SERVICE MANUAL AND SPARE PARTS LIST - BUKH …

1 SERVICE MANUAL AND SPARE PARTS LISTSERVICE MANUAL AND SPARE PARTS LISTCod. 3 M (HBW 35)ZF 5 M (HBW 50)ZF 10 M (HBW 100)ZF 12 M (HBW 125) / HBW 10ZF 15 M (HBW 150)ZF 15 MA (HBW 150 A)ZF 15 MIV (HBW 150 V)ZF 25 M (HBW 250)ZF 25 MAZF 30 MManual and SPARE PARTS List ZF M line3 This ZF M MANUAL has been preparedfor all those who have to do with ZF-HURTH Marine reversing gearbox unitsof the ZF M line, including models ZF 3M, ZF 5 M, ZF 10 M, ZF 12 M, ZF 15 M,ZF 15 MA, ZF 25 M, ZF 25 MA, ZF 30 M,ZF 15 MIV, in particular for- power plant suppliers- shipyards- craft ownersThe ZF M MANUAL is intended as an aidfor handling ZF M transmissions and willanswer all questions that may arise indaily operation and in connection with theinstallation and repair of ZF M MANUAL contains.

2 - Technical description of the gearboxunits and a number of important tech-nical data;- Instructions for proper installation of thegearbox in the craft;- Explanatory notes on correct operationand maintenance;- Detailed description of all disassemblyand reassembly procedures (withdrawings);- Troubleshooting table with possiblecauses of trouble and the required re-medial action;- SPARE PARTS list with stock numbers ofall sparte PARTS ;- Explosion-View drawings showingeach part with the reference numeralsused in the problems will be encountered in han-dling, installing and operating the ZF Mgearbox if the instructions in this manualare followed. Should a repair be neces-sary, a qualified technician will have nodifficulty in doing the repair work in ac-cordance with the detailed instructionsgiven on the following addition, ZF M SERVICE Stations (dis-tributors and dealers) are available forany repairs and for supplying the spareparts required.

3 The manufacturer will al-ways be glad to name the SERVICE Sta-tion nearest to your transmission units are covered by aworldwide guarantee given by the manu-facturer. The manufacturer s warrantywill be subject to the condition that:- the instructions in this MANUAL arestrictly observed in handling no work is performed by persons notauthorized by ZF-HURTH no changes or alterations of any kindare made on the to observe these points willinvalide all and any warranty : never start doing any work onthe transmission unless and until theengine and the propeller have come toa complete and SPARE PARTS List ZF M line4 Table of data and ZF 3 M boat reversinggearbox ZF 5 M boat reversinggearbox ZF 10 M boat reversinggearbox ZF 12 M boat reversinggearbox ZF 15 M boat reversinggearbox ZF 15 MA boat reversinggearbox ZF 15 MIV boat reversinggearbox ZF 25 M boat reversinggearbox ZF 25 MA boat reversinggearbox Ident.

4 Clutch and seals1, of the of gearboxwith of gearboxwith of engine-gearbox assembly in the of gearbox inthe of Cooling Engine-gearbox of or moving in for level the shift cableand transmission fluiidList of recommended the cooling and disassemblingthe actuating lever cover the bearing the gearboxsections and removing theinput and output the shifting the intermediate the input the output the quill the intermediategear shaft in the gearbox sectionwithout the shifting forkin the gearbox section the actuatinglever cover the the pre-assembledgears to determine settingvalue a the the the input Reassembling the output Reassembling the quill Final assembly of Measuring the gear sets ofinput shaft

5 And output Mounting the actuating levercover Mounting the cooling to adjust the shiftinglever PARTS (Explosion view) MANUAL and SPARE PARTS List ZF M descriptionZF-HURTH Marine boat reversing gear-box units of the ZF M line are servo-au-tomatically controlled helical gear trans-missions developed for use in pleasurecraft and commercial craft. The servo-operated multiple-disc clutchrequires only minimum effort for shifting,making the ZF M transmission suitablefor single-lever remote control via a rodlinkage or shift emergency situations the ZF M per-mits direct reversing at engine speedabove idle torque capacity of the clutch is ex-actly rated, preventing shock loads fromexceeding a predetermined value to en-sure maximum protection of the engineand thus providing the effect of a transmission units are characterizedby low weight and small overall dimen-sions.

