ZF ZF 63 IV User manual

ZF 63 IV
ZF 80 IV
ZF 80-1 IV
ZF 85 IV
FEBRUARY 2006
cod.
310.01.0009h
Repair Manual
and
Spare Parts List

TABLE OF CONTENTS
INTRODUCTION. . ................................... 3
1. MAJOR COMPONENTS. . .......................... 5
1.1 MAJOR TRANSMISSIONS COMPONENTS . . . .....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 63 IV, ZF 80 IV, ZF 80-1 IV and ZF 85 IV . . . . 9
3.2 REMOVAL DIPSTICK . ......................... 10
3.3 REMOVAL BREATHER VALVE . ................ 10
3.4 OUTPUT FLANGE............................. 10
3.5 REMOVAL 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 Disassemb e the transmission housing
haves................................... 12
3.6.2 Remova of shafts and gears. . . ............ 12
3.6.3 Remova of radia shaft sea s . . ............ 12
3.6.4 Remova of f uid in et pipe . ................ 13
3.7 TAPERED ROLLER BEARINGS. ................ 14
3.7.1 Disassemb ing the outer races of
taper ro er bearing . ..................... 14
3.7.2 Remova of inner races of
taper ro er bearings ..................... 14
3.8 REVERSING 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. . . ......................... 19
4.1.5 Assemb e piston rings..................... 19
4.2 INTERMEDIATE AND REVERSAL SHAFT ....... 20
4.2.1 Mounting inner races of tapered
ro er bearings. . ......................... 20
4.3 OUTPUT SHAFT ...............................20
4.3.1 Preparations for assemb y ..................20
4.3.2 Mounting inner race of
tapered ro er bearing . . . ...................20
4.3.3 Pressing the gear on . . . ...................20
4.4 PREASSEMBLY OF HOUSING ..................21
4.4.1 Assemb y of outer races
(tapered ro er bearings) . ...................21
4.4.2 Insta ation of f uid suction pipe . . . ..........21
4.4.3 Assemb ing input shaft sea . . ..............22
4.4.4 Mounting the breather fi ter . . . ..............22
4.5 MEASURING THE BEARING CLEARANCE/
ADJUSTING THE PRETENSION OF BEARINGS . 23
4.5.1 Genera . . ................................23
4.5.2 Mounting outer races of tapered ro er
bearings into housing . . ...................23
4.5.3 Inserting gear set into housing . . . ..........23
4.5.4 Measuring bearing c earance
on input shaft . ...........................24
4.5.5 Measuring bearing c earance at
intermediate and reversa shafts . ..........24
4.5.6 Measuring the bearing c earance
on the output shaft .......................25
4.5.7 Adjusting the pretension c earance
of bearings . . . ...........................25
4.5.8 Fina assemb y of the housing . . . ..........26
4.6 CONTROL BLOCK . ...........................27
4.6.1 Mounting the contro b ock . . ..............27
4.7 FLUID FILTER ................................27
4.7.1 Mounting the f uid fi ter . ...................27
4.8 MAKING THE TRANSMISSION
READY FOR OPERATION . . ...................27
4.8.1 Fi ing up with Transmission F uid .........27
4.8.2 Inserting f uid fi ter into housing . ..........27
4.8.3 Check f uid eve . . .......................28
5. ADJUSTMENT DATA . ...........................29
5.1 SHIFTING PRESSURE . .......................29
5.1.1 ZF 80-1 IV VERSION - ZF 85 IV . . . ..........29
5.1.2 ZF 63 IV - ZF 80 IV VERSION . ..............29
5.1.3 ZF 63 IV INDMAR VERSION . ..............30
5.2 LUBE OIL DELIVERY RATE. ...................30
5.2.1 ZF 80-1 IV VERSION - ZF 85 IV . . . ..........30
5.2.2 ZF 63 IV - ZF 80 IV VERSION . ..............31
5.2.3 ZF 63 IV INDMAR VERSION . ..............31
6. HYDRAULIC DIAGRAM...........................32
7. TIGHTENING TORQUES. . . .......................33
8. FUNCTION TEST ................................34
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Repair Manua and Spare Parts List Tab e of contents

