ZF 63 A, 63, 80 A, 80 A new version, 85 Repair Manual & Parts List
...
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 Parts 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 fluid filter . . . .......................9
3.1.2 Suction of transmission fluid . . . ..............9
3.1.3 Suction of transmission fluid on
ZF 80A, ZF 80-1A and ZF 85A . ..............9
3.2 DIPSTICK . . .................................. 10
3.3 BREATHER VALVE. . . ......................... 10
3.4 OUTPUT FLANGE............................. 10
3.5 CONTROL BLOCK . . . ......................... 11
3.5.1 Neutral Safety Switch ..................... 11
3.5.2 Neutral Safety Switch Check . . . ............ 11
3.6 HOUSING . . .................................. 12
3.6.1 Transmission housing halves. . . ............ 12
3.6.2 Shafts and gears ......................... 12
3.6.3 Radial shaft seals ......................... 12
3.6.4 Fluid inlet pipe . . ......................... 13
3.7 TAPERED ROLLER BEARINGS. ................ 14
3.7.1 Outer races of tapered roller bearing . ....... 14
3.7.2 Inner races of tapered roller bearings ....... 14
3.8 CLUTCH PACK . .............................. 15
3.8.1 Removal of the clutch discs ................ 15
4. ASSEMBLY...................................... 17
INTRODUCTION.................................. 17
4.1 INPUT SHAFT . . .............................. 17
4.1.1 Mount discs into reversing clutch ........... 17
4.1.2 Install needle bearings and gear ............ 18
4.1.3 Assemble butting rings .................... 18
4.1.4 Mounting inner races of tapered
roller bearings. . . ......................... 18
4.1.5 Assemble piston rings ..................... 18
4.2 INTERMEDIATE SHAFT. . . ..................... 19
4.2.1 Mounting inner races of tapered
roller bearings. . . ......................... 19
4.3 OUTPUT SHAFT .............................. 19
4.3.1 Mounting inner race of tapered
roller bearing............................. 19
4.4 PREASSEMBLY OF HOUSING ..................20
4.4.1 Assembly of outer races
(tapered roller bearings) . ...................20
4.4.2 Installation of fluid suction pipe and baffle. . . . 20
4.4.3 Assembling input shaft seal . . . ..............21
4.4.4 Mounting the breather filter . . . ..............21
4.5 MEASURING THE BEARING CLEARANCE/
ADJUSTING THE PRETENSION OF BEARINGS . . 22
4.5.1 General. . . ................................22
4.5.2 Mounting outer races of tapered roller
bearings into housing . . . ...................22
4.5.3 Inserting gear set into housing ..............22
4.5.4 Measuring bearing clearance on input
shaft . ....................................23
4.5.5 Measuring bearing clearance at
intermediate shaft . . .......................23
4.5.6 Measuring the bearing clearance on the
output shaft...............................23
4.5.7 Adjusting the pretension/clearance of
bearings. . ................................24
4.5.8 Final assembly of the housing ..............24
4.6 CONTROL BLOCK . . ...........................25
4.6.1 Mounting the control block . . . ..............25
4.7 FLUID FILTER . ................................25
4.7.1 Mounting the fluid filter . ...................25
4.8 OUTPUT FLANGE . . ...........................25
4.9 MAKING THE TRANSMISSION
READY FOR OPERATION . . . ...................26
4.9.1 Filling up with transmission Fluid . ..........26
4.9.2 Check fluid level . . . .......................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 . ................................30
9. TROUBLESHOOTING . . ...........................31
10. AUTOMATIC TRANSMISSION FLUID ..............36
11. SPARE PARTS LIST
ZF63A -ZF63 - ZF80A -ZF80-1A...............39
Preface . . .........................................39
Name plate . . . ....................................39
FIG. 1 ZF 63 A. ....................................40
FIG. 1 ZF 63 . . ....................................42
FIG. 1 ZF 80 A - ZF 80-1 A . . .......................44
1
Repair Manual and Spare Parts List Table 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 Mechanical selector valve
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . . ..... 56
FIG. 4 Old electric selector valve with proportional valves
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 Old electric selector valve ON/OFF 12V, 26 bar
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . . ..... 62
FIG. 7 New electric selector valve ON/OFF 12V - 26 bar
New electric selector valve ON/OFF 24V - 26 bar
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . ..... 64
FIG. 8 New electric selector valve ON/OFF 12V - 26 bar
with trolling valve
New electric selector valve ON/OFF 24V - 26 bar
with trolling valve
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . ..... 66
ZF 63A - ZF 63 KIT COMPONENTS . . . .............. 68
ZF 80A - ZF 80-1A KIT COMPONENTS .............. 69
12. SPARE PARTS LIST ZF 80 A - ZF 80-1 A
NEW VERSION . ................................ 71
Preface . . ........................................ 71
Name plate . . . .................................... 71
FIG. 1 ZF 80 A - ZF 80-1 A . . . ....................... 72
FIG. 2 ZF 80 A - ZF 80-1 A . . . ....................... 74
FIG. 3 Mechanical selector valve
ZF 80A - ZF 80-1A . . . ....................... 78
FIG. 4 Old electric selector valve ON/OFF 12V, 26 bar
ZF 80A - ZF 80-1A . . . ....................... 80
FIG. 5 New electric selector valve ON/OFF 12V - 26 bar
New electric selector valve ON/OFF 24V - 26 bar
ZF 80A - ZF 80-1A . . . ....................... 82
FIG. 6 New electric selector valve ON/OFF 12V - 26 bar
with trolling valve
New electric selector valve ON/OFF 24V - 26 bar
with trolling valve
ZF 80A - ZF 80-1A . . . ....................... 84
KIT COMPONENTS ZF 80A - ZF 80-1 A .............. 86
13. SPARE PARTS LIST ZF 85A .. ................... 87
Preface .......................................... 87
Name plate. . ..................................... 87
FIG. 1 ZF 85 A . . . ................................. 88
FIG. 2 ZF 85 A . . . ................................. 90
FIG. 3 Mechanical selector valve
ZF85A.................................... 92
FIG. 4 Electric selector valve ON/OFF 12V - 26 bar
Electric selector valve ON/OFF 24V - 26 bar
ZF85A.................................... 94
FIG. 5 Electric selector valve ON/OFF 12V - 26 bar
with trolling valve
Electric selector valve ON/OFF 24V - 26 bar
with trolling valve
ZF85A.................................... 96
KIT COMPONENTS ZF 85A ........................ 98
2
Repair Manual and Spare Parts List Table of contents
INTRODUCTION
This manual gives specific instructions for the proper repair on
ZF 63 - ZF 63 A - ZF 80 A - ZF 80-1 A - ZF 85 A transmissions.