6 The gearbox castings are madeof a high-strength, corrosion-resistantaluminium alloy, chromized for improvedseawater resistance and optimumadhesion of choice of gear ratios, a high efficiencyrating and low-noise operation are otherprominent features of the ZF M transmissions are immersion-lubri-cated. Maintenance is restricted to oillevel checks (see Maintenance , chap-ter 4).The shafts are supported by heavy-dutytaper roller bearings and the gearbox isdesigned to take the axial propeller thrust(for permissible values see Technicaldata , item ).Transmission sizes are available forright-hand (RH) and left-hand (LH)rotation of the input shaft, the directionof rotation being specified as seen by anobserver facing the input gear lever positions A, the engine shaftand the propeller shaft rotate in oppo-site directions, in position B in the samedirection (Fig.)

7 1).On model ZF 15 MIV, the directions ofrotation are the other way round (Fig. 2).Engine manufacturers should note thatthe direction of rotation refers to an ob-server facing the flywheel, so that left-hand rotation of the engine correspondsto right-hand rotation of the gearbox in-put 1 Fig. 2 MANUAL and SPARE PARTS List ZF M ZF 3 MPower diagramBased on engine power B to DIN 6270;shock factorK = to applied, if engine has 1 cylinderK = for 2 cylindersK = for 3 cylindersTransmission input speed (rpm)Transmission power inputTechnical dataZF 3 M-2 RZF 3 M-3 RShifting position A :1 Shifting position B :1 Input torque (ft lb)40 (29,5)30 (22,1)Power input (hp)15 (20)Input speed thrust (lb)1000 (225)Weight without fluidkg (lb)8 ( )Fluid gradeAutomatic-Transmission-Fluid (ATF) MANUAL and SPARE PARTS List ZF M line7 All dimensions in mmFig.

8 3 ZF 3 M54 MANUAL and SPARE PARTS List ZF M ZF 5 MPower diagram for Pleasure Craft DutyBased on engine power B to DIN 6270;shock factorK = to applied, if engine has 1 cylinderK = for 2 cylindersK = for 3 cylindersTransmission power inputZF 5 20275000818 17235000 Max input power 15 kWMODELRATIOPOWER / RPMINPUT POWER CAPACITYMAXWEIGHTBELL HSGS. A Pos B PoskWhpkWhp kWhp kWhpRPMkglbAND NOTES2800 rpm3000 rpm 3600 rpm A POS = continuous running position (normally AHEAD). B POS = reverse = Borg Warner = For all M (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine , 2 cylinder engine ,3 cylinder engine and SPARE PARTS List ZF M line9 Fig. 4 ZF 5 MAll dimensions in mm54 MANUAL and SPARE PARTS List ZF M line10** Max.

9 95 Nm (70 ft lb) admissible for main travelling direction with gearlever set to B ZF 10 MPower diagram for Pleasure Craft DutyBased on engine power B to DIN 6270;shock factorK = to applied, if engine has 1 cylinderK = for 2 cylindersK = for 3 cylindersTransmission input speed (rpm)Transmission power input1,8 MODELRATIOPOWER / RPMINPUT POWER CAPACITYMAXWEIGHTBELL HSGS. A Pos B PoskWhpkWhp kWhp kWhpRPMkglbAND NOTES2800 rpm3000 rpm 3600 rpmZF 10 4, 5, Max input power 38 34465000 Ratio B 25335000max torque 95 Nm. B Pos. maxtorque 95 Nm. A POS = continuous running position (normally AHEAD). B POS = reverse = Borg Warner = For all M (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine , 2 cylinder engine ,3 cylinder engine and SPARE PARTS List ZF M line11 Fig.

10 5 ZF 10 MAll dimensions in mm54 MANUAL and SPARE PARTS List ZF M ZF 12 MPower diagram for pleasure craftBased on engine power B to DIN 6270;shock factor K = to applied,if engine has fewer than 4 input speed (rpm)Transmission power inputZF 12 476350001329 SAE 4, 5, 40545000 Max input power 55 kWMODELRATIOPOWER / RPMINPUT POWER CAPACITYMAXWEIGHTBELL HSGS. A Pos B PoskWhpkWhp kWhp kWhpRPMkglbAND NOTES2800 rpm3000 rpm 3600 rpm A POS = continuous running position (normally AHEAD). B POS = reverse = Borg Warner = For all M (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine , 2 cylinder engine ,3 cylinder engine and SPARE PARTS List ZF M line13 Fig. 6 ZF 12 MModel without mounting flangea) Clockwise rotation b) Oil dipstick and filler screw 17 mm c) M 8/12 deep, holes same on both sides d) Oil drain plug 17 mm widthacross flats e) Spline profile similar B 10 x 23 x 29 DIN 5464 f) Minimum lever travelModel with mounting flangeAll dimensions in mmManual and SPARE PARTS List ZF M line14** Max.