 1 to 2 s), a
delay timer must also be installed in between, with settings of min. 3 s and max. 10 s.
Lubricating oil pressure (measuring point 22)
Lubricating oil pressure can be monitored at measuringpoint 22 using either a pressure gauge or a pressure-sensing switch. Depending on the transmission input shaft
speed and transmission oil temperature, the lubricating
oil pressure will be in the area stated in section Monitoring values. When monitoring with a pressure-sensing switch, adjust it so that a warning signal is transmitted if lubrication oil pressure drops below the warning
value specified in section Monitoring values.
57
Installation
6.11 Necessary measures before operating the

transmission for the first time
6.11.1Oil fill, oil level check
See Maintenance section for correct procedure.
6.11.2Installation check
By hand rotate the engine and then the propshaft.
Check for ease of operation.
Check that clamping bolts of mounting brackets on
transmission and foundation are securely tightened.
Check that connecting bolts between propeller shaft
flange and transmission output shaft flange are
tightend securely.
Check that connecting bolts on the transmission
input end are tightened securely.
Check that connections have monitoring instuments.
Check that oil cooler is connected to the coolant
system.
If a remote mounted cooler is used.
Check that this oil cooler is safely connected with the
transmission lubrication system.
Check that all rotating components have protective
covers.
Check that all transmission components (pipes,
sensors, plugs, wires) are not damaged.
Check that all electrical interfaces to the
transmission are finally wired and all cable/wire
entrances are sealed.
Check that all hoses, wires and cables are fitted free
of scuffing.
Function check on selector mechanism

On mechanically actuated transmissions each shift position can be read using the scale on the control unit and the
circular markings on the selector shaft. Mechanically actuated transmissions in particular must be carefully
checked to see whether the specified shift positions are
assured.
On electrically actuated transmissions check operating
voltage or power consumption at an appropiate place as
near as possible to the plug connection for the electrical
control unit.
58
ZF 7500/7600 Series
ZF 7500/7600 Series
Operation
During operation, the transmission does not require any

attention except for monitoring of the indicators for
transmission temperature and oil pressures.
DANGER!
The transmissions clutches are disengaged in
Neutral shift position. The propeller shaft can
still keep turning.
If you require the propeller shaft to be stationary , then it is necessary to provide a propeller
shaft brake or other shaft interlock.
7.1
Change-over procedure
In our experience, the change-over procedures described

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

vessel moving at higher speed (not applicable for non-reversing transmissions)
Move engine throttle control to idling. Leave transmission control lever in ahead, in order to utilize the
engine braking effect on the propeller until the engine
speed has dropped to approx. 1.2 x idling speed. Now
move transmission control lever to astern and keep it
in this position for approx. 1 or 2 secs. before
increasing the engine speed to the required operating
speed.
7.1.4 Emergency change-over in case of danger (not
applicable for non-reversing transmissions)
In case of emergency, it is of course possible to carrry out
a change-over from ahead to astern at higher engine
speeds, too. However, in this case as well, we would recommend a time lag of approx. 1 or 2 secs. after the
astern direction has been engaged, before increasing
the engine speed.
During such manoeuvres, please note that in many cases
(depending on the type of vessel etc.), the time needed to
bring the vessel to a stop is not shortened at all or only
very slightly compared with the change-over sequence
described above. Therefore, in spite of the increased load
on the propulsion unit, in most cases, the chances of
avoiding a collision are not greatly reduced.
7.1.1 Change-over from neutral to ahead or

neutral to astern
7.2
(The propeller shaft is at rest or only rotates very slowly)
7.2.1 Occasional trailing operation
Move engine throttle control to idling, select desired travel direction and keep lever in this position for 1 or 2 secs.
before increasing the engine speed to the required operating speed.
It is possible to carry out occasional trailing operations

with the basic transmission version installed (without
trailing oil pump).
7.1.2 Change-over from ahead to astern

with vessel moving at low speed
(not applicable for non-reversing transmissions)
Move engine throttle control to idling. Move transmission control lever from present travel direction to opposite direction and keep it in this position for approx. 1 or
2 secs. before increasing the engine speed to the required
operation speed.
Operation with engine stationary and propeller trailing
The transmission oil temperature must be monitored

(measuring points 11 and 12 located in oil sump). The
max. oil temperature must not exceed 75C. If the temperature exceeds this level, the vessel speed must be reduced. If necessary, the engine can be started up for a
short time until the transmission oil temperature falls below the max. permissible value as a result of coolant circulation (transmission in forwards or neutral position).
Trailing operation of max. 15 hours is permissible in
emergencies.
59
Operation
7.2.2 Regular trailing operation

If regular trailing operation lasting more than 5 hours
without interruption is necessary, a trailing oil pump
must be installed.
This oil pump is fitted on the transmission housing in
the output shaft area. It is driven by the transmission
output shaft via a gear train. The oil pumps always
delivers oil to the oil circuit in the same direction,
irrespective of the output rotation direction. When the
engine is at a standstill and the output shaft is turning,
this oil pump supplies lubricating oil to the
transmission. This means that it is permissable to
operate the unit as long as is required when the
engine is at a standstill and the propeller is rotating.
The oil temperature must be monitored and may not
exceed 105C (the oil sump temperature is
approximately equal to the clutch disc temperature). If
the oil temperature is too high, it can be cooled either by
reducing the trailing speed of the ship or by passing
water through the transmission oil cooler. The coolant
can either be taken via a special valve from the operating
engine coolant system , or it can be supplied through a
separately driven water pump. For dimensions, reckon
on a coolant capacity equal to max. 25% of the water
capacity during normal operation. If the transmission
oil temperature rises to above 90C, the transmission
must remain in neutral after the engine has been started
until the temperature drops below 90C. Only then is
normal operation permitted.
60
ZF 7500/7600 Series
ZF 7500/7600 Series
7.3
Operation with the manual mechanical

actuation
If a fault develops in the actuating system, the

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

This section applies if the transmission has a mechanical
transmission actuation (see section 6.9.1)
DANGER!
Engine and transmission components can get
very hot (danger of burns). In addition in the engine room there is danger of rotating parts.
Take appropriate safety precautions.
Mechanical emergency actuation is to be performed in
the following sequenz:
Operation
DANGER!
When the mechanical emergency operation is
used the remote transmission control for this
transmission does not function.
It is essential that the person in charge of the
craft is aware of this situation. In port or when
travelling on a narrow or busy waterway, stop
the engine and have the craft towed.
To deactivate the mechanical emergency actuation,
stop the engine and hook the linkage for the remote
mecanical actuator onto the seleector lever of the
control unit. Check the setting..
7.3.2 Mechanical emergency operation of the electrical transmission actuation (except NR2, NR2H,
NR2B type transmission)
This section applies if the transmission has an electrical
transmission actuation as discribed in section 6.9.2.
For NR2, NR2H, NR2B see section 7.3.3
DANGER!
- Stop the engine

- Unhook the push-pull cable or the linkage of the
mechanical remote control
- Move the selector lever manually to the Neutral
position
- Start the engine and set it to idling speed
- Move the selector lever manually to the desired
shifting position until it stops. The selector lever
remains in that position. Appropiate measures must
be taken to secure the selector lever and prevent it
from jumping out of the ahead or astern position
which might occure e. g. due to vibrations.
61
Operation
ZF 7500/7600 Series
Standard version
If the power supply fails, the transmission automatically
shifts to neutral. This version has the cap nut and the actuating PIN 140 (see sketch in this section).
142
140
141
143
In order to change over manually using the selector lever

of the control unit, it is necessary to change over the mechanically shifted valve (see sketch in this section, items
141).
This is done by installing the actuating PIN 140 the other
way round. This actuating PIN can be accessed once the
cap nut has been screwed off. The cap nut must then be
screwed back on. The selector lever can now be manually shifted as with the mechanical transmission actuation
version.
Special version
If electrical power fails, the shift position is retained.
This version has not the cap nut and the actuating PIN
140 (see sketch in this section).
With this version shifts can be performed manually on

