Operating Instructions

Transmission oil cooler for

ZF marine transmission

ZF 2000

ZF 2500

ZF 3000

ZF 4600 with pipe bundle cooler

ZF 7500/7600 with pipe bundle cooler

ZF 9000
2

These operating instructions are protected by copy-

right. Any reproduction and dissemination in whatever
form also in adapted, paraphrased or extracted form
in particular as a reprint, pho-tomechanical or elect-
ronic reproduction or as a storage in data-processing
equipment or data net-works without approval by the
holder of the copyright is prohibited and will be prose-
cuted under civil and criminal law.
Technical subject to alterations in design.

Edition: 2009/02

Index of revisions:

Document No.: 3000.758.102

Printed in Germany
ZF Friedrichshafen AG, 2009

ZF MARINE GMBH
88038 Friedrichshafen
Deutschland
Telephone +49 7541 77-2207
Telefax +49 7541 77-4222
info.zfmarine@zf.com

ZF Edition: february 2009 / 3000.758.102

 3

2.7 Tool-kit ........................................................14

TABLE OF CONTENTS 2.7.1 Tools for cleaning
transmission oil cooler ........................14
1 Assembly ............................................................ 5 2.8 Maintenance system job sheets ..................15
1.1 Cooling systems ........................................... 5
1.1.1 Open sea water cycle cooling system .. 5 3 Troubleshooting ............................................... 37
1.1.2 Closed cycle cooling system ................ 5 3.1 Table of faults (ZF 2000 und ZF 7500) ........37
1.2 Transmission oil cooler ................................. 5 3.2 Table of faults (ZF 2500) .............................39
1.2.1 Cooler design ...................................... 5 3.3 Table of faults (ZF 3000, ZF 4600, ZF 4660,
1.2.2 Requirements cooling-water circuit ..... 5 ZF 7600 und ZF 9000) .................................40
1.2.2.1 Arrangement of the transmission 3.4 Fault clearance ............................................42
oil cooler in the cooling-water 3.4.1 Closing leaking pipes .........................42
circuit ................................... 5 3.4.2 Leaking o-rings ..................................42
1.2.2.2 Temperatures ....................... 5
1.2.2.3 Flow rates ............................ 5
1.2.2.4 Water pressure ..................... 6
1.2.2.5 Filtering ................................ 6
1.2.3 Earthing ............................................... 6
1.2.3.1 Free-standing transmission ... 6
1.2.3.2 Flanged transmission ............ 6
1.2.4 Cooler drainage ................................... 6
1.2.4.1 Draining the water in case of
longer standstill .................... 6
1.3 Pipework ...................................................... 7
1.3.1 Installation ........................................... 7
1.3.2 Screw-in socket ................................... 7
1.3.3 Flow velocity ....................................... 7
1.3.4 Materials of the cooling-water pipe ..... 7
1.3.5 Earthing cooling-water pipe ................. 7
1.4 General notes ............................................... 8
1.4.1 Clearance for maintenance works ........ 8

2 Maintenance ...................................................... 9
2.1 Assembly of transmission oil cooler (ZF 3000,
ZF 4600, ZF 4660, ZF 7600, ZF 9000) .......... 9
2.1.1 Pipe bundle ......................................... 9
2.1.2 Housing ............................................... 9
2.1.3 Receivers ............................................. 9
2.1.4 Gaskets ............................................... 9
2.2 Installation position of
transmisson oil cooler .................................. 10
2.3 Assembly of transmission oil cooler
(ZF 2000, ZF 7500) ..................................... 11
2.3.1 Pipe bundle ....................................... 11
2.3.2 Housing ............................................. 11
2.3.3 Receivers ........................................... 11
2.3.4 Cover ................................................. 11
2.3.5 Gaskets ............................................. 11
2.4 Installation position of
transmisson oil cooler .................................. 12
2.5 Maintenance time schedule ........................ 13
2.5.1 Regular maintenance jobs . . . . . . . . 13
2.5.2 Additional one-off maintenance jobs
on new or overhauled transmission . 13
2.5.3 Maintenance work before
shut-down / stop . . . . . . . . . . . . . . . 13
2.5.3.1 Closed cycle cooling system 13
2.5.3.2 Open cycle cooling system . 13
2.6 Maintenance job schedule .......................... 14
2.6.1 Maintenance level / maintenance jobs 14

