ZF 63 IV, ZF 80 IV, ZF 80-1 IV, ZF 85 IV Repair Manual & Parts List
ZF 63 IV
ZF 80 IV
ZF 80-1 IV
Repair Manual
and
Spare Parts List
ZF 85 IV
FEBRUARY 2006
cod.
310.01.0009h
Repair Manual and Spare Parts List Table of contents
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 fluid filter . . .......................9
3.1.2 Suction of transmission fluid . . ..............9
3.1.3 Suction of transmission fluid on
ZF 63IV, ZF 80IV, 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 Neutral Safety Switch ..................... 11
3.5.2 Neutral Safety Switch Check. . . ............ 11
3.6 HOUSING . . .................................. 12
3.6.1 Disassemble the transmission housing
halves................................... 12
3.6.2 Removal of shafts and gears. . . ............ 12
3.6.3 Removal of radial shaft seals . . ............ 12
3.6.4 Removal of fluid inlet pipe . ................ 13
3.7 TAPERED ROLLER BEARINGS. ................ 14
3.7.1 Disassembling the outer races of
taper roller bearing . ..................... 14
3.7.2 Removal of inner races of
taper roller bearings ..................... 14
3.8 REVERSING CLUTCH PACK . . . ................ 15
3.8.1 Removal of the clutch discs................ 15
4.3 OUTPUT SHAFT ...............................20
4.3.1 Preparations for assembly ..................20
4.3.2 Mounting inner race of
tapered roller bearing . . . ...................20
4.3.3 Pressing the gear on . . . ...................20
4.4 PREASSEMBLY OF HOUSING ..................21
4.4.1 Assembly of outer races
(tapered roller bearings) . ...................21
4.4.2 Installation of fluid suction pipe . . . ..........21
4.4.3 Assembling input shaft seal . . ..............22
4.4.4 Mounting the breather filter . . . ..............22
4.5 MEASURING THE BEARING CLEARANCE/
ADJUSTING THE PRETENSION OF BEARINGS . 23
4.5.1 General. . ................................23
4.5.2 Mounting outer races of tapered roller
bearings into housing . . ...................23
4.5.3 Inserting gear set into housing . . . ..........23
4.5.4 Measuring bearing clearance
on input shaft . ...........................24
4.5.5 Measuring bearing clearance at
intermediate and reversal shafts . ..........24
4.5.6 Measuring the bearing clearance
on the output shaft .......................25
4.5.7 Adjusting the pretension clearance
of bearings . . . ...........................25
4.5.8 Final assembly of the housing . . . ..........26
4.6 CONTROL BLOCK . ...........................27
4.6.1 Mounting the control block . . ..............27
4.7 FLUID FILTER ................................27
4.7.1 Mounting the fluid filter . ...................27
4.8 MAKING THE TRANSMISSION
READY FOR OPERATION . . ...................27
4.8.1 Filling up with Transmission Fluid .........27
4.8.2 Inserting fluid filter into housing . ..........27
4.8.3 Check fluid level . . .......................28
5. ADJUSTMENT DATA . ...........................29
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. . . ......................... 19
4.1.5 Assemble piston rings..................... 19
4.2 INTERMEDIATE AND REVERSAL SHAFT ....... 20
4.2.1 Mounting inner races of tapered
roller bearings. . ......................... 20
5.1 SHIFTING PRESSURE . .......................29
5.1.1 ZF 80-1IV VERSION - ZF 85 IV . . . ..........29
5.1.2 ZF 63IV - 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 80-1IV VERSION - ZF 85 IV . . . ..........30
5.2.2 ZF 63IV - 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
1
Repair Manual and Spare Parts List Table of contents
9. TROUBLESHOOTING. ........................... 35
10. AUTOMATIC TRANSMISSION FLUID ............. 40
11. SPARE PARTS LIST ZF63 IV - ZF80 IV - ZF80-1 IV . 43
Preface . ........................................ 43
Name plate . . .................................... 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 Mechanical selector valve
ZF 63 IV - ZF 80 IV - ZF 80-1 IV ............. 54
FIG. 4 Old electric selector valve with
proportional valves