the selector lever without installing the actuating PIN the
other way round.
101
106
011 749
101
Electric transmission actuation
106
Electrical connection
140
Actuating pin for item 141
141
Valve for mechanical emergency actuation
142
Setting for electrical actuation
143
Setting for mechanical auxiliary actuation
NOTE:
There are two versions of electrical transmission actuation. These are:
standard version
special version
62
Appart from some reversing transmissions alle non reversing transmissions have the special version.
Mechanical emergency actuation is to be performed in
the following sequenz:
Set the engine speed to idling speed
Remove plug on electrical actuation (see sketch in
this section item 106)
With standard version only:
Change over the mechanically shifted valve (see
sketch in this section).
This is done by installing the actuating PIN 140 the
other way round (accessible once cap nut has been
unscrewed). A small oil leak is possible when cap
nut is removed. The cap nut must be tightened again.
Move the selector lever manually to the desired
shifting position until it stops. The selector lever
remains in that position. Appropiate measures must
be taken to secure the selector lever and prevent it
from jumping out of the ahead or astern position
which might occure e. g. due to virbrations.
ZF 7500/7600 Series
DANGER!
Operation
7.3.3.1Mechanical emergency control for version

with auxiliary screws

101
To deactivate the mechanical manual actuation

Stop the engine
Fit plug on electrical actuation (see sketch in this
section, item 106)
106
With standard version only: Change over the

mechanically shifted valve (see sketch in this
section, item 141
006 626
Check that plug and cap screw are fitted and

tightened
106
7.3.3 Mechanical emergency operation of the electrical transmission actuation of NR2, NR2H,
NR2B type transmission
101
Should problems arise with the electrical transmission

actuation or should the power supply fail, the
transmission can be shifted manually.
DANGER!
NOTE:
There are two versions of mechanical emergency control. These are:
- Mechanical emergency control with auxiliary screw
- Mechanical emergency control with push / pull
slider
2
006 625

106 electrical connection
1, 2 screw plug
NOTE:
For mechanical emergency control an actuating PIN
max. diameter 6 mm, min length 80 mm is required.
Small oil leak is possible when screw plug 1 or 2 is removed.
63
Operation
Shifting process:
Engage
Set engine speed to neutral speed
ZF 7500/7600 Series
7.3.3.2Mechanical emergency control for version

with push / pull slider
106
Remove plug (item 106) on electrical actuation

device (item 101)
101
Remove screw plug 1 (screw 2 with NR2H left

version)
Place PIN (max. diameter 6 mm, min. length 80 mm)
into opening and move control valve until it stops
Fit screw plug 1 (2 with NR2H left version)
Disengage
Set engine speed to idling speed
Remove plug on electrical actuation device (item
101)
Remove screw plug 2 (screw 1 with NR2H left
version)
NR2H left version

106
101
Place PIN (max. diameter 6 mm, min. length 80 mm)

into opening and move control value until it stops
Fit screw plug 2 (1 with NR2H left version)
DANGER!
To deactivate mechanical manual actuation
Stop engine
Fit plug (item 106) on electrical actuation device
(item 101)
Check that plug (item 106) and screw 1 and 2 are
fitted and tightened
A
C
NR2H right version
C
Push/pull slider
B
Wing nut
Protective cover

106 electrical connection
Shifting process:
Set engine speed to idling speed
Unfasten wing nut and remove protective cover.
Rotate protective cover 180 upwards and fix it
again with wing nut to ensure it does not become
mislaid.
Remove plug (item 106) on electrical actuation
device (item 101)
To engage clutch push slider towards control
housing (limited by a stop)
To disengage clutch pull slider away from the
control housing (limited by a stop)
64
ZF 7500/7600 Series
Operation
DANGER!
To deactivate mechanical manual actuation
Stop the engine
Fit plug (item 106) on electrical actuation device
(item 101)
Shift push/pull slider to neutral position
Fit protective cover
Check that plug (item 106) and cover are fitted and
tightened
65
Operation
7.4
Operation with emergency shift

(Come home screws, not with NR2,
NR2B, NR2H transmissions)
If no power transmission occurs despite manual control,

(section 7.3) there is a fault in the transmission. In such
cases, the clutch discs of the shift clutches can be
pressed together mechanically by means of the clamp
bolts in the transmission (some transmission
configurations e.g. with intermediate shaft PTO may not
allow this access to the clamp bolts).
The clutches for counter-enginewise direction of
rotation and for enginewise direction of rotation both
have three clamp bolts which are accessible from outside
the transmission (front end of housing opposite the
transmission input side). The openings in the housing
are sealed with screw plugs.
The emergency control can be used under the following
conditions:
a) The oil pressure at measuring point 2 must be at
least 3.5 bar in the transmission at operating
temperature. In this case, unrestricted operation is
permissible.
b) No oil pressure at measuring point 2, but
lubricating oil pressure at measuring point 22 is at
least 1 bar at normal operating temperature with an
input speed of approx. 40% of normal operating
speed. In this case, max. 50% engine speed is
permissible.
The special key required for operating the emergency
control (SW 8 Allen key, length 280 mm) is available
from ZF under order number 1X56 137 055.
Only one shift clutch in the transmission may be closed
at any one time, otherwise power will be transmitted in
both directions of rotation and the transmission will
jam. When the emergency control is in use, the normal
transmission actuation system must be rendered
inoperative for the same reason. The marks on the
graduated circle should be aligned with the neutral
position of the quadrant located on the control unit.
66
ZF 7500/7600 Series
ZF 7500/7600 Series
Operation
The emergency control must be operated as follows:

1.
Stop the engine
2.
Decide which clutch is to be used
3.
Loosen and remove the screw plugs
4.
Insert the key as far as possible in one of the

three holes. Turn the engine or transmission
input shaft slowly until clamp bolt contacts
Allen key.
(The direction of rotation is unimportant, but the
required position must be reached after a
maximum 120 turn.)
With draw Allen key approx. 30 mm and turn
engine or transmission input shaft very slightly
(approx. 1) until Allen key can be inserted in
clamp bolt.
Tighten the clamp bolt right down by turning it
several times in clockwise direction. Repeat this
procedure with the other two clamp bolts by
inserting the key in the appropriate openings;
turning the input shaft will not be necessary. Then
tighten all three bolts to a torque of approx. 50 Nm.
Close the bores in the housing using the screw
plugs.
5.
6.
44
Emergency control for enginewise direction of rotation
34
Emergency control for counter-enginewise direction of rotation
With the emergency control set up in this way, the

engine can be started and the vessel can be taken to the
nearest repair dock.
To make the emergency control inoperative, proceed
as above (steps 1 to 4). Then, turn clamp bolt
anticlockwise as far as the stop (a torque of approx. 10
Nm is necessary). Repeat the procedure with the other
two clamp bolts. Finally, seal the bores in the housing
using the screw plugs.
67
Maintenance
ZF 7500/7600 Series
Maintenance
8.1
Maintenance schedule
Regular Maintenance
Maintenance
level
Operating
hours
Limit
A1
every day
of operation
3 months
see also K1, K2
A2
500
6 months
A3
2000
2 year
A4
4000 to 6000
5 years
A5
during every
basic overhaul
of engine
operating
condition
of transmission
Additional maintenance jobs on new or overhauled

transmissions, necessary only once
Maintenance
level
Procedure
Limit
Z1
50 to 100
12 months
Necessary measures for protection against

corrosion after a long period out of use
Maintenance
level
Procedure
K1
every 10 20 days
up to 6 months
K2
at end of
operating period
9 months
K3
at end of
operating period
max. 36 months
The operating hours given in the maintenance schedule

as well as the test and maintenance jobs given in the
maintenance work plan are based on average operating
data. Therefore, these are only guidelines. Under certain
operating conditions, it may be necessary to change the
time schedule and maintenance work plan.
Also, it is useful to adapt the operating hours given in
the maintenance schedule to the corresponding engine
maintenance interval, as long as the operating hours
given are not exceeded to a great extent. This is
especially applicable for maintenance levels A 4, A 5
and K.
The necessary protective measures against corrosion
after a long period out of use for a transmission installed
in a vessel are largely dependent on temperature
fluctuations, atmospheric humidity and the salt content
of the atmosphere in the machine room. Therefore the
recommended measures and data can only be seen as
rough guide values. In case of doubt, we recommend
using the same protective measures for marine gears as
for engines.
For a period up to 3 months out of use, in normal cases,
no protective measures against corrosion are necessary.
Limit
If the period without use is less than 6 months ,we
recommend that measure K 1 be carried out every 10 to
20 days. Before the craft is put into operation again, it
may be necessary to change the oil (see Maintenance
stage Z 1), depending on the condition of the oil
already in the transmission
K 2 is a preservation measure and should be
implemented immediately at the end of operation if a
period of more than 6 months without use is intended.
K 2 may also be implemented instead of K1 in the case
of shorter periods out of use.
K 3 is a long-term preservation measure and allows for
a period of max. 36 month without marine gear use.
Preservation can also be carried out acc. to K 2 instead
of K 3. This preservation measure must, however, be
repeated every 9 months.
68
ZF 7500/7600 Series
8.2
Protection against corrosion, preservation
K 1 Protection against corrosion