3000.758.102 / Edition: february 2009 ZF

4

ZF Edition: february 2009 / 3000.758.102

Assembly
1 ASSEMBLY
1.1 Cooling systems
1.1.1 Open sea water cycle cooling system
Fig. 1: Open sea water cycle system
In the case of the open sea water circuit, sea water
runs through the transmission oil cooler as cooling
agent. The ductwork has to be designed so that in
case of standstill of the plant either the feed line or the
return line of the transmission oil cooler can drain. This
line must be connected to the lower con-nection of
the transmission oil cooler.
1.1.2 Closed cycle cooling system
Fig. 2: Closed cycle cooling system
In the case of this arrangement, the cooling-water cir-
cuit for the motor and the transmission is separa-ted
from the sea water circuit. The heat transmission of
the motor/transmission oil circuit to the sea water
happens via a separate heat exchanger or via sur-face
attemperators in the outer skin of the ship. Nor-mally,
the heat transfer medium in the motor cooling circuit
is a mixture of water and an anticorrosive agent. Thus,
corrosion in the cooling system is lar-gely reduced. Gi-
ven the cleanliness of the medium, the transmission
oil cooler is hardly exposed to silta-tion or pitting cor-
rosion.
3000.758.102 / Edition: february 2009
5
1.2 Transmission oil cooler
1.2.1 Cooler design
water inlet
water outlet
oil outlet oil inlet
Fig. 3: Schematic assembly of the cooler
1.2.2 Requirements cooling-water circuit
The amount of heat generated in the transmission is
dissipated through the oil cooler. The oil cooler, which
is part of the basic model of the transmission, is
mounted to, installed in or fixed onto the transmission
housing.
For the admissible water flow rate and the pressure
loss between cooling-water inlet and outlet, see tech-
nical specifications in the transmission installation dra-
wing. The indicated water pressure at the
cooling-water inlet must not be exceeded. The cooler
is so designed that the heat dissipation is sufficient at
a transmission ambient temperature of 60C and a
water inlet temperature according to the transmission
installation drawing - also at full transmission load and
maximum speed.
1.2.2.1 Arrangement of the transmission oil cooler
in the cooling-water circuit
The correct transmission temperature is set by adju-
sting the cooling-water flow rate. For doing this, an
exchangeable gland, a valve or the like has to be pro-
vided in the ductwork. Therefore, the water circuit of
the transmission oil cooler should be arranged in the
bleed off of the motor cooling-water circuit (see sec-
tion Cooling systems on page5). The closed cooling
circuit should be the preferred one since the cooling
water is cleaner in this case.
1.2.2.2 Temperatures
Max. cooling-water inlet temperature:
see transmission installation drawing
1.2.2.3 Flow rates
Max. admiss. cooling-water flow rate:
see transmission installation drawing
Min. admiss. cooling-water flow rate:
see transmission installation drawing
ZF
6 Assembly
1.2.2.4 Water pressure
Max. admiss. cooling water pressure at inlet:
see transmission installation drawing
1.2.2.5 Filtering
Suction filter on the water side required with mesh
size: see transmission installation drawing
This is necessary in order to prevent contaminations
such as solid matters or shells from ingressing into the
cooler and the conduits since they would obstruct the
cooler. An obstructed cooler or individually obstructed
cooler pipes lead to a reduced cooling thermal perfor-
mance.
Fig. 4: Contamination (wood shavings) caused by a
filter screen with a too big mesh size (Exa-
mple)
Note:
In case of obstructed cooler pipes, the required flow
velocity is not reached. This can lead to deposits or to
foul and consequently to pitting corrosion.
1.2.3 Earthing
In order to avoid galvanic corrosion, it is important that
there is no electric potential difference at the sea water
containing components. Therefore, the transmission
and therefore also the cooler have to be connected
with the earthbus so that they are antistatic - as all
other sea water containing components.
Material: copper
Min. cross section: 16 mm2
It must be made sure that the junctions of the earth
strap are free of colour or of other electrically insula-
ting materials.
ZF
1.2.3.1 Free-standing transmission
Fig. 5: Earthing with free-standing transmission
1.2.3.2 Flanged transmission
Fig. 6: Earthing with flanged transmission
1.2.4 Cooler drainage
Ideally, the cooling-water circuit has to be designed so
that the transmission oil cooler is automatically drai-
ned if the cooling-water pump is in standstill.
Note:
The bacteria in the standing water form degradation
products which deposit in the cooler. In case of a sur-
face which has not been passivated yet, this can lead
to pitting corrosion. The passivation of the surfaces is
only built-up after some time of operation in oxy-
gen-rich water.
1.2.4.1 Draining the water in case of longer stand-
still
If the plant is switched off for a longer period of
time(standstill time see section Maintenance work
before shut-down / stop on page13) the water has to
be drained if the sea water circuit is open.
Note:
This is only necessary, if the cooler is not automatically
drained when the cooling-water pump is in standstill.
In order to be able to drain the cooling circuit, a drain
plug or drain valve has to be provided. The connection
must lie deeper than the cooler so that the cooler can
drain completely.
Edition: february 2009 / 3000.758.102
Assembly
1.3 Pipework
1.3.1 Installation
All required oil pipes are connected fixed and ready
for operation. The connections for the cooling-water
inlet and outlet are closed by means of blind flanges
upon delivery. These flanges can be used as welding
flanges during the installation of the cooling-water
pipe. For uncoupling, an elastic adapter (compensa-
tor, hose piece) must be put between these flanges
and the cooling-water pipes on the side of the ship.
The exact position of the connections can be taken
from the corresponding transmission installation dra-
wing. The flow direction of the water must be adhered
to, i.e. water inlet and water outlet must not be ex-
changed.
The temperature increase of the cooling water in the
transmission oil cooler is maximally 5C. The mixing
temperature for the motor cooling circuit increases by
approx. 0.5C and is therefore irrelevant. The indica-
ted maximum rate of cooling-water flowing through
the transmission oil cooler must not be exceeded;
otherwise there is the risk of cavitation in the cooler.
The minimum flow rate must not lie below since the
flow velocity would be too low and there would be the
risk that the cooler silts up early or is impaired by salt
excretion of the water flow.
1.3.2 Screw-in socket
The maximum admissible thread depth in the connec-
tion threads for the cooling water amounts to 20 mm
in order to avoid an obstruction of the flow in the area
in front of the pipe plates.
Fig. 7: Thread depth in the connection threads for
the cooling water (example)
Note:
The maximum screw-in length of 20 mm is only appli-
cable for the transmission oil coolers for ZF 3000,
ZF 4600, ZF 4660 and ZF 7600 transmissions.
Note:
For transmission oil coolers for the ZF 9000 transmis-
sion the maximum screw-in length is 27 mm.
3000.758.102 / Edition: february 2009
7
1.3.3 Flow velocity
Minimum flow velocity: 1.5 m/s
Maximum flow velocity: 3.0 m/s
The cross sections of the conduits are to be designed
so that at nominal speed the minimum flow velocity is
reached and the maximum flow velocity is not excee-
ded.
Fig. 8: Fouling: Organic sediments on the pipe bun-
dle caused by low flow velocity and long
down time (example)
1.3.4 Materials of the cooling-water pipe
When choosing the materials for the water pipes, it
must be taken into account that different materials
cannot be combined at random. If a more precious
metal is combined with a less precious metal, the less
precious metal will corrode.
Material of the pipes and the stop valves in the sea
water circuit: Copper alloy, e.g. CuNi10Fe1Mn
Galvanised steel pipes must not be used since there is
the risk that the zinc coating is partially eaten away by
galvanic processes and that iron corrosion parts depo-
sit at the discs or the flange pipes of the cooler. Within
a short period of time, pitting corrosion would damage
the cooler.
1.3.5 Earthing cooling-water pipe
In order to avoid galvanic corrosion, it is important that
there is no electric potential difference at the sea wa-
ter-containing components.
Therefore, all cooling-water pipes must be connected
with the earth bus of the ship in an antistatic manner.
If there is an insulating separation line in the pipe
(hose or compensator), this must be bridged by an
earth strap in an antistatic manner (see section Eart-
hing on page6).
ZF
8 Assembly

1.4 General notes

1.4.1 Clearance for maintenance works

The cooler has to be maintained in regular intervals

according to the maintenance instruction. Therefore, a
corresponding clearance has to be provided for the di-
sassembly of the pipe bundle.

Fig. 9: Required clearance for the disassembly of

the pipe bundle (example)

ZF Edition: february 2009 / 3000.758.102

Maintenance
2 MAINTENANCE
2.1 Assembly of transmission oil cooler (ZF 3000, ZF 4600, ZF 4660, ZF 7600, ZF 9000)
3 5 6 10 11 12 13 14
Fig. 10: Schematic assembly of transmission oil cooler (example)
1 housing 5 cylindrical bolt
2 reciever 6 washer
3 cover 7 pipe plate
4 fixing plate 8 o-ring
Note:
The actual assembly of the transmission oil cooler can
differ in details.
2.1.1 Pipe bundle
The pipe bundle consists of two identical pipe plates
(7) facing each other with three splines each. The
cooling pipes (10) are expanded into the pipe plates.
Between the pipe plates on the outside of the pipes
there is a surface enlargement mounted in the form of
fins (11) and positively connected with the pipes.
Along the whole length of the fin package there are
slits which serve for housing sealing strips (12). A dif-
ferent number of baffle plates (13) can have been
mounted in the fin package. After assembly, each of
the inner O-ring splines of the pipe plates seals in the
housing. The outer splines serve as gaskets in the re-
ceivers. This prevents media from mixing in case of a
failure of the gaskets and makes leak detection easier.
In the middle spline, fixing plates (4) engage with a
pipe plate, which fix this pipe plate after assembly and
which allow a thermal expansion of the facing pipe
plate.
2.1.2 Housing
The housing (1) serves for housing the pipe bundle
and constitutes the outer pressure chamber. It is a
standardised cast housing made of an aluminium alloy
or of grey cast iron.
3000.758.102 / Edition: february 2009
9
1 7 8 4 9 2
9 divider 13 baffle plate
10 pipe 14 fin ring
11 fin
12 sealing strip
2.1.3 Receivers
The receivers are the both covers made of bronze and
cast iron, which are situated at both ends. Together
with the pipe bundle, the receivers form the pressure
chamber of the cooling medium. The receivers are
fixed to the housing by means of screws. On the side
of the cooler, there are metal sheets inserted between
the receiver and the housing. These metal sheets fix
the pipe plate. On the side of the water connection of
the cooler, a receiver (2) with two connections is in-
stalled and on the other side, there is a return cover
(3) installed. For sealing the two chambers in the re-
ceiver, there is a plastic or aluminium divider (9) in-
serted into the pipe plate on the connection side.
When assembled, this divider seals between pipe
plate and receiver and thus divides the current of the
medium flowing through the cooler along the pipe.
2.1.4 Gaskets
The gaskets of the pipe plates consist of O-rings. The
pipe threads at the connection are sealed by means of
a copper or aluminium ring. The pipe bundle is sealed
lengthwise on the side with a sealing strip (12) to-
wards the housing. The sealing strip is made of the
same material as the O-rings.
Note:
The O-rings are available from the customer service of
ZF Marine GmbH by indicating the item number.
ZF
10 Maintenance