Please follow the procedures carefully to insure quality service.
ZF HURTH MARINE recommends to read the manual completely
before starting with repairs, as some of the procedures described
are rather complex.
Along with standard tools, ZF HURTH MARINE recommends the
use of special tools, necessary to perform repairs correctly. The
special tools are available through your local ZF HURTH MARINE
dealer.
This manual is based on the technical information at the time of
printing. The manual has been checked carefully in order to avoid
errors. However ZF HURTH MARINE is not liable for any misrepresentations, errors of description or omissions.
Modifications on future manuals may be introduced without prior
notice.
3
Repair Manual 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 aluminum die cast
2
Gears
1.1
Oil filter
2.1
Input shaft with reversing clutch pack assembly
1.2
Oil dipstick
2.2
Intermediate shaft
1.3
Breather valve
2.3
Output shaft
1.4
Oil drain plug (ZF 80A, ZF 80-1A, ZF 85A)
3
Control block
5
Repair Manual 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 Loctite fast cleaner N
o
. 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 assembly:
.
Loctite 243 medium-hard for securing oil plug on
ZF 80A - 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 80-1A
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 all standard tools, such as, torque
wrenches, open-end wrenches, allen keys and extractors, are available.
All fixtures for pressing parts in or out should be used in
conjunction with a hydraulic or manual press.
EXTRACTOR
Tapered roller 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 - spline 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 roller bearing inner race - control
block side. P/N 224.836.009 (456170)
EXTRACTOR Tapered roller bearing outer races basic
unit P/N 978.25.0021.0 (454422)
ADAPTER FOR
BASIC UNIT 454422
50
A
B
BASIC UNIT
LEGS KIT (composed of three legs)
P/N 978.25.0006.0 (477776)
Part number
ZF 63
ZF 63 A
ZF 80 A
ZF 80-1 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 clearance
input shaft P/N 219.354.3 (618582)
LEVER
CLAMPING SCREW
INPUT SHAFT
DIAL INDICATOR
MANDREL
For disassembly and assembly
Shaft seal - input side : P/N 224.836.005 (454425)
Shaft seal - 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 assembling input shaft seal on the input spline side
Bushing P/N 20.0012.01 to insert input shaft seal
Only for models: ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
Mandrel P/N 20.0012.02 to assemble input shaft seal
Only for models: ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
Mandrel P/N 20.1072.01 to assemble input shaft seal
Only for model: ZF 85 A
7
Repair Manual and Spare Parts List Section 2
SHIM
To determinate the correct preload of the tapered roller
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 clearance intermediate shaft
P/N. 224.836.008 (458105)
PUNCH
for assembly Seal - 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 oil suction
pipe into housing P/N 20.1041.00
8
Repair Manual and Spare Parts List Section 2
3. DISASSEMBLY
9
Repair Manual and Spare Parts List Section 3
FIG. 1 - 1
1
2
3
FIG. 1 - 2
INTRODUCTION
Clean the transmission thoroughly on the outside before disassembly.
The repair area should be clean and well lighted.
ZF HURTH MARINE recommends using a swiveling
stand for aiding in assembly and disassembly.
3.1 FLUID FILTER
3.1.1 Remove fluid filter
Turn the screw that fixes the oil filter cover in a counterclockwise direction and remove the filter from its housing (item 1, fig. 1-1). Use a 6 mm Allen wrench.
Pull filter element off (item 2, fig.1-1).
Check O-rings (item 3 and 4, fig. 1-1) for wear, replace if
necessary.
3.1.2 Suction of transmission fluid
Push hose of suction pump (item 1, Fig. 1-2) through
the suction pipe (item 2, Fig. 1-2) down to the bottom
of the housing and suck the fluid off.