Start the engine and let it run at idling speed or slightly
faster for at least 5 minutes in order to lubricate the
tranmission thoroughly. The tranmission can be in
neutral, or in either direction of rotation. Repeat this
procedure every 10 or 20 days. Before putting marine
gear into service again, check the oil for condensation
water (emulsion effect).
This check must take place immediately after the engine
has been turned off - the oil must not show any turbid
aspect.
K 2 Preservation
After operation, drain the transmission oil and top up
with anti-corrosion oil to at least the low oil level mark
on the dipstick (see description of maintenance work).
Use anti-corrosion oil grades C 642 or C 644 acc. to
MIL-L-21 260.
Immediately afterwards, allow the engine to run in the
position enginewise rotation or counter-enginewise
rotation for approx. 5 to 10 minutes at increased
engine speed (max. 50% of the nominal operating
speed). Shut off the engine. Protect exterior steel parts
against corrosion.
Maintenance
K 3 Long term preservation

Drain off the oil in the transmission after operation and
fill with anti-corrosion oil up to the low oil level mark
on the dipstick (see description of maintenance work).
Use anti-corrosion oil C 642 or C 644 acc. to MIL-L-21
260.
Immediately afterwards, allow transmission to run in
the position enginewise rotation or
counterenginewise rotation for approx. 5 to 10
minutes at increased engine speed (max. 50% of the
nominal operating speed). Shut off the engine, then
completely fill the transmission with anti-corrosion oil.
Protect the exterior steel parts against corrosion.
Putting into operation after the K 3 long term
preservation procedure
Drain off anti-corrosion oil down to usual oil level and
allow the engine to run for approx. 5 minutes. Then,
drain off the anti-corrosion oil completely and fill
transmission with the specified oil grade (see
Maintenance work 141).
Extension of preservation period for another 9 months

Allow engine to run for approx. 5 minutes. Then, drain
off the preservation oil and fill the transmission with the
correct grade and amount of oil specified for operation.
Start the engine again and allow to run for at least 15
minutes. During this period, the transmission selector
clutches must be actuated several times. Then, repeat
K2 preservation procedure.
Putting into operation after the K 2 preservation
procedure
Start the engine and allow to run for approx. 5 minutes
so that any condensation water which may have
collected in the transmission is mixed with the
anticorrosion oil. Drain off the anti-corrosion oil and
fill transmission with the specified oil grade (see
Maintenance work 141).
69
Maintenance
8.3
ZF 7500/7600 Series
Maintenance work plan
Maintenance level
Maintenance jobs
Regular
A5
A4
Tools required
One-off
A3
A2
A1
Z1
101
Check oil level
none
102
Turn oil filter handle
none
103
Visual check
none
121
Clean outside of transmission
none
122
Re-tightening all screw/bolt connections

accessible from outside
123
Check control position settings
none
124
Lubricate external moving parts
none
141
Change oil
tool kit
142
Clean oil filter
tool kit
161
Visually check flexible coupling
none
162
Visually check flexible engine and transmission mounting
none
163
Visually check clutch discs
tool kit
164
Visually check gearing
tool kit
165
Check oil pump
W1
166
Check control unit
W1
167
Check actuating unit
W1
Clean oil cooler
------
173
Check input shaft seal
none
174
Check output shaft seal
none
104
tool kit
168
169
170*
172*
200* Basic transmission overhaul

T1 + T1 + T1
T2 + T2
NB
--
--
T1
* = See workshop manual for instructions

NB = Spare parts as necessary
70
Spare parts required

T1, T2 = See spare parts list for part sets
W1
= See operating instructions for tool kit
W2
= See workshop manual for tool kit
W2
ZF 7500/7600 Series
8.4
Maintenance
Special versions / Special scope of supply
If there are differences in the operation and

maintenance of special versions or special scope of
supply which are not dealt within the following
sections, refer to the appropriate specifications.
8.4.1 Special scope of supply - Transmissions with
additional trailing oil pump (item 18)
This oil pump is mounted on the transmission housing
at the opposite end to the input or on the input end of
the transmission housing .
It is driven by a layshaft coming off the transmission
output shaft. The pump supplies oil to the oil circuit in a
constant direction, regardless of the direction of rotation
of the output shaft (see diagram, section 6.10). During
operation with engine stationary and propeller trailing,
the pump is responsible for supplying lubricating oil to
the transmission. It is thus permissible to operate in this
mode for an unlimited period of time.
Additional operating requirements (see section 7.2)
During operation with engine stationary and propeller
trailing, the transmission actuator must be in neutral.
8.5
Trouble shooting
If defects occur in the drive system, the transmission is

very often assumed to be the cause. But, in many cases,
faults may arise due to external influences on the
transmission.
The trouble shooting table below lists the principle
faults which may occur, their possible causes and their
remedy.
Oil pressure need not be monitored when the engine is
stationary. The transmission oil temperature must be
monitored for compliance with the data in section 2
There is another measuring point (41) for oil
temperature monitoring available (see section 6.10.2).
Additional note for maintenance
If it proves impossible to rectify a fault using this

information, you are advised to contact the nearest ZF
service station. If you wish to repair faults or perform
repairs on the transmission yourself, you should request
a copy of the workshop manual and the transmission
spare parts list from the service department at our
Friedrichshafen plant.
The Maintenance jobs 101 and 102 must also be carried

out daily during operation with stationary engine and
rotating propeller (see section 7.2).
71
Maintenance
Fault
Ecessive gear oil temperature
(measuring points 11*, 12* and 41*)
ZF 7500/7600 Series
Possible cause
Remedial action
Insufficient water flow through cooler
Increase water flow
Sludge in oil cooler
Clean water end of cooler,see

workshop manual
Gear ratio not properly engaged,

clutch slipping
Adjust shift mechanism
Transmission oil temperature too

low
Excessive water flow through cooler
Decrease water flow
Pressure before oil cooler and filter

too high (measuring point 5*)
Clogged filter
Clean filter and drain off oil

sludge
Clogged oil cooler
Clean oil side of cooler
No oil in transmission
Add oil
Wrong rotation direction at

transmission input
Use special transmission

version
Defective indicator
Repair fault
Oil viscosity too low
Use a recommended oil grade

(see list of lubricants)
Incorrect oil pump ratio
Select oil pump ratio in

accordance with engine
operating speed range
Defective oil pump
Renew
Pressure valve leaking
Repair fault
Time switch for pressure modulation

defective
See remedy for clutch slipping
No operating oil pressure

Operating oil pressure too low

If the fault cannot be rectified, the lubricating oil supply to the transmission is also at risk.
Proceed at reduced engine speed until repairs can be carried out.
Engine stalls following rapid change
from Ahead to Astern
72
Engine idle speed too low
Increase engine idle speed

range
Change in direction effected too

quickly or effected at excessive craft
speed
Change direction as
recommended in section 7.1.3
ZF 7500/7600 Series
Maintenance
Fault
Possible cause
Remedies
Excessive operating oil pressure

(meas. points 2*, 21 * and 27*)
Oil viscosity too high
Use a recommended oil grade (see list

of lubricants)
Incorrect oil pump ratio
Select oil pump ratio in accordance

with engine operating speed range
Drive interrupted between

transmission input and output;
clutch not transmitting torque
For mechanical transmission actuation, Adjust

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

electrical system defective
Check: Actuation of manual selector
lever renders normal operation
Repair fault in electrical system
No operating oil pressure
See remedy for no or insufficient

operating oil pressure
Drive between transmission input For possible causes and remedies refer
and output cannot be interrupted; to clutch not transmitting torque
clutch does not
open
*See Monitoring diagram section 6.10
73
Maintenance
Fault
ZF 7500/7600 Series
Possible cause
Remedies
Clutch slips at high engine speeds Insufficient operating oil pressure

