Repair Manual and Spare Parts List ZF 63 A

Repair Manual and Spare Parts List ZF 63 A
Repair Manual
and
Spare Parts List
ZF 63 A
ZF 63
ZF 80 A
ZF 80-1 A
ZF 85 A
FEBRUARY 2006
cod. 310.01.0054i
Repair Manual and Spare Parts List
Table of contents
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
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
1.4 STANDARD TOOLS AND FIXTURE . . . . . . . . . . . . . . . 6
4.5 MEASURING THE BEARING CLEARANCE/
ADJUSTING THE PRETENSION OF BEARINGS . . 22
2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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
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 80 A, ZF 80-1 A and ZF 85 A . . . . . . . . . . . . . . . 9
3.2 DIPSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5.5 Measuring bearing clearance at
intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5.6 Measuring the bearing clearance on the
output shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3 BREATHER VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5.7 Adjusting the pretension/clearance of
bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.4 OUTPUT FLANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5.8 Final assembly of the housing . . . . . . . . . . . . . . 24
3.5 CONTROL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6 CONTROL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5.1 Neutral Safety Switch . . . . . . . . . . . . . . . . . . . . . 11
3.5.2 Neutral Safety Switch Check . . . . . . . . . . . . . . . 11
4.6.1 Mounting the control block . . . . . . . . . . . . . . . . . 25
3.6 HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6.1
3.6.2
3.6.3
3.6.4
Transmission housing halves. . . . . . . . . . . . . . .
Shafts and gears . . . . . . . . . . . . . . . . . . . . . . . . .
Radial shaft seals . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid inlet pipe . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
12
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
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
3.8.1 Removal of the clutch discs . . . . . . . . . . . . . . . . 15
5. ADJUSTMENT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1 SHIFTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 LUBE OIL DELIVERY RATE . . . . . . . . . . . . . . . . . . . . . 27
4. ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. HYDRAULIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.8 CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1.1
4.1.2
4.1.3
4.1.4
Mount discs into reversing clutch . . . . . . . . . . .
Install needle bearings and gear. . . . . . . . . . . .
Assemble butting rings . . . . . . . . . . . . . . . . . . . .
Mounting inner races of tapered
roller bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.5 Assemble shims, support shims and
retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.5 Assemble piston rings . . . . . . . . . . . . . . . . . . . . .
17
18
18
18
18
19
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
7. TIGHTENING TORQUES. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8. FUNCTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10. AUTOMATIC TRANSMISSION FLUID . . . . . . . . . . . . . . 36
11. SPARE PARTS LIST
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A. . . . . . . . . . . . . . . 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
FIG.
FIG.
FIG.
FIG.
2
2
2
3
ZF 63 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
ZF 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ZF 80 A - ZF 80-1 A. . . . . . . . . . . . . . . . . . . . . . . . . 52
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 63 A - ZF 63 KIT COMPONENTS . . . . . . . . . . . . . . . . . 68
ZF 80 A - ZF 80-1 A KIT COMPONENTS . . . . . . . . . . . . . . 69
12. SPARE PARTS LIST
ZF 80 A (016, 017, 018, 019, 020, 021 VERSION)
ZF 80-1 A (024, 025, 026, 027, 029, 030 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 80 A - ZF 80-1 A . . . . . . . . . . . . . . . . . . . . . . . . . . 78
FIG. 4 Old electric selector valve ON/OFF 12V, 26 bar
ZF 80 A - ZF 80-1 A . . . . . . . . . . . . . . . . . . . . . . . . . . 80
FIG. 5 New electric selector valve ON/OFF 12V - 26 bar
New electric selector valve ON/OFF 24V - 26 bar
ZF 80 A - ZF 80-1 A . . . . . . . . . . . . . . . . . . . . . . . . . . 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 80 A - ZF 80-1 A . . . . . . . . . . . . . . . . . . . . . . . . . . 84
KIT COMPONENTS ZF 80 A - ZF 80-1 A . . . . . . . . . . . . . . 86
2
Table of contents
13. SPARE PARTS LIST ZF 85 A . . . . . . . . . . . . . . . . . . . . .
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Name plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIG. 1 ZF 85 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIG. 2 ZF 85 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIG. 3 Mechanical selector valve
ZF 85 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIG. 4 Electric selector valve ON/OFF 12V - 26 bar
Electric selector valve ON/OFF 24V - 26 bar
ZF 85 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 85 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KIT COMPONENTS ZF 85 A . . . . . . . . . . . . . . . . . . . . . . . .
87
87
87
88
90
92
94
96
98
14. SPARE PARTS LIST ZF 80 A
(ZF 85 A DERIVATE VERSION) . . . . . . . . . . . . . . . . . . . 99
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Name plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
FIG. 1 ZF 80 A (ZF 85 A DERIVATE VERSION) . . . . . . 100
FIG. 2 ZF 80 A (ZF 85 A DERIVATE VERSION) . . . . . . 102
FIG. 3 Mechanical selector valve
ZF 80 A (ZF 85 A DERIVATE VERSION) . . . . . . 104
FIG. 4 Electric selector valve ON/OFF 12V - 26 bar
Electric selector valve ON/OFF 24V - 26 bar
ZF 80 A (ZF 85 A DERIVATE VERSION) . . . . . . 106
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 A (ZF 85 A DERIVATE VERSION) . . . . . . 108
KIT COMPONENTS ZF 80 A
(ZF 85 A DERIVATE VERSION) . . . . . . . . . . . . . . . . . . . . 110
Repair Manual and Spare Parts List
Introduction
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
4
Repair Manual and Spare Parts List
Section 1
1. MAJOR COMPONENTS
1.1 TRANSMISSION SET-UP
The main components of the ZF Marine Transmissions are:
ITEM
1
1.1
1.2
1.3
1.4
DESCRIPTION
ITEM
2
2.1
2.2
2.3
3
Two-piece aluminum die cast
Oil filter
Oil dipstick
Breather valve
Oil drain plug (ZF 80A, ZF 80-1A, ZF 85A)
1.2
DESCRIPTION
Gears
Input shaft with reversing clutch pack assembly
Intermediate shaft
Output shaft
Control block
2.1
2
2.3
2.2
1
1.3
3
1.1
1.4
5
Repair Manual and Spare Parts List
Section 1
1.2 CLEANERS AND SEALANTS
For cleaning:
Cold cleaner such as benzene, thrichloroethane 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 medium-hard for securing oil plug on
ZF 80 A - ZF 80-1 A - ZF 85 A
1.3. MEASURING TOOLS
.