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 Old electric selector valve
ON/OFF 12V, 26 BAR
ZF 63 IV - ZF 80 IV - ZF 80-1 IV ............. 60
FIG. 7 New electric selector valve ON/OFF 12V - 26 bar
New electric selector valve ON/OFF 24V - 26 bar
ZF 63 IV - ZF 80 IV - ZF 80-1 IV ............. 62
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 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 80 IV (029 - 030 - 031 - 032 - 033 VERSION)
ZF 80 - 1 IV (034 - 035 - 036 - 037 - 038 VERSION)
Preface ........................................ 69
Name plate . .................................... 69
FIG. 1 ZF 80 IV, ZF 80 - 1 IV ....................... 70
FIG. 2 ZF 80 IV, ZF 80 - 1 IV ....................... 72
FIG. 3 Mechanical selector valve
ZF80IV, ZF80-1IV....................... 76
FIG. 4 Old electric selector valve
ON/OFF 12V, 26 bar ZF 80 IV, ZF 80 - 1 IV . . . 78
FIG. 5 New electric selector valve ON/OFF 12V - 26 bar
New electric selector valve ON/OFF 24V - 26 bar
ZF80IV, ZF80-1IV....................... 80
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
ZF80IV, ZF80-1IV....................... 82
KIT COMPONENTS
ZF80IV, ZF80-1IV ............................. 84
.. 69
13. SPARE PARTS LIST ZF 85 IV . ................... 85
Preface . . . ..................................... 85
Name plate..................................... 85
FIG. 1 ZF 85 IV ................................. 86
FIG. 2 ZF 85 IV ................................. 88
FIG. 3 Mechanical selector valve ZF 85 IV . . . ...... 90
FIG. 4 Electric selector valve ON/OFF 12V - 26 bar
Electric selector valve ON/OFF 24V - 26 bar
ZF85IV ................................. 92
FIG. 5 Electric selector valve ON/OFF 12V - 26 bar
with trolling valve
Electric selector valve ON/OFF 24V - 26 bar
with trolling valve
ZF85IV ................................. 94
KIT COMPONENTS ZF 85IV . . ................... 96
14. SPARE PARTS LIST ZF 80 IV
(ZF 85 IV DERIVATE VERSION) . . . ............... 97
Preface .......................................... 97
Name plate. . ..................................... 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 Mechanical selector valve
ZF 80 IV (ZF 85IV DERIVATE VERSION) ..... 102
FIG. 4 Electric selector valve ON/OFF 12V - 26 bar
Electric selector valve ON/OFF 24V - 26 bar
ZF 80 IV (ZF 85IV DERIVATE VERSION) ..... 104
FIG. 5 Electric selector valve ON/OFF 12V - 26 bar
with trolling valve
Electric selector valve ON/OFF 24V - 26 bar
with trolling valve
ZF 80 IV (ZF 85IV DERIVATE VERSION) ..... 106
KIT COMPONENTS ZF 80IV
(ZF 85IV DERIVATE VERSION). . .................. 108
2
Repair Manual and Spare Parts List Introduction
INTRODUCTION
This manual gives specific instructions for the proper repair on
ZF 63 IV - ZF 80 IV - ZF 80-1 IV - ZF 85 IV model 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
4
Repair Manual and Spare Parts List Section 1
1. MAJOR COMPONENTS
1.1 MAJOR TRANSMISSIONS COMPONENTS
The main components of the ZF Marine Transmissions are:
ITEM
1
1.1
1.2
1.3
1.4
DESCRIPTION
Two-piece aluminum die cast
Oil filter
Oil dipstick
Oil drain plug
Breather valve
1.4
3
1.1
1
ITEM
2
2.1
2.2
2.3
3
DESCRIPTION
Gears
Input shaft with reversing clutch pack assembly
Intermediate shafts
Reversal shaft
Control block
2
2.1
2.3
2.2
2.4
1.3
1.2
5
Repair Manual and Spare Parts List Section 1
1.2 CLEANERS AND SEALANTS
For cleaning:
Cold cleaner such as benzine, trichloroethane or Loctite fast cleaner 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 assembly:
.
Loctite 243 for securing screws, medium-hard
|
.
Loctite 245 for securing output flange on spline
.
Loctite 518 for housing surfaces.
.
Loctite 574 for outer diameter sealing rings.
.
Grease: Staburags NBU 30, KluÈber Co. for radial
shaft seals
.
ATF Fluid:
4.4 liters (1.1 US gallons) for ZF 63 IV
7.0 liters (1.85 US gallons) for ZF 80IV - ZF 80-1 IV.
7.0 liters (1.85 US gallons) 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
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.)