(meas. points 2*, 21* and 27*)
See remedy for insufficient operating

oil pressure. If the fault cannot be
rectified on board, proceed with
reduced engine speed - so that the
clutch does not slip - until repairs can
be carried out. Avoid changes in
direction, but if unavoidable the
vessel propeller should be almost at a
standstill and the engine idle speed
as low as possible.
Oil level sinks rapidly (as indicated Leaks at housing joints, oil pipes or
by the dipstick); see section 6.11.1 shaft seals
oil level check
Oil cooler leaking into cooling water
system
Repair mechanical fault

Repair fault, renew cooler if necessary
Oil level increases (see section

6.11.1 oil level check)
Water entering the oil circuit from the Repair mechanical fault
cooling system
Transmission too loud in certain

speed ranges
Torsional vibration resonance of drive Avoid critical speed range. Install a

unit in engine speed range
more suitable torsionally flexible
coupling (see section 6.4)
Transmission too loud in

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

unit in engine idle speed range
Engine stalls during rapid change

from ahead to astern
Engine idle speed too low
Increase engine idle speed
Change in direction effected too

too high
Changes in direction should be quickly

or with travel speed carried out as per
section 7.1.3 recommendations.
74
ZF 7500/7600 Series
8.6
Maintenance
ZF service stations, Spare parts
If a transmission fault cannot be rectified using the remedies in section 8.5 Trouble shooting, please contact the
nearest ZF service station.
A list of ZF service stations with the current telex and
telephone numbers can be obtained from ZF Friedrichshafen AG, or the internet www.zf-marine.com.
When carrying out repairs, use only genuine ZF spare
parts.
Please give the following information when ordering
spare parts and making enquiries
- Model type
- Serial number
- Spec./parts list number
- Transmission ratio
This information is stamped on the transmission type
plate.
In the case of marine gears with classification, note that
spare parts without classification are always supplied under the item numbers stated. If a version with classification is required, the desired type of test must be stated in
addition to the item number. This is also necessary, if the
transmission spec./parts list is quoted when ordering, and
when requesting exchange units.
75
Maintenance
76
ZF 7500/7600 Series
ZF 7500/7600 Series
Maintenance system job sheets
9 Maintenance system job sheets

Page
101
Check oil level ................................................................................................................................................... 2
102
Turn oil filter handle .......................................................................................................................................... 6
103
Carry out visual check ....................................................................................................................................... 8
121
Clean outside of transmission ..........................................................................................................................10
122
Retighten all screw/bolt connections accessible from outside......................................................................... 12
123
Check control position settings........................................................................................................................14
124
Lubricate external moving parts ...................................................................................................................... 16
141
Change oil ........................................................................................................................................................18
142
Clean the oil filter and filter chamber .............................................................................................................. 20
161
Visually check flexible coupling .....................................................................................................................22
162
Visually check flexible engine and transmission mounting (if fitted).............................................................24
163
Visually check clutch discs..............................................................................................................................26
164
Visually check gearing.....................................................................................................................................28
165
Check oil pump ................................................................................................................................................30
166
Check control unit............................................................................................................................................34
167
Check actuation device (mechanical, electrical)..............................................................................................38
168
Re-calibrate gauge ...........................................................................................................................................44
169
Clean oil cooler ................................................................................................................................................46
173
Check input shaft seal ......................................................................................................................................48
174
Check output shaft seal ....................................................................................................................................50
ZF 7500/7600 Series
MAINTENANCE SYSTEM JOB SHEET

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed
in conjunction with
maintenance job no.
Time required in
minutes
101
A1
----------
10
Description of
101
maintenance work
Check oil level
Only withdraw the oil dipstick when the engine is at a standstill, otherwise risk of burns due to
hot oil spraying out.
Safety measures
Only top up the oil when the engine is at a standstill, otherwise risk of burns due to hot oil
spraying out.
Tools
------------------------------
Parts
------------------------------
Material
Non-fraying cloth
Test equipment
------------------------------
Procedure
see next page
Location:
2
Date:
Page: 1
of: 2
ZF 7500/7600 Series

During initial fill, following repairs and after cleaning
the oil filter, note that some of the oil remains in the oil
cooler, in the oil lines and in the filter chamber rather
than flowing back into the transmission housing. You
should therefore recheck the oil level after a short period of operation.
ZF 7550 V
The correct oil level is between the upper and lower

marks on the oil dipstick.
max.
min.
004 666
To add oil, unscrew the oil filler plug and top up the oil.
ZF 7550 V
3
ZF 7500/7600 Series
During initial fill, following repairs and after cleaning

the oil filter, note that some of the oil remains in the oil
cooler, in the oil lines and in the filter chamber rather
than flowing back into the transmission housing. You
should therefore recheck the oil level after a short period of operation.
ZF 7550 NR2H
The correct oil level is between the upper and lower

marks on the oil dipstick.
max.
min.
004 666
To add oil, unscrew the oil filler plug and top up the oil.
ZF 7550 NR2H
4
ZF 7500/7600 Series
ZF 7500/7600 Series

Transmission type:
BW 7500/7600 Series
Maintenance
job no.
Maintenance level
If possible, to be performed in conjunction

with maintenance job no.
Time required in
minutes
102
A1
----------
Description of
maintenance
work
102
Safety measures
------------------------------
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
see next page
Location:
6
Turn oil filter handle
Date:
Page: 1
of: 2
ZF 7500/7600 Series
Slowly rotate the handle of the slot-type filter clockwise

through 1 to 2 full turns.
ZF 7500 A
ZF 7550 A
ZF 7550 NR2H
7
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
103
A1
121
10
Description of
103
maintenance work
Carry out visual check
Safety measures
Always keep your distance when visually checking rotating parts, otherwise risk of getting
caught in the rotating part
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
see next page
Location:
Date:
Page: 1
of: 2
ZF 7500/7600 Series
Check for leaks at the points the input shaft and output
shaft protrude from the transmission housing as well as
at the oil line ports, monitoring equipment ports and
coolant ports (visual check).
ZF 7550 A
ZFW 7540
ZF 7550 NR2H
9
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
121
A2
103
30
Description of
121
maintenance work
Clean outside of transmission
Safety measures
Only use cleaning products that meet the requirements of the regulations for the prevention of
accidents.
Tools
Ships tools
Parts
Cleaning products
Material
------------------------------
Test equipment
------------------------------
Procedure
see next page
Location:
10
Date:
Page: 1
of: 2
ZF 7500/7600 Series
Clean the outside of the transmission using cleaning

products to make the visual check easier see job 103.
Important: Do not allow cleaning products to come
into contact with rubber parts, hose lines and shaft
seals.
ZF 7550 A
ZF 7550V
ZF 7550 NR2H
11
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
122
Z1
----------
20
Description of
122
maintenance work
Retighten all screw/bolt connections accessible from outside.
Safety measures
Only retighten the connections when the transmission is at a standstill.
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
see next page
Location:
12
Date:
Page: 1
of: 2
ZF 7500/7600 Series
Retighten all accessible screw/bolt connections.