.
.
.
.
Loctite 245 for securing output flange on spline.
Loctite 518 for housing surfaces.
Loctite 574 for outer diameter sealing rings.
Grease: Staburags NBU 30, Klueber Co. for radial
shaft seals.
ATF FLUID:
3.8 litres (1.0 US.gallons) for ZF 63
4.0 litres (1.05 US.gallons) for ZF 63 A
5.5 litres (1.5 US.gallons) for ZF 80 A - ZF 80-1 A
5.5 litres (1.5 US.gallons) for ZF 85 A
1.4. STANDARD TOOLS AND FIXTURE
WRENCH for hexagon bolts (8 - 17 - 19 - 22 mm) (7/8")
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
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
PLASTIC HAMMER (1000 g) and sturdy screwdriver
DIAL FACE CAN BE TURNED
TO ZERO POSITION
ACCURACY OF READING:
SMALL HAND 1 mm (.03937 in)
LARGE HAND
1/100 mm (.0004 in)
EXTRACTOR minimum diameter 130 m
MEASURING DEPTH
APPROX. 11 mm (.433 in)
FEELER GAUGE
6
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)
CLAMPING RING for measuring the bearing clearance
input shaft P/N 219.354.3 (618582)
LEVER
CLAMPING SCREW
INPUT SHAFT
DIAL INDICATOR
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
EXTRACTOR SPLIT RING
Input shaft. Taper roller bearing inner race - control
D
block side. P/N 224.836.009
(456170)
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
EXTRACTOR Tapered roller bearing outer races basic
unit P/N 978.25.0021.0 (454422)
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
LEGS KIT (composed of three legs)
P/N 978.25.0006.0 (477776)
50
A
B
ADAPTER FOR
BASIC UNIT 454422
BASIC UNIT
Part number
ZF 63
ZF 63 A
978.25.0009.0 (477853)
l
978.25.0011.0 (477854)
l
978.25.0012.0 (477856)
l
978.25.0013.0 (477857)
l
978.35.0016.0 (477895)
ZF 80 A
ZF 80-1 A
ZF 85 A
ZF 80 A ]
l
l
l
l
l
Mandrel P/N 20.1072.01 to assemble input shaft seal
Only for model: ZF 85 A - ZF 80 A (ZF 85 A DERIVATE
VERSION)
] (ZF 85 A DERIVATE VERSION)
7
Repair Manual and Spare Parts List
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
Section 2
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
SPECIAL HEX HEAD BOLT WITH BEARING
for measuring the bearing clearance intermediate shaft
P/N. 224.836.008 (458105)
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
4
2
FIG. 1 - 1
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 80 A, ZF 80-1 A and ZF 85 A
1
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.
2
3
FIG. 1 - 2
9
Repair Manual and Spare Parts List
Section 3
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).
1
FIG. 2 - 1
1
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.
FIG. 3 - 1
1
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. 41).
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.
2
3
4
FIG. 4 - 1
1
FIG. 4 - 2
10
Repair Manual and Spare Parts List
Section 3
3.5 CONTROL BLOCK
4
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).
2
3
FIG. 5 - 1
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.)
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
Neutral
position
Battery 12 V DC
1a
Lamp 8.4 A
A or B
position
1b
FIG. 5 - 3
11
Repair Manual and Spare Parts List
Section 3
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.
1
FIG. 6 - 1a
3
1
2
FIG. 6 - 1b
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.
4
1
3
2
FIG. 6 - 2
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).
FIG. 6 - 3a
12
Repair Manual and Spare Parts List
Section 3
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).
FIG. 6 - 3b
3.6.4 Fluid inlet pipe
Replacing the seal:
ZF 63 A - ZF 63 (Fig. 6-4a)
. Remove baffle plate (item 2).
. Remove suction pipe (item 3).
. Drive out seal (item 1).
1
2
3
OLD VERSION
3
NEW VERSION
FIG. 6 - 4a
ZF 80 A - ZF 80-1 A - ZF 85 A (Fig. 6-4b)
Remove suction pipe (item 2).
. Drive out seal (item 1).
.
1
2
FIG. 6 - 4b
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 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
FIG. 7 - 1
correct position during reassembling.
Shims are located under outer races of the cover
only.
3.7.2 Inner races of tapered roller bearings
3
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 - ZF 80 A
(ZF 85 A 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. 7-2c).
14
2
1
INPUT SPLINE SIDE
FIG. 7 - 2a
1
CONTROL BLOCK SIDE
FIG. 7 - 2b
2
3
FIG. 7 - 2c
Repair Manual and Spare Parts List
Section 3
3.8 CLUTCH PACK
3.8.1 Removal of the clutch discs
Control block side (Fig. 8-1a)
ZF 63 A - 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.
4
5
2
3
1
6
FIG. 8 - 1a
Control block side (Fig. 8-1b)
ZF 80 A - 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.
5
2
4
7
3
1
6
FIG. 8 - 1b
Control block side (Fig. 8-1c)
ZF 85 A - ZF 80 A (ZF 85 A DERIVATE VERSION)
. 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.
5
4
2
1
3
6
FIG. 8 - 1c
15
Repair Manual and Spare Parts List
Input spline side (fig. 8-2a)
ZF 63 A (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.
Section 3
4
5
2
3
1
6
FIG. 8 - 2a
Input spline side (fig. 8-2b)
ZF 80 A - ZF 80-1 A
ZF 63 A (only ratio 2.7)
ZF 85 A
. Remove thrust washer (1) off using two screwdrivers.
. Take off gear (2), needle bearings (3) and spacer
(4).
.
16
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.
5
2
6
4
1
3
7
FIG. 8 - 2b
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 swiveling
stand, described in the disassembly section to aid in
the assembly.
Thoroughly clean all mating surfaces from any Loctite
or gasket material.
| WARNING |
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
Cleaners and solvents can be toxic and potentially
harmful without proper ventilation.
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.
1
2
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).