3.1.3 Suction of transmission fluid on
ZF 80A, ZF 80-1 A and ZF85 A
Remove the plug (item 3, Fig. 1-2) and let the oil flow
from the proper hole.
+
|
IMPORTANT
|
The used oil and the oil filter are to be handled as
special waste that pollute the environment.
For the safe disposal of used oil and filter, take all
the measures required by the relevant local rules
and legislation.
Swiveling stand ZF
Output - half side up
Swiveling stand ZF
Input - half side up
1
3
4
2
3.2 DIPSTICK
Unscrew dipstick (item 1, Fig. 2-1) (counterclockwise)
and pull out of housing. Replace O-Ring if present
(check parts list section 11).
3.3 BREATHER VALVE
Unscrew breather valve (item 1, Fig. 3-1). Wash valve
in a detergent, let dry and dip in oil, then let oil drip off.
3.4 OUTPUT FLANGE
Lock output flange in swivel frame.
Unscrew hex head bolt (item 1, Fig. 4-1).
Remove disc (item 2, Fig. 4-1) and O-ring (item 3, Fig. 4-
1).
Screw hex bolt (item 1, Fig. 4-1) in again.
Place extractor on the transmission and pull output
flange (item 1, Fig. 4-2) off.
10
Repair Manual and Spare Parts List Section 3
1
FIG. 2 - 1
1
FIG. 3 - 1
1
2
3
4
FIG. 4 - 1
1
FIG. 4 - 2
3.5 CONTROL BLOCK
Unscrew allen head bolts (item 1, Fig. 5-1)
Pull control block (item 2, Fig. 5-1) together with seal
(item 3, Fig. 5-1) off the input shaft.
Remove key (item 4, Fig. 5-1) from input shaft (item 5,
Fig. 5-1).
3.5.1 Neutral Safety Switch
Unscrew neutral safety switch (item 1, Fig. 5-2).
Note: Use 7/8 inch wrench for hex bolts.
To reassemble switch:
tightening torque: 25 Nm (18.5 ft.lb.)
3.5.2 Neutral Safety Switch Check
To check for proper operation of the switch perform one
of the following tests:
A: Ohm meter
Connect the ohm meter leads to the terminal connection of the switch.
With the pin (item 1a Fig. 5-3) extended you should get
a reading, indicating a good switch.
Compressing the pin (item 1b Fig. 5-3) you should have
«O» reading,
B: 12 volt light
Connect the neutral safety switch with a light in series
to a 12 volt battery. The switch is good when the light
goes out when the center pin (item 1b Fig. 5-3) is compressed.
11
Repair Manual and Spare Parts List Section 3
1
2
3
4
FIG. 5 - 1
1
FIG. 5 - 2
1
a
1
b
FIG. 5 - 3
Battery 12 V DC Lamp 8.4 A
Neutral
position
Battery 12 V DC
Lamp 8.4 A
AorB
position
3.6 HOUSING
3.6.1 Transmission housing halves
Using an adequate drift punch, top the locating pins
(item 1, Fig. 6-1a and 6-1b) out of the housing.
Loosen and remove all hex head bolts and lock
washers (item 2 and 3, Fig. 6-1b). Using a plastic hammer slightly top the split line of the case halves to break
the seal. Then remove the input side of the housing.
3.6.2 Shafts and gears
Take the gear set out of the housing
.
Intermediate shaft (item 2, Fig. 6-2).
.
Input shaft (item 1, Fig. 6-2).
.
Output shaft (item 3, Fig. 6-2).
Check all gears, bearings and three piston rings on the
input shaft (item 4, Fig. 6-2) for signs of wear or failure.
If any of the gears are damaged or showing signs of excessive wear ZF HURTH MARINE recommends replacing the complete gear set.
When tapered roller bearings on the input shaft need to
be replaced, the butting rings and needle bearings
should also be replaced. To check for correct clutch operation, rotate the gears on the input shaft. If it is hard
to turn the gears, the clutch is probably damaged.
3.6.3 Radial shaft seals
Input shaft seal
Using a seal mandrel inside the housing top the input
shaft seal out.
Discard seal and replace with a new one. (Fig. 6-3a).
12
Repair Manual and Spare Parts List Section 3
1
FIG. 6 - 1a
1
3
2
FIG. 6 - 1b
2
1
4
3
FIG. 6 - 2
FIG. 6 - 3a
Output shaft seal
Using a mandrel punch top the output flange seal out
from the other side of the housing. Discard seal and replace with a new one. (Fig. 6-3b).
3.6.4 Fluid inlet pipe
Replacing the seal:
ZF 63A - ZF 63 (Fig. 6-4a)
.
Remove baffle plate (item 2).
.
Remove suction pipe (item 3).
.
Drive out seal (item 1).
ZF 80A - ZF 80-1 A - ZF85 A (Fig. 6-4b)
.
Remove suction pipe (item 2).
.
Drive out seal (item 1).
13
Repair Manual and Spare Parts List Section 3
FIG. 6 - 3b
1
2
3
3
OLD VERSION
NEW VERSION
FIG. 6 - 4a
1
2
FIG. 6 - 4b
3.7 TAPERED ROLLER BEARINGS
Check for failed bearings or excessive bearing wear.