2.2 Installation position of transmisson oil

cooler

Fig. 11: ZF 3000 Fig. 14: ZF 7600

Fig. 12: ZF 4600 Fig. 15: ZF 9000

Fig. 13: ZF 4660

ZF Edition: february 2009 / 3000.758.102

Maintenance 11

2.3 Assembly of transmission oil cooler (ZF 2000, ZF 7500)

5 6 4
5

3 8 7 10 1 9 7 8 5 2

Fig. 16: Schematic assembly of transmission oil cooler (example)

1 housing 5 cylindrical bolt
2 reciever 6 washer
3 cover 7 pipe plate
4 pipe bundle compl. 8 o-ring
Note:
The actual assembly of the transmission oil cooler can
differ in details.
2.3.1 Pipe bundle
The pipe bundle (4) consist of two identical pipe
plates (7), positioned opposite of each other, and of
the cooling pipes (9). The cooling pipes are expanded
into the pipe plates. In total, five baffle plates (10) are
mounted on the cooling pipes of the pipe bundle. The
plates directionally lead the oil flow through the cas-
ing. The two o-rings (8) one on the side of the clo-
sure the other on the side of the receiver seal the
pipe bundle in the casing on the oil side. The outer
o-rings (8) serve for sealing the water side at the cover
(3) and at the receiver (2). This prevents media from
mixing in case of a failure of the gaskets.
2.3.2 Housing
The housing (1) serves for housing the pipe bundle
and constitutes the outer pressure chamber. It is a
standardised cast housing made of an aluminium alloy
or of grey cast iron.
9 pipe
10 baffle plates
2.3.4 Cover
On the other side, a reverser cover (3) is installed. The
cover is also made of cast bronze. The cover is at-
tached to the housing (1) by means of three bolts (5).
A spacer plate (6) is arranged between the cover and
the housing. The spacer plate serves for fixation of the
o-rings (8).
2.3.5 Gaskets
The connection flanges on the water side are sealed
by means of flat gaskets. The pipe plates are sealed
with a total of four identical o-rings (8). For versions
with the transmission oil cooler directly flanged to the
transmission housing, the oil connections are sealed
by means of o-rings inserted into the splines. For versi-
ons with the transmission oil cooler mounted exter-
nally, the pipe connection threads are sealed by
means of a copper ring.
Note:
The O-rings are available from the customer service of
ZF Marine GmbH by indicating the item number.

2.3.3 Receivers

A receiver (2) is installed on the water connection side

of the cooler. The receiver is made of cast bronze. The
receiver is attached to the housing (1) by means of
three bolts (5) Between the receiver and the housing,
the pipe bundle (4) is fixed by means of the sheet con-
nected to the pipe plate.

3000.758.102 / Edition: february 2009 ZF

12 Maintenance

2.4 Installation position of transmisson oil

cooler

Fig. 17: ZF 2000

Fig. 18: ZF 7500

ZF Edition: february 2009 / 3000.758.102

Maintenance 13

2.5 Maintenance time schedule Special operating conditions as well as technical de-
The maintenance system for marine transmissions is mands can require additional maintenance work and/
based on a preventive maintenance concept. The pre- or changes of maintenance intervals.
ventive maintenance enables an advance planning
The maintenance work number stated in the mainte-
and ensures a high availability.
nance system operating sheet indicates the respective
Note: maintenance position. It serves as reference for the re-
quired tools and amount of parts.
NOTEThe time intervals according to which the main-
tenance work is to be executed, as well as the scope
of the described control and maintenance work are the
average result of operating experience and thus only to
be seen as approximate values.

2.5.1 Regular maintenance jobs

Maintenance level Application groups Interval At least every

(operating hours)
A1 All Every day of operation 3 months
A2 All 500 h 6 months
A3.1 All ---------------- 1 year
C and M ---------------- 5 years
A4
L and P ---------------- 8 years
All Each time the engine undergoes a Transmission
A5
basic overhaul operating condition

Tab. 1: Regular maintenance job for transmission oil cooler

2.5.2 Additional one-off maintenance jobs on new or overhauled transmission

Maintenance level Operating hours At least every

Z1 50 to 100 12 months
Z2 ---------------- 2 months

Tab. 2: Additional one-off maintenance jobs on new or overhauled transmission

2.5.3 Maintenance work before shut-down / stop

2.5.3.1 Closed cycle cooling system 2.5.3.2 Open cycle cooling system
With a closed cycle cooling system the cooler can be For a temporary stop of the facility (< 2 weeks) the
kept filled. cooler can be kept filled.

For a longer stop of the facility (> 2 weeks) the cooler

is to be emptied on the water side.
Note:
This is only required, if the cooler is not emptied auto-
matically with the cooling water pump being stopped.

Cooling system Down time Measures

Open system / sea > 2 weeks Empty transmission oil cooler on water side.
water
Rinse additionally with clean water
If possible, dry pipe bundle from the inside with
compressed air.

Tab. 3: Standstill times / draining cooling water

3000.758.102 / Edition: february 2009 ZF

14 Maintenance

2.6 Maintenance job schedule

2.6.1 Maintenance level / maintenance jobs

Maintenance level Maintenance jobs

Regular One-off
A5 A4 A3.1 A2 A1 Z1 Z2
103 Carry out visual check
122 Retighten all screw/bolt connections
169 Realise visual examination and clean
transmission oil cooler
200 Basic transmission overhaul

Tab. 4: Maintenance level / maintenance jobs

2.7 Tool-kit

2.7.1 Tools for cleaning transmission oil cooler

Nylon brush for ZF 3000, ZF 4600, ZF 4660, ZF 7600

und ZF 9000:
(ZF part no. 1X56.190.838)
Nylon brush for ZF 2000 und ZF 7500:
(ZF part no. 1X56.190.840)

ZF Edition: february 2009 / 3000.758.102

Maintenance 15

2.8 Maintenance system job sheets

Index job sheets

Maintenance operation Page
103 Carry out visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

122 Retighten all accessible screw/bolt connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

169 Realise visual examination and clean oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Edition: february 2009 / 3000.758.102 ZF

16 Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission oil cooler
Maintenance Maintenance level If possible, to be performed in Time required in
job no. conjunction with maintenance minutes
job no.

103 A1 -------- 5

Description of
maintenance work 103
Carry out visual check

Carry out visual examination of rotating parts with sufficient distance in order to avoid the risk
Safety measures
of being pulled in by the rotating part.

Tools ------------------------------

Parts ------------------------------

Material ------------------------------

Test equipment ------------------------------

Check the leak tightness of the oil cooler and the oil level (water leakage in oil or oil leakage
Procedure
in water when engine has been stopped).

Location: Date: Page: 1 of: 1

ZF Edition: february 2009 / 3000.758.102

Maintenance 17

3000.758.102 / Edition: february 2009 ZF

18 Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission oil cooler
Maintenance Maintenance level If possible, to be performed in Time required in
job no. conjunction with maintenance minutes
job no.

122 Z1 -------- 5

Description of
122 Retighten all accessible screw/bolt connections
maintenance work

Safety measures Retighten bolted connections only with transmission stopped.

Tools ------------------------------

Parts ------------------------------

Material ------------------------------

Test equipment ------------------------------

Procedure Re-tighten the screwed connections from and to the transmission oil cooler

Location: Date: Page: 1 of: 1

ZF Edition: february 2009 / 3000.758.102

Maintenance 19

3000.758.102 / Edition: february 2009 ZF

20 Maintenance

MAINTENANCE SYSTEM JOB SHEET

Transmission oil cooler
Maintenance Maintenance level If possible, to be performed in Time required in
job no. conjunction with maintenance minutes
job no.