FIG. 1 - 1a
FIG. 1 - 1b
2
2
1
1
FIG. 1 - 1c
FIG. 1 - 1d
17
Repair Manual and Spare Parts List
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.
Section 4
ZF 63 A (Ratio= 2.7 only)
ZF 80 A - ZF 80-1 A - ZF 85 A
ZF 63 A (no Ratio= 2.7)
ZF 63
.
2
2
1
1
3
Control block side
. Repeat same procedure of input sline.
Spacer is only in ZF 80 A and ZF 80-1 A.
4.1.3 Assemble butting rings
NOTE
.
.
FIG. 1 - 2
Make sure thrust washer is fully pressed on and
gear is free to rotate.
Thrust washer must not be bent.
1
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.
D
4.1.4 Mounting inner races of tapered roller
bearings
Heat inner race of tapered roller bearing (item 1, Fig. 14) 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.
120 ˚C
248 ˚F
FIG. 1 - 3
1
| CAUTION |
2
Handle heated tapered roller bearing inner race only
with special gloves!
NOTE
For pressing, apply sleeve to inner race but not to
rollers.
FIG. 1 - 4
2
4.1.5 Assemble shims, support shims and
retaining ring ZF 85 A - ZF 80 A (ZF 85 A
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.
3
1
| WARNING! |
.
.
18
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.
FIG. 1 - 5
Repair Manual and Spare Parts List
Section 4
4.1.6 Assemble piston rings
Mount piston ring seals (item 1, Fig. 1-6) onto input shaft.
1
+
Make sure the interlocking position of the piston
| IMPORTANT |
rings are staggered on the shaft.
FIG. 1 - 6
4.2 INTERMEDIATE SHAFT
120 ˚C
248 ˚F
4.2.1 Mounting inner races of tapered roller
bearings
1
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.
2
120 ˚C
248 ˚F
FIG. 2 - 1
4.3 OUTPUT SHAFT
120 ˚C
248 ˚F
1
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.
120 ˚C
248 ˚F
2
FIG. 3 - 1
19
Repair Manual and Spare Parts List
Section 4
4.4 PREASSEMBLY OF HOUSING
1
4.4.1 Assembly of outer races
(tapered roller bearings)
2
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.
FIG. 4 - 1
OLD VERSION
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).
NEW VERSION
4
3
1
2
3
ZF80 A - ZF80-1 A
OLD VERSION
NEW VERSION
4
1
3
1
3
ZF63A - ZF63
1
FIG. 4 - 2a
3
ZF85 A
2
1
A
1
FIG. 4 - 2b
4.4.2.2 Installation of baffle (Fig. 4-2d)
(ZF 63 A - 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).
1
A
FIG. 4 - 2c
2
1
FIG. 4 - 2d
20
Repair Manual and Spare Parts List
Section 4
1
NOTE
A
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.
1 mm
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.
1 mm
4.4.3 Assembling input shaft seal
1
FIG. 4 - 3a
A
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 - ZF 80 A (ZF 85 A 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.
FIG. 4 - 3b
ZF 63 - ZF 63 A
ZF 80 A - ZF 80-1 A
ZF 85 A
ZF 80 A (ZF 85 A DERIVATE VERSION)
1
3
2
2
1
FIG. 4 - 3c
1
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 243.
Apply thin coat of Loctite 574 to the oil breather (item 1,
Fig. 4-4).
Tighten carefully during assembly (hand-tight).
Cheek leakage during a later test run. Retighten
slightly if it leaks.
FIG. 4 - 4
21
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 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
3
2
1
Pretension (mm)
FIG. 5 - 1
Shaft
Input
Intermediate
Output
ZF 80 A - ZF 80-1 A
0.02-0.12
0.00-0.12
0.00-0.12
ZF 85 A - ZF 80 A ]
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
Input
Intermediate
Output
Pretension (inches)
Shaft
ZF 80 A - ZF 80-1 A
0.001-0.005 0.000-0.005 0.000-0.005
ZF 85 A - ZF 80 A ]
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
] (ZF 85 A DERIVATE VERSION)
3
4.5.2 Mounting outer races of tapered roller
bearings into housing
2
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.
1
| 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
FIG. 5 - 2
4
3
2
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
1
FIG. 5 - 3
Repair Manual and Spare Parts List
4.5.4 Measuring bearing clearance on input
shaft
Section 4
1
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 bearings 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 (intermediate shaft moves up) until bearing clearance is
overcome (Fig. 5-5b).
FIG. 5 - 4
2
1
FIG. 5 - 5a
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 required in section 5.1 determine the required thickness of shims.
4.5.6 Measuring the bearing clearance on
the output shaft
FIG. 5 - 5b
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 adjust 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 pretension required in section 5.1 will determine the required thickness of shims.
FIG. 5 - 6
23
Repair Manual and Spare Parts List
Section 4
4.5.7 Adjusting the pretension/clearance of
bearings
1
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 lockwashers (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.
2
4
4
3
5
1
FIG. 5 - 7a
| 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
50
A
B
ADAPTER FOR
BASIC UNIT 454422
BASIC UNIT
FIG. 5 - 7b
Repair Manual and Spare Parts List
Section 4
4.6 CONTROL BLOCK
2
4.6.1 Mounting the control block
NOTE
1
Piston rings (item 1, Fig. 6-1) have to be replaced, if
thickness is less than 2.39 mm (0.094in).
3
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
5
FIG. 6 - 1
4.7 FLUID FILTER
2
4.7.1 Mounting the fluid filter
.
.
.
4
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.)
3
1
FIG. 7 - 1
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 insert into output flange.
Tight output flange down on output shaft with bolt (item
3, Fig 8-1) and washer (4).
Tightening torque:
ZF 63 A - ZF 63
: 100 Nm (74 ft.lb.)
ZF 80 A - ZF 80-1 A : 100 Nm (74 ft.lb.)
ZF 85 A
: 100 Nm (74 ft.lb.)
Z
1
2
3
4
X
FIG. 8 - 1
25
Repair Manual and Spare Parts List
Section 4
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. 91)
Quantity:
ZF 63
: 4.0 US-qts (3.8 liters)
ZF 63 A
: 4.2 US-qts (4.0 liters)
ZF 80 A - ZF 80-1 A : 5.8 US-qts (5.5 liters)
ZF 85 A
: 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.