3.7.1 Outer races of tapered roller bearing
Remove the outer races out of the housing halves by
means of the special tool (Fig. 7-1) or by heating the
housing halves in an oven to approx. 120 ëC (248 F):
Put the housing in the oven upside down, so the outer
races will fall down.
|
WARNING
|
Use protective gloves when handling the heated
housing and outer races.
+
|
IMPORTANT
|
Regard location of shims under each outer race for
correct position during reassembling.
Shims are located under outer races of the cover
only.
3.7.2 Inner races of tapered roller bearings
NOTE
.
Input shaft - spline side
.
The extractor (Fig. 7-2a) is required for pulling
the inner races off.
For extracting the inner races proceed as follows:
.
Screw in adapter onto the puller (item 1).
.
Place adapter onto the roller cage.
.
Tighten collar to rollers by means of cap nut (item
2).
.
Screw spindle (item 3)against shaft and pull bearing evenly and carefully off.
|
WARNING
|
Improper use of the extractor when removing the
races, could cause damage to the race or slip off.
Input shaft - Control block side
The inner race and the gear on the control block side
can be removed by using the split ring and a standard
hydraulic press (fig. 7-2b).
Input shaft - Control block side ZF 85 A
.
Remove the retaining ring (item 1, Fig. 7-2c) using
a plier.
.
Scrap the retaining ring.
.
Remove the washer (item 2, Fig. 7-2c).
.
Remove the shims (item 3, Fig. 7-2c).
14
Repair Manual and Spare Parts List Section 3
FIG. 7 - 1
3
2
1
INPUT SPLINE SIDE CONTROL BLOCK SIDE
FIG. 7 - 2a FIG. 7 - 2b
1
2
3
FIG. 7 - 2c
3.8 CLUTCH PACK
3.8.1 Removal of the clutch discs
Control block side (Fig. 8-1a)
ZF 63A - ZF 63
.
Remove thrust washer (1) off using two screwdrivers.
.
Take off gear (2) and, needle bearings (3).
.
Removal of pressure plate.
Press snap ring (5) against periphery of pressure
plate (4) by means of screwdrivers. Extract them together. The discs (6) can now be removed from the
clutch housing.
Control block side (Fig. 8-1b)
ZF 80A - ZF 80-1 A
.
Remove thrust washer (1) off using screwdrivers.
.
Take off gear (2), needle bearings (3), and spacer
(7).
.
Removal of pressure plate.
Press snap ring (5) against periphery of pressure
plate (4) by means of screwdrivers. Extract them together. The discs (6) can now be removed from
clutch housing.
Control block side (Fig. 8-1c)
ZF 85A
.
Remove thrust washer (1) off using two screwdrivers.
.
Take off gear (2) and needle bearing (3).
.
Removal of pressure plate.
Press snap ring (5) against periphery of pressure
plate (4) by means of screwdrivers. Extract them together. The discs (6) can now be removed from the
clutch housing.
15
Repair Manual and Spare Parts List Section 3
4
5
2
1
6
3
FIG. 8 - 1a
4
7
2
1
3
6
5
FIG. 8 - 1b
4
5
2
1
6
3
FIG. 8 - 1c
Input spline side (fig. 8-2a)
ZF 63A (no ratio 2.7) - ZF 63
.
Remove thrust washer (1) off using two screwdrivers.
.
Take off gear (2) and needle bearings (3).
.
Remove pressure plate (5). Press snap ring (4)
against periphery of pressure plate by means of
screwdrivers. Extract them together. The discs (6)
can now be removed from the clutch housing.
Input spline side (fig. 8-2b)
ZF 80A - ZF 80-1 A
ZF 63A (only ratio 2.7)
ZF 85A
.
Remove thrust washer (1) off using two screwdrivers.
.
Take off gear (2), needle bearings (3) and spacer
(4).
.
Remove pressure plate (6). Press snap ring (5)
against periphery of pressure plate by means of
screwdrivers. Extract them together.
The discs (7) can now be removed from the clutch
housing.
16
Repair Manual and Spare Parts List Section 3
5
2
1
3
6
4
FIG. 8 - 2a
6
4
2
1
3
7
5
FIG. 8 - 2b
4. ASSEMBLY
17
Repair Manual and Spare Parts List Section 4
1
2
FIG. 1 - 1a
FIG. 1 - 1b
1
2
FIG. 1 - 1d
2
1
FIG. 1 - 1c
INTRODUCTION
A well-lighted work area that is free from dirt and chips,
will facilitate the work considerably.
ZF HURTH MARINE recommends to use a swiveling
stand, described in the disassembly section to aid in
the assembly.
Thoroughly clean all mating surfaces from any Loctite
or gasket material.
|
WARNING
|
Cleaners and solvents can be toxic and potentially
harmful without proper ventilation.
Use caution when using such cleaners.
Always wear protective gloves and glasses!
The next assembly procedure requires the following:
.
An electric oven or heating lamp for heating the
housing halves will be required when mounting
the bearings.
.
A hydraulic or mechanical press
4.1 INPUT SHAFT
4.1.1 Mount discs into reversing clutch
Equip both sides coupling with new outer disc (item 1,
Fig. 1-1a) and new inner disc (item 2, Fig. 1-1a).