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
6
PLASTIC HAMMER (1000 g) and sturdy screwdriver
EXTRACTOR minimum diameter 130 m
PLIER
Repair Manual and Spare Parts List Section 2
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 IV
- P/N 978.35.0019.0 (500465) ZF 80 IV - ZF 80-1 IV ZF 85 IV
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 propeller 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 seal control block 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
EXTRACTOR SPLIT RING
Input shaft.
Taper roller bearing inner race - control block side.
D
P/N 224.836.009 (456170)
EXTRACTOR Tapered roller bearing outer races basic
unit P/N 978.25.0021.0 (454422)
LEGS KIT (composed of three legs)
P/N 978.25.0006.0 (477776)
50
A
ADAPTER FOR
BASIC UNIT
ZF 63 IV ZF 80 IV - ZF 80-1 IV - ZF 85 IV
BASIC UNIT 454422
B
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)
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 IV - ZF 80 IV - ZF 80-1 IV
Mandrel P/N 20.0012.02 to assemble input shaft seal
Only for models: ZF 63 IV - ZF 80 IV - ZF 80-1 IV
Mandrel P/N 20.1072.01 to assemble input shaft seal
Only for model: ZF 85 IV - ZF 80 IV (ZF 85IV DERIVATE
VERSION)
7
Repair Manual and Spare Parts List Section 2
SHIM
To determinate the correct preload of the tapered roller
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 clearance intermediate shaft
P/N. 224.836.008 (458105)
PUNCH
for assembly Seal - suction pipe
ZF 80 IV - ZF80-1 IV - ZF 85 IV P/N 20.1021.00
ZF 63 IV: P/N 20.1029.00
CENTRE SQUARE PUNCH To position the oil suction
pipe into housing P/N 20.1041.00
8
Repair Manual and Spare Parts List Section 3
3. DISASSEMBLY
INTRODUCTION
Clean the transmission thoroughly on the outside before disassembly.
Swiveling stand ZF
Output - half side up
The repair area should be clean and well lighted.
ZF HURTH MARINE recommends using a swiveling
stand for aiding in assembly and disassembly.
Swiveling stand ZF
Input - half side up
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 63 IV, ZF 80 IV, ZF 80-1 IV and
ZF 85 IV
Remove the plug (item 3, Fig. 1-2) and let the oil flow
from the proper hole.
3
1
4
2
FIG. 1 - 1
1
|
+
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.
IMPORTANT
|
2
3
FIG. 1 - 2
9
Repair Manual and Spare Parts List Section 3
3.2 REMOVAL 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 REMOVAL BREATHER VALVE
1
FIG. 2 - 1
1
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
Unscrew socket head bolts (item 1, Fig. 4-1) up to four
opposite ones.
Apply forcing plate and position screw heads with regard to forcing plate boreholes by means of Allen key
( item 1, Fig. 4-2). Using an Allen key, turn screws positioned in the output flange against forcing plate.
This will press the output flange off the output shaft
(Fig. 4-2).
FIG. 3 - 1
1
FIG. 4 - 1
10
1
FIG. 4 - 2
Repair Manual and Spare Parts List Section 3
3.5 REMOVAL 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 neutral safety switch:
tightening torque: 25 Nm (18.5 ft.lb.)
1
2
3
5
4
FIG. 5 - 1
1
FIG. 5 - 2
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.
Battery 12 V DC Lamp 8.4 A
Battery 12 V DC
Lamp 8.4 A
Neutral
position
1
a
AorB
position
1
b
FIG. 5 - 3
11
Repair Manual and Spare Parts List Section 3
3.6 HOUSING
3.6.1 Disassemble the transmission housing
halves
Using a 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.
|
+
Only transmission type ZF 63 IV, i=2.0 and i=2.5.
First remove radial shaft seal ring (item 4, Fig. 6-1b)
to remove the housing half.
IMPORTANT
|
1
FIG. 6 - 1a
3
4
3.6.2 Removal of shafts and gears
Take the gear set out of the housing
.
intermediate shaft (item 1, Fig. 6-2)
.
input shaft (item 2, Fig. 6-2)
.
output shaft (item 4, Fig. 6-2)
.
reversal shaft (item 3 Fig. 6-2).
Check all gears, bearings and three piston rings on the
input shaft (item 2, 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 taper roller bearings need replacing on the input
shaft, the butting rings and needle bearings should
also be replaced. When replacing inner roller bearings
use the same manufacturer.
