ZF ZF 63 IV Repair Manual & Parts List Download

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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

Summary of Contents for ZF 63 IV

Page 1: ...ZF63IV ZF80IV ZF80 1IV ZF85IV FEBRUARY 2006 cod 310 01 0009h Repair Manual and Spare Parts List ...

Page 2: ......

Page 3: ...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 PRETEN...

Page 4: ... FIG 5 New electric selector valve ON OFF 12V 26 bar New electric selector valve ON OFF 24V 26 bar ZF 80 IV ZF 80 1 IV 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 ZF 80 IV ZF 80 1 IV 82 KIT COMPONENTS ZF 80 IV ZF 80 1 IV 84 13 SPARE PARTS LIST ZF 85 IV 85 Preface 85 Name plate 85 FIG 1 ZF 85 IV 86 FIG ...

Page 5: ...ng 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 misre presentations errors of...

Page 6: ...4 ...

Page 7: ...ION 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 shafts 1 3 Oil drain plug 2 3 Reversal shaft 1 4 Breather valve 3 Control block 5 Repair Manual 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 ...

Page 8: ...r 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 80 IV 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 DIAL GAUGE INCREMENTS DIAL FACE CAN BE TURNED TO ZERO POSITION ACCURACY OF READING SMAL...

Page 9: ...IV ZF 80 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 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 si...

Page 10: ...ECIAL 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 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 oil suction pipe into housing P N 20 1041 00 8 Repair Manual and Spare Parts List Section 2 ...

Page 11: ...er 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 flo...

Page 12: ...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 re gard to forcing plate boreholes by means of Allen key item 1 Fig 4 2 Using an Allen key turn screws posi tioned in the output flange against forcing plate This will press the output flange off the output shaft Fig 4 2 10 Repair Manual and Sp...

Page 13: ...eration of the switch perform one of the following tests A Ohm meter Connect the ohm meter leads to the terminal connec tion 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 goo...

Page 14: ...nput shaft item 2 Fig 6 2 for signs of wear or failure If any of the gears are damaged or showing signs of ex cessive wear ZF HURTH MARINE recommends repla cing 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 ope...

Page 15: ...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 13 Repair Manual and Spare Parts List Section 3 1 FIG 6 3b 3 2 1 FIG 6 4 ...

Page 16: ...and carefully 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 hydraulik press Fig 7 2b Input shaft Control block side ZF 85 IV ZF 80 IV ZF 85 IV DERIVATE VERSION 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 ...

Page 17: ...rewdrivers 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 15 Repair Manual and Spare Parts List...

Page 18: ...16 ...

Page 19: ...ves 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...

Page 20: ...peat 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 in put 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 18...

Page 21: ...ms 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...

Page 22: ...unting 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 o...

Page 23: ... 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...

Page 24: ...meter 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 models ZF 85 IV ZF 80 IV ZF 85 IV DERIVATE VERSION Smear Loctite 574 on the outside diameter of the i...

Page 25: ...ounting 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 tem perature press outer races carefully up to stop of hous ing half usin...

Page 26: ...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 ...

Page 27: ... 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 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 deter...

Page 28: ...ween 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 be fore applying the Loctite 518 and w...

Page 29: ...ings item 1 and 2 Fig 7 1 with some ATF fluid and mount them Install filter element item 3 Fig 7 1 into the trans mission 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 ...

Page 30: ...ter a short driving period NOTE Some transmissions may have different oil dip sticks 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 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...

Page 31: ...p n 3312 108 001 29 Repair Manual and Spare Parts List Section 5 SHIFTING PRESSURE bar DRIVING SPEED rpm SHIFTING PRESSURE psi MAX 400 350 300 250 200 150 100 50 0 5000 4000 3000 2000 1000 0 0 10 20 30 5 15 25 500 1500 2500 3500 4500 MIN SHIFTING PRESSURE bar DRIVING SPEED rpm SHIFTING PRESSURE psi MAX MIN 400 350 300 250 200 150 100 50 0 5000 4000 3000 2000 1000 0 0 10 20 30 5 15 25 500 1500 2500...

Page 32: ...pair Manual and Spare Parts List Section 5 SHIFTING PRESSURE bar DRIVING SPEED rpm SHIFTING PRESSURE psi MAX MIN 400 350 300 250 200 150 100 50 0 5000 4000 3000 2000 1000 0 0 10 20 30 5 15 25 500 1500 2500 3500 4500 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 5000 4000 3000 2000 1000 0 0 10 20 30 MIN 7 91 4 22 3 17 2 64 2 11 1 58 1 05 0 53 500 150...

Page 33: ...IVERY RATE min DRIVING SPEED rpm DELIVERY RATE gal min 7 39 6 86 6 33 5 80 5 28 4 75 3 69 0 5000 4000 3000 2000 1000 0 0 10 20 30 MIN 7 91 4 22 3 17 2 64 2 11 1 58 1 05 0 53 500 1500 2500 3500 4500 5 15 25 DELIVERY RATE min DRIVING SPEED rpm DELIVERY RATE gal min MIN 7 39 6 86 6 33 5 80 5 28 4 75 3 69 0 5000 4000 3000 2000 1000 0 0 10 20 30 7 91 4 22 3 17 2 64 2 11 1 58 1 05 0 53 500 1500 2500 350...