FIG. 9 - 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).
B
1
A
O-RING
+
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
Housing
Housing
| IMPORTANT |
MAX
MIN
MAX
MIN
FIG. 9 - 2
Repair Manual and Spare Parts List
Section 5
5. ADJUSTMENT DATA
30
400
MAX.
25
350
MIN.
22
21.5
300
20
250
15
200
SHIFTING PRESSURE (psi)
SHIFTING PRESSURE (bar)
5.1 SHIFTING PRESSURE
150
10
100
5
0
50
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
DRIVING SPEED (rpm)
0
ZF 63 A - ZF 63 - ZF 80 A; mechanical selector valve 23 bar p/n 3312 108 001
ZF 80-1 A - ZF 85 A - ZF 80 A (ZF 85 A DERIVATE VERSION); mechanical selector valve 26 bar p/n 3313 108 001
7.91
7.39
6.86
6.33
5.80
5.28
DELIVERY RATE ( /min)
30
25
20
S
EL
D
O
LM
L
A
N.
MI
15
4.75
4.22
3.69
3.17
2.64
2.11
1.58
10
5
0
DELIVERY RATE (gal. /min)
5.2 LUBE OIL DELIVERY RATE
1.05
0.53
0
500
1000
1500
2000
2500
3000
3500
4000
5000
4500
DRIVING SPEED (rpm)
0
ZF 63 A - ZF 63 - ZF 80 A; mechanical selector valve 23 bar p/n 3312 108 001
ZF 80-1 A - ZF 85 A - ZF 80 A (ZF 85 A DERIVATE VERSION); mechanical selector valve 26 bar p/n 3313 108 001
27
28
Fluid sump
Fluid filter
Filte grade 60µ
Fluid delivery pump
Basic lubricating throttle valve
Lube pressure relief valve
Measuring point for shift pressure M10x1
B
Shifting valve
for A-0-B
position
0
A
A
B
Illustration shows shifting pos. «B»
Shifting
pressure
relief valve
Neutral position
switch indication
by electric signal
Connection for
temperature probe
indicating at abt.
110°C 3/8” - 18 NPSF
Direction of
water flow
oil cooler
= Shifting pressure 21.5+2 bar
= Fluid 2+0.5 bar
= Leakage fluid
Repair Manual and Spare Parts List
Section 6
6. HYDRAULIC DIAGRAM
Repair Manual and Spare Parts List
Section 7
7. TIGHTENING TORQUES
PART
SIZE
TORQUE
IN lb.ft.
TORQUE
IN Nm
LOCTITE
Mounting brackets bolts
ZF 63 A - ZF 63
M12
min 55.5 - max 57
min 75 - max 77
-
Mounting brackets bolts
ZF 80 A - ZF 80-1 A - ZF 85 A
M12
min 55.5 - max 57
min 75 - max 77
-
Output flange bolt
ZF 63 A - ZF 63
M16
74
100
243
Housing bolts
M10
30
40
-
Control block bolts
M8
13
18
243
Shifting lever bolt
M8
17
23
-
Output flange bolt
ZF 80 A - ZF 80-1 A - ZF 85 A
M16
74
100
243
Fluid filter bolt
M8
min 4 - max 6
min 5 - max 8
-
Oil breather
-
Hand tight
Hand tight
574
Fluid dipstick
-
Hand tight
Hand tight
-
Oil drain plug
-
30
40
243
M16
26
35
243
-
9
12
-
Control block pressure screw
M10
9
12
-
Screw ZF 63 A
M5
4
5
243
Screw ZF 80 A - ZF 80-1 A - ZF 85 A
M6
7
9
243
Neutral safety switch
-
18.5
25
-
Control block guide bolt
-
9
12
-
Control block temperature plug
-
26
35
-
Stud bolt
Control block stop screw
29
Repair Manual and Spare Parts List
Section 8
8. FUNCTION TEST
When the transmission has been completely assembled
and filled up with transmission fluid, it would be convenient to make a function test.
This test can be carried out on a bench test rig, or in a
boat. If no fluid cooler can be connected, a hydraulic
hose must be connected between the inlet and outlet
of the hydraulic pump.
Measuring instruments required:
. Pressure gauge 0-40 bar (0-580 psi), with connecting thread M10x1.
. Temperature 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. Output 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
Temperature
Durat.
minutes
Test
800-1000
neutral
40ëC/104 ëF
5
1, 2
600-800
(idling speed)
A<->B
position repeatedly
40ëC/104 ëF
-
1, 2, 3
1500-2500
B position
80ëC / 176 ëF
-
1, 2, 4
600-800
(idling speed)
A<->B
position repeatedly
80ëC/176 ëF
-
1, 2, 3
idling - max. speed
A position
80ëC/176 ëF
-
1, 2, 5], 6]
600-800
(idling speed)
A->B
position 80ëC/176 ëF
-
-
1, 2
idling - max. speed
B position
80ëC/176 ëF
-
1, 2, 5], 6]
80ëC/176 ëF
-
At different speeds.
30
Repair Manual and Spare Parts List
Section 9
9. TROUBLESHOOTING
In case of trouble, check first whether all items of the mounting and operating instructions have been completed
with. The subsequent tables will assist you in troubleshooting.
Symptom
Possible cause
1.1 Shifting lever is loose.
1. Transmission cannot be shifted.
2. Delayed shift time.
3. Clutch is slipping, i.e. propeller
speed too low as compared to
engine speed.
1.2 Remote control does not permit
lever travel required.
1.3 Remote control faulty.
1.4 No shifting pressure available.
1.1 Tighten clamping bolt on shifting lever.
1.2 Lift remote control off, if gears can be
shifted by hand, adjust remote control
1.3 Repair remote control.
1.4 Refer to 7.
2.1 Shift linkage misadjust not allowing
full engagement.
2.1 Lift remote control off, if gear can be.
shifted by hand, adjust remote control.
If the transmission cannot be shifted
correctly by hand, replace the control
block.
3.1 Inadmissible fluid used.
3.1 Drain fluid, refill with prescribed fluid,
flush transmission while engine 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
piston rings.