NOTE
.
For exact quantity of inner (item 2, Fig. 1-1a) and
outer discs (item 1, Fig. 1-1a), please refer to the
spare parts list at the end of this manual.
.
Stagger the position of the notches on the outer
discs as shown in Fig. 1-1b.
Starting with one of the outer discs, bild up the clutch.
The lugs on the outer discs have to be positioned in line
with each other as shown in Fig. 1-1b.
Install snap ring into groove of clutch housing securing
the pressure plate.
Place end disc (item 1, Fig. 1-1c) and snap ring (item 2,
Fig. 1-1c) engaging it into clutch housing groove.
Check correct position of end disc (item 1, Fig. 1-1c).
Repeat same procedure on opposite side of clutch
(Fig. 1-1d).
4.1.2 Install needle bearings and gear
Input spline side
.
Install needle bearing (item 1, fig. 1-2) onto shaft.
.
Slide spacer (item 3, fig. 1-2) where required.
.
Align splines on clutch discs previously installed
and install gear (item 2, fig. 1-2).
Make sure clutch gear is fully installed, engaging all
clutch discs.
Control block side
.
Repeat same procedure of input sline.
Spacer is only in ZF 80 A and ZF80-1 A.
4.1.3 Assemble butting rings
NOTE
.
Make sure thrust washer is fully pressed on and
gear is free to rotate.
.
Thrust washer must not be bent.
Position shaft assembly on suitable holding fixture.
Using a tube with a bore dia. of 35 mm (1.38 inch) in
and a plastic hammer gently drive thrust washer in position. (item 1, Fig. 1-3). Repeat same procedure on opposite side.
4.1.4 Mounting inner races of tapered roller
bearings
Heat inner race of tapered roller bearing (item 1, Fig. 1-
4) to approx. 120 ë(248 ëF) and push onto input shaft.
After cooling down, press bearing carefully against button ring (item 2, Fig. 1-4) by means of a sleeve and a
manual press or a copper brass punch.
|
CAUTION
|
Handle heated tapered roller bearing inner race only
with special gloves!
NOTE
For pressing, apply sleeve to inner race but not to
rollers.
4.1.5 Assemble shims, support shims and
retaining ring (ZF 85 A)
.
Place the shims (item 1, Fig. 1-5).
.
Install the washer (item 2, Fig. 1-5).
.
Put the retaining ring (item 3, Fig. 1-5) in the groove
of the input shaft using a plier.
|
WARNING!
|
.
Correct the shim thickness:
check that there is no slack between washer and
the retaining ring.
.
Maximum permissible clearance should be 0.05
mm.
Use a feeler gauge to check it.
18
Repair Manual and Spare Parts List Section 4
1
2
2
1
3
FIG. 1 - 2
ZF 63 A (Ratio= 2.7 only)
ZF 80 A - ZF 80-1 A - ZF 85A
ZF 63 A (no Ratio= 2.7)
ZF 63
D
1
FIG. 1 - 3
120 ˚C
248
˚
F
1
2
FIG. 1 - 4
3
2
1
FIG. 1 - 5
4.1.6 Assemble piston rings
Mount piston ring seals (item 1, Fig. 1-6) onto input shaft.
+
|
IMPORTANT
|
Make sure the interlocking position of the piston
rings are staggered on the shaft.
4.2 INTERMEDIATE SHAFT
4.2.1 Mounting inner races of tapered roller
bearings
Heat inner races of tapered roller bearings (item 1 and
2, Fig. 2-1) to approx. 120 ëC (248 ëF) and push them
onto the intermediate shaft up against the shaft collar.
|
WARNING
|
Handle heated taper roller bearing inner races only
with protective gloves!
When the inner races have cooled down, drive them
carefully against the collar using a copper/brass punch.
NOTE
Apply copper/brass punch on inner race and not on
the rollers.
4.3 OUTPUT SHAFT
4.3.1 Mounting inner race of tapered roller
bearing
Heat inner races of taper roller bearings (item 1 and 2,
Fig. 3-1) to approx. 120 ëC (248ëF) and push them onto
output shaft up against shaft collar.
|
CAUTION
|
Handle heated tapered roller bearing inner races
only with protective gloves!
When the inner races have cooled down, drive them
carefully against the collar using a copper/brass
punch.
NOTE
Apply copper/brass punch on inner race and not on
the rollers.
19
Repair Manual and Spare Parts List Section 4
1
2
120 ˚C
248
˚
F
120
˚
C
248
˚
F
FIG. 2 - 1
120 ˚C
248
˚
F
120
˚
C
248
˚
F
1
2
FIG. 3 - 1
1
FIG. 1 - 6
4.4 PREASSEMBLY OF HOUSING
4.4.1 Assembly of outer races
(tapered roller bearings)
Heat output half of the housing (item 1, Fig. 4-1) in an
oven to approx. 120 ëC (248 ëF).
Insert outer races (item 2, Fig.4-1) into housing.
|
WARNING
|
Handle heated tapered roller bearings outer races
on with protective gloves.
When housing has cooled down to ambient temperature, with a copper/brass punch seat outer races carefully into housing.
4.4.2 Installation of fluid suction pipe and
baffle
4.4.2.1 Installation of fluid suction pipe
.