Page 34: ...essure 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 ...

Page 35: ...ZF 80 1 IV ZF 85 IV M12 74 100 243 Control block bolts M8 13 18 243 Shifting lever bolt M8 17 23 Ð Stud bolts M16 26 35 243 Screw M5 4 5 243 Oil drain plug Ð 30 40 243 Oil breather Ð Hand tight Hand tight 574 Fluid dipstick Ð Hand tight Hand tight Ð Filter cover screw M8 min 4 max 6 min 5 max 8 Ð Control block stop screw Ð 9 12 Ð Control block pressure screw M10 9 12 Ð Neutral safety switch 18 5 2...

Page 36: ...e gauge 0 120ëC 0 250ëF connecting thread 3 8 18NPSF Flow meter 0 35 liters min 0 10 gals min Tests to be carried out 1 Fluid leaks 2 Noise emission 3 Direction of rotation LH RH 4 Lube oil temperature 5 Shifting pressure 6 Lube oil flow rate The function test should be carried out follows Motor speed rpm Shift lever position Durat minutes Test 800 1000 neutral 5 1 2 600 800 idling speed A B posit...

Page 37: ...runs in neutral position drain fluid refill transmission 3 2 Refer to 9 3 3 Refer to 6 3 4 Disassemble transmission replace clutch discs 3 5 Disassemble transmission replace clutch 4 Transmission locked in gear 4 1 Medium piston ring in input shaft in control block is faulty 4 2 Warped discs due to over heating of slipping clutch 4 3 Needle bearings on input shaft are worn out 4 1 Remove control b...

Page 38: ...er lines and clean fluid cooler on water side 8 4 Replace control block containing fluid pump 8 5 Remove control block replace piston rings In case of wear in the control block due to faulty piston rings re place control block as well 8 6 Refer to 3 8 7 Dismount transmission and coupling replace all faulty parts 8 8 Dismount transmission replace inner disc support and or clutch 8 9 Correct bypass ...

Page 39: ...facture 15 Low pressure 15 1 Fine filter is dirty 15 2 Fluid level in transmission is low 15 3 Control block is broken 15 4 Problem at control valve 15 5 Piston rings on input shaft are faulty 15 6 Piston rings inside the clutch are faulty 15 7 Defective cover filter air suction 15 8 Oil suction hose not properly adjusted 15 9 Fitting key in input shaft for fluid pump drive is broken 15 10 Possibl...

Page 40: ...fluid refill with prescribed fluid 18 8 Repair leakage at cooler or replace cooler Change transmission fluid 18 9 Remove control block and replace piston rings 19 Noise hydraulic 19 1 Oil filter is dirty 19 2 Fluid level in transmission is low 19 3 Oil suction hose not properly adjusted 19 4 Defective cover filter air suction at idle speed 19 5 Coupling under load 19 6 Wrong shimming 19 7 Defectiv...

Page 41: ...radially broken due to torsional vibration 23 1 Replace discs replace any other faulty parts 23 2 Disassemble transmission replace needle bearings 23 3 Replace the intermediate gear 23 4 Replace the discs and change the damper with a proper one 24 Water in the oil 24 1 Fluid cooler faulty 24 2 Water in bilge 24 1 Repair leakage at cooler or replace cooler 24 2 Remove water from the bilge and check...

Page 42: ...LFMATIC G2 22329 HUILE RENAULT DIESEL STARMATIC ELFMATIC G3 TRANSANTAR DF3 ELLER MONTAN COMP DUISBURG D ELLMO AUTOMATIK FLUID 22233 MANUFACTURER PRODUCT ENGEN PETROLEUM CAPE TOWN ZA ENGEN ATF 22D ERTOIL SA MADRID E TRANSMISIONES AUTOMATICAS D2 ESSO AG HAMBURG D ESSO ATF D 21611 ESSO ATF F 30320 ESSO ATF D 21065 FIAT LUBRIFICANTI VILLASTELLONE I TUTELA GI A FINA EUROPE SA BRU È SSEL B FINAMATIC II ...

Page 43: ...VNAFT JS CO BRATISLAVA SLO MADIT AUTOMATIC SONOL ISRAEL LTD HAIFA IL DEXRON 2 D MANUFACTURER PRODUCT SOPROGRASA SA MADRID E SOPRAL 164 STATOIL STAVANGER N TRANSWAY DX III F 30373 TRANSWAY DX II STL TECNOL ESCALQUENS F TECNOL TECMATIC D2 SUN OIL COMPANY AARTSELAAR B SUNAMATIC 149 SUNAMATIC 153 SUOMEN PETROOLI OY HAMINA SF TEBOIL FLUID E F 30301 TEBOIL FLUID D SVENSKA STATOIL AB NYNA ÈSHAMN S TRANSW...