3.2 Fluid contains water.
3.3 Shifting pressure too low.
3.4 Wear on clutch discs.
3.5 Piston rings are damaged.
4. Transmission locked in gear.
Remedy
4.1 Medium piston ring in input shaft in 4.1 Remove control block, replace piston
control block is faulty.
ring, if control block is worn, replace
likewise.
4.2 Warped discs due to overheating of 4.2 Refer to 3.
slipping clutch.
4.3 Needle bearings on input shaft are 4.3 Disassemble transmission, replace
worn out.
needle bearing and check for damage
input shaft and gears.
5.1 Rotary slide valve in control block is 5.1 Replace control block.
worn.
5.2 Faulty needle bearing on input shaft. 5.2 Disassemble transmission and input
5. Output shaft turns in neutral position.
shaft, replace bearing concerned and
other damaged parts.
5.3 Warped discs due to overheating of 5.3 Refer to 3.
slipping clutch.
6.1 Fluid filter clogged.
6.2 Fluid level in transmission too low.
6.3
6. Shifting pressure too low.
6.4
6.5
6.6
6.1 Replace fine filter.
6.2 Top-up with fluid; in case of fluid loss
check transmission, cooler and
pipelines for leakage also refer to
10 through 13.
Fluid pump is worn out.
6.3 Replace control block containing fluid
pump.
Spring in shifting pressure relief valve 6.4 Replace control block.
is broken.
Piston rings on input shaft are faulty. 6.5 Remove control block and replace
piston rings. In case of wear in control
block due to faulty piston rings
replace block as well.
Piston rings in clutch are faulty.
6.6 Disassemble transmission, replace
piston rings..
31
Repair Manual and Spare Parts List
Symptom
7. No shifting pressure available.
Section 9
Possible cause
Remedy
7.1 Direction of engine rotation does not
agree with arrow on transmission
front cover.
7.2 No fluid in the transmission.
7.3 Fine filter is dirty.
7.4 Fluid level in transmission is too low.
7.1 Replace with suitable rotation engine.
7.2 Refill with fluid.
7.3 Replace fine filter.
7.4 Top-up with fluid. In case of loss of
fluid check transmission, cooler and
pipelines for leakage, also refer to
10 through 13.
7.5 Replace control block.
7.5 Fluid pump worn out.
7.6 Pump key in input shaft for fluid pump 7.6 Remove control block. Replace pump
key, and any other faulty parts.
drive is broken.
7.7 Spring of shifting pressure relief valve 7.7 Replace control block.
is broken.
8.1 Fluid cooler is too small.
8.2 Excessive fluid in transmission.
8.3
8.4
8.5
8. Excessive fluid temperature.
8.6
8.7
8.8
8.9
8.1 Use a larger fluid cooler.
8.2 Remove excessive fluid with commercial suction pump.
Fluid cooler is dirty on water side.
8.3 Detach coolant water lines and clean
fluid cooler on water side.
Worn fluid pump in control block.
8.4 Replace control block containing fluid
pump.
Faulty piston rings in control block. 8.5 Remove control block, replace piston
rings. In case of wear in the control
block due to faulty piston rings replace control block as well.
Clutch is slipping.
8.6 Refer to 3.
Clutch does not open completely due 8.7 Dismount transmission and clutch, reto worn disc support.
place all faulty parts.
Clutch does not open completely due 8.8 Dismount transmission and clutch, reto broken cup springs.
place all faulty parts.
With fluid cooler in bypass and unfa- 8.9 Correct bypass pipeline.
vorable arrangement of pipelines too
little coolant water flows through
bypass to cooler.
9.1 Fluid cooler faulty.
9. Water in the fluid, fluid looks milky.
9.1 Repair leakage at cooler or replace
cooler. Change transmission fluid.
9.2 High water level in engine compart- 9.2 Remedy cause for water level in enment, water entering at output shaft
gine compartment. Change transmisseal.
sion fluid.
10.1 Breather clogged with paint or dirt
10. Fluid leakage at input or output 10.2 Shaft seal faulty
shaft
10.3 Excessive fluid in transmission
11. Fluid leakage at breather.
11.1 Excessive fluid in transmission.
10.1 Remove paint or dirt from breather
Replace seal. If seal location on
shaft is worn, regrind.
10.3 Remove excessive fluid with
commercial suction pump.
11.1 Pump excessive fluid out with commercial hand pump.
12.1 Bolts are not tight at the prescribed 12.1 Tighten bolts to prescribed torque.
torque.
not properly spread onto
12. Fluid leakage at joints or screw con- 12.2 Loctite
12.2 Reseal after removing old Loctite
sealing
surface.
nections.
and cleaning. Finish mating faces
with oilstone.
12.3 Gasket has been used several 12.3 Replace gasket.
times.
32
Repair Manual and Spare Parts List
Symptom
13. Transmission noise becomes
louder.
14. Chattering transmission noise
mainly at low engine speed.
Possible cause
Remedy
13.1 Fluid level too low so that pump
sucks in air.
13.2 Damage starting on flexible coupling
due to wear or fatigue probably due
to misalignment between engine
and transmission.
13.3 Beginning damage of bearings in
transmission, e.g. due to torsional
vibration, running without fluid,
overload, wrong alignment of
transmission.
13.4 Beginning damage of gearing, e.g.
due to torsional vibrations, running
without fluid, overload.
13.5 Fluid suction pipe in transmission
has come loose.
13.1 Top up with fluid to marking on dipstick.
13.2 Replace flexible coupling. Cheek
alignment between engine and
transmission.
13.3 Disassemble transmission, replace
bearings concerned and other faulty
parts. Find causes and remedy.
13.4 Disassemble transmission, replace
faulty parts.
13.5 Disassemble transmission fix fluid
suction pipe.
14.1 The engine or propeller generates 14.1 Mount a flexible coupling with a diftorsional vibrations in the drive unit
ferent stiffness factor between enwhich produces a hammering noise
gine and transmission; a coupling
in the transmission.
with a higher stiffness factor might
be sufficient. Otherwise analyze the
torsional vibrations to find out the required stiffness for the coupling.
14.2 Misaligned cardan shafts on input or 14.2 Mount and align cardan shaft strictly
according to instructions issued by
output.
cardan shaft manufacturer.