169 Z2 -------- 180

Description of
169 Realise visual examination and clean oil cooler
maintenance work

Safety measures ------------------------------

Tools Tool kit WI (see corresponding instructions manual)

Parts ------------------------------

Material ------------------------------

Test equipment ------------------------------

Procedure See opposite page

Location: Date: Page: 1 of: 1

ZF Edition: february 2009 / 3000.758.102

Maintenance 21

ZF 2000 und ZF 7500

5 6 4
5

1 housing
2 reciever
3 cover
4 pipe bundle compl.
5 cylindrical bolt
6 distance plate
7 pipe plate
8 o-rings
9 pipe
10 baffle plates

3 8 7 10 1 9 7 8 5 2
Fig. 19: Schmatic design of the transmission oil cooler (ZF 2000, ZF 7500, example)
The numbers in the brackets refer to figure 19. 9. Remove the o-rings on both sides of the pipe bun-
dle.
Note:
The O-rings that have to be demounted must be ex-
changed on each maintenance.

Disassembly of the transmission oil cooler

(without extraction the pipe bundle)
1. Clearly mark the position of the bolted flanges to
each other.
2. Block all tubing.
3. Empty the transmission oil cooler on the water
side.
4. Remove the tubing on the water side.
Fig. 20: Disassembly of the o-rings (ZF 2000, exa-
5. Wait for 30 min after the facility has been stop-
mple)
ped, until the oil pressure has decreased.
10. The pipe bundle must be secured against the
6. Empty the transmission oil cooler on the oil side;
housing (1) by means of a screw and an appropri-
for this purpose drain the oil from the oil filter and
ate number of washers.
the transmission (see maintenance system opera-
ting sheets 141 and 142).
7. Remove the fastening screws on the transmission
oil cooler and detach the transmission oil cooler.
Note:
Step 5-7 is only necessary in case of transmissions
where the cover (3) cannot be dismantled for lack of
space.
8. Remove the reciever (2) and the cover (3) by loos-
ening the screws on the reciever/cover-hous-
ing-connection.

Fig. 21: Pipe bundle secured with a bolt (ZF 2000,

example)
Note:
Now, the water side may be inspected and mechani-
cally cleaned.

3000.758.102 / Edition: february 2009 ZF

22 Maintenance

Water-side cleaning Disassembly of the transmission oil cooler

(with extraction the pipe bundle)
The transmission oil cooler has to be cleaned on the
water side at least 1x a year. Avoid excessive dirt on
the pipes.
Note:
The time intervals for maintenance have to be reduced
in case of a long ship operation at harbours or in other
dirty waters and according to the experiences of the
operator.
In case of little dirt the water side can be cleaned me-
chanically:
1. Disassemble the transmission oil cooler as
described Disassembly of the transmission oil
cooler (without extraction the pipe bundle) on
page21 .
2. Clean each pipe of the pipe bundle on the inside
by means of a nylon brush (see section Tool-kit
on page14).
1. Clearly mark the position of the bolted flanges to
each other.
2. Block all tubing.
3. Empty the transmission oil cooler on the water
side..
4. Remove the tubing on the water side.
5. Wait for 30 min after the facility has been stop-
ped, until the oil pressure has decreased.
6. Empty the transmission oil cooler on the oil side,
for this purpose drain the oil from the oil filter and
the transmission (see maintenance system opera-
ting sheets 141 and 142).
7. Remove the fastening screws on the transmission
oil cooler and detach the transmission oil cooler.
8. Remove the reciever (2) and the cover (3) by loo-
sening the screws of the reciever/cover housing
connection.
9. Remove the o-rings on both sides of the pipe bun-
dle.

Fig. 22: Cleaning of pipes with a nylon brush

(ZF 2000, example)
Note:
Do not use metal brushes for the cleaning of the
pipes.
Fig. 23: Disassembly of the o-rings (ZF 2000, exa-
Note: mple)
Firmly bonded deposits may not be removed with
10. Remove the spacer plate (6) on the side opposite
tools. In such a case the pipe bundle has to be
the water side.
cleaned chemically. This can be done with the pipe
bundle still installed by coating the pipes with a chem-
ical solution. In doing so you have to take into account
that the plastic partition and the O-rings will not be af-
fected by the chemical solution. A chemical cleaning
should only be done by specialised staff.
Note:
Suppliers of cleaning agents are, for example, Ashland
Chemicals (www.ashchem.com), Henkel Ober-
flchentechnik (www.henkel.com) and Ondeo Nalco
(www.nalco.com). Suppliers of complete cleanings
are, for example, Vecom (www.vecom.nl) and Ondeo
Nalco (www.nalco.com).
Fig. 24: Remove spacer plate (ZF 2000, example)

ZF Edition: february 2009 / 3000.758.102

Maintenance
11. Push the pipe bundle to the water side that far (if
required, use an auxiliary tool) until the o-ring on
the opposite side is loosened.
12. Remove the o-ring.
Fig. 25: Disassembly of the o-ring on the side oppo-
site to the water side (ZF 2000, example)
13. Draw out the pipe bundle towards the water side.
In doing this, the pipe bundle must be removed
from the housing very carefully, in order not to
damage the diverter plates.
Fig. 26: Disassembly of the pipe bundle
(ZF 2000, example)
14. Remove the o-ring on the water side of the pipe
bundle by slipping it over the pipe bundle.
Fig. 27: Remove o-ring on the water side
(ZF 2000, example)
3000.758.102 / Edition: february 2009
23
Assembly of the transmission oil cooler (without
extraction of the pipe bundle)
The assembly of the transmission oil cooler is carried
out in reverse order as the disassembly of the cooler.
1. Remove the securing bolt, including the washers
from the pipe bundle.
2. Lubricate the outer o-rings with a suitable type of
grease and mount onto the pipe bundle.
Fig. 28: Assemble the outer o-ring
(ZF 2000, example)
3. Parallelly mount the receiver (2) and the cover (3)
on the two sides of the transmission oil cooler and
evenly slip them onto the outer o-ring
Note:
When slipping the receiver (2) and the cover (3) onto
the o-rings it must be observed that the o-ring do not
shear off.
4. Assemble the receiver (2) and the cover (3) by
means of three bolts, tightening the conjugate
bolts alternating from receiver to cover, applying
the correct tightening torque (see table 5 Tighte-
ning torques on page23).
Transmission Screw /
Tightening torque
type strength
ZF 2000 M8 / 8.8 23 Nm
ZF 7500 M10 / 8.8 46 Nm
Tab. 5: Tightening torques
5. In transmissions where the transmission oil cooler
has been removed from the transmission housing,
the cooler must be positioned onto the transmis-
sion housing and fixed to the housing by means of
four fastening bolts.
6. Mount the flanged sockets with new gaskets to
the receiver (2).
7. Connect the pipelines on the water side.
8. Open and re-fill all pipelines.
ZF
24 Maintenance

9. Bleed the transmission oil cooler on the water 4. Lubricate the o-ring for the side of the pipe bun-
side. dle opposite the water side with a suitable type of
grease and assemble the o-ring on the side oppo-
10. Fill the transmission with oil.
site the water side.
Note:
Step 10 is only required, if the transmission oil cooler
has been removed for cleaning the transmission
housing.

Assembly of the transmission oil cooler

(after extraction of the pipe bundle)
1. Grease the o-ring for the water side of the pipe
bundle.
2. Carefully slip the o-ring over the pipe bundle to
the stop on the water side.

Fig. 31: Assembly of the o-ring on the side opposite

to the water side
(ZF 2000, example)
Note:
During assembly of the o-ring it must be observed that
the ring does not shear off.
5. Mount the spacer plate (6) on the side opposite
the water side.

Fig. 29: Assemble o-ring on the water side.

(ZF 2000, example)
Note:
During assembly of the o-ring it must be observed that
the ring does not shear off.
3. Carefully insert the pipe bundle into the housing
(1).