Page 44: ...42 ...

Page 45: ...rial number Item no Part name Identification no quantity of parts required The spare parts list is referring to the following versions ZF 63 IV versions 14 1 29 R 15 1 56 R 16 2 00 R 17 2 48 R versions 001 1 29 R 002 1 56 R 003 2 00 R 004 2 48 R versions 012 1 29 R 013 1 56 R 014 2 00 R 015 2 48 R ZF 80 IV versions 04 1 21 R 05 1 40 R 01 1 64 R 02 2 01 R 03 2 49 R versions 001 1 21 R 002 1 40 R 00...

Page 46: ...ZF 63 IV 44 Repair Manual and Spare Parts List ZF 63 IV FIG 1 1 2 3 4 5 6 7 8 9 10 11 12 16 17 18 19 20 21 23 24 25 26 27 28 29 30 26 26 26 26 26 27 25 25 26 24 22 15 14 31 13 33 32 6 8 NEW VERSION ...

Page 47: ...ssy 1 17 0634 304 688 442731 Guarnizione OR O Ring 1 18 0634 306 204 105542 Guarnizione OR O Ring 1 19 3312 301 037 Filtro olio Oil filter 1 new part number 20 3312 301 008 439653 Guarnizione Gasket 1 21 978 31 701 02 465996 Asta livello olio Oil dipstick 1 3312 201 003 500991 Asta livello olio OR Oil dipstick OR 1 22 0634 304 405 501211 Guarnizione OR O Ring 1 23 3312 301 024 469243 Coperchio Cov...

Page 48: ...F 80 1 IV 46 Repair Manual and Spare Parts List ZF 80 IV ZF 80 1 IV FIG 1 1 2 4 5 6 7 8 10 11 12 13 16 17 18 19 20 21 22 25 26 27 26 26 29 30 27 27 27 27 28 25 26 27 26 27 24 9 3 23 31 15 14 33 32 7 9 NEW VERSION ...

Page 49: ...12 199 031 463772 Filtro olio completo Oil filter assy 1 18 0634 304 688 442731 Guarnizione OR O Ring 1 19 0634 306 204 105542 Guarnizione OR O Ring 1 20 3312 301 037 Filtro olio Oil filter 1 new part number 21 3312 301 008 439653 Guarnizione Gasket 1 22 978 61 701 01 480700 Asta livello olio Oil dipstick 1 3313 201 002 500990 Asta livello olio OR Oil dipstick OR 1 23 0634 304 405 501211 Guarnizio...

Page 50: ...ZF 63 IV 48 Repair Manual and Spare Parts List ZF 63 IV FIG 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 29 31 34 13 11 12 14 15 16 17 18 19 20 10 6 8 23 28 30 24 25 26 27 28 32 33 34a ...

Page 51: ... 022 439393 Spessore 0 1 mm Shim 0 1 mm 2 3312 304 023 439394 Spessore 0 15 mm Shim 0 15 mm 2 3312 304 024 439395 Spessore 0 3 mm Shim 0 3 mm 2 3312 304 025 439396 Spessore 0 5 mm Shim 0 5 mm 2 29 0635 370 020 159808 Cuscinetto a rulli conici Tapered roller bearing 1 30 0635 376 005 446130 Cuscinetto a rulli conici Tapered roller bearing 1 Vers 14 001 012 Rapporto I 1 29 Vers 14 001 012 Ratio I 1 ...

Page 52: ...0 1 IV 50 Repair Manual and Spare Parts List ZF 80 IV ZF 80 1 IV FIG 2 1 2 3 4 7 6 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 15 13 14 16 17 18 19 20 21 22 12 7 9 25 31 11 10 5 33 37 ...

Page 53: ...di ingresso Input shaft and 1 Ratio I 1 6 2 0 2 5 cilindro frizione clutch housing 3313 199 029 500238 Albero di ingresso Input shaft and 1 Ratio I 1 2 1 4 cilindro frizione clutch housing 24 0635 501 939 500390 Cuscinetto a rulli conici Tapered roller bearing 1 25 3313 302 042 439630 Spessore 0 1 mm Shim 0 1 mm 2 3313 302 043 439631 Spessore 0 15 mm Shim 0 15 mm 2 3313 302 044 439632 Spessore 0 2...

Page 54: ...medio Z2 53 Z6 37 Intermediate shaft Z2 53 Z6 37 1 37 3313 199 051 486681 Albero di uscita Z7 47 Output shaft Z7 47 1 SOLO PER ZF 80 1 IV ONLY FOR ZF 80 1 IV Vers 006 Rapporto I 1 64 Vers 006 Ratio I 1 64 34 3313 302 035 500838 Ingranaggio Z1 33 Forward gear Z1 33 1 35 3313 199 061 Albero d inversione Z4 39 Z5 34 Reversing shaft Z4 39 Z5 34 1 36 3313 199 062 Albero intermedio Z2 46 Z6 39 Intermedi...