15.1
15.2
15.3
15.4
15.5
15.6
15. Low pressure.
Section 9
15.7
15.8
15.9
Fine filter is dirty.
Fluid level in transmission is low.
Control block is broken.
Problem at control valve.
Piston rings on input shaft
are faulty.
Piston rings inside the clutch
are faulty.
Defective cover filter : air suction.
Oil suction hose not properly
adjusted.
Fitting key in input shaft for fluid
pump drive is broken.
15.1
15.2
15.3
15.4
15.5
15.6
15.7
15.8
15.9
15.10 Possible wear of the piston ring 15.10
grooves.
Replace fine filter.
Refill with fluid.
Replace control block.
Replace control block.
Remove control block and replace
piston rings.
Disassemble transmission, replace
piston rings.
Replace cover filter.
Replace the seal and adjust correctly the suction hose.
Remove control block replace fitting key, replace any other faulty
parts.
Replace the input shaft.
16.1 Porosity.
16.2 Seals.
16.3 Joints.
16.4
16.5
16. Oil leakage.
16.6
16.7
16.8
16.9
16.10
16.11
16.1 Replace faulty parts.
16.2 Replace seals.
16.3 Check if bolts are tighten with the
correct torque. Clean the surface
and reseal with Loctite 518.
Bracket with flatness error.
16.4 Replace bracket.
Bolts are not tight.
16.5 Reseal and tighten bolts with prescribed torque.
16.6 Tighten or replace.
Fittings loosen.
16.7 Tighten dipstick or replace o-ring
Dipstick is not tight.
dipstick.
Filter is not tight.
16.8 Tighten filter or replace o-ring filter
Excessive fluid in transmission.
16.9 Remove excessive fluid with commercial suction pump.
Breather clogged with paint or dirt 16.10 Remove paint or dirty from
(fluid leakage at output shaft).
breather.
Aluminium washers used more 16.11 Replace aluminium washers.
times.
33
Repair Manual and Spare Parts List
Symptom
Possible cause
17.1 Excessive fluid in transmission.
17.2 Oil cooler is dirty.
17. High oil temperature.
17.3 No water in circuit.
17.4 Undersized cooler.
17.5 Clutch is slipping.
17.6 Excessive friction of the
reverse clutch.
17.7 Possible bypass in the cooling
circuit.
18.1
18.2
18.3
18.4
Low pressure.
Fluid level in transmission is low.
Shift lever not properly adjusted.
Trolling lever not in the detent
position.
18.5 Wear on clutch discs.
18. Slipping clutch
18.6 Piston rings in clutch are faulty.
18.7 Inadmissible fluid used.
18.8 Water in the fluid.
19. Noise.
20. Engagement not possible.
21. Slow engagement.
22. Hard shifting.
34
Section 9
Remedy
17.1 Remove excessive fluid with commercial suction pump.
17.2 Replace the cooler and check the
water circuit.
17.3 Check the cooling circuit.
17.4 Replace the cooler with a proper
one.
17.5 Refer to 18.
17.6 Check the clutch play and the correct position of the piston.
17.7 Reduce the bypass.
18.1
18.2
18.3
18.4
18.5
18.6
18.7
18.8
Refer to 15.
Refill with fluid.
Regulate at the end of the way.
Ajust the lever at the detent
position.
Disassemble transmission, replace
clutch discs.
Disassemble transmission, replace
piston rings.
Drain fluid, refill with prescribed
fluid.
Repair leakage at cooler or replace
cooler. Change transmission fluid.
Remove control block and replace
piston rings.
18.9 Piston rings on input shaft
are faulty.
18.9
- 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.
19.1 Replace oil filter.
19.2 Refill with fluid.
19.3 Replace the seal and adjust
correctly the suction hose.
19.4 Replace cover filter.
- at idle speed
19.5 Coupling.
19.5 Replace.
- under load
19.6 Wrong shimming.
19.7 Defective gears.
19.6 Re-shim.
19.7 Replace defective gears.
20.1
20.2
20.3
20.4
20.5
20.6
20.1
20.2
20.3
20.4
20.5
20.6
Fluid level in transmission is low.
Fine filter is dirty.
Incorrect shift lever position.
Coupling is damaged.
Control block.
Shifting lever is loose.
20.7 Low pressure.
Refill with fluid.
Replace fine filter.
Regulate at the end of the way.
Replace coupling.
Replace control block.
Tighten clamping bolt on
shifting lever.
20.7 Refer to 15.
21.1 Fluid level in transmission is low.
21.2 Shift lever.
21.3 Regulate.
21.1 Refill with fluid.
21.2 Low pressure.
21.3 Refer to 15.
22.1 Shift lever.
22.2 Control block is dirty.
22.1 Regulate.
22.2 Disassemble the control valve and
clean.
Repair Manual and Spare Parts List
Symptom
Section 9
Possible cause
Remedy
23.1 Warped discs due to overheating.
23. Transmission is dragging in
neutral.
23.1 Replace discs, replace any other
faulty parts.
23.2 Needle bearings on input shaft are 23.2 Disassemble transmission, replace
faulty.
needle bearings.
23.3 Intermediate gear moved from the 23.3 Replace the intermediate gear.
shaft and touching the clutch drum.
23.4 Discs of the reverse clutch radially 23.4 Replace the discs and change the
broken due to torsional vibration.
damper with a proper one.
24.1 Fluid cooler faulty.
24. Water in the oil.
24.2 Water in bilge.
24.1 Repair leakage at cooler or replace
cooler.
24.2 Remove water from the bilge and
check the oil seal.
35
Repair Manual and Spare Parts List
Section 10
10. AUTOMATIC TRANSMISSION FLUID
MANUFACTURER
PRODUCT
MANUFACTURER
PRODUCT
ADDINOL MINERALOÈL
GMBH, KRUMPA/D
. ADDINOL ATF D IID
. ADDINOL ATF D III
ENGEN PETROLEUM,
CAPE TOWN/ZA
. ENGEN ATF 22D
AGIP PETROLI SPA, ROM/I
.
.
.
.