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.
2
1
FIG. 6 - 1b
2
3
2
1
4
FIG. 6 - 2
3.6.3 Removal of 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
seal. (item 2, Fig. 6-3a).
NOTE
For transmission types ZF63 IV, i=2.0 and i=2.5
(item 2, Fig. 6-3a) the radial shaft seal ring has already been removed before dismounting the housing half.
12
1
2
FIG. 6 - 3a
Repair Manual and Spare Parts List Section 3
Output shaft seal
Using a mandrel punch top the output seals out from
1
the housing. Discard seals and replace with a new seal
(Fig. 6-3b and Fig. 6-3a item 1).
3.6.4 Removal of fluid inlet pipe
For replacing the seal (item 3, Fig. 6-4):
.
Remove plate screws (1)
.
Remove suction pipe (2)
.
Drive out seal (3) after removing dipstick and filter.
3
2
1
FIG. 6 - 3b
FIG. 6 - 4
13
Repair Manual and Spare Parts List Section 3
3.7 TAPERED ROLLER BEARINGS
Check for failed bearings or excessive bearing wear.
3.7.1 Disassembling the outer races of taper
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. 120ëC (248ëF).
Put the housing in the oven upside down, so the outter
races will fall out.
|
WARNING
Use protective gloves when handling the heated
housing and outer races.
|
+
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 Removal of inner races of taper roller
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:
.
.
.
.
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
hydraulik press (Fig. 7-2b).
Input shaft - Control block side ZF 85 IV - ZF80 IV
(ZF 85 IV DERIVATE VERSION)
.
.
.
.
Intermediate and reversal shaft
The inner race of bearings can be drawn off with a commercial extracting unit.
IMPORTANT
bearings
insert collet
place collet onto the roller cage
tighten collet to rollers by means of cap nut
screw spindle against shaft and pull bearing evenly
and carefully off.
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).
|
|
FIG. 7 - 1
INPUT SPLINE SIDE CONTROL BLOCK SIDE
FIG. 7 - 2a
FIG. 7 - 2b
1
FIG. 7 - 2c
2
3
|
WARNING
Improper use of the extractor when removing the
races, could cause damage to the races or slipp off.
Output shaft
For extracting the inner races (item 1 and 2, Fig. 7-2d)
proceed as follows:
.
cut bearing cage (item 3, Fig. 7-2d) open and remove rollers
.
place gear on a sleeve
.
press output shaft off the gear. Pay attention for
pressing-out direction of output shaft Fig. 7-2d.
The bearing inner race (item 1, Fig. 7-2d) will be extracted at the same time.
Extracting force required: approx. 400kN
14
|
1
3
2
FIG. 7 - 2d
Repair Manual and Spare Parts List Section 3
3.8 REVERSING CLUTCH PACK
3.8.1 Removal of the clutch discs
.
Remove the tapered roller bearing inner races
(item 1 and 2, Fig. 8-1a) and the gear (item 3,
Fig. 8-1a) using the tools described in section 2.
1
3
2
FIG. 8 - 1a
.
Lift butting rings (item 1, Fig. 8-1b) off using two
screwdrivers.
.
Pull gear (item 2, Fig. 8-1b) and needle bearings
off.
.
Removal of pressure plate: Pressing snap ring
against periphery of pressure plate (item 1, Fig.
8-1c) by means of screwdrivers. Extract it together
with end disc (item 1, Fig. 8-1c). The clutch discs
can now be removed from the coupling housing.
Repeat same procedure to remove pressure plate
on the opposite side.
1
2
FIG. 8 - 1b
1
FIG. 8 - 1c
15
16
Repair Manual and Spare Parts List Section 4
4. ASSEMBLY
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 swivelling
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!
|
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.
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
1
2
FIG. 1 - 1a
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).
2
1
FIG. 1 - 1c
FIG. 1 - 1b
2
1
FIG. 1 - 1d
17
Repair Manual and Spare Parts List Section 4
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 IV and ZF 80-1 IV.
4.1.3 Assemble butting rings
Press on new thrust washers (item 1, Fig. 1-3a) onto input shaft.
Make sure thrust washers are fully pressed on and
have even contact with gears.
Thrust washers must not be bent. For easier mounting
use a tube with a bore dia. of 35 mm (1.38 in).