Page 55: ...53 ...

Page 56: ... 63 IV ZF 80 IV ZF 80 1 IV MECHANICAL SELECTOR VALVE 54 Repair Manual and Spare Parts List ZF 63 IV ZF 80 IV ZF 80 1 IV FIG 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 6 13 5 6 16 13 23 24 20 22 21 ...

Page 57: ... 621 500065 Guarnizione Gasket 1 9 3312 308 034 500026 Vite di fermo Stop screw 1 10 0636 309 007 455756 Tappo Plug 1 11 0631 405 061 500107 Tappo Plug 1 12 0636 302 053 103465 Tappo Plug 1 13 0634 801 302 107410 Rosetta Washer 3 14 3312 308 037 500028 Vite di guida Guide bolt 1 15 3312 308 047 500044 Molla Spring 1 16 0635 460 014 106695 Sfera Ball 2 17 3312 308 029 455764 Interruttore completo N...

Page 58: ...ECTRIC SELECTOR VALVE WITH PROPORTIONAL VALVES 56 Repair Manual and Spare Parts List ZF 63 IV ZF 80 IV ZF 80 1 IV FIG 4 3 4 5 6 7 8 9 10 11 12 13 14 15 18 19 20 21 16 17 22 23 24 25 12 10 12 10 15 14 13 11 12 10 5 6 7 8 9 4 26 26 2 27 1 ...

Page 59: ...312 308 059 501516 Grano Drilled plug 2 12 0634 801 302 107410 Rosetta Washer 4 13 0636 101 651 501525 Vite Screw 2 14 0630 001 096 501527 Rondella Washer 2 15 1043 326 045 Fermo valvola Valve lock 2 16 3312 308 063 501562 Tappo Plug 1 17 0634 306 524 Anello OR O Ring 1 18 0636 101 727 442377 Vite Screw 6 19 0630 302 090 442372 Rosetta Washer 6 20 0630 532 004 501529 Anello elastico Snap ring 1 21...

Page 60: ...ZF 63 IV ZF 80 IV ZF 80 1 IV 58 Repair Manual and Spare Parts List ZF 63 IV ZF 80 IV ZF 80 1 IV FIG 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 17 18 19 20 15 16 21 22 10 9 10 11 12 7 8 ...

Page 61: ...ite Screw 2 10 0634 801 302 Rosetta Washer 3 11 4656 306 013 Pistoncino ammortizzatore Piston 2 12 0732 042 539 Molla ammortizzatore Spring 2 13 0631 405 062 501530 Tappo Plug 1 14 3312 308 051 501496 Vite torna a casa A Come home screw A 1 15 0636 302 068 500744 Tappo Plug 1 16 0634 801 260 500897 Rosetta Washer 1 17 0636 302 065 501520 Vite Screw 1 18 0634 801 281 227851 Rosetta Washer 1 19 3312...

Page 62: ...ZF 63 IV ZF 80 IV ZF 80 1 IV OLD ELECTRIC SELECTOR VALVE ON OFF 12V 26 BAR 60 Repair Manual and Spare Parts List ZF 63 IV ZF 80 IV ZF 80 1 IV FIG 6 F1420176 4 5 1 6 3 2 2 9 8 10 F1420175 7 ...

Page 63: ...Dummy plug 1 4 0636 302 053 Tappo M10x1 Screw plug M10x1 1 Ma 12 Nm 5 0634 801 302 Rosetta Washer 1 6 0636 309 007 Tappo Screw plug 1 Ma 30 Nm 7 3316 117 001 Assieme connettore Connector kit 2 8 0636 101 727 Vite T E M8x40 Cap screw M8x40 6 9 0630 302 090 Rosetta Spring washer 6 10 3312 308 020 Guarnizione Gasket 1 Installare con 12 V To be installed with 12 V power supply 61 Repair Manual and Spa...

Page 64: ...V ZF 80 1 IV NEW ELECTRIC SELECTOR VALVE ON OFF 12V 26 BAR NEW ELECTRIC SELECTOR VALVE ON OFF 24V 26 BAR 62 Repair Manual and Spare Parts List ZF 63 IV ZF 80 IV ZF 80 1 IV FIG 7 6 1 2 2 3 4 5 7 8 9 10 10 11 F1420178 10 ...

Page 65: ... 727 Vite T E M8x40 Cap screw M8x40 4 9 0630 302 090 Rosetta elastica Spring washer 6 10 3316 117 001 Assieme connettore Connector kit 2 11 3312 308 020 Guarnizione Gasket 1 Installare con 12 V To be installed with 12 V power supply Installare con 24 V To be installed with 24 V power supply F1420179 Per convertire la elettrovalvola da 12V a 24V sostituire solo il solenoide con il ricambio a cod 33...