AGIP SCHMIERTECHNIK,
WUÈRZBURG/D
È L ATF-D
. AUTOL GETRIEBEO
È L ATF III D
. AUTOL GETRIEBEO
ARAL LUBRICANTS GMBH,
BOCHUM/D
AVIA MINERALOÈL-AG,
MUÈNCHEN/D
È L ATF 22
. ARAL GETRIEBEO
È L ATF 55 F-30589
. ARAL GETR.O
AGIP ATF II D
AGIP ATF D 309
AGIP ATF PLUS
AGIP DEXRON III
. AVIA FLUID ATF 86
BLASER SWISSLUBE,
HASLE-RUÈEGSAU/CH
. BLASOL 229
BP OIL DEUTSCHLAND,
HAMBURG/D
. FRONTOL UNIVERSAL-ATF 100
BP OIL INTERNATIONAL,
LONDON/GB
.
.
.
.
BUCHER+CIE AG,
LANGENTHAL/CH
. MOTOREX ATF SUPER D-22656
. MOTOREX ATF DEXRON III MC
CALPAM GMBH,
ASCHAFFENBURG/D
. PAMATIC FLUID 289
. CALPAMATIC FLUID III F
CALTEX PETROLEUM
CORP., LONDON/GB
.
.
.
.
.
CALTEX
CALTEX
CALTEX
CALTEX
CALTEX
CASTROL LTD,
SWINDON/GB
.
.
.
.
.
.
CASTROL TQ-D (22765)
CASTROL TQ DEXRON III F-30520
CASTROL TRANSMAX S (F-30319)
CASTROL TRANSMAX T (F-30359)
CASTROL TQ-D (21289)
CASTROL ATF 21293
AUTRAN DX II
AUTRAN MBX
AUTRAN DX III (F-30370)
AUTRAN DX III (F-30381)
ATF-HDA
ATF-HDM
TEXAMATIC 1278
TEXAMATIC 7045
TEXAMATIC 1205A
CEPSA, MADRID/E
. CEPSA ATF-70
CHEVRON PRODUCTS CO.,
RICHMOND/USA
. CHEVRON ATF F-30108
CITGO PETROLEUM CORP.,
TULSA/USA
. CITGO ATF DEXRON III F-30167
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,
BRUÈSSEL/B
. FINAMATIC II-D
FUCHS LUBRICANTS (UK),
DERBY/GB
FUCHS MINERALOÈLWERKE,
MANNHEIM/D
. SILKTRAN MP-ATF
. SILKTRAN PSV ATF
. TITAN ATF 4000
GINOUVES GEORGES SA,
LA FARLEDE/F
. YORK LT 785
GULF OIL (GB) LTD,
CHELTENHAM/GB
. UNIFLUID
. ATF 2
HANDELSMIJ NOVIOL B.V.,
NIJMEGEN/NL
. KENDALL ATF DEXRON IID
HOMBERG GMBH+CO KG,
WUPPERTAL/D
. HOMBERG-GETRIEBE-FLUID D
IGOL FRANCE, PARIS/F
. IGOL ATF 420
INA RAFINERIJA
ZAGREB/CROATIA
. INA-ATF SUPER
ITALIANA PETROLI,
GENOVA/I
. TRANSMISSION FLUID DX
JAPAN ENERGY CORP.,
TOKYO/JAPAN
KAÈPPLER K., STUTTGART/D
. JOMO ATF K
È L IID 23
. SELECTOL FLUID GETR.O
KLOÈCKNER ENERGIEHANDEL
GMBH, KOÈLN/D
. DEUTZ OEL ATF-D
KROON OIL BV, ALMELO/NL
. ATF DEXRON IID
. ALMIROL ATF
KUWAIT PETROLEUM,
HOOGVLIET/NL
.
.
.
.
Q8 AUTO 15
Q8 AUTO 14 (IID-21677)
Q8 AUTO 14 (IID)
Q8 AUTO 14 (IID-21883)
C.J.DIEDERICHS SOÈHNE,
WUPPERTAL/D
. CIDISOL-HYDR.-FLUID
LEPRINCE+SIVEKE GMBH,
HERFORD/D
. LEPRINXOL FLUID CN
DE OLIEBRON B.V.,
ZWIJNDRECHT/NL
. ATF DMM
. ATF 289
LIQUI MOLY / MEGUIN,
ULM/D
. ATF IIE
. MEGOL ATF IID
DEA MINERALOÈL AG,
HAMBURG/D
. DEAMATIC
. DEAFLUID 4011
. DEAFLUID 3003
LUBRICATION ENGIN.,
FORT WORTH/USA
. AUTOMATIC TRANSMISSION
. INTER OIL INTER MATIC ATF D2
DEUTSCHE SHELL AG,
HAMBURG/D
. MAC ATF D-21666
MAURAN SA, ODARS/F
MIN.OÈL-RAFFIN.
DOLLBERGEN, UETZE/D
DUCKHAMS OIL,
BROMLEY/GB
. UNIMATIC
ELF LUBRIFIANTS, PARIS/F
.
.
.
.
.
ELFMATIC G3
ELLER-MONTAN-COMP.,
DUISBURG/D
36
DEXRON IID
FLUID
ÈL
. PENNASOL FLUID-GETR.O
TYP PCN
MOBIL OIL, WEDEL/D
. MOBIL ATF 220 D20104 / D21685
. MOBIL ATF F-30107
. MOBIL ATF 220 D21412 / D22187
MOBIL SEKIYU KABUS.
KAISHA, TOKYO/J
. MOBIL ATF 220Y (D-21412)
MOL HUNGARIAN OIL,
KOMARON/H
. CARRIER ATF
. TRANSANTAR DF3
MORRIS LUBRICANTS,
SHREWSBURY/GB
. LIQUIMATIC DII
. ELLMO-AUTOMATIK-FLUID 22233
NAFTEC, ALGIER/DZ
. TASSILIA
TRANSANTAR DF2
ANTAR 22329
ELFMATIC G2 22329
HUILE RENAULT DIESEL
STARMATIC
Repair Manual and Spare Parts List
MANUFACTURER
PRODUCT
NANHAI SUPERIOR
LUB-OIL, CHINA
. NANHAI ATF (D2)
NIS-RAFINERIJA NAFTE
BEOGRAD/YU
OEST G. MIN.OÈLWERK,
FREUDENSTADT/D
. GALAX MATIC DAC
. ATF T 4011
OMEX PETROLEUM PTY,
BELLEVUE/AUS
. OMEX ATF DEXRON II
OMV AG, SCHWECHAT/A
. OMV ATF D II (D22427)
. OMV ATF III (F-30580)
OPTIMOL OÈLWERKE,
HAMBURG/D
. OPTIMOL ATF T 4011
OSWALD KLUTH,
BARGFELD-STEGEN/D
PAKELO MOTOR OIL,
SAN BONIFACIO/I
PANOLIN AG, MADETSWIL/CH
PARS OIL CO., TEHRAN/IR
. UNIVERSAL ATF-D
. MULTIPURPOSE TRANSM.