9. TROUBLESHOOTING. ........................... 35
1 . AUTOMATIC TRANSMISSION FLUID ............. 4
11. SPARE PARTS LIST ZF63 IV - ZF8 IV - ZF8 -1 IV . 43
Preface . ........................................ 43
Name p ate . . .................................... 43
FIG. 1 ZF 63 IV . . ................................ 44
FIG. 1 ZF 80 IV - ZF 80-1 IV ...................... 46
FIG. 2 ZF 63 IV . . ................................ 48
FIG. 2 ZF 80 IV - ZF 80-1 IV ...................... 50
FIG. 3 Mechanica se ector va ve
ZF 63 IV - ZF 80 IV - ZF 80-1 IV ............. 54
FIG. 4 O d e ectric se ector va ve with
proportiona va ves
ZF 63 IV - ZF 80 IV - ZF 80-1 IV ............. 56
FIG. 5 ZF 63 IV - ZF 80 IV - ZF 80-1 IV ............. 58
FIG. 6 O d e ectric se ector va ve
ON/OFF 12V, 26 BAR
ZF 63 IV - ZF 80 IV - ZF 80-1 IV ............. 60
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 IV - ZF 80 IV - ZF 80-1 IV ............. 62
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 IV - ZF 80 IV - ZF 80-1 IV ............. 64
KIT COMPONENTS ZF 63 IV ...................... 66
KIT COMPONENTS ZF 80 IV - ZF 80-1 IV . ......... 67
12. SPARE PARTS LIST
ZF 8 IV ( 29 - 3 - 31 - 32 - 33 VERSION)
ZF 8 - 1 IV ( 34 - 35 - 36 - 37 - 38 VERSION) .. 69
Preface ........................................ 69
Name p ate . .................................... 69
FIG. 1 ZF 80 IV, ZF 80 - 1 IV ....................... 70
FIG. 2 ZF 80 IV, ZF 80 - 1 IV ....................... 72
FIG. 3 Mechanica se ector va ve
ZF80IV, ZF80-1IV....................... 76
FIG. 4 O d e ectric se ector va ve
ON/OFF 12V, 26 bar ZF 80 IV, ZF 80 - 1 IV . . . 78
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
ZF80IV, ZF80-1IV....................... 80
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
ZF80IV, ZF80-1IV....................... 82
KIT COMPONENTS
ZF80IV, ZF80-1IV ............................. 84
13. SPARE PARTS LIST ZF 85 IV . ................... 85
Preface . . . ..................................... 85
Name p ate..................................... 85
FIG. 1 ZF 85 IV ................................. 86
FIG. 2 ZF 85 IV ................................. 88
FIG. 3 Mechanica se ector va ve ZF 85 IV . . . ...... 90
FIG. 4 E ectric se ector va ve ON/OFF 12V - 26 bar
E ectric se ector va ve ON/OFF 24V - 26 bar
ZF85IV ................................. 92
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
ZF85IV ................................. 94
KIT COMPONENTS ZF 85 IV . . ................... 96
14. SPARE PARTS LIST ZF 8 IV
(ZF 85 IV DERIVATE VERSION) . . . ............... 97
Preface .......................................... 97
Name p ate. . ..................................... 97
FIG. 1 ZF 80 IV (ZF 85 IV DERIVATE VERSION) ...... 98
FIG. 2 ZF 80 IV (ZF 85 IV DERIVATE VERSION) ..... 100
FIG. 3 Mechanica se ector va ve
ZF 80 IV (ZF 85 IV DERIVATE VERSION) ..... 102
FIG. 4 E ectric se ector va ve ON/OFF 12V - 26 bar
E ectric se ector va ve ON/OFF 24V - 26 bar
ZF 80 IV (ZF 85 IV DERIVATE VERSION) ..... 104
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
ZF 80 IV (ZF 85 IV DERIVATE VERSION) ..... 106
KIT COMPONENTS ZF 80 IV
(ZF 85 IV DERIVATE VERSION). . .................. 108
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Repair Manua and Spare Parts List Tab e of contents