Page 66: ...C SELECTOR VALVE ON OFF 12V 26 BAR WITH TROLLING VALVE NEW ELECTRIC SELECTOR VALVE ON OFF 24V 26 BAR WITH TROLLING VALVE 64 Repair Manual and Spare Parts List ZF 63 IV ZF 80 IV ZF 80 1 IV FIG 8 F1420178 10 6 1 2 3 4 5 8 9 10 11 13 7 10 12 10 ...

Page 67: ...30 302 090 Rosetta elastica Spring washer 6 10 3316 117 001 Assieme connettore Connector kit 3 11 3312 108 027 Trolling valve Trolling device 1 12 3312 308 096 Valvola proporzionale 12V Proportional valve 12V 1 Ma 27 Nm 3312 308 124 Valvola proporzionale 24V Proportional valve 24V 1 Ma 27 Nm 13 3312 308 020 Guarnizione Gasket 1 Installare con 12 V To be installed with 12 V power supply Installare ...

Page 68: ...h disc Outer clutch disc 1 1 8 10 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 5 8 22 26 24 25 27 29 30 23 23 23 23 28 28 28 28 3312 199 022 0635 501 940 3312 302 040 0635 501 937 0635 501 942 0635 501 941 0635 372 007 0635 370 020 0635 376 005 3312 302 023 3312 302 024 3312 302 025 3312 302 026 3312 304 022 3312 304 023 3312 304 024 3312 304 025 501217 441438 447754 106652 159808 446130 277213 277214 277215 2...

Page 69: ...3313 199 025 0635 501 937 3312 302 040 0635 501 939 0635 501 938 0635 374 005 0635 372 007 0635 370 017 0635 373 010 3313 302 042 3313 302 043 3313 302 044 3313 302 045 3313 302 046 3312 304 022 3312 304 023 3312 304 024 3312 304 025 3313 304 031 3313 304 030 3313 304 029 3313 304 028 501219 447754 441438 333859 229784 106652 464199 480757 439630 439631 439632 439633 439634 439393 439394 439395 43...

Page 70: ...68 ...

Page 71: ...is Manual the relative Spare Parts List should be ordered from ZF HURTH MARINE The indicated dimensions and standards are as such not enough for ordering parts When ordering parts please state Transmission type Transmission version Serial number Item no Part name Identification no quantity of parts required The spare parts list is referring to the following versions ZF 80 IV versions 029 1 21 R 03...

Page 72: ...032 033 ZF 80 1 IV versions 034 035 036 037 038 70 Repair Manual and Spare Parts List ZF 80 IV ZF 80 1 IV FIG 1 1 2 4 5 6 7 10 11 12 13 16 17 18 19 20 21 22 25 26 27 26 26 29 30 27 27 27 27 28 25 26 27 26 27 24 9 3 23 15 14 8 31 32 ...

Page 73: ...ing 1 14 0630 001 085 167010 Rosetta Washer 1 15 0636 101 475 320202 Vite M8x30 Screw M8x30 1 16 3312 301 007 438637 Filtro olio Oil filter 1 old part number 17 3312 199 031 463772 Filtro olio completo Oil filter assy 1 18 0634 304 688 442731 Guarnizione OR O Ring 1 19 0634 306 204 105542 Guarnizione OR O Ring 1 20 3312 301 037 Filtro olio Oil filter 1 new part number 21 3312 301 008 439653 Guarni...

Page 74: ...0 1 IV versions 034 035 036 037 038 72 Repair Manual and Spare Parts List ZF 80 IV ZF 80 1 IV FIG 2 1 2 3 4 7 6 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 34 35 36 15 13 14 16 17 18 19 20 21 22 12 7 9 25 31 11 10 5 33 37 ...

Page 75: ... 1 6 2 0 2 5 cilindro frizione clutch housing 3313 199 084 Albero di ingresso Input shaft and 1 Ratio I 1 2 1 4 cilindro frizione clutch housing 24 0635 501 939 Cuscinetto a rulli conici Tapered roller bearing 1 25 3313 302 042 439630 Spessore 0 1 mm Shim 0 1 mm 2 3313 302 043 439631 Spessore 0 15 mm Shim 0 15 mm 2 3313 302 044 439632 Spessore 0 2 mm Shim 0 2 mm 2 3313 302 045 439633 Spessore 0 5 ...

Page 76: ... 37 3313 199 094 Albero di uscita Z7 47 Output shaft Z7 47 1 SOLO PER ZF 80 1 IV ONLY FOR ZF 80 1 IV Vers 034 Rapporto I 1 21 Vers 034 Ratio I 1 21 34 3313 302 055 Ingranaggio Z1 32 Forward gear Z1 32 1 35 3313 199 095 Albero d inversione Z4 39 Z5 33 Reversing shaft Z4 39 Z5 33 1 36 3313 199 096 Albero intermedio Z2 47 Z6 45 Intermediate shaft Z2 47 Z6 45 1 37 3313 199 043 500516 Albero di uscita ...

Page 77: ...75 ...

Page 78: ...030 031 032 033 ZF 80 1 IV versions 034 035 036 037 038 MECHANICAL SELECTOR VALVE 76 Repair Manual and Spare Parts List ZF 80 IV ZF 80 1 IV FIG 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 6 13 5 6 16 13 23 24 20 22 21 ...