Fig. 32: Mount the spacer plate (ZF 2000, example)

6. Lubricate the outer o-rings with a suitable type of
grease and mount onto the pipe bundle.

Fig. 30: Assembly of the pipe bundle

(ZF 2000, example)

ZF Edition: february 2009 / 3000.758.102

Maintenance 25

Replacement of the pipe bundle

Fig. 33: Assemble the outer o-ring (ZF 2000, exa-
mple)
7. Parallelly mount the receiver (2) and the cover (3)
on the two sides of the transmission oil cooler and
evenly slip them onto the outer o-ring.
Note:
When slipping the receiver (2) and the cover (3) onto
the o-rings it must be observed that the o-ring do not
shear off.
8. Assemble the receiver (2) and the cover (3) by
means of three bolts, applying the correct tight-
ening torque (see table 6 Tightening torques on
page25).
If more than 10% of the pipes in the bundle are
leaking/not tight, the entire pipe bundle must be re-
placed.
1. Assemble the transmission oil cooler as described
in the section Disassembly of the transmission oil
cooler (with extraction the pipe bundle) on
page22.
2. Remove the defective pipe bundle.
3. Insert the new pipe bundle.
4. Assemble the transmission oil cooler as described
in the section Assembly of the transmission oil
cooler (after extraction of the pipe bundle) on
page24.
Revision
After assembly, both the oil side and the water side
must be revised. During this operation it must be ob-
served that the pressure (oil side and water side) does
not exceed the value stated in the transmission instal-
lation drawing and/or on the type plate.

Transmission Screw /
Tightening torque
type strength
ZF 2000 M8 / 8.8 23 Nm
ZF 7500 M10 / 8.8 46 Nm

Tab. 6: Tightening torques

9. Position the cooler onto the transmission housing
and fix it to the housing by means of four faste-
ning bolts.
10. Mount the flanged sockets with new gaskets to
the receiver (2).
11. Connect the pipelines on the water side.
12. Open and re-fill all pipelines.
13. Bleed the transmission oil cooler on the water
side.
14. Fill the transmission with oil.

3000.758.102 / Edition: february 2009 ZF

26 Maintenance

ZF 2500 8. Extract the pipe bundle from the transmission

housing.
Note:
With every maintenance operation, the o-rings and
the gasket that must be disassembled, have to be re-
placed.

Cleaning process on the water side

The water side of the transmission oil cooler must be
cleaned at least once per year. Excessive contamina-
tion of the pipes must be avoided.
Note:
The time intervals for maintenance must be adjusted
(shortened) for long-term operation of the ship in har-
bours and other soiled waters, and/or according to the Fig. 34: Disassembly of the pipe bundle (ZF 2500,
operator's experience. example)
Note:
Assembly of the transmission oil cooler
Tightly sticking deposits must not be removed by
means of tools. In such a case the pipe bundle must The assembly of the transmission oil cooler is carried
be chemically cleaned. This operation may be carried out in reverse order as the disassembly of the cooler.
out in assembled condition by spraying chemical
1. Carefully insert the pipe bundle into the transmis-
cleaning solution onto the pipes. It must be ensured
sion housing.
that the condition of the o-rings is not affected by the
chemical solution. Chemical cleaning should only be
carried out by expert personnel.
Note:
Suppliers of suitable cleaning agents are e.g. Ashland
Chemicals (www.ashchem.com), Henkel Ober-
flchentechnik (www.henkel.com) and Ondeo Nalco
(www.nalco.com). Providers of complete cleaning
services are e.g. Vecom (www.vecom.nl) und Ondeo
Nalco (www.nalco.com).

Disassembly of the transmission oil cooler

1. The position of the screwed flanges to each other
must be marked in order to be identified at
assembly. Fig. 35: Assembly of the pipe bundle (ZF 2500, exa-
mple)
2. Close all pipelines.
2. Replace the gasket at the cover.
3. Drain the transmission oil cooler on the water
side.
4. Remove the pipelines on the water side.
5. After shut down of the system wait for minimum
30 minutes until the oil pressure has decreased.
6. Drain the transmission oil cooler on the oil side;
for this the oil must be drained from the oil filter
and the transmission (see Maintenance System -
Operation Sheets 141 and 142 in the instructions
manual of the respective transmission series).
7. Disassemble the cover by unscrewing the bolts at
the cover-housing connection.
Fig. 36: Replace gasket (ZF 2500, example)

ZF Edition: february 2009 / 3000.758.102

Maintenance 27

3. Place the cover onto the pipe bundle and the

transmission housing assembling it by means of
eight bolts, tightening the conjugate bolts in an
alternating fashion, applying the correct tighten-
ing torque (see table 7 Tightening torques on
page27).

Transmission Screw /
Tightening torque
type strength
ZF 2500 M10 / 8.8 46 Nm

Tab. 7: Tightening torques

Note:
When assembling the cover, it must be observed that
the gasket between pipe bundle and cover is positio-
ned correctly.
4. Mount the flanged sockets with new gaskets to
the cover.
5. Connect the pipelines on the water side.
6. Open and re-fill all pipelines.
7. Bleed the transmission oil cooler on the water
side.
8. Fill the transmission with oil.

Replacement of the pipe bundle

If more than 10% of the pipes in the bundle are
leaking/not tight, the entire transmission oil cooler
must be replaced.
1. Disassemble the transmission oil cooler as
described in the section Disassembly of the
transmission oil cooler on page26.
2. Remove the defective transmission oil cooler.
3. Insert the new transmission oil cooler.
4. Assemble the transmission oil cooler as described
in the section Assembly of the transmission oil
cooler on page26.

Revision
After assembly, both the oil side and the water side
must be revised. During this operation it must be ob-
served that the pressure (oil side and water side) does
not exceed the value stated in the transmission instal-
lation drawing and/or on the type plate.

3000.758.102 / Edition: february 2009 ZF

28 Maintenance

ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF 9000

1 housing
2 reciever
3 cover
4 fixing plate
5 cylindrical bolt
6 washer
7 pipe plate
8 o-ring
9 divider
10 pipe
11 fin
12 sealing strip
13 baffle plate
3 5 6 10 11 12 13 14 1 7 8 4 9 2 14 fin ring

Fig. 37: Schematic Design of the transmission oil cooler ZF 3000, ZF 4600, ZF 4660, ZF 7600, ZF 9000, example)
The numbers in the brackets refer to figure 37. 9. Remove the o-rings from the outer spline of the
pipe plates and secure the pipe bundle against
Note:
the housing (19 in the middle spline of the pipe
The O-rings that have to be demounted must be
plates using four bolts and the four fixing plates
exchanged on each maintenance.
(4).
Disassembly of the Transmission oil cooler
(without extraction of the pipe bundle)
1. Clearly mark the position of the bolted flanges to
each other.
2. Block all tubing.
3. Empty the Transmission oil cooler on the water
side.
4. Remove the tubing on the water side.
5. Wait for 30 min after the facility has been stop-
ped, until the oil pressure has decreased.
6. Empty the Transmission oil cooler on the oil side;
for this purpose drain the oil from the oil filter and Fig. 38: Pipe bundle secured with fixing plates
the Transmission (see maintenance system opera- (ZF 3000, example)
ting sheets 141 and 142).
7. Remove the fastening screws on the Transmission
oil cooler and detach the Transmission oil cooler.
Step 5-7 is only necessary in case of Transmissions
where the cover (3) cannot be dismantled for lack of
space.
8. Remove the reciever (2) and the cover (3) by loo-
sening the screws on the reciever/
cover-housing-connection.