Pay particular attention to the following connections:
Engine to flexible coupling
Flywheel housing to bell housing
Mounting bracket to transmission
Mounting bracket to foundation.
Also check the ports/connections to and from the oil
cooler as well as the monitoring equipment
ports/connections. Retighten them as necessary.
You should retighten the bolts to the specified torque
when the transmission is cold (approx. 20 C).
ZF 7550 A
ZFW 7540
ZF 7550 NR2H
13
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
123
A2
----------
15
Description of
123
maintenance work
Check control position settings
Safety measures
Block the engine starting device,

otherwise risk of the craft moving off.
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
see next page
Location:
14
Date:
Page: 1
of: 2
ZF 7500/7600 Series
Only required in the case of the mechanical transmission actuation version.
Action force 25 N when radius is 105 mm
124
104 123
103
24
24
121
122
30
24
24
3
10 10
8,1
120
103 Counter-enginewise position

104 Enginewise position
105 Control lever for mechanical actuation
121 End stop
122 Undefined position
(this range must be quickly bypassed)
123 Safe neutral range
124 Switch for warning interrupt
(special scope of supply)
004 974
105
Check the Astern position in the same way. The positions indicated must be safely and reliably obtainable.
Adjust the mechanism on the transmission linkage if
necessary. Under no circumstances must the control lever remain in the undefined range between Neutral
and Ahead or Neutral and Astern.
105
121
105
105
Loosen the mechanical connection between the transmission control lever and the transmission linkage or
pull-push cable.
Select Neutral on controls and move the transmission control lever to Neutral detent position.
Holes on the transmission control lever and shift linkage or on the yoke end of the pull-push cable must be
aligned.
Select Ahead on controls and move the transmission
control lever as far as the enginewise or counter-enginewise detent position. Hole in the transmission
control lever must be aligned with the hole in the linkage or on the yoke end.
137
004 496
15
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
124
A2
----------
15
Description of
124
maintenance work
Lubricate external moving parts

(Only required in the case of the mechanical transmission actuation version).
Safety measures
------------------------------
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Lightly lubricate the moving parts of the mechanical transmission actuator (yoke end on
transmission control lever, linkage connections and connection to controls) with lithium
saponified grease.
Location:
16
Date:
Page: 1
of: 2
ZF 7500/7600 Series
17
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
141
A3
142 / 163 / 164
30
Description of
141
maintenance work
Change oil
Safety measures
Block the engine starting device.

Change the oil at an oil temperature of max. 40 50 C, otherwise risk of burns.
Collect used oil in a suitably large oil container, otherwise risk of environmental pollution.
Oil capacity:
ZF 7500 / 7549 / 7550 / 7600 / 7650
75dm3
ZF 7500 A/ 7550 A / 7600 A / 7650 A
75dm3
ZF 7500 V / 7550 V / 7600 V / 7650 V
75dm3
ZF 7540 / W 7540 / 7640 / 7641 / 7645 / 7646 80dm3
ZFW 7500 / 7510 / 7661 / 7666 / 7561 /
7566 / W 7610 / W 7615
120dm3
ZF 7550 NR2 / 7650 NR2
50dm3
ZF 7550 NR2B / 7650 NR2B
50dm3
ZF 7550 NR2H / 7650 NR2H
ZF 7549 C / 7500 C / 7850 C
50dm3
Tools
Ships tools
Parts
New gasket/sealing rings
Material
Oil grade:
Approved oils as per applicable ZF List of Lubricants TE-EL 04 for ZF Marine
Transmissions. The currently applicable list of lubricants is supplied with the transmission. It
can be ordered from any ZF service center and it is available on the internet (see section 3).
Test equipment
------------------------------
Procedure
see next page
Location:
18
Date:
Page: 1
of: 2
ZF 7500/7600 Series
If possible, perform this job in conjunction with

maintenance job 142.
Withdraw the oil dipstick, unscrew the oil drain plug
and drain the oil.
Remove the oil by suction if the transmission is fitted
with an oil suction device.
082958
After fitting a new seal, screw in and tighten the oil

drain plug.
ZF 7550 A
Close the oil suction device if one is fitted.
To add oil, unscrew the oil filler plug or take off the inspection hole cover.
Add fresh oil.
Oil capacity:
ZF 7500 / 7549 / 7550 / 7600 / 7650
75dm3
ZF 7500 A/ 7550 A / 7600 A / 7650 A 75dm3
ZF 7500 V / 7550 V / 7600 V / 7650 V 75dm3
ZF 7540 / W 7540 / 7640 / 7641 /
7645 / 7646
80dm3
ZFW 7500 / 7510 / 7661 / 7666 /
7561 / 7566 / W 7610 / W 7615
120dm3
ZF 7550 NR2 / 7650 NR2
50dm3
ZF 7550 NR2B / 7650 NR2B
50dm3
ZF 7550 NR2H / 7650 NR2H
ZF 7549 C / 7500 C / 7850 C
50dm3
Then fit a new seal on the oil filler plug (or a new gasket
on the inspection hole cover) and re-insert the oil filler
plug (or re-attach the inspection hole cover).
Finally, check the oil level - see maintenance job 101.
Using the oil dipstick is the only way to obtain an accurate reading.
ZF 7550 A
ZFW 7510
19
ZF 7500/7600 Series

ZF 7500/7600 Series
Transmission type:
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
142
A3
141 / 163 / 164
30
Description of
142
maintenance work
Safety measures
Clean the oil filter and filter chamber.

Collect used oil in a suitably large oil container, otherwise risk of environmental pollution.
Escaping oil quantity: Approx. 2 dm3
Tools
Ships tools
Parts
Gasket
Material
Oil grade:
Approved oils as per applicable ZF List of Lubricants TE-EL 04 for ZF Marine Transmissions. The currently applicable list of lubricants is supplied with the transmission. It can be
ordered from any ZF service center and it is available on the internet (see section 3).
Test equipment
------------------------------
Procedure
see next page
Location:
20
Date:
Page: 1
of: 2
ZF 7500/7600 Series

maintenance jobs 141, 163 and 164.
Turn the oil filter handle as described in maintenance
job 102 when the transmission is at a standstill.
ZF 7550 A
Unscrew sludge drain plug A and bleed the filter chamber; collect the escaping oil in a container.
Escaping oil quantity approx. 2 dm3.
Open pure oil drain B and collect the escaping oil in a

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

spirit; turn the handle several times when doing this (do
not dismantle the filter). Then clean the filter chamber
using diesel oil or cleaning grade spirit.
Always use a brush for cleaning, never fraying cloths or
mechanical means such as screwdrivers, scrapers, etc.
Fit a new filter gasket and seal before installing the filter and sludge drain plug.
Installation procedure is the reverse of removal procedure.
ZF 7550 A
B
ZF 7550 NR2H
21
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
161
A4
----------
30
Description of
161
maintenance work
Visually check flexible coupling
Safety measures
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
see next page
Location:
22
Date:
Page: 1
of: 2
ZF 7500/7600 Series
Check that the rims of the flexible coupling are in perfect condition. To do this, slowly turn over the engine
and check the rubber parts by looking through the inspection hole in the bell housing.
004 681
Check the rubber parts for signs of cracking, embrittlement and overheating.
004 682
Check the markings (if there are any) for distortion.
004 683
23
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
162
A4
----------
15
Description of
162
maintenance work
Visually check flexible engine and transmission mounting (if fitted)
Safety measures
------------------------------
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
Check that the rubber-metal mountings on the engine and transmission are in perfect condition.
The rubber parts must not show any signs of cracking, embrittlement or other damage.
Location:
24
Date:
Page: 1
of: 2
ZF 7500/7600 Series
25
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
163
A4
141 / 142 / 164
15
Description of
163
maintenance work
Visually check clutch disks
Safety measures

Remove all parts which could fall into the transmission once the inspection hole cover has been
opened (mechanics should empty their breast pockets).
Tools
Ships tools
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
see next page
Location:
26
Date:
Page: 1
of: 2
ZF 7500/7600 Series
It is advisable for this job to be performed when

changing the oil see maintenance job 141.
Remove the inspection hole cover.
082 477
ZF 7550 V
Check the clutch discs. The discs must not show any
signs of overheating and it must be possible to move
them in axial direction (see table for disc play per pack).
Also check the play between the individual discs
ZFW 7510
.
Number of outer
discs
3084 302 003
4.00 - 0.05 mm
Number of outer
discs
3084 302 073
4.25 - 0.05 mm
Number of outer
discs
0501 211 377
4.50 - 0.05 mm
Permissible
disc play
ZF 7550 A
10
2.0 - 2.4 mm
ZF 7550 V
10
2.0 - 2.4 mm
ZF 7540
10
2.0 - 2.4 mm
ZF W7540
10
2.0 - 2.4 mm
ZF 7550 NR2H
10
3.6 - 4.0 mm
Transmission
version
27
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
164
A4
141 / 142 / 163
15
Description of
164
maintenance work
Visually check gearing
Safety measures