Page 79: ...te di fermo Stop screw 1 10 0636 309 007 455756 Tappo Plug 1 11 0631 405 061 500107 Tappo Plug 1 12 0636 302 053 103465 Tappo Plug 1 13 0634 801 302 107410 Rosetta Washer 3 14 3312 308 037 500028 Vite di guida Guide bolt 1 15 3312 308 047 500044 Molla Spring 1 16 0635 460 014 106695 Sfera Ball 2 17 3312 308 029 455764 Interruttore completo Neutral safety switch assy 1 18 001 105 0158 105527 Guarni...

Page 80: ...ions 029 030 031 032 033 ZF 80 1 IV versions 034 035 036 037 038 OLD ELECTRIC SELECTOR VALVE ON OFF 12V 26 BAR 78 Repair Manual and Spare Parts List ZF 80 IV ZF 80 1 IV FIG 4 F1420176 4 5 1 6 3 2 2 9 8 10 F1420175 7 ...

Page 81: ...appo Dummy plug 1 4 0636 302 053 Tappo M10x1 Screw plug M10x1 1 Ma 12 Nm 5 0634 801 302 Rosetta Washer 1 6 0636 309 007 Tappo Screw plug 1 Ma 30 Nm 7 3316 117 001 Assieme connettore Connector kit 2 8 0636 101 727 Vite T E M8x40 Cap screw M8x40 6 9 0630 302 090 Rosetta Spring washer 6 10 3312 308 020 Guarnizione Gasket 1 Installare con 12 V To be installed with 12 V power supply 79 Repair Manual an...

Page 82: ...3 ZF 80 1 IV versions 034 035 036 037 038 NEW ELECTRIC SELECTOR VALVE ON OFF 12V 26 BAR NEW ELECTRIC SELECTOR VALVE ON OFF 24V 26 BAR 80 Repair Manual and Spare Parts List ZF 80 IV ZF 80 1 IV FIG 5 6 1 2 2 3 4 5 7 8 9 10 10 11 F1420178 10 ...

Page 83: ... 101 727 Vite T E M8x40 Cap screw M8x40 4 9 0630 302 090 Rosetta elastica Spring washer 6 10 3316 117 001 Assieme connettore Connector kit 2 11 3312 308 020 Guarnizione Gasket 1 Installare con 12 V To be installed with 12 V power supply Installare con 24 V To be installed with 24 V power supply F1420179 Per convertire la elettrovalvola da 12V a 24V sostituire solo il solenoide con il ricambio a co...

Page 84: ...4 035 036 037 038 NEW ELECTRIC SELECTOR VALVE ON OFF 12V 26 BAR WITH TROLLING VALVE NEW ELECTRIC SELECTOR VALVE ON OFF 24V 26 BAR WITH TROLLING VALVE 82 Repair Manual and Spare Parts List ZF 80 IV ZF 80 1 IV FIG 6 F1420178 10 6 1 2 3 4 5 8 9 10 11 13 7 10 12 10 ...

Page 85: ... 9 0630 302 090 Rosetta elastica Spring washer 6 10 3316 117 001 Assieme connettore Connector kit 3 11 3312 108 027 Trolling valve Trolling device 1 12 3312 308 096 Valvola proporzionale 12V Proportional valve 12V 1 Ma 27 Nm 3312 308 124 Valvola proporzionale 24V Proportional valve 24V 1 Ma 27 Nm 13 3312 308 020 Guarnizione Gasket 1 Installare con 12 V To be installed with 12 V power supply Instal...

Page 86: ... 31 31 3313 199 025 0635 501 937 3312 302 040 0635 501 939 0635 501 938 0635 374 005 0635 372 007 0635 370 017 0635 373 010 3313 302 042 3313 302 043 3313 302 044 3313 302 045 3313 302 046 3312 304 022 3312 304 023 3312 304 024 3312 304 025 3313 304 031 3313 304 030 3313 304 029 3313 304 028 501219 447754 441438 333859 229784 106652 464199 480757 439630 439631 439632 439633 439634 439393 439394 43...

Page 87: ...icated differs from that printed in this Manual the relative Spare Parts List should be ordered from ZF HURTH MARINE The indicated dimensions and standards are as such not enough for ordering parts When ordering parts please state Transmission type Transmission version Serial number Item no Part name Identification no quantity of parts required The spare parts list is referring to the following ve...

Page 88: ...ZF 85 IV versions 002 003 004 86 Repair Manual and Spare Parts List ZF 85 IV FIG 1 1 2 4 5 6 7 10 11 12 13 16 17 18 19 20 21 22 25 26 27 26 26 29 3 27 27 27 27 28 25 26 27 26 27 24 9 23 14 15 8 30 31 ...