INTRODUCTION
This manua gives specific instructions for the proper repair on
ZF 63 IV - ZF 80 IV - ZF 80-1 IV - ZF 85 IV mode 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 misre-
presentations, errors of description or omissions.
Modifications on future manua s may be introduced without prior
notice.
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Repair Manua and Spare Parts List Introduction

4

1. MAJOR COMPONENTS
1.1 MAJOR TRANSMISSIONS COMPONENTS
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 shafts
1.3
Oi drain p ug
2.3
Reversa shaft
1.4
Breather va ve
3
Contro b ock
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Repair Manua and Spare Parts List Section 1
1
3
1.1
1.4
1.3
1.2
2.1
2
2.3 2.2
2.4

1.2 CLEANERS AND SEALANTS
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Repair Manua and Spare Parts List Section 1
For c eaning:
Co d c eaner such as benzine, trich oroethane or Loc-
tite fast c eaner No. 7063.
| WARNING |
Keep detergents away from your skin, do not drink
and do not inhale their vapors!
Always wear protective gloves and safety glasses!
Note accident prevention rules!
For assemb y:
. Loctite 243 for securing screws, medium-hard
. Loctite 245 for securing output f ange on sp ine .
.
Loctite 518 for housing surfaces.
. Loctite 574 for outer diameter sea ing rings.
. Grease: Staburags NBU 30, K u
Èber Co. for radia
shaft sea s
. ATF F uid:
4.4 iters (1.1 US ga ons) for ZF 63 IV
7.0 iters (1.85 US ga ons) for ZF 80 IV - ZF 80-1 IV.
7.0 iters (1.85 US ga ons) for ZF 85 IV.
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 bo ts (8 - 17 - 19 - 22 mm) (7/8")
ALLEN WRENCH (6 mm)
HEXAGON SOCKET WRENCH (6 - 8 - 17 - 19 mm)
TORQUE WRENCH
adjustab e up to 180 Nm (152 ft. b.)
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 IV
- P/N 978.35.0019.0 (500465) ZF 80 IV - ZF 80-1 IV -
ZF 85 IV
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)
ZF 63 IV ZF 8 IV - ZF 8 -1 IV - ZF 85 IV
Ð 978.25.0009.0 (477853)
Ð 978.25.0011.0 (477854)
978.25.0013.0 (477857)
Ð
978.30.0014.0 (477858) 978.30.0014.0 (477858)
Ð 978.35.0016.0 (477895)
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 prope er side:
- P/N 978.30.0001.0 (500445) ZF 63 IV
- P/N 20.1040.01 ZF 80 IV - ZF 80-1 IV - ZF 85 IV
Output shaft sea contro b ock side:
- P/N 978.30.0003.0 (500447) ZF 63 IV
- P/N 20.1040.02 ZF 80 IV - ZF 80-1 IV - ZF 85 IV
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 IV - ZF 80 IV - ZF 80-1 IV
Mandre P/N 20.0012.02 to assemb e input shaft sea
On y for mode s: ZF 63 IV - ZF 80 IV - ZF 80-1 IV
Mandre P/N 20.1072.01 to assemb e input shaft sea
On y for mode : ZF 85 IV - ZF 80 IV (ZF 85 IV DERIVATE
VERSION)
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Repair Manua and Spare Parts List Section 2

SHIM
To determinate the correct pre oad of the tapered ro er
bearings.
- P/N 20.1017.00 ZF 63 IV
- P/N 20.1019.00 ZF 80 IV - ZF 80-1 IV - ZF 85 IV
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
ZF 80 IV - ZF 80-1 IV - ZF 85 IV P/N 20.1021.00
ZF 63 IV: P/N 20.1029.00
CENTRE SQUARE PUNCH To position the oi suction
pipe into housing P/N 20.1041.00
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Repair Manua and Spare Parts List Section 2