Repeat same procedure on apposite side (item 1,
Fig. 1-3b)
ZF 80IV - ZF 80-1IV
ZF 85IV
2
3
ZF 63IV
2
1
1
FIG. 1 - 2
1
18
FIG. 1 - 3a
1
D
FIG. 1 - 3b
Repair Manual and Spare Parts List Section 4
4.1.4 Mounting inner races of tapered roller
bearings
Heat inner race of tapered roller bearing (item 1, Fig. 1-
4) to approx. 120ë (248ëF) and push onto input shaft.
After cooling down, press bearing carefully against butting ring (item 2, Fig. 1-4) by means of a sleeve and a
hydraulic or manual press.
|
CAUTION
Handle heated tapered roller bearing inner race only
with special gloves!
|
248
˚
120 ˚C
F
1
2
NOTE
For pressing, apply sleeve to inner race but not to
rollers.
FIG. 1 - 4
4.1.5 Assemble shims, support shims and
retaining ring ZF 85 IV - ZF 80 IV
(ZF 85 IV DERIVATE VERSION)
.
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.
|
4.1.6 Assemble piston rings
Mount piston ring seals (item 1, Fig. 1-6) onto input
shaft.
|
+
Make sure the interlocking position of the piston
rings are staggered on the shaft.
IMPORTANT
|
2
3
1
FIG. 1 - 5
1
FIG. 1 - 6
19
Repair Manual and Spare Parts List Section 4
4.2 INTERMEDIATE AND REVERSAL 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. 120ëC (248ëF) and push them onto the
intermediate or reversal shaft upagainst the shaft collar.
|
WARNING
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 brass punch.
|
NOTE
Apply copper/brass punch on inner race and not on
the rollers.
4.3 OUTPUT SHAFT
4.3.1 Preparations for assembly
Finish press fit on output shaft and gear with a very fine
emery paper. Then clean both parts thoroughly.
|
WARNING
Cleaners and solvents can be toxic and potentually
harmful without proper ventilation. Use caution
when using such cleaners.
Always wear protective gloves and glasses!
|
1
120
C
˚
F
248
˚
2
1
2
FIG. 2 - 1
4.3.2 Mounting inner race of tapered roller
bearing
Heat inner races of tapered roller bearings (item 1 and
2, Fig. 3-1) to approx. 120ë (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 brass punch.
|
NOTE
Apply copper/brass punch on inner race and not on
the rollers.
4.3.3 Pressing the gear on
|
ATTENTION
ONLY ZF 63 IV: with transmission ratio of 1.3 to 2.0
the ring (item 1 Fig. 3-2) must be mounted
.
Provide press fit of output shaft with a thin coat of
glycerol.
.
With a transmission ratio of 1.3 to 2.0, a washer
(item 1, Fig. 3-2) should be inserted.
.
Press gear (item 2, Fig. 3-2) on shaft (item 3, Fig. 3-
2), by means of a hydraulic press.
Pressing force required: 200 kN
After having pressed the gear on, mount second inner race of bearing (item 4, Fig. 3-2) as described
under 3.2.
|
120 ˚C
248
˚
F
1
2
FIG. 3 - 1
4
2
1
3
FIG. 3 - 2
20
Repair Manual and Spare Parts List Section 4
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. 120ëC (248ëF).
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 press seat outer races carefully into housing.
4.4.2 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 2, 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).
|
1
120 ˚C
248
˚
F
2
2
FIG. 4 - 1
1
2
FIG. 4 - 2a
1
A
FIG. 4 - 2b
2
1
A
FIG. 4 - 2c
21
Repair Manual and Spare Parts List Section 4
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 items 1-2, Fig. 43b) and grease lips with KLUEBER STABURAGS NBU
30.
For transmission ZF 63 IV ratio I=1.56 only use grease
Fa KLUEBER AMBLIGON TA 15/2.
Put a new shaft seal 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 does not run on
the former running point of the shaft.
Only for transmission size i = 2.0 and i = 2.5.
The radial shaft seal ring (item 1, Fig. 4-3b) of the input half of the housing can only be mounted after
the housing halves have been mounted with the
gear set.
ALTERNATIVELY (Fig. 4-3c)
For models ZF 63 IV - ZF 80 IV - ZF 80-1 IV
.
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.
1
ZF 63IV - ZF 80IV
ZF 80-1IV
3
1
A
FIG. 4 - 3a
2
FIG. 4 - 3b
ZF 85IV - ZF 80 IV
(ZF 85 IV DERIVATE VERSION)
1
2
For models ZF 85 IV - ZF 80 IV (ZF 85 IV DERIVATE
VERSION)
.