Fig. 39: Pipe bundle secured with fixing plates

(ZF 9000, example)

ZF Edition: february 2009 / 3000.758.102

Maintenance
Note:
Now, the water side may be inspected and mechani-
cally cleaned. In transmission where the transmission
oil cooler has not been removed, the oil side may re-
main pressurised.
10. Remove the divider (9)
Fig. 40: Disassembly of the pipe bundle
(ZF 3000, example)
Fig. 41: Disassembly of the pipe bundle
(ZF 9000, example)
Cleaning process on the water side
The water side of the transmission oil cooler must be
cleaned at least once per year. Excessive contamina-
tion of the pipes must be avoided.
Note:
The time intervals for maintenance must be adjusted
(shortened) for long-term operation of the ship in har-
bours and other soiled waters, and/or according to the
operator's experience.
In case of slight contamination the water side may
merely be cleaned mechanically.
1. Disassemble the transmission oil cooler as
described in the sectio Disassembly of the Trans-
mission oil cooler (without extraction of the pipe
bundle) on page28.
3000.758.102 / Edition: february 2009
29
2. Clean every pipe of the pipe bundle on the inside
using a nylon brush (see chapter Tool-kit on
page14).
Fig. 42: Cleaning the pipes by means of a nylon
brush (ZF 3000, example)
Fig. 43: Cleaning the pipes by means of a nylon
brush (ZF 9000, example)
Note:
Metal brushes must never be used for cleaning the
pipes.
Note:
Tightly sticking deposits must not be removed by
means of tools. In such a case the pipe bundle must
be chemically cleaned. This operation may be carried
out in assembled condition by spraying chemical
cleaning solution onto the pipes. It must be ensured
that the condition of the o-rings and the plastic divider
is not affected by the chemical solution. Chemical
cleaning should only be carried out by expert person-
nel.
Note:
Suppliers of suitable cleaning agents are e.g. Ashland
Chemicals (www.ashchem.com), Henkel Ober-
flchentechnik (www.henkel.com) and Ondeo Nalco
(www.nalco.com). Providers of complete cleaning
services are e.g. Vecom (www.vecom.nl) und Ondeo
Nalco (www.nalco.com).
ZF
30 Maintenance

Disassembly of the transmission oil cooler (with 9. Remove the o-rings from the outer spline of the
extraction of the pipe bundle) pipe plates.
1. The position of the screwed flanges to each other
must be marked in order to be identified at
assembly.
2. Close all pipelines.
3. Drain the transmission oil cooler on the water
side.
4. Remove the pipelines on the water side.
5. Nach dem Abstellen der Anlage 30 min warten,
bis der ldruck abgebaut ist.
6. Drain the transmission oil cooler on the oil side;
for this the oil must be drained from the oil filter
and the transmission (see Maintenance System - Fig. 45: Disassembly of the outer o-ring
Operation Sheets 141 and 142 in the instructions (ZF 3000, example)
manual of the respective transmission series).
7. Unscrew the attachment bolts from the transmis-
sion oil cooler and remove the cooler.
8. Remove the receiver (2) and the cover (3) by loos-
ening the bolts from the receiver-housing and
cover-housing connections.
Note:
Four fixing plats (4) are located between the receiver
(2) and the housing (1). These plates must be installed
on the same side when assembling the unit. Observe
the identification F on the housing flange, for this pur-
pose.

Fig. 46: Disassembly of the outer o-ring

(ZF 9000, example)
Note:
On one pipe plate an identification mark for the instal-
lation position is provided opposite the housing. The
edge of the pipe plate and the adjacent housing
flange each contain one half of an X. This mark must
be observed.

Fig. 44: Identification mark F for the fixing plates

(example)

Fig. 47: Identification mark X for the installation of

the pipe bundle (ZF 3000, example)

ZF Edition: february 2009 / 3000.758.102

Maintenance 31

12. Draw out the pipe bundle towards the side it was
inserted at. In doing this, the pipe bundle must be
removed from the housing very carefully, in order
not to damage the fin package. If possible, the
pipe bundle should be supported by large-surface
transport slings.

Fig. 48: Identification mark X for the installation of

the pipe bundle (ZF 9000, example)
10. Push the pipe bundle towards the water side that
far (if required, use an auxiliary tool) until the
o-ring on the inner spline is visible.
Fig. 51: Disassembly of the pipe bundle
11. Remove the o-ring of the inner spline. (ZF 3000, example)

Fig. 52: Disassembly of the pipe bundle

Fig. 49: Disassembly of the inner o-ring
(ZF 9000, example)
(ZF 3000, example)
Note:
The splines for the accommodation of the o-rings must
not be damaged. When extracting the pipe bundle,
the diverter plate (13) may fall out.
Note:
When disassembling vertically installed coolers (appli-
cable for transmission series ZF 4600) it must be en-
sured by appropriate means that the pipe bundle
cannot slide downwards once the fixing plates have
been removed. For this purpose, it is recommended to
have an additional set of fixing plates (4) ready and to
start the disassembly operation on the side on which
no fixing plates are installed. The pipe bundle must be
secured during this step. After disassembly of the sec-
Fig. 50: Disassembly of the inner o-ring
ond receiver (2) controlled extraction of the bundle is
(ZF 9000, example)
facilitated.
Note:
For assembly, only one set of fixing plates (4) must be
installed, on the side containing the identification
mark F.

3000.758.102 / Edition: february 2009 ZF

32 Maintenance

Assembly of the transmission oil cooler (without

extraction of the pipe bundle)
The assembly of the transmission oil cooler is carried
out in reverse order as the disassembly of the cooler.
1. Remove the four bolts and the four fixing plates
(4).
2. Lubricate the outer o-rings with a suitable type of
grease and insert into the corresponding outer
spline of the pipe plates (7).

Fig. 55: Correct installation of the divider (9) must be

observed (ZF 3000, example)

Fig. 53: During assembly the outer o-ring must be

taken into consideration (ZF 3000, example)

Fig. 56: Correct installation of the divider (9) must be

observed (ZF 9000, example)
Note:
With two-way transmission oil coolers a divider (9)
must be inserted into the pipe plate on the water side
(receiver (2) with two connections).
4. Insert the four fixing plates (4) into the middle
Fig. 54: During assembly the outer o-ring must be spline of the pipe plate (7) on the water side
taken into consideration (ZF 9000, example) (receiver (2) with two connections) observing the
identification mark F.
3. Verify the correct installation position of the
divider (9) on the water side. 5. Parallelly mount the receiver (2) and the cover (3)
on the corresponding pipe plates (7) and evenly
slip them onto the outer o-ring.
Note:
When slipping the receiver (2) and the cover (3) onto
the o-rings it must be observed that the o-ring do not
shear off.

ZF Edition: february 2009 / 3000.758.102

Maintenance 33

6. Assemble the receiver (2) and the cover (3) by

means of four bolts, tightening the conjugate
bolts alternating from receiver to cover, applying
the correct tightening torque (see table 8 Tighte-
ning torques on page33).

Transmission Screw /
Tightening torque
type strength
ZF 3000 M10 / 8.8 46 Nm
ZF 4600
ZF 4660
ZF 7600
ZF 9000 M16 / 8.8 195 Nm

Tab. 8: Tightening torques

7. In cases where the transmission oil cooler has
been removed from the transmission housing, the
cooler must be positioned onto the transmission
housing and fixed to the housing by means of four
fastening bolts.
8. Mount the flanged sockets to the receiver (2).
9. Connect the pipelines on the water side.
10. Open and re-fill all pipelines.
11. Bleed the transmission oil cooler on the water
side.
12. Fill the transmission with oil.
Note:
Step 12 is only required, if the transmission oil cooler
has been removed for cleaning the transmission hous-
ing.

3000.758.102 / Edition: february 2009 ZF

34 Maintenance

Assembly of the transmission oil cooler (after

extraction of the pipe bundle)
The assembly of the transmission oil cooler is carried
out in reverse order as the disassembly of the cooler.
1. Grease the sealing strips (12) of the pipe bundle.
The operational medium may be used for this pur-
pose.
Note:
Sealing strips (12) must only be replaced if they are
damaged. The sealing strips must be effective over the
entire length of the pipe bundle.
2. Carefully insert the pipe bundle into the housing
(1).
Fig. 59: During assembly the sealing strips (12) and
the fin ring (14) must be taken into consider-
ation (ZF 3000, example)

Fig. 57: Assembly of the pipe bundle

(ZF 3000, example)

Fig. 60: During assembly the sealing strips (12) and

the fin ring (14) must be taken into consider-
ation (ZF 9000, example)
Note:
On one pipe plate an identification mark for the instal-
lation position is provided opposite the housing. The
edge of the pipe plate and the adjacent housing
flange each contain one half of an X. This mark must
be observed.