Page 89: ...zione OR O Ring 1 13 0634 306 204 105542 Guarnizione OR O Ring 1 14 0630 001 085 167010 Rosetta Washer 1 15 0636 101 475 320202 Vite M8x30 Screw M8x30 1 16 3312 301 007 438637 Filtro olio Oil filter 1 old part number 17 3312 199 031 463772 Filtro olio completo Oil filter assy 1 18 0634 304 688 442731 Guarnizione OR O Ring 1 19 0634 306 204 105542 Guarnizione OR O Ring 1 20 3312 301 037 Filtro olio...

Page 90: ...s 002 003 004 88 Repair Manual and Spare Parts List ZF 85 IV FIG 2 37 1 2 3 4 7 8 9 10 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 33 38 39 40 15 13 14 16 17 19 20 21 22 23 12 7 6 26 32 11 5 34 41 18 36 35 ...

Page 91: ...lli conici Tapered roller bearing 1 30 0635 372 007 106652 Cuscinetto a rulli conici Tapered roller bearing 1 31 3312 304 022 439393 Spessore 0 1 mm Shim 0 1 mm 2 3312 304 023 439394 Spessore 0 15 mm Shim 0 15 mm 2 3312 304 024 439395 Spessore 0 3 mm Shim 0 3 mm 2 3312 304 025 439396 Spessore 0 5 mm Shim 0 5 mm 2 32 3313 304 031 477560 Spessore 0 1 mm Shim 0 1 mm 2 3313 304 030 477558 Spessore 0 1...

Page 92: ...ZF 85 IV versions 002 003 004 MECHANICAL SELECTOR VALVE Repair Manual and Spare Parts List ZF 85 IV FIG 3 90 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 6 13 5 6 16 13 23 24 20 22 21 ...

Page 93: ...55756 Tappo Plug 1 11 0631 405 061 500107 Tappo Plug 1 12 0636 302 053 103465 Tappo Plug 1 13 0634 801 302 107410 Rosetta Washer 3 14 3312 308 037 500028 Vite di guida Guide bolt 1 15 3312 308 047 500044 Molla Spring 1 16 0635 460 014 106695 Sfera Ball 2 17 3312 308 029 455764 Interruttore completo Neutral safety switch assy 1 18 001 105 0158 105527 Guarnizione OR O Ring 1 19 3312 308 039 500030 B...

Page 94: ...85 IV versions 002 003 004 ELECTRIC SELECTOR VALVE ON OFF 12V 26 BAR ELECTRIC SELECTOR VALVE ON OFF 24V 26 BAR 92 Repair Manual and Spare Parts List ZF 85 IV FIG 4 6 1 2 2 3 4 5 7 8 9 10 10 11 F1420178 10 ...

Page 95: ...8 0636 101 727 Vite T E M8x40 Cap screw M8x40 4 9 0630 302 090 Rosetta elastica Spring washer 6 10 3316 117 001 Assieme connettore Connector kit 2 11 3312 308 020 Guarnizione Gasket 1 Installare con 12 V To be installed with 12 V power supply Installare con 24 V To be installed with 24 V power supply F1420179 Per convertire la elettrovalvola da 12V a 24V sostituire solo il solenoide con il ricambi...

Page 96: ...004 ELECTRIC SELECTOR VALVE ON OFF 12V 26 BAR WITH TROLLING VALVE ELECTRIC SELECTOR VALVE ON OFF 24V 26 BAR WITH TROLLING VALVE 94 Repair Manual and Spare Parts List ZF 85 IV FIG 5 6 1 2 3 4 5 8 9 10 11 13 7 10 12 10 F1420178 10 ...

Page 97: ...x40 4 9 0630 302 090 Rosetta elastica Spring washer 6 10 3316 117 001 Assieme connettore Connector kit 3 11 3312 108 027 Trolling valve Trolling device 1 12 3312 308 096 Valvola proporzionale 12V Proportional valve 12V 1 Ma 27 Nm 3312 308 124 Valvola proporzionale 24V Proportional valve 24V 1 Ma 27 Nm 13 3312 308 020 Guarnizione Gasket 1 Installare con 12 V To be installed with 12 V power supply I...

Page 98: ...3313 302 042 3313 302 043 3313 302 044 3313 302 045 3313 302 046 3312 304 022 3312 304 023 3312 304 024 3312 304 025 3313 304 031 3313 304 030 3313 304 029 3313 304 028 0630 000 193 0630 000 298 0630 000 274 447754 447754 333859 229784 106652 464199 480757 439630 439631 439632 439633 439634 439393 439394 439395 439396 477560 477558 477557 447551 Kit cuscinetti Cuscinetto a rullini conici Cuscinett...

Page 99: ...the type and version indicated differs from that printed in this Manual the relative Spare Parts List should be ordered from ZF HURTH MARINE The indicated dimensions and standards are as such not enough for ordering parts When ordering parts please state Transmission type Transmission version Serial number Item no Part name Identification no quantity of parts required The spare parts list is refer...

