ZF 63 A User manual

ZF 63 A
ZF 63
ZF 80 A
ZF 80-1 A
ZF 80 A NEW VERSION
ZF 80-1 A NEW VERSION
ZF 85 A
NOVEMBER 2005
cod.
310.01.0054h
Repair Manual
and
Spare arts List

TABLE OF CONTENTS
INTRODUCTION. . ................................... 3
1. MAJOR COMPONENTS. . .......................... 5
1.1 TRANSMISSION SET-UP . .......................5
1.2 CLEANERS AND SEALANTS . . . ..................6
1.3 MEASURING TOOLS . ...........................6
1.4 STANDARD TOOLS AND FIXTURE . ..............6
2. SPECIAL TOOLS . . ............................... 7
3. DISASSEMBLY ................................... 9
INTRODUCTION....................................9
3.1 FLUID FILTER . . ................................9
3.1.1 Remove f uid fi ter . . . .......................9
3.1.2 Suction of transmission f uid . . . ..............9
3.1.3 Suction of transmission f uid on
ZF 80 A, ZF 80-1 A and ZF 85 A . ..............9
3.2 DIPSTICK . . .................................. 10
3.3 BREATHER VALVE. . . ......................... 10
3.4 OUTPUT FLANGE............................. 10
3.5 CONTROL BLOCK . . . ......................... 11
3.5.1 Neutra Safety Switch ..................... 11
3.5.2 Neutra Safety Switch Check . . . ............ 11
3.6 HOUSING . . .................................. 12
3.6.1 Transmission housing ha ves. . . ............ 12
3.6.2 Shafts and gears ......................... 12
3.6.3 Radia shaft sea s ......................... 12
3.6.4 F uid in et pipe . . ......................... 13
3.7 TAPERED ROLLER BEARINGS. ................ 14
3.7.1 Outer races of tapered ro er bearing . ....... 14
3.7.2 Inner races of tapered ro er bearings ....... 14
3.8 CLUTCH PACK . .............................. 15
3.8.1 Remova of the c utch discs ................ 15
4. ASSEMBLY...................................... 17
INTRODUCTION.................................. 17
4.1 INPUT SHAFT . . .............................. 17
4.1.1 Mount discs into reversing c utch ........... 17
4.1.2 Insta need e bearings and gear............ 18
4.1.3 Assemb e butting rings .................... 18
4.1.4 Mounting inner races of tapered
ro er bearings. . . ......................... 18
4.1.5 Assemb e piston rings ..................... 18
4.2 INTERMEDIATE SHAFT. . . ..................... 19
4.2.1 Mounting inner races of tapered
ro er bearings. . . ......................... 19
4.3 OUTPUT SHAFT .............................. 19
4.3.1 Mounting inner race of tapered
ro er bearing............................. 19
4.4 PREASSEMBLY OF HOUSING ..................20
4.4.1 Assemb y of outer races
(tapered ro er bearings) . ...................20
4.4.2 Insta ation of f uid suction pipe and baff e. . . . 20
4.4.3 Assemb ing input shaft sea . . . ..............21
4.4.4 Mounting the breather fi ter . . . ..............21
4.5 MEASURING THE BEARING CLEARANCE/
ADJUSTING THE PRETENSION OF BEARINGS . . 22
4.5.1 Genera . . . ................................22
4.5.2 Mounting outer races of tapered ro er
bearings into housing . . . ...................22
4.5.3 Inserting gear set into housing ..............22
4.5.4 Measuring bearing c earance on input
shaft . ....................................23
4.5.5 Measuring bearing c earance at
intermediate shaft . . .......................23
4.5.6 Measuring the bearing c earance on the
output shaft...............................23
4.5.7 Adjusting the pretension/c earance of
bearings. . ................................24
4.5.8 Fina assemb y of the housing ..............24
4.6 CONTROL BLOCK . . ...........................25
4.6.1 Mounting the contro b ock . . . ..............25
4.7 FLUID FILTER . ................................25
4.7.1 Mounting the f uid fi ter . ...................25
4.8 OUTPUT FLANGE . . ...........................25
4.9 MAKING THE TRANSMISSION
READY FOR OPERATION . . . ...................26
4.9.1 Fi ing up with transmission F uid . ..........26
4.9.2 Check f uid eve . . . .......................26
5. ADJUSTMENT DATA . . ...........................27
5.1 SHIFTING PRESSURE . . .......................27
5.2 LUBE OIL DELIVERY RATE. . ...................27
6. HYDRAULIC DIAGRAM. ...........................28
7. TIGHTENING TORQUES...........................29
8. FUNCTION TEST . ................................3
9. TROUBLESHOOTING . . ...........................31
1 . AUTOMATIC TRANSMISSION FLUID ..............36
11. SPARE PARTS LIST
ZF63A - ZF63 - ZF8 A - ZF8 -1A...............39
Preface . . .........................................39
Name p ate . . . ....................................39
FIG. 1 ZF 63 A. ....................................40
FIG. 1 ZF 63 . . ....................................42
FIG. 1 ZF 80 A - ZF 80-1 A . . .......................44
1
Repair Manua and Spare Parts List Tab e of contents