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
NOTA
Due to the taper thread, the breather (item 1, Fig. 4-
4) do need not to be coated with Loctite 243.
Apply thin coat of Loctite 574 to the breather (item
1, Fig. 4-4).
Tighten carefully during assembly (hand-tight).
Check leakage during a later test run. Retighten slightly
if it leaks.
22
1
2
FIG. 4 - 3c
1
FIG. 4 - 4
Repair Manual and Spare Parts List Section 4
4.5 MEASURING THE BEARING CLEARANCE/ADJUSTING THE PRETENSION
OF BEARINGS
4.5.1 General
The required pretention 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 at least shims of 0.2 mm (0.0079 in.) thickness
from the shims packages which were removed during
disassembly.
ZF 63 IV - ZF80 IV - ZF 80-1 IV - ZF 85 IV
Pretension Input Intermdial/reversal Output
mm
inches
0.02 - 0.12 0.00 - 0.12 0.05 - 0.15
0.000787 - 0.00472 0.00 - 0.00472 0.001968 - 0.00591
243
1
FIG. 5 - 1
4.5.2 Mounting outer races of tapered roller
bearings into housing
Heat "input" half of the housing (item 1, Fig. 5-2) in an
oven to approx. 120ëC (248ëF); insert shims (item 2)
and outer races (item 3) of bearings into the housing
(Fig. 5-2).
|
WARNING
Handle heated housing half only with protective
gloves!
When housing half has cooled down to ambient temperature, press outer races carefully up to stop of housing half using a press.
|
4.5.3 Inserting gear set into housing
Finish housing mating facehalves with an oilstone or a
fine finishing file.
|
CAUTION
Make sure to keep any dirt out of housing.
.
Insert gears into housing
.
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 torques of bolts: 40 Nm (30 ft. lb.)
|
3
120 ˚C
248
˚
F
1
2
FIG. 5 - 2
1
4
2
3
FIG. 5 - 3
23
Repair Manual and Spare Parts List Section 4
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 319.354.3 (618582) to the
spline of the input shaft (item 1, Fig. 5-4).
c) "0" dial indicator to obtain accurate reading.
d) With two levers carefully pry on the clamping ring
and record end play of shaft.
This step must be done very carefully to obtain the
actual bearing clearance.
NOTE
This step must be done very carefully to obtain the
actual bearing clearance.
e) Carry out steps "a" and "d" for several times.
f) The bearing clearance measured plus the pretension
required in section 5.1 will determine the required
thickness of shims.
Round off the determined shims thickness to 0.05
mm (0.001968 in.).
1
FIG. 5 - 4
4.5.5 Measuring bearing clearance at
intermediate and reversal shafts
a) Unscrew plug (item 1, Fig. 5-5a) from the housing.
b) Screw bolt (tool no. 224.836.008 - 458105) (item 2,
Fig. 5-5a) into intermediate shaft.
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 "0" indicator (Fig. 5-5b).
f) Screw hexagon nut carefully against housing flange
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" 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.
NOTE
Round off the determined shimr thickness to 0.05
mm (0.001968 in.).
i) Unscrew bolt with nut and remove dial gauge with
support.
l) Repeat same procedure for reversal shaft.
FIG. 5 - 5a
24
FIG. 5 - 5b
Repair Manual and Spare Parts List Section 4
4.5.6 Measuring the bearing clearance on
the output shaft
a) Mounting the output flange.
Drive parallel pins (item 1, Fig. 5-6a) into output
flange (item 2, Fig. 5-6a).
Screw output flange with socket head bolts (item 3,
Fig. 5-6a) on output shaft.
Tightening torque:
32 Nm (23.6) ZF 63 IV;
100 Nm (73.8 ft.lb.) ZF 80 IV - ZF80-1 IV - ZF 85 IV.
b) Turn output shaft repeatedly to permit bearings to
seat.
c) Mount dial gauge support securely onto housing,
and "0" indication gauge.
d) Place dial gauge onto bolt head.
e) Lift output shaft carefully, using two screwdrivers,
and record measurement (Fig. 5-6b).
NOTE
This step should be done very carefully to obtain the
actual bearing clearance.
f) Carry out steps "b" and "e" for several times.
g) The bearing clearance measured plus the preten-
sion required in section 5.1 will determine the re-
quired thickness of shims.