Fig. 58: Assembly of the pipe bundle

(ZF 9000, example)
Note:
When inserting the pipe bundle, it must be observed
that the sealing strips (12) are not shifted or crimped.

Fig. 61: Identification mark X for the installation of

the pipe bundle (ZF 3000, example)

ZF Edition: february 2009 / 3000.758.102

Maintenance 35

Note:
When inserting the pipe plates (7) into the sealin sur-
faces, it must be observed that the o-ring do not shear
off.
5. Lubricate the outer o-rings with a suitable type of
grease and insert into the corresponding outer
spline of the pipe plates (7).

Fig. 62: Identification mark X for the installation of

the pipe bundle (ZF 9000, example)
3. Insert the fin ring (14) into the diverter plate (13)
and press down during installation of the pipe
bundle.
Fig. 65: During assembly the outer o-ring must be
4. Lubricate the inner o-rings with a suitable type of taken into consideration (ZF 3000, example)
grease and insert into the corresponding inner
spline of the pipe plates (7).

Fig. 66: During assembly the outer o-ring must be

taken into consideration (ZF 9000, example)
Fig. 63: During assembly the inner o-ring must be
taken into consideration (ZF 3000, example) 6. Verify the correct installation position of the
divider (9) on the water side.

Fig. 64: During assembly the inner o-ring must be

taken into consideration (ZF 9000, example) Fig. 67: Correct installation of the divider (9) must be
observed (ZF 3000, example)

3000.758.102 / Edition: february 2009 ZF

36 Maintenance

14. Bleed the transmission oil cooler on the water

side.
15. Fill the transmission with oil.

Replacement of the pipe bundle

If more than 10% of the pipes in the bundle are leak-
ing/not tight, the entire pipe bundle must be replaced.
1. Disassemble the transmission oil cooler as
described in the section Disassembly of the
transmission oil cooler (with extraction of the pipe
bundle) on page30.
2. Remove the defective pipe bundle.
3. Insert the new pipe bundle.
Fig. 68: Correct installation of the divider (9) must be
observed (ZF 9000, example) 4. Assemble the transmission oil cooler as described
in the section Assembly of the transmission oil
Note: cooler (after extraction of the pipe bundle) on
With two-way transmission oil coolers a divider (9) page34.
must be inserted into the pipe plate on the water side
(receiver (2) with two connections). Revision
7. Insert the four fixing plates (4) into the middle After assembly, both the oil side and the water side
spline of the pipe plate (7) on the water side must be revised. During this operation it must be ob-
(receiver (2) with two connections) observing the served that the pressure (oil side and water side) does
identification mark F. not exceed the value stated in the transmission instal-
8. Parallelly mount the receiver (2) and the cover (3) lation drawing and/or on the type plate.
on the corresponding pipe plates (7) and evenly
slip them onto the outer o-ring.
Note:
When slipping the receiver (2) and the cover (3) onto
the o-rings it must be observed that the o-ring do not
shear off.
9. Assemble the receiver (2) and the cover (3) by
means of four bolts, tightening the conjugate
bolts alternating from receiver to cover, applying
the correct tightening torque (see table 9 Tighte-
ning torques on page36).

Transmission Screw /
Tightening torque
type strength
ZF 3000 M10 / 8.8 46 Nm
ZF 4600
ZF 4660
ZF 7600
ZF 9000 M16 / 8.8 195 Nm

Tab. 9: Tightening torques

10. Position the cooler onto the transmission housing
and fix it to the housing by means of four fasten-
ing bolts.
11. Mount the flanged sockets to the receiver (2).
12. Connect the pipelines on the water side.
13. Open and re-fill all pipelines.

ZF Edition: february 2009 / 3000.758.102

Troubleshooting 37

3 TROUBLESHOOTING

3.1 Table of faults (ZF 2000 und ZF 7500)

Failure Possible cause Inspection / remedy

Oil escapes into the water
Oil escapes from the cooler
Drain and disassemble the cooler,
disassemble receivers / covers,
secure pipe bundle with fixing plates
and bolt;
Pipes in the oil cooler give 5 bare compressed air onto the
Oil level too low
are leaky jacket;
identify defective pipe on the pipe
plates;
close the defective pipe by means of
a copper plug
Drain the cooler on the water and on
the oil side and disassemble it;
Visible oil leakage at O-ring on pipe plate /
disassemble receivers / covers,
the cover housing is defective
extract pipe bundle;
replace o-rings (all)
O-ring transmission Drain cooler on the water and on the
Visible oil leakage at
flange connection oil side and disassemble it;
the transmission
defective replace all o-rings

Drain cooler on the water and on the

oil side and disassemble it;
Water leakage into O-ring on pipe plate /
disassemble receivers / covers,
the oil; oil level too water chamber is
secure pipe bundle with fixing plate
high, milky defective
and bolt;
replace all o-rings.

Water escapes from the cooler Drain transmission oil cooler on the
water side,
Visible water lea- O-ring on pipe plate / disassemble receivers /covers,
kage at the cover cover is defective secure pipe bundle with fixing plate
and bolt;
replace all o-rings.
Visible water lea-
Sealing pipe connec- Replace gasket at the flanged
kage at the flanged
tion defective socket.
socket

3000.758.102 / Edition: february 2009 ZF

38 Troubleshooting

Failure Possible cause Inspection / remedy

Water intake temperature is too
Cooling water intake
high,
temperature is too
consider nominal values in the
high
transmission installation drawing.
Cooling water out- Delivery rate of the cooling water
flow temperature pump too low;
Water flow rate is too
too high; tempera- consider nominal values in the
low
ture measurement transmission installation drawing;
by means of click-on increase delivery rate
sensor, measuring Possibly foreign material in the pipe
whether water or in the cooler, which causes clog-
intake and water ging; clean pipe / pipe bundle.
outflow have a tem-
perature difference Water flow in the Water side is more contaminated
of about 2C to 5C cooler is hindered than usual (e.g. through thick depo-
Transmission oil temperature sits); clean transmission oil cooler.
too high
More than 10% of the pipes are
leaky - replace entire transmission oil
cooler.
Oil side is more contaminated than
usual (e.g. through thick deposits);
clean fins.
Pipe bundle installed correctly?
Cooling water out-
Heat transfer from oil If this is not the case, the pipe bun-
flow temperature
to water is hindered dle must be installed correctly.
not too high
Are all pressure chamber de-aer-
ated?
If this is not the case, de-aerate pres-
sure chamber.
Tab. 10: Table of faults

ZF Edition: february 2009 / 3000.758.102

Troubleshooting
3.2 Table of faults (ZF 2500)
Failure
Oil escapes into the water Oil level too low
Visible oil leakage at
Oil escapes from the cooler
the cover
Water leakage into
the oil; oil level too
Water escapes from the
high, milky
cooler
Visible water leakage
at the flanged socket
Cooling water out-
flow temperature too
high; temperature
measurement by
means of click-on
sensor, measuring
whether water intake
and water outflow
have a temperature
difference of about Water flow in the
cooler is hindered
Transmission oil temperature 2C to 5C.
too high
Cooling water out-
Heat transfer from oil
flow temperature not
to water is hindered
too high
Tab. 11: Table of faults
3000.758.102 / Edition: february 2009
39
Possible cause Inspection / remedy
Drain transmission oil cooler,
disassemble receiver,
remove cooler from the transmission
housing,
Pipes in the cooler are
identify the defective pipe on the
leaky
pipe plates,
close the defective pipe by means of
copper plugs or replace transmission
oil cooler.
Drain transmission oil cooler on the
water side and on the oil side;
O-ring of gasket of the
Disassemble cover,
cover is defective
replace o-ring and gasket of the
cover.
Drain transmission oil cooler on the
Gasket of the receiver water side and on the oil side,
defective disassemble receiver,
replace gasket of the receiver.
Sealing pipe connec- Replace gasket at the flanged
tion defective socket.
Cooling water intake Water intake temperature is too
temperature is too high; consider nominal values in the
high transmission installation drawing.
Delivery rate of the cooling water
pump too low;
Water flow rate is too
consider nominal values in the trans-
low
mission installation drawing;
increase delivery rate
Possibly foreign material in the pipe
or in the cooler, which causes clog-
ging; clean pipe / pipe bundle.
Water side is more contaminated
than usual (e.g. through thick depos-
its); clean transmission oil cooler.
More than 10% of the pipes are
leaky - replace entire transmission oil
cooler.
Oil side is more contaminated than
usual (e.g. through thick deposits);
clean fins.
Transmission oil cooler installed cor-
rectly?
If this is not the case, the cooler
must be installed correctly.
Are all pressure chamber de-aer-
ated? If this is not the case, de-aer-
ate pressure chamber.
ZF
40 Troubleshooting