FIG. 2 ZF 63 A .................................... 46
FIG. 2 ZF 63 . .................................... 50
FIG. 2 ZF 80 A - ZF 80-1 A. . ....................... 52
FIG. 3 Mechanica se ector va ve
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . . ..... 56
FIG. 4 O d e ectric se ector va ve with proportiona va ves
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . . ..... 58
FIG. 5 ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . . ..... 60
FIG. 6 O d e ectric se ector va ve ON/OFF 12V, 26 bar
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . . ..... 62
FIG. 7 New e ectric se ector va ve ON/OFF 12V - 26 bar
New e ectric se ector va ve ON/OFF 24V - 26 bar
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . ..... 64
FIG. 8 New e ectric se ector va ve ON/OFF 12V - 26 bar
with tro ing va ve
New e ectric se ector va ve ON/OFF 24V - 26 bar
with tro ing va ve
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . ..... 66
ZF 63 A - ZF 63 KIT COMPONENTS . . . .............. 68
ZF 80 A - ZF 80-1 A KIT COMPONENTS .............. 69
12. SPARE PARTS LIST ZF 8 A - ZF 8 -1 A
NEW VERSION . ................................ 71
Preface . . ........................................ 71
Name p ate . . . .................................... 71
FIG. 1 ZF 80 A - ZF 80-1 A . . . ....................... 72
FIG. 2 ZF 80 A - ZF 80-1 A . . . ....................... 74
FIG. 3 Mechanica se ector va ve
ZF 80 A - ZF 80-1 A . . . ....................... 78
FIG. 4 O d e ectric se ector va ve ON/OFF 12V, 26 bar
ZF 80 A - ZF 80-1 A . . . ....................... 80
FIG. 5 New e ectric se ector va ve ON/OFF 12V - 26 bar
New e ectric se ector va ve ON/OFF 24V - 26 bar
ZF 80 A - ZF 80-1 A . . . ....................... 82
FIG. 6 New e ectric se ector va ve ON/OFF 12V - 26 bar
with tro ing va ve
New e ectric se ector va ve ON/OFF 24V - 26 bar
with tro ing va ve
ZF 80 A - ZF 80-1 A . . . ....................... 84
KIT COMPONENTS ZF 80 A - ZF 80-1 A .............. 86
13. SPARE PARTS LIST ZF 85 A . . ................... 87
Preface .......................................... 87
Name p ate. . ..................................... 87
FIG. 1 ZF 85 A . . . ................................. 88
FIG. 2 ZF 85 A . . . ................................. 90
FIG. 3 Mechanica se ector va ve
ZF85A.................................... 92
FIG. 4 E ectric se ector va ve ON/OFF 12V - 26 bar
E ectric se ector va ve ON/OFF 24V - 26 bar
ZF85A.................................... 94
FIG. 5 E ectric se ector va ve ON/OFF 12V - 26 bar
with tro ing va ve
E ectric se ector va ve ON/OFF 24V - 26 bar
with tro ing va ve
ZF85A.................................... 96
KIT COMPONENTS ZF 85 A ........................ 98
2
Repair Manua and Spare Parts List Tab e of contents

INTRODUCTION
This manua gives specific instructions for the proper repair on
ZF 63 - ZF 63 A - ZF 80 A - ZF 80-1 A - ZF 85 A transmissions.
P ease fo ow the procedures carefu y to insure qua ity service.
ZF HURTH MARINE recommends to read the manua comp ete y
before starting with repairs, as some of the procedures described
are rather comp ex.
A ong with standard too s, ZF HURTH MARINE recommends the
use of specia too s, necessary to perform repairs correct y. The
specia too s are avai ab e through your oca ZF HURTH MARINE
dea er.
This manua is based on the technica information at the time of
printing. The manua has been checked carefu y in order to avoid
errors. However ZF HURTH MARINE is not iab e for any misrepre-
sentations, errors of description or omissions.
Modifications on future manua s may be introduced without prior
notice.
3
Repair Manua and Spare Parts List Introduction

4

1. MAJOR COMPONENTS
1.1 TRANSMISSION SET-UP
The main components of the ZF Marine Transmissions are:
ITEM DESCRIPTION ITEM DESCRIPTION
1
Two-piece a uminum die cast
2
Gears
1.1
Oi fi ter
2.1
Input shaft with reversing c utch pack assemb y
1.2
Oi dipstick
2.2
Intermediate shaft
1.3
Breather va ve
2.3
Output shaft
1.4
Oi drain p ug (ZF 80A, ZF 80-1A, ZF 85A)
3
Contro b ock
5
Repair Manua and Spare Parts List Section 1
1
1.2
1.3
1.1
1.4
3
2.1
2.3
2.2
2