Remove all parts which could fall into the transmission once the inspection hole cover has been
opened (mechanics should empty their breast pockets).
Tools
Ships tools
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
see next page
Location:
28
Date:
Page: 1
of: 2
ZF 7500/7600 Series
It is advisable for this job to be performed when

changing the oil see maintenance job 141.
082 477
ZF 7550 NR2H
Check the clutch discs. The discs must not show any
signs of overheating and it must be possible to move
them in axial direction (see table for disc play per pack).
Also check the play between the individual discs
ZF 7550 NR2H
29
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
165
A4
----------
180
Description of
maintenance work
165
Check oil pump

Engine-driven pump
Trailing pump
(primary pump)
(secondary pump) not fitted in basic transmission
Safety measures
Block the engine starting device if you intend to remove the oil pump.
Tools
Tool kit WI
Parts
------------------------------
Material
Set of seals and gaskets
Test equipment
------------------------------
Procedure
see next page
Location:
30
Date:
Page: 1
of: 3
ZF 7500/7600 Series
Engine-driven pump (primary pump)

NOTE
The oil pump is a complete part and is not generally dismantled. However, checking or cleaning work may require the pump to be dismantled. Pay particular attention to inspecting the dismantled pump for scoring,
mounting play and impeller/pinion end play.
Removing and dismantling
Remove the pipes as necessary.
Remove the pump housing.
Clearly mark the pump components.
Remove the retaining ring from the pump shaft.
Pull off the drive gear.
Remove the Woodruff key.
Remove the bolts (2) from the pump cover.
Knock out the tapered pins (6) in the direction indicated by the arrow and remove the cover (1).
ZF 7550 A
1
Cover
Cover mounting bolt
Compression spring
Spring cup
Valve seat
3
4
Tapered pin
Assembling
NOTE
- Carefully clean the components.
- Check the components.
- Apply a thin coat of oil on moving parts.
If previously removed, install the spring (3) with a

preload of 510+20 N.
If previously removed, insert the valve seat (5) using
Loctite no. 275.
Lightly coat the mating face of the pump cover with
sealant and then mount it.
Insert the Woodruff key into the pump shaft.
Heat the drive pinion to approx. 85 C and slide it
onto the pump shaft.
Clip the retaining ring into the annular groove in the
pump shaft.
Lightly coat the mating face of the pump housing
with sealant and then mount it.
Install the pipes.
ZF 7550 V
31
ZF 7500/7600 Series
Engine-driven pump (primary pump)
NOTE
The oil pump is a complete part and is not generally dismantled. However, checking or cleaning work may require the pump to be dismantled. Pay particular attention
to inspecting the dismantled pump for scoring, mounting
play and impeller/pinion end play.
ZF 7550 NR2H
Remove the pipes as necessary.

Remove the pump (1) housing.
Clearly mark the pump components.
Remove the screws (6) from the drive gear (4).
Pull off the drive gear (4).
Remove the Woodruff key (2).
Remove the bolts (7) from the pump cover.
Remove the cover (8).
Pump
Fit-in key
O-ring
Drive gear
Retaining ring
Bolt drive gear
Bolt cover
Cover
Assembling
NOTE
- Carefully clean the components.
- Apply a thin coat of oil on moving parts.
The assembly and mounting is funded by reverse order as the removing and dismantling.
32
ZF 7500/7600 Series
1
2 3
4 5
Trailing pump (secondary pump)

NOTE
The oil pump is a complete part and is not generally dismantled. However, checking or cleaning work may require the pump to be dismantled.
When checking the pump, pay particular attention to ensuring that the end play is within the wear limit, see the
following chart. Check the pump components for traces
of running in.
Component
O-ring
Socket head bolt
Woodruff key
Drive gear
Retaining ring
Inner rotor
Outer rotor
Eccentric ring
End play
End play A
In new condition Wear limit
0.01 - 0.055 mm max. 0.15 mm
0.025 - 0.055 mm max. 0.1 mm
0.025 - 0.055 mm max. 0.1 mm
Eccentric ring
Inner rotor
Outer rotor

- Remove the pipes as necessary.
- Unscrew the mounting bolts from the oil pump.
- Lift off the oil pump (use a lever to help you if necessary).
- Unclip the retaining ring (5).
- Pull off the drive gear (4).
- Catch the Woodruff key (3).
- Remove the mounting bolts from the pump cover
and take off the cover.
- Remove the pump idler gear shaft and idler gear (6).
Assembling
NOTE
- Carefully clean the components
- Apply a thin coat of oil on the moving parts.
- Install the pump idler gear shaft and idler gear (6).
- Insert the pump components into the pump housing.
- Replace and securely bolt on the cover.
- Insert the fitted key (3) into the pump shaft.
- Heat the drive pinion (4) to approx. 85 C and slide
it onto the pump shaft.
- Clip the retaining ring (5) into the annular groove in
the pump shaft.
33
ZF 7500/7600 Series

ZF 7500/7600 Series
Transmission type:
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
166
A4
----------
120
Description of
166
maintenance work
Check control unit
Safety measures
Tools
Tool kit WI
Parts
Gaskets
Material
------------------------------
Test equipment
------------------------------
Procedure
see next page
Location:
34
Date:
Page: 1
of: 2
ZF 7500/7600 Series
2
3
4
56
5
6
57
12
14
1
8
9
10
11
15
16
17
18
19
13
31
32
33
20
34
21
35
36
22
23
24
25
55
54
53
52
51
50
49
26
27
28
29
30
37
38
39
40
47
41
42
46
48
45
44
43
Control unit (not NR2, NR2H, NR2B type transmissions)

20 Cover
1
Nut + bolt
21 Gasket
2
Lever
22 Dowel
3
Hexagon bolt
23 Woodruff key
4
Hexagon bolt
24 Selector shaft
5
Rivet
25 Needle cage
6
Plate
26 Screw plug
7
Hexagon nut
27 Ball
8
Adapter
28 Slotted stopper
9
Disc
29 Ball
10 Washer
30 Orifice
11 O-ring
31 Hexagon bolt
12 Bracket
32 Cover
13 Connector, upper section
33 Gasket
14 Switch
34 Piston
15 Compression spring
35 Rectangular ring
16 Washer
17 Washer
37 Bushing
18 Circlip
38 Washer
19 Detent pin
* Special scope of supply
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
Compression spring
Control housing
Ball
Stopper
Gasket
Screw plug
Control piston
Washer
Control piston
Stopper
O-ring
Piston
Bushing
Compression spring
Disc
Ball
Ball
Screw plug
Screw plug
Check control unit:

NOTE
If possible, replace the control unit in its entirety rather than dismantling it. If the control unit has to be dismantled
for cleaning purposes or in order to replace compression springs, it does not need to be reset afterwards. However,
the transmission must undergo a pressure test.
35
ZF 7500/7600 Series
2
9
10
11
1
8
12
13
14
15
16
17
18
4
20
3
19
21
22
23
Control unit NR2, NR2H, NR2B type transmissions

11 Ball
1
Hexagon bolt
12 Hexagon bolt
2
Hexagon bolt
13 Hexagon bolt
3
Snap ring
14 Cover
4
Compression spring
15 Orifice
5
Control housing
16 Piston
6
Spacer bush
17 Rectangular ring
7
Washer
18 Screw plug
8
Gasket
19 Gasket
9
Screw plug
10 Screw plug
21
22
23
Bushing
Control piston
Screw plug
Check control unit:

NOTE
If possible, replace the control unit in its entirety rather than dismantling it. If the control unit has to be dismantled
for cleaning purposes or in order to replace compression springs, it does not need to be reset afterwards. However,
the transmission must undergo a pressure test.
36
ZF 7500/7600 Series
37
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
167
A4
----------
180
Description of
167
maintenance work
Check actuation device (mechanical, electrical)
Safety measures
Tools
Tool kit WI
Parts
see part kits T1 and T2
Material
Cleaning products
Test equipment
------------------------------
Procedure
see next page
Location:
38
Date:
Page: 1
of: 5
ZF 7500/7600 Series
6
5
4
1
2

Mechanical actuation device (not with NR2, NR2H, NR2B type transmissions)
5
End cover
1
Hexagon bolt
6
Gasket
2
Screw plug
7
Hexagon bolt
3
Screw plug
4
Hexagon bolt
Checking the mechanical actuation device
Removing
- Remove the pipes as necessary.
- Remove the cover (5) with gasket (6).
39
ZF 7500/7600 Series
25
24
23
17
20
19
22
21
18
8
7
16
14
11
10
13
12
15
3
2
Electrical actuation device, version 3MGV (not with NR2, NR2H, NR2B type transmissions)
1
2
3
4
5
6
7
8
9
Socket head bolt