Page 100: ...sions 048 049 050 98 Repair Manual and Spare Parts List ZF 80 IV ZF 85 IV Derivate version FIG 1 1 2 4 5 6 7 10 11 12 13 16 17 18 19 20 21 22 25 26 27 26 26 29 3 27 27 27 27 28 25 26 27 26 27 24 9 23 14 15 8 30 31 ...

Page 101: ...ng 1 13 0634 306 204 105542 Guarnizione OR O Ring 1 14 0630 001 085 167010 Rosetta Washer 1 15 0636 101 475 320202 Vite M8x30 Screw M8x30 1 16 3312 301 007 438637 Filtro olio Oil filter 1 old part number 17 3312 199 031 463772 Filtro olio completo Oil filter assy 1 18 0634 304 688 442731 Guarnizione OR O Ring 1 19 0634 306 204 105542 Guarnizione OR O Ring 1 20 3312 301 037 Filtro olio Oil filter 1...

Page 102: ...100 Repair Manual and Spare Parts List ZF 80 IV ZF 85 IV Derivate version FIG 2 37 1 2 3 4 7 8 9 10 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 33 38 39 40 15 13 14 16 17 19 20 21 22 23 12 7 6 26 32 11 5 34 41 18 36 35 ...

Page 103: ...ered roller bearing 1 30 0635 372 007 106652 Cuscinetto a rulli conici Tapered roller bearing 1 31 3312 304 022 439393 Spessore 0 1 mm Shim 0 1 mm 2 3312 304 023 439394 Spessore 0 15 mm Shim 0 15 mm 2 3312 304 024 439395 Spessore 0 3 mm Shim 0 3 mm 2 3312 304 025 439396 Spessore 0 5 mm Shim 0 5 mm 2 32 3313 304 031 477560 Spessore 0 1 mm Shim 0 1 mm 2 3313 304 030 477558 Spessore 0 15 mm Shim 0 15...

Page 104: ...IV versions 048 049 050 MECHANICAL SELECTOR VALVE 102 Repair Manual and Spare Parts List ZF 80 IV ZF 85 IV Derivate version FIG 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 6 13 5 6 16 13 23 24 20 22 21 ...

Page 105: ...ug 1 11 0631 405 061 500107 Tappo Plug 1 12 0636 302 053 103465 Tappo Plug 1 13 0634 801 302 107410 Rosetta Washer 3 14 3312 308 037 500028 Vite di guida Guide bolt 1 15 3312 308 047 500044 Molla Spring 1 16 0635 460 014 106695 Sfera Ball 2 17 3312 308 029 455764 Interruttore completo Neutral safety switch assy 1 18 001 105 0158 105527 Guarnizione OR O Ring 1 19 3312 308 039 500030 Boccola Bushing...

Page 106: ...s 048 049 050 ELECTRIC SELECTOR VALVE ON OFF 12V 26 BAR ELECTRIC SELECTOR VALVE ON OFF 24V 26 BAR 104 Repair Manual and Spare Parts List ZF 80 IV ZF 85 IV Derivate version FIG 4 6 1 2 2 3 4 5 7 8 9 10 10 11 F1420178 10 ...

Page 107: ... Vite T E M8x40 Cap screw M8x40 4 9 0630 302 090 Rosetta elastica Spring washer 6 10 3316 117 001 Assieme connettore Connector kit 2 11 3312 308 020 Guarnizione Gasket 1 Installare con 12 V To be installed with 12 V power supply Installare con 24 V To be installed with 24 V power supply F1420179 Per convertire la elettrovalvola da 12V a 24V sostituire solo il solenoide con il ricambio a cod 3312 1...

Page 108: ...ELECTOR VALVE ON OFF 12V 26 BAR WITH TROLLING VALVE ELECTRIC SELECTOR VALVE ON OFF 24V 26 BAR WITH TROLLING VALVE 106 Repair Manual and Spare Parts List ZF 80 IV ZF 85 IV Derivate version FIG 5 6 1 2 3 4 5 8 9 10 11 13 7 10 12 10 F1420178 10 ...

Page 109: ...302 090 Rosetta elastica Spring washer 6 10 3316 117 001 Assieme connettore Connector kit 3 11 3312 108 027 Trolling valve Trolling device 1 12 3312 308 096 Valvola proporzionale 12V Proportional valve 12V 1 Ma 27 Nm 3312 308 124 Valvola proporzionale 24V Proportional valve 24V 1 Ma 27 Nm 13 3312 308 020 Guarnizione Gasket 1 Installare con 12 V To be installed with 12 V power supply Installare con...

Page 110: ...313 302 043 3313 302 044 3313 302 045 3313 302 046 3312 304 022 3312 304 023 3312 304 024 3312 304 025 3313 304 031 3313 304 030 3313 304 029 3313 304 028 0630 000 193 0630 000 298 0630 000 274 447754 447754 333859 229784 106652 464199 480757 439630 439631 439632 439633 439634 439393 439394 439395 439396 477560 477558 477557 447551 Kit cuscinetti Cuscinetto a rullini conici Cuscinetto a rulli Cusc...

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