Position oil suction pipe (item 1, Fig. 4-2a) in the
housing.
.
Put one drop of Loctite 243 into screw threaded
hole.
.
Lightly tighten the screw (item 3, Fig. 4-2a).
.
Insert centre square punch and tighten definitely
the screw.
.
Adjust oil suction pipe to measure "A" (A=26 mm)
(Fig. 4-2b).
.
Put some ATF fluid on the seal seat and on the oil
suction pipe using a brush.
.
Press into housing over the oil suction pipe the seal
(item 2, fig. 4-2c) using the appropriate punch
(Fig. 4-2c).
4.4.2.2 Installation of baffle (Fig. 4-2d)
(ZF 63A - ZF 63)
Put one drop of Loctite 243 on the screw thread (item 1)
and screw baffle plate (item 2) into the housing. After
tightening the screws bend plate lugs when present
over the hexagon of screws (see fig. 4-2d).
20
Repair Manual and Spare Parts List Section 4
2
1
FIG. 4 - 1
2
1
3
4
4
3
ZF80 A - ZF80-1 A
ZF85 A
3
OLD VERSION
NEW VERSION
1
1
3
NEW VERSION
1
3
1
OLD VERSION
ZF63A - ZF63
FIG. 4 - 2a
1
A
FIG. 4 - 2b
2
1
A
FIG. 4 - 2c
2
1
FIG. 4 - 2d
4.4.3 Assembling input shaft seal
Apply thin coat of Loctite 574 on periphery of new radial
shaft seal rings (item 1, Fig. 4-3a and Fig. 4-3b) and
grease lips with KLUEBER STABURAGS NBU 30.
Put it onto the mounting mandrel.
Drive shaft seal uniformly into the housing by tapping
slightly onto the mounting mandrel.
NOTE
The sealing lip (A) on the shaft seal should point into
the inside of the housing. The radial shaft seal must
be adjusted so that the sealing lip runs on the
grounded surface of the shaft.
ALTERNATIVELY (Fig. 4-3c):
For models ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
.
Smear loctite 574 on the outside diameter of the input shaft seal using a roller.
.
Lubricate the inside lip with Kluber Staburags
NBU30 grease.
.
Insert the input shaft seal (item 2) into input shaft
using the appropriate bushing p/n 20.0012.01 (item 1).
.
Use mandrel p/n 20.0012.02 (item 3) to position the
input shaft seal in the correct way.
For model ZF 85 A
.
Smear loctite 574 on the outside diameter of the input shaft seal using a roller.
.
Lubricate the inside lip with Kluber Staburags
NBU30 grease.
.
Insert the input shaft seal (item 2) into input shaft using
the appropriate mandrel p/n 20.1072.01 (item 1).
.
Position the input shaft seal in the correct way.
4.4.4 Mounting the breather filter
Due to the taper thread, the breather (item 1, Fig. 4-4)
need not to be coated with Loctite 574.
Tighten carefully during assembly (hand-tight).
Cheek leakage during a later test run. Retighten
slightly if it leaks.
21
Repair Manual and Spare Parts List Section 4
1
1 mm
A
FIG. 4 - 3a
1
1 mm
A
FIG. 4 - 3b
1
2
3
ZF 63 - ZF 63 A
ZF 80 A - ZF 80-1 A
1
FIG. 4 - 4
1
2
FIG. 4 - 3c
ZF 85 A
4.5 MEASURING THE BEARING CLEARANCE/ADJUSTING THE PRETENSION
OF BEARINGS
4.5.1 General
The required pretension/play of bearings of the individual shafts in the housing is obtained by using shims
of different thickness under the outer races of the taper
roller bearings. Shims which have been removed during disassembly may be reused.
First adjustment must refer to bearing clearance.
Take out from the front cover (Fig. 5-1) at least shims of
0.2 mm (0.0079 in.) thickness from the shims packages
which were removed during disassembly.
Adjustment values
Pretension (mm)
Shaft Input Intermediate Output
ZF 80A - ZF 80-1A 0.02-0.12 0.00-0.12 0.00-0.12
ZF 85A 0.02-0.12 0.00-0.12 0.1-0.15
ZF 63 A - ZF 63 0.02-0.12 0.00-0.12 0.05-0.15
Pretension (inches)
Shaft Input Intermediate Output
ZF 80A - ZF 80-1A 0.001-0.005 0.000-0.005 0.000-0.005
ZF 85A 0.001-0.005 0.000-0.005 0.004-0.006
ZF 63 A - ZF 63 0.001-0.005 0.000-0.005 0.002-0.006
4.5.2 Mounting outer races of tapered roller
bearings into housing
Heat input half housing (item 1, Fig. 5-2) in an oven to
approx. 120 ëC (248 ëF) and insert shims (item 2) and
outer races (item 3) of bearings into it.
|
WARNING
|
Handle heated housing half only with protective
gloves!
When half housing has cooled down to ambient temperature, press outer races carefully down using a copper/brass punch.
4.5.3 Inserting gear set into housing
Finish housing mating face halves with an oilstone.
|
CAUTION
|
Make sure to keep any dirt out of housing.
.
Holding the half housing on a swiveling stand, insert gears into it.
.