Screw plug
Screw plug
Socket head bolt
Outer casing
Gasket
Screw
Solenoid valve
Socket head bolt
10
11
12
13
14
15
16
17
18
Screw
Solenoid valve
Screw
Solenoid valve
Connector
Screw
Wiring harness, complete
Screw plug
Intermediate housing
19
20
21
22
23
24
25
Screw plug
Gasket
Circlip
Snap ring
Piston
Piston carrier
Snap ring
Checking electrical actuation device, version 3MGV

Removing
- Screw off the electrical connector.
- Remove outer casing (5) with gasket (6).
- Remove intermediate housing (18) with valves
and gasket (20).
- Loosen the cable lugs and remove the valves.
- Pull out the piston carrier with piston from the
control housing.
Checking
Check the electrical actuation components for wear and
replace them if necessary.
40
Assembling mounting
NOTE
- Renew parts according to T2.
ZF 7500/7600 Series
27
26
25
19
22
21
20
10
24
23
11
18
16
13
12
15
14
17
6
3
2
Electrical actuation device, version 2MGV (not with NR2, NR2H, NR2B type transmissions)
1
2
3
4
5
6
7
8
9
Socket head bolt

Cap nut
Screw plug
Socket head bolt
Outer casing
Threaded bushing
Gasket
Pin
Screw
10
11
12
13
14
15
16
17
18
Solenoid valve
Socket head bolt
Screw
Solenoid valve
Screw
Solenoid valve
Connector
Screw
Wiring harness, complete
19
20
21
22
23
24
25
26
27
Screw plug
Intermediate housing
Screw plug
Gasket
Circlip
Snap ring
Piston
Piston carrier
Snap ring
Checking the actuation device, electrical

Removing
- Screw off the electrical connector.
- Remove outer casing (5) with gasket (7).
- Remove intermediate housing (20) with valves
and gasket (22).
- Loosen the cable lugs and remove the valves.
- Pull out the piston carrier with piston from the
control housing.
Assembling mounting
NOTE
Checking
41
ZF 7500/7600 Series
16
17
18
19
10
11
2
8
12
13
14
28
21
22
27
23
26
21
20
22
24
15
25
Electrical actuation device for NR2, NR2H, NR2B type transmissions

11 Hexagon bolt
1
Screw plug
12 Screw
2
Screw plug
3
Screw plug
13 Cover
4
Hexagon bolt
14 Control housing
5
Hexagon bolt
15 Screw
6
Cover
16 Screw plug
7
Gasket
17 Ball
8
Control piston
9
Gasket
19 Dowel
10 Screw
20 Gasket
21
22
23
24
25
26
27
28
Solenoid valve
Screw
Gasket
Outer casing
Screw
Wiring harness
Screw
Connector
Checking the actuation device, electrical
Checking
Removing

1. Remove the pipes as necessary.

2. Screw off the electrical connectors.
3. Remove the outer casing (24) with gasket (23).
4. Remove the control housing (14) with valves and
gasket (20).
5. Loosen the cable lugs and remove the valves.
6. Remove the covers (6) and (13).
7. Remove the control piston (8).
42
Check the control piston (8) and the control piston hole
in the housing (14) for damage and protect against future damage.
Assembling - mounting
NOTE
ZF 7500/7600 Series
43
ZF 7500/7600 Series

ZF 7500/7600 Series
Transmission type:
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
168
A4
----------
----------
Description of
168
maintenance work
Re-calibrate gauge
Safety measures
------------------------------
Tools
Tool kit
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
see next page
Location:
44
Date:
Page: 1
of: 2
ZF 7500/7600 Series

Check that the oil pressure and oil temperature gauges
display the correct values.
Option 1:
Connect calibrated gauges in parallel and compare the
displayed values. The error (difference) must not be
more than 10 % in the operating range concerned.
Option 2:
Remove the gauges and have them re-calibrated or use
replacement gauges.
45
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
169
A4
----------
60
Description of
169
maintenance work
Clean oil cooler
Safety measures
------------------------------
Tools
Tool kit WI
Parts
------------------------------
Material
Set of seals and gaskets
Test equipment
------------------------------
Procedure
see next page
Location:
46
Date:
Page: 1
of: 2
ZF 7500/7600 Series
General information
ZF 7550 A
Extract from manufacturers specifications:

Clean the heat exchangers at regular intervals to ensure
consistent performance. The level of contamination
will depend on the application location; therefore, you
should keep track of the operating hours and determine
the cleaning interval yourself.
Heat exchanger disassembly procedure
1. Mark the position of the attached flanges in relation
to each other.
2. Remove the pipes as necessary.
3. Unscrew the fixing nuts on the oil cooler and remove
the oil cooler.
4. Unscrew the fixing bolts from the cooler. Remove
the cover and water connection housing. Collect the Orings.
5. Pull the pipe bundle out of the cooler housing. Collect the O-rings and bush.
Cleaning the oil side
1. Flush the coolers using a suitable cleaning product.
Flush against the normal oil flow direction to loosen
any dirt in particular debris from multi-disk clutches
and band brakes deposited on the oil cooler blades.
This dirt will be flushed out by the cleaning product.
Place a suitable filter in the main flow so that the
flushed out impurities can be separated from the cleaning product. You should continue cleaning until inspection reveals that the cleaning product flowing out is as
pure as the cleaning product flowing in..
ZF 7550 NR2H
2. If coolers cleaned in this way are kept in storage as
spare parts, i.e. not immediately reinstalled nor flushed
with transmission oil, they must be flushed with a preserving agent.
Cleaning the water end
Check the contamination before cleaning the water
end. If a greasy coating of lime is present, the water end
must be degreased before cleaning.
Flushing with water and anti-liming agent removes the
lime; a 10 to 15% solution of hydrochloric acid may
also be used. An inhibitor additive must be added to
this solution to prevent it from reacting with the metal
surfaces.
After cleaning, thoroughly flush the water end with clean water. Then fill the oil end with the same oil that is
to be used in subsequent operation. Then drain the oil.
Cleaning will be much more effective and cleaning
time shorter if circulation is in the opposite direction to
circulation during normal operation, both at the oil end
and at the water end.
Assembling the heat exchanger
6. Insert the O-ring into the cooler housing.
7. Thread the pipe bundle into the cooler housing.
8. Turn the cooler and insert the O-ring and bush.
9. Install the cover and water connection housing with
O-ring. (See marking for position.)
Checking
After assembly, check the oil end and the water end.
The pressure indicated on the drawing or the type plate
(oil and water end) must not be exceeded.
47
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
173
A4
121
15
Description of
173
maintenance work
Check input shaft seal

(in conjunction with maintenance job 121 if possible)
Safety measures
------------------------------
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
see next page
Location:
48
Date:
Page: 1
of: 2
ZF 7500/7600 Series

Check the input shaft seal for leaks. Collect any escaping oil.
Check the oil level at suitable intervals and top up the
oil as necessary.
Replace the input shaft seal as soon as possible.
ZF 7550 A
ZF 7550 A
ZF 7550 NR2H
49
ZF 7500/7600 Series

Transmission type:
ZF 7500/7600 Series
Maintenance
job no.
Maintenance level
in conjunction with
maintenance job no.
Time required in
minutes
174
A4
121
15
Description of
174
maintenance work
Check output shaft seal

(in conjunction with maintenance job 121 if possible)
Safety measures
------------------------------
Tools
------------------------------
Parts
------------------------------
Material
------------------------------
Test equipment
------------------------------
Procedure
see next page
Location:
50
Date:
Page: 1
of: 2
ZF 7500/7600 Series