3.3 Table of faults (ZF 3000, ZF 4600,

ZF 4660, ZF 7600 und ZF 9000)

Failure Possible cause Inspection / remedy

Drain and disassemble the cooler,
disassemble receivers / covers,
secure pipe bundle with fixing plates
and bolt;
Pipes in the cooler are give 5 bare compressed air onto the
Oil escapes into the water Oil level too low
leaky jacket;
identify defective pipe on the pipe
plates;
close the defective pipe by means of
a copper plug
Drain the cooler on the water and on
the oil side and disassemble it; disas-
Visible oil leakage at O-ring on pipe plate /
semble receivers / covers, extract
the cover housing is defective
pipe bundle;
Oil escapes from the cooler
replace o-rings (all)
Drain cooler on the water and on the
Visible oil leakage at O-ring transmission
oil side and disassemble it;
the transmission flange defective
replace all o-rings
Drain the cooler on the water and on
the oil side and disassemble it; disas-
Water leakage into O-ring on pipe plate /
semble receivers / covers, secure
the oil; oil level too water chamber is
pipe bundle with fixing plate and
high, milky defective
bold;
replace o-rings (all).
Water escapes from the coo-
Drain transmission oil cooler on the
ler
water side, disassemble receivers /
Visible water leakage O-ring on pipe plate /
covers, secure pipe bundle with
at the cover cover is defective
fixing plate and bolt;
replace all o-rings.
Visible water leakage Sealing pipe connec- Replace gasket at the flanged
at the flanged socket tion defective socket.

ZF Edition: february 2009 / 3000.758.102

Troubleshooting 41

Failure Possible cause Inspection / remedy

Cooling water intake Water intake temperature is too
temperature is too high,
high consider nominal values in the trans-
mission installation drawing.
Water flow rate is too Delivery rate of the cooling water
low pump too low;
Cooling water out- consider nominal values in the trans-
flow temperature too mission installation drawing;
high; temperature increase delivery rate
measurement by
means of click-on Gland for the bleed off too large;
sensor, measuring use smaller gland; choke the valve
whether water intake Possibly foreign material in the pipe
and water outflow or in the cooler, which causes clog-
have a temperature ging; clean pipe / pipe bundle.
difference of about
Water side is more contaminated
2C to 5C.
Water flow in the than usual (e.g. through thick depos-
cooler is hindered its);
clean pipe bundle.
Transmission oil temperature
too high More than 10% of the pipes are
leaky,
replace entire pipe bundle.
Oil side is more contaminated than
usual (e.g. through thick deposits);
clean fins.
Is divider correctly assembled on the
two-way receiver and are the fixing
plates mounted on this side;
if this is not the case, assemble
Cooling water out- divider correctly.
Heat transfer from oil
flow temperature not
to water is hindered Is the pipe bundle assembled cor-
too high
rectly? Inspect identification mark X;
if this is not the case, assemble pipe
bundle correctly.
Are all pressure chamber de-aer-
ated?
If this is not the case, de-aerate pres-
sure chamber.
Tab. 12: Table of faults

3000.758.102 / Edition: february 2009 ZF

42 Troubleshooting

3.4 Fault clearance sassembly of the transmission oil cooler (without ex-
traction the pipe bundle) on page21 (ZF 2000 und
3.4.1 Closing leaking pipes ZF 7500) or Disassembly of the Transmission oil coo-
ler (without extraction of the pipe bundle) on page28
If there is suspicion of the pipes having become leaky, (ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF 9000).
proceed as under the sections Disassembly of the In case of a defect on the oil side, proceed as under
transmission oil cooler (without extraction the pipe the sections Disassembly of the transmission oil coo-
bundle) on page21 (ZF 2000 und ZF 7500), Disas- ler (with extraction the pipe bundle) on page22
sembly of the transmission oil cooler on page26 (ZF 2000 und ZF 7500) or Disassembly of the trans-
(ZF 2500) or Disassembly of the Transmission oil coo- mission oil cooler (with extraction of the pipe bundle)
ler (without extraction of the pipe bundle) on page28 on page30 (ZF 3000, ZF 4600, ZF 4660, ZF 7600
(ZF 3000, ZF 4600, ZF 4660, ZF 7600 und ZF 9000). und ZF 9000).
After cleaning the pipe plates, from the escaping me-
Note:
dium it can be seen which pipe is leaking. The leaking
In such a case the pipe bundle must not be removed
pipe must be closed from both sides.
from the housing completely.
Note:
Note:
For this purpose, ZF Marine GmbH offers special
Spare o-rings are available at customer service of
plugs. Thus, continued operation is possible without
ZF Marine GmbH. The o-ring must be mounted as de-
having to replace the entire cooler.
scribed under the sections Assembly of the transmis-
1. For disassembly of the transmission oil cooler, sion oil cooler (after extraction of the pipe bundle) on
proceed as under the sections Disassembly of page24 (ZF 2000 und ZF 7500) or Assembly of the
the transmission oil cooler (without extraction the transmission oil cooler (after extraction of the pipe
pipe bundle) on page21 (ZF 2000 und bundle) on page34 (ZF 3000, ZF 4600, ZF 4660,
ZF 7500), Disassembly of the transmission oil ZF 7600 und ZF 9000).
cooler on page26 (ZF 2500) or Disassembly of
the Transmission oil cooler (without extraction of
the pipe bundle) on page28 (ZF 3000, ZF 4600,
ZF 4660, ZF 7600 und ZF 9000).
2. Thoroughly clean the defective pipe down to the
offset of the plug.
Note:
It must be ensured that this area on the inner side of
the pipe is free from corrosion and pitting.
3. Press in the plug with a suitable device such that
it is flush.
Note:
The plug must not be hammered in too heavily since
adjacent expanded portions could then be damaged.
A maximum of 10% oft he pipes may be closed with-
out a noticeable degradation in performance occur-
ring. Disassembly of individual defective pipes is not
possible. If more than 10% of the pipes are defective,
this type of repair is not longer permissible as the ther-
mal performance becomes too low.

3.4.2 Leaking o-rings

If a leaking point is detected between the receiver ort

he cover and the housing, this is an indication for a
defective o-ring at the pipe plate. The type of escaping
medium allows for detection, at which point of the
pipe plate (ZF 2000, ZF 7500) or at which spline of
the pipe plate (ZF 3000, ZF 4600, ZF 4660, ZF 7600
and ZF 9000) the defect is present. In case of a defect
on the water side, proceed as under the sections Di-

ZF Edition: february 2009 / 3000.758.102

Troubleshooting 43

3000.758.102 / Edition: february 2009 ZF

ZF Marine GmbH
88038 Friedrichshafen
Deutschland
Telephone +49 7541 77-2207
Telefax +49 7541 77-4222
info.zfmarine@zf.com

Transmission and Chassis Engineering