3
2
1
FIG. 5 - 6a
NOTE
Round off the determined shim thickness to 0.05
mm (0.001968 in.).
h) Unscrew bolt with washer and dial gauge with sup-
port.
4.5.7 Adjusting the pretension clearance
of bearings
When the thickness of shims has been determined, the
transmission must be disassembled again.
a) Unscrew output flange (see Fig. 5.6a).
b) Using a adequate drift punch, drive the parallel pins
(item 1, Fig. 5-7a) with slight blows out of the hous-
ing.
c) Loosen hex bolts with lockwashers (items 2 and 3,
Fig. 5-7a) and remove input side of housing (item
4, Fig. 5-7a).
d) Remove gears from the housing (Fig. 5-7b).
FIG. 5 - 6b
4
1
2
3
FIG. 5 - 7a
FIG. 5 - 7b
25
Repair Manual and Spare Parts List Section 4
e) Pull outer races of bearings out of the "drive" hous-
ing half using the extracting unit (Fig. 5-7c) or heat
the half of the 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.
|
50
A
ADAPTER FOR
BASIC UNIT 454422
B
BASIC UNIT
FIG. 5 - 7c
c) Insert outer races of bearings. When the housing
half has reached ambiet temperature, drive outer
races of bearings up to the stop, using a copper
punch.
d) Insert gears again.
e) Fill space between seal and dust lips of shaft seal
rings with a high quality bearing grease (KLUEBER
STABURAGS NBU 30).
f) Apply a thin coat of Loctite 518 on mating face of "in-
put" housing half and join both housing halves.
|
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.
g) Drive parallel pins into housing to align housing
halves, before tightening.
h) Apply Loctite 243 on to mounting bolts (item 2 and 3,
Fig. 5-7a) and torque them to 40 Nm (30 ft lb).
i) Check pretension of bearings accord-ing to sections
5.4, 5.5 and 5.7.
|
CAUTION
|
|
There must be no measurable bearing clearance.
j) Only for transmission size i=2.0 and i=2.5
ZF 63 IV. Press radial shaft seal (item 1, Fig. 4-3b)
with a suitable pipe into the "drive" housing half.
NOTE
The sealing lip on the radial shaft seal show to the
inside of the housing. The radial shaft seal must
be so adjusted that the sealing lip does not bear
on the former running point of the shaft.
k) Mount the output flange again. (see chapter 5.6).
26
Repair Manual and Spare Parts List Section 4
4.6 CONTROL BLOCK
4.6.1 Mounting the control block
New piston rings (item 1, Fig. 6-1) have already been
assembled according to section 4.1.5.
a) Insert key (item 2, Fig. 6-1) into groove of shaft.
b) Place new gasket (item 3, Fig. 6-1) onto control
block.
Key slot in pump-drive wheel should be aligned (Fig. 6-
c)
1).
d) Slide control block carefully on input shaft.
e) Push 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) Screw control block tight. Tightening torque of
screws: 18 Nm (13 ft.lb.).
5
4
3
1
2
4.7 FLUID FILTER
4.7.1 Mounting the fluid filter
FIG. 6 - 1
2
.
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 MAKING THE TRANSMISSION
READY FOR OPERATION
4.8.1 Filling up with Transmission Fluid
Filling with ATF fluid into the dipstick opening (Fig. 8-1).
ATF (Automatic Transmission Fluid) such as, per list on
chapter X.
Fluid quantity:
ZF 63 IV: 4.4 liters (1.1 US gallons)
ZF 80 IV - ZF 80-1 IV: 7.0 liters (1.85 US gallons)
ZF 85 IV: 7.0 liters (1.85 US gallons)
4
1
3
FIG. 7 - 1
FIG. 8 - 1
4.8.2 Inserting fluid filter into housing
Insert fluid filter into housing and tighten clockwise by
hand. (Fig. 8-2).
FIG. 8 - 2
27
Repair Manual and Spare Parts List Section 4
4.8.3 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 8-3) 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. 8-3 item A)
B) It is threaded (Fig. 8-3 item B).
B
Housing
1
O-RING
Housing
A
|
+
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
B) Oil dipstick and housing hole threaded: dipstick not
IMPORTANT
completely inserted into hole.
inserted into the housing hole (not screw in).
|
MAX
MIN
MAX
MIN
FIG. 8 - 3
28
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