Mount input housing half (item 1, Fig. 5-3) with all
bolts, lock washers (item 2 and 3, Fig. 5-3) and parallel pins (item 4, Fig. 5-3).
.
Tightening torque of bolts: 40 Nm (30 ft.lb.).
22
Repair Manual and Spare Parts List Section 4
3
2
1
FIG. 5 - 1
1
2
3
FIG. 5 - 2
4
3
2
1
FIG. 5 - 3
23
Repair Manual and Spare Parts List Section 4
1
FIG. 5 - 4
2
1
FIG. 5 - 5a
FIG. 5 - 5b
FIG. 5 - 6
4.5.4 Measuring bearing clearance on input
shaft
a) Turn input shaft several times to permit bearings to
seat.
b) Fit clamping ring (tool p/n 219.354.3 (618582)) to the
spline of the input shaft (item 1, Fig. 5-4).
c)
Adjust to «O», dial indicator to obtain accurate reading.
d) With two levers carefully pry on the clamping ring
and record end play of shaft.
NOTE
This step must be done very carefully to obtain the
actual bearing clearance.
e) Carry out steps, a) and d) several times.
f) The bearing clearance measured plus the pretension
required in section 5.1 determine the required thickness of shims.
4.5.5 Measuring bearing clearance at
intermediate shaft
a) Unscrew plug (item 1, Fig. 5-5a) from the housing.
b) Screw in special tool (p/n 224.836.008 (458105))
(item 2, Fig. 5-5a) into intermediate shaft hole.
c) Mount dial gauge support securely onto housing.
d) Turn intermediate shaft several times to permit bear-
ings to seat.
e) Adjust the dial indicator needle on top of the bolt
head and «O» to dial indicator (Fig. 5-5b).
f) Screw hexagon nut carefully against housing (inter-
mediate shaft moves up) until bearing clearance is
overcome (Fig. 5-5b).
NOTE
This step should be done very carefully to obtain the
actual bearing clearance.
g) Carry out steps d) and f) several times.
h) The clearance measured plus the pretension re-
quired in section 5.1 determine the required thick-
ness of shims.
4.5.6 Measuring the bearing clearance on
the output shaft
a) Insert output flange onto the output shaft and screw
in nut ring.
b) Install bolt and spacer on input shaft.
c)
Turn output shaft repeatedly to permit bearings to seat.
d) Mount dial gauge support securely onto housing.
e) Place dial gauge onto top of the output shaft and ad-
just it to «0» reading.
f) Lift output shaft carefully, using two screwdrivers,
and record measurement (Fig. 5-6).
NOTE
This step should be done very carefully to obtain the
actual bearing clearance.
g) Carry out steps c) and f) for several times.
h) The bearing clearance measured plus the preten-
sion required in section 5.1 will determine the re-
quired thickness of shims.
4.5.7 Adjusting the pretension/clearance of
bearings
When the thickness of shims has been determined, the
transmission must be disassembled again.
a)
Using a adequate drift punch, drive the parallel pins
(item 1, Fig. 5-7a) with slight blows, out of the housing.
b) Loosen hex bolts (item 2 and 3, Fig. 5-7a) with lock-
washers (item 4, Fig. 5-7a) and remove input side of
housing (item 5, Fig. 5-7a).
c) Pull outer races of bearings out of the input side of
the housing using the extracting unit (Fig. 5-7b) or
heating the half housing in an oven to approx.
120ëC (248ëF) and remove the outer races of bearings together with shims.
|
WARNING
|
Handle heated housing half and outer race only with
protective gloves!
NOTE
Make sure to keep the shims with each outer race
and not mix them together.
4.5.8 Final assembly of the housing
a) Heat input side of the housing in an oven to approx.
120ëC (248 ëF).
|
WARNING
|
Handle heated housing only with protective gloves!
b) Insert the required shims for proper pretension into
bearings bore under bearing outer race.
c) Insert outer races of bearings. When the housing
has reached ambient temperature, drive outer races
of bearings down to the stop, using a copper punch.
d) Insert shafts.
e) Fill space between seal and dust lips of shaft seal
rings with a high quality bearing grease (Staburags
Kluber NBU 30).
f) Apply a thin coat of Loctite 518 on mating surface of
input side of the housing and join both housing
halves together.
g) Drive parallel pins into housing to align housing
halves, before tightening.
h) Install mounting bolts (item 2 and 3, Fig. 5-7a) and
torque them to 40 Nm (30 ft.lb.).
NOTE
There must be not measurable bearing clearance.
|
WARNING
|
The necessary time for a complete polymerization is
5 hours: we recommend therefore to clean carefully
the mating surfaces with Loctite 7063 cleaner before applying the Loctite 518 and wait the requested
time before the spin test.
24
Repair Manual and Spare Parts List Section 4
1
4
2
4
3
1
5
FIG. 5 - 7a
ADAPTER FOR
BASIC UNIT 454422
50
A
B
BASIC UNIT
FIG. 5 - 7b
4.6 CONTROL BLOCK
4.6.1 Mounting the control block
NOTE
Piston rings (item 1, Fig. 6-1) have to be replaced, if
thickness is less than 2.39 mm (0.094in).
a) Insert key (item 2, Fig. 6-1) into groove of shaft.
b) Place new seal (item 3, Fig. 6-1) onto control block.
c) Align key and slot in rotor pump.
d) Slide control block carefully on input shaft.
e) Insert lock washers (item 4, Fig. 6-1) on socket head
bolts (item 5, Fig. 6-1) and provide screw threads
each with a drop of Loctite 243.
f) Tight control block bolts. Tightening torque:
18 Nm (14 ft.lb.).
4.7 FLUID FILTER
4.7.1 Mounting the fluid filter
.