1.2 CLEANERS AND SEALANTS
6
Repair Manual and Spare Parts List Section 1
For cleaning:
Cold cleaner such as benzene, thrichloroethane or Loc-
tite fast cleaner N
o 7063
| WARNING |
Keep detergents away from yo r skin, do not drink
and do not inhale their vapors! Always wear protec-
tive gloves and safety glasses!
Note accident prevention r les!
For assembly:
. Loctite 243 medium-hard for securing oil plug on
ZF 80 A - ZF 80-1 A - ZF 85 A
. Loctite 245 for securing output flange on spline
. Loctite 518 for housing surfaces
. Loctite 574 for outer diameter sealing rings
. Grease: Staburags NBU 30, Klueber Co for radial
shaft seals
. ATF FLUID:
3 8 litres (1 0 US gallons) for ZF 63
4 0 litres (1 05 US gallons) for ZF 63 A
5 5 litres (1 5 US gallons) for ZF 80 A - ZF 80-1 A
5 5 litres (1 5 US gallons) for ZF 85 A
1.3. MEASURING TOOLS
MICROMETER
Measuring gauge from 0-25 mm (0-1 0 in )
Accurancy of reading 1/100 mm (0 0004 in )
DIAL INDICATOR GAUGE WITH ARM-TYPE
SUPPORT
DIAL GAUGE INCREMENTS
DIAL FACE CAN BE TURNED
TO ZERO POSITION
ACCURACY OF READING:
SMALL HAND 1 mm (.03937 in)
LARGE HAND
1/100 mm (.0004 in)
MEASURING DEPTH
APPROX. 11 mm (.433 in)
FEELER GAUGE
1.4. STANDARD TOOLS AND FIXTURE
WRENCH for hexagon bolts (8 - 17 - 19 - 22 mm) (7/8")
ALLEN WRENCH (6 mm)
HEXAGON SOCKET WRENCH (6 - 8 - 17 - 19 mm)
TORQUE WRENCH
adjustable up to 180 Nm (152 ft lb )
PLASTIC HAMMER (1000 g) and sturdy screwdriver
EXTRACTOR minimum diameter 130 m
PLIER

2. SPECIAL TOOLS
It is assumed that a standard too s, such as, torque
wrenches, open-end wrenches, a en keys and extrac-
tors, are avai ab e.
A fixtures for pressing parts in or out shou d be used in
conjunction with a hydrau ic or manua press.
EXTRACTOR
Tapered ro er bearing inner races
Basic Unit P/N 978.25.0017.0 (454421)
ADAPTER for basic unit 978.25.0017.0 (454421).
For bearing input shaft - sp ine side.
- P/N 978.25.0018.0 (469686) ZF 63 A - ZF 63
- P/N 978.35.0019.0 (500465) ZF 80 A - ZF 80-1 A -
ZF 85 A
D
EXTRACTOR SPLIT RING
Input shaft. Taper ro er bearing inner race - contro
b ock side. P/N 224.836.009 (456170)
EXTRACTOR Tapered ro er bearing outer races basic
unit P/N 978.25.0021.0 (454422)
ADAPTER FOR
BASIC UNIT 454422
50
AB
BASIC UNIT
LEGS KIT (composed of three legs)
P/N 978.25.0006.0 (477776)
Part number ZF 63
ZF 63 A
ZF 8 A
ZF 8 -1 A ZF 85 A
978.25.0009.0 (477853) ll
978.25.0011.0 (477854) lll
978.25.0012.0 (477856) l
978.25.0013.0 (477857) l
978.35.0016.0 (477895) ll
CLAMPING RING for measuring the bearing c earance
input shaft P/N 219.354.3 (618582)
LEVER
CLAMPING SCREW
INPUT SHAFT
DIAL INDICATOR
MANDREL
For disassemb y and assemb y
Shaft sea - input side : P/N 224.836.005 (454425)
Shaft sea - output side:
- P/N 224.836.006 (454426) ZF 63 A - ZF 63
- P/N 978.35.0005.0 (500449) ZF 80 A - ZF 80-1 A -
ZF 85 A
For assemb ing input shaft sea on the input sp ine side
Bushing P/N 20.0012.01 to insert input shaft sea
On y for mode s: ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
Mandre P/N 20.0012.02 to assemb e input shaft sea
On y for mode s: ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
Mandre P/N 20.1072.01 to assemb e input shaft sea
On y for mode : ZF 85 A
7
Repair Manua and Spare Parts List Section 2

SHIM
To determinate the correct pre oad of the tapered ro er
bearings.
- P/N 20.1005.00 ZF 63 A
- P/N 20.1018.00 ZF 63
- P/N 20.1016.00 - ZF80 A - ZF 80-1 A - ZF 85 A
SPECIAL HEX HEAD BOLT WITH BEARING
for measuring the bearing c earance intermediate shaft
P/N. 224.836.008 (458105)
PUNCH
for assemb y Sea - suction pipe
- P/N 20.1021.00 ZF 80 A - ZF 80-1 A - ZF 85 A
- P/N 20.1029.00 ZF 63 A - ZF 63
CENTRE SQUARE PUNCH To position the oi suction
pipe into housing P/N 20.1041.00
8
Repair Manua and Spare Parts List Section 2