Check the output shaft seal for leaks. Collect any escaping oil.
Check the oil level at suitable intervals and top up the
oil as necessary.
Replace the output shaft seal as soon as possible.
ZF 7550 A
ZF 7550 A
ZF 7550 NR2H
51
ZF 7500/7600 Series
Sealers
(extract from the manufacturers instructions for use)
The manufacturers instructions for use are always binding.
HYLOMAR
Universal seal SQ 32 M-Special, for use on housing and
cover mating faces).
Permanent plastic universal seal SQ 32M Special
(CFC-free), MARSTON, lchemie GmbH, 53909
Zlpich, Germany, tel. (022 52) 2566 and 2725.
Instructions for use
Degrease the mating faces (Hylomar Cleaner) before
use and then apply HYLOMAR on both sides. Wait for
the sealant to dry (approx. 10 minutes) before commencing assembly. Retighten the bolts after 10-15 minutes. If the faces are planed flat, sealer only needs to be
applied on one side.
Grease
See List of Lubricants
Cleaners (for removing grease from tapered surfaces

for oil press fits). Acetone, spirits (caution: Highly inflammable) or standard cleaners that do not leave a
greasy residue.
Glycerin for oil press fits in Series BW 160 through

195. Oil or glycerin can be used for fitting in the case of
other transmission types.
We recommend you use HYLOMAR CLEANER to remove old gasket residues, oil and grease.
Temperature resistant from -50 C to +250 C.
Loctite: No. 640

No. 275
Loctite Deutschland GmbH, Munich
Loctite Europa GmbH, Vienna
Instructions for use
Clean the parts. Apply enough of the product to fill the
gap. Join the parts together and let the product harden.
Dyken Read DX-296 for tooth flank contact pattern acceptance in the case of transmissions subject to classification society acceptance.
Dyken-Read DX-296/8 oz, Helling,

Sandorkai 1, 21107 Hamburg, tel. (040) 376010,
telex 213611 + 2165082, fax (040) 37601100
Made in Germany.
Subject to technical change without notice!
52
ZF Marine Transmissions
Corrosion-proofing
Guidelines for corrosion-proofing of marine transmissions during storage at

ZF agencies and intermediaries.
Anti-corrosion protection and corrosion-proofing for ZF transmissions installed in
marine craft.
Guidelines for marine transmissions:

Anti-corrosion protection, packing types, storage conditions and storage periods
Extract from: F 43258/RT 3332
Level Storage period
Ex works anti-corrosion protection Packing type
Storage conditions
Max. 12 months Internal corrosion-proofing:

before first op- Corrosion inhibiting oil to
eration
MIL-L-21260 or TL 9150-0037,
C-640
External corrosion-proofing:
- Bright metal parts with corrosion inhibitor to MIL-C-16173D grade 4,
K 19, or TL 8030-015, grade 4.
- Housing
a) Finished by ZF using single-component synthetic resin lacquer,
shade RAL 7001.
b) Wash priming by ZF, client must
apply either 1 or 2-component
lacquer as soon as packing materials have been removed. Then, if
unit is to go into interim storage
for longer than 12 months, repack
as described in level II.
Transmission covered with polythene sack in wetstrength, glued

plywood case.
Remove packing materials immediately

after receipt and check external corrosion-proofing. If protective film is damaged, touch up or completely recoat with
suitable corrosion inhibitor. Store in enclosed area at steady temperature and at
low relative humidity.
Protect from dirt and damp between installation until first operation.
II
Max. 36 months
before installation + max. 12
months between installation and first operation
Internal corrosion-proofing:
Corrosion inhibiting oil to
MIL-L-21260 or TL 9150-0037,
C-640
External corrosion-proofing:
- Bright metal parts with corrosion inhibitor to MIL-C-16173D grade 4,
K 19, or TL 8030-015, grade 4.
- Finish on housing: Single-component synthetic resin lacquer, shade
RAL 7001.
Packed in drying
agent by specialist
outside company
in accordance with
TL 8100-001,
packing grade A.
Quantity of drying
agent calculated
acc. to DIN 55474
or TL 8100-004.
Packing shall contain a humidity
gauge which can
be read from outside.
Do not open packing on receipt! Check

for damage. Check reading on humidity
gauge. Store in enclosed area at steady
temperature and at low relative humidity.
Protect from dirt and damp between installation and first operation.
As II
As II
In addition, after 36 months of storage,
check humidity inside packing every 4
months by reading humidity gauge. If
humidity is too high, call in specialist
outside company to replace drying agent
and barrier cover and to check external
corrosion-proofing.
All apertures in housing must be securely sealed.

III
As II
More than 36
months before
installation +
max. 12 months
between installation and first
operation
Separate Anti-corrosion protection and corrosion-proofing guidelines apply to the period between first operation and entry into regular
operation and to downtime. See Description, Installation, Operation and Maintenance publication.
1. Guideline for corrosion-proofing of marine transmissions during storage at

ZF agencies and intermediaries
CAUTION
The corrosion-proofing measures described below must be carried out by ZF-authorized personnel. Otherwise, warranty claims shall be deemed null and void.
Series transmissions supplied by ZF have anti-corrosion
protection according to level I of Guidelines for marine
transmissions: Anti-corrosion protection, packing type,
storage conditions and storage periods F 43258/
RT 3332-289.
The storage conditions stipulated in these guidelines apply: Store in enclosed area at steady temperature and low
relative humidity.
Renew corrosion-proofing after 12 months at the latest.
The transmissions may then be stored for a further 12
months. If transmissions then need to be stored for a further period, renew corrosion-proofing every 6 months.
Corrosion-proofing procedure:
Fill the transmission with corrosion inhibiting oil, up
to the upper mark on the oil dipstick. Use corrosion
inhibiting oil C 642 or C 644 to MIL- L-21260.
While rotating the input and output shafts, spray the
internal components of the transmission with corrosion inhibiting oil.
Replace the inspection hole cover.
Repeat corrosion-proofing on bright external steel
parts.
Renewing corrosion-proofing:
Remove the inspection hole cover and inspect the internal components of the transmission. While rotating the
input and output shafts, spray the internal components of
the transmission with corrosion inhibiting oil. Renew
corrosion-proofing on bright external steel parts.
Measures to be taken before supplying stored transmissions:
Renew corrosion-proofing and drain corrosion inhibiting
oil before delivery of the stored transmission. Inform
customer that marine transmissions purchased through
ZF agencies offer anti-corrosion protection for a maximum of 12 months.
2. Anti-corrosion protection and corrosion-proofing of ZF transmissions installed in marine craft

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

ZF Marine Transmission - Operating Manual

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ZF Marine Transmission - Operating Manual

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Operating Instructions

ZF 7500, ZF 7549, ZF 7550

Subject to alterations in design

Summary of technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Direction of propeller rotation for forward drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Connection of monitoring devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

ZF 7500/7600 Operating Instructions

8) For operation with engine at a standstill and

14) Not within the standard ZF scope of supply

13) Not included in table above

PVF = Pressure before filter

11) Without trailing pump

PK = Clutch oil pressure

17) Not included in table above

16) For remote display

15) Not included in table above

10) Not included in table above

9) For normal operation

7) The nominal clutch pressure is specified in the

Pressure gauge 0 to 25 bar

6) Warning must be set to not functioning when in shift

5) Warning with time delay of between 3 to 10 s

3) Use distributor piece

2) For visual and acoustic warning

1) Refer to section 5.3 for arrangement of measuring

For further details, refer to section 2

Minimum monitoring 14)

Clutch oil pressure

Monitoring data for ZF 7550 NR2/NR2B/NR2H, ZF 7650 NR2/NR2B/NR2H, ZF 7600 NR2/NR2B/NR2H

8) For operation with engine at a standstill and

PKN = Nominal clutch oil pressure

11) Without trailing pump

19) For transmission with PKN = 17.5 bar

13) Not included in table above

18) For transmission with PKN = 16 bar

12) With trailing pump (not within the standard ZF

PVF = Pressure before filter

PK = Clutch oil pressure

17) Not included in table above

16) For remote display

15) Not included in table above

10) Not included in table above

9) For normal operation

7) The nominal clutch pressure is specified in the

Pressure gauge 0 to 25 bar

6) Warning must be set to not functioning when in shift

5) Warning with time delay of between 3 to 10 s

3) Use distributor piece

2) For visual and acoustic warning

1) Refer to section 5.3 for arrangement of measuring

For further details, refer to section

Minimum monitoring 14)

Clutch oil pressure

Summary of technical data

Summary of technical data

Direction of rotation, transmission input shaft

Design engine speed

Engine idling speed

approx. 1 650 to 2 300

approx. 1 100 to 1 650

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

Smallest permissible distance

800 for d < 150