Wet O-rings (item 1 and 2, Fig. 7-1) with some ATF
fluid and mount them.
.
Install filter element (item 3, Fig. 7-1) into the transmission.
.
Lock cover (item 4 Fig. 7-1) to the transmission
using an allen wrench. Tightening torque: min. 5
Nm - max 8 Nm (min. 4 ft.lb. - max 6 ft.lb.)
4.8 OUTPUT FLANGE
Provide spline (X) of output shaft with a thin coat of Loctite 245 and sealing lip (Z) of shaft seal with a thin coat
of ATF fluid. (Fig. 8-1)
Fit output flange (item 1, Fig. 8-1).
Provide O-ring (item 2, Fig. 8-1) with ATF fluid and in-
sert into output flange.
Tight output flange down on output shaft with bolt (item
3, Fig 8-1) and washer (4).
Tightening torque:
ZF 63A - ZF 63 : 100 Nm (74 ft.lb.)
ZF 80A - ZF 80-1 A : 100 Nm (74 ft.lb.)
ZF 85A : 100 Nm (74 ft.lb.)
25
Repair Manual and Spare Parts List Section 4
1
2
3
4
5
FIG. 6 - 1
4
2
1
3
FIG. 7 - 1
1
2
4
3
X
Z
FIG. 8 - 1
4.9 MAKING THE TRANSMISSION
READY FOR OPERATION
4.9.1 Filling up with transmission Fluid
Filling with ATF fluid into the fluid filter opening. (Fig. 9-
1)
Quantity:
ZF 63 : 4.0 US-qts (3.8 liters)
ZF 63A : 4.2 US-qts (4.0 liters)
ZF 80A - ZF 80-1 A : 5.8 US-qts (5.5 liters)
ZF 85A : 5.8 US-qts (5.5 liters)
ATF (Automatic Transmission Fluid) such as, per list on
section IX.
Fit filter element as specified in section 4.7.1.
4.9.2 Check fluid level
Carry out a trial run after oil filling.
Set shifting lever to neutral position (N). Start engine
and let it run idle for a short time to fill the cooler and
pipelines with transmission oil. Stop the engine and
check oil level again. If necessary, top up with oil. Excessive oil should be removed. The fluid level on the
dipstick (item 1, figure 9-2) should be between the
min. and max. marks. The fluid level should be
checked again after a short driving period.
NOTE
Some transmissions may have different oil dipsticks, depending on the version:
A) When inserted into the housing hole, it expands by
turning the handle in clockwise direction. (Fig. 9-2
item A)
B) It is threaded (Fig. 9-2 item B).
+
|
IMPORTANT
|
Oil check with threaded dipstick (B) must be done in
a different way compared with the one not threaded
(A):
A) Oil dipstick and housing hole not threaded: dipstick
completely inserted into hole.
B) Oil dipstick and housing hole threaded: dipstick not
inserted into the housing hole (not screw in).
26
Repair Manual and Spare Parts List Section 4
FIG. 9 - 1
MAX
A
B
MIN
Housing
MAX
MIN
O-RING
Housing
1
FIG. 9 - 2
5. ADJUSTMENT DATA
5.1 SHIFTING PRESSURE
5.2 LUBE OIL DELIVERY RATE
27
Repair Manual and Spare Parts List Section 5
= ZF 63 A - ZF 63 - ZF 80 A
SHIFTING PRESSURE (bar)
DRIVING SPEED (rpm)
SHIFTING PRESSURE (psi)
= ZF 80-1 A -
MAX.
MIN.
400
350
300
250
200
150
100
50
0
500040003000200010000
0
10
20
30
5
15
25
500 1500 2500 3500 4500
ZF 85 A
DELIVERY RATE ( /min)
DRIVING SPEED (rpm)
DELIVERY RATE (gal. /min)
7.39
6.86
6.33
5.80
5.28
4.75
3.69
0
500040003000200010000
0
10
20
30
MIN. ALL MODELS
7.91
4.22
3.17
2.64
2.11
1.58
1.05
0.53
6. HYDRAULIC DIAGRAM
28
Repair Manual and Spare Parts List Section 6
Fluid sump
oil cooler
A
0
B
AB
= Shifting pressure 21.5
+2
bar
= Fluid 2
+0.5
bar
= Leakage fluid
Measuring point for shift pressure M10x1
Lube pressure relief valve
Basic lubricating throttle valve
Fluid delivery pump
Fluid filter
Filte grade 60µ
Fluid sump
Shifting valve
for A-0-B
position
Neutral position
switch indication
by electric signal
Shifting
pressure
relief valve
Connection for
temperature probe
indicating at abt.
110°C 3/8” - 18 NPSF
Direction of
water flow
Illustration shows shifting pos. «B»
oil cooler
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