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,
NYNAÈSHAMN/S
. TRANSWAY DX III (F-30373)
TAMOIL LUBES, GENEVA/CH
. TAMOIL ATF II D
TEXACO LUBRICANTS
COMP., BEACON/USA
. ATF MERCON / DEXRON III
TEXACO SERVICES LTD,
BRUÈSSEL/B
.
.
.
.
.
.
.
FLUID IID
. PANOLIN ATF MULTI 21996
. PANOLIN ATF DEXRON III
. PARS ENTEGHAL-E AUTOMATIC
OIL
PAZ LUBRICANTS &
CHEMICALS, HAIFA/IL
. PAZBO EZF
PENNZOIL PRODUCT COMP.,
HOUSTON/USA
. PENNZOIL ATF F-30110
PETRO-CANADA,
MISSISSAUGA/CDN
PETROL OFISI A.S.,
BAKANLIKLAR/TR
PETROLEX, KWIDZYN/PL
Section 10
. DEXRON III/MERC.ATF (F-30395)
. PETROL OFISI ATF II
TOTAL RAFFINAGE DISTR.,
PARIS/F
TOTAL SOUTH AFRICA,
JOHANNESBURG/ZA
TURBOTANK BOÈSCHE
BOÈDEKER, BREMEN/D
TEXAMATIC 7045
TEXAMATIC 4261
TEXAMATIC 7080
TEXTRAN PSM
TEXAMATIC 4011
TEXAMATIC 4291
TEXAMATIC 9226
. TOTAL FLUIDE ATX
. TOTAL FLUIDE IID
. TOTAL FLUIDE AT 42
. TOTAL FLUIDE ATD
. TURBO UNIV. ATF MERCON 4011
. VECO MATIC IID
UFANEFTECHIM REFINERY,
UFA/RUS
. UFALUB ATF
PRINZ-SCHULTE,
FRECHEN/D
. AERO-LINE ATF-2
. AERO-LINE ATF-D
UNIL DEUTSCHLAND GMBH,
BREMEN/D
. UNIL MATIC CN T 4011
REPSOL DISTRIBUCION SA,
MADRID/E
. REPSOL MATIC ATF
VALVOLINE INC.,
LEXINGTON/USA
. VALVOLINE MULTI-PURPOSE ATF
S.A.E.L, ALCOBENDAS/E
. GULF ATF DII D-22233
SASOL OIL, RANDBURG/ZA
SCHMIERSTOFFRAFFINERIE
SALZBERGEN/D
SHELL ASEOL AG, BERN/CH
. SASOL ATF DXII
VALVOLINE INTERNAT.,
DORDRECHT/NL
. VALVOLINE ATF TYPE D
VEBA OEL AG,
GELSENKIRCHEN/D
È L DIID
. MOVARA ATF-GETRIEBEO
SHELL INTERNATIONAL,
LONDON/GB
. SHELL DONAX TA (D-21666)
. SHELL DONAX TG (F-30358)
VEEDOL INTERNATIONAL,
SWINDON/GB
. VEEDOL ATF-M (22764)
. VEEDOL ATF DEXRON III F-30521
. VEEDOL UNITRANS S PLUS
SLOVNAFT JS CO,
BRATISLAVA/SLO
. MADIT AUTOMATIC
SONOL ISRAEL LTD, HAIFA/IL
. DEXRON 2 D
. WINTERSHALL ATF D
. ASEOL ATF DB UNIVERSAL
YACCO SA,
ST PIERRE-LES-ELBEUF/F
ZELLER+GMELIN GMBH&CO,
EISLINGEN/D
. YACCO ATF D
DIVINOL FLUID 666
37
38
Section 11 : Spare parts list
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
Repair Manual and Spare Parts List
11. SPARE PARTS LIST ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
Preface
The spare parts list is only valid for the type and versions of transmission, as shown below.
You will find the transmission type and version on your
transmission name plate.
If 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
. Serial number
. Item no.
. Part name
. Identification no.
. quantity of parts required.
The spare parts list is referring to the following versions:
ZF 63 A
ZF 63
ZF 80 A
ZF 80-1 A
versions 21 (1.22 R); 22 (1.56 R); 24 (2.04 R); 25 (2.52 R); 30 (2.70 R);
versions 001 (1.22 R); 002 (1.56 R); 003 (2.04 R); 004 (2.52 R); 012 (2.52 R uprated); 005 (2.70 R);
versions 015 (1.22 R); 016 (1.56 R); 017 (2.04 R); 018 (2.52 R); 035 (2.52 R); 020 (2.52 R uprated);
021 (2.70 R); 034 (2.70 R);
versions 01 (1.51 R); 02 (1.93 R); 03 (2.48 R); 04 (2.78 R);
versions 009 (1.25 R); 001 (1.51 R); 002 (1.93 R); 003 (2.48 R); 004 (2.78 R);
versions 010 (1.25 R); 011 (1.51 R); 013 (1.93 R); 014 (2.48 R); 015 (2.78 R);
versions 15 (1.20 R); 16 (1.41 R); 17 (1.57 R); 18 (1.96 R); 19 (2.50 R); 20 (2.85 R);
versions 001 (1.20 R); 002 (1.41 R); 003 (1.57 R); 004 (1.96 R); 005 (2.50 R); 006 (2.85 R);
versions 009 (1.21 R); 010 (1.41 R); 007 (1.57 R); 008 (1.96 R); 011 (2.50 R); 012 (2.85 R);
Name plate
The name plate is mounted to the transmission
39
40
2
3
12
1
36
10
15
30
7
14
11
6
5
13
8
37
9
38
4
19
31
35
32
22
21
16
33
34
17
18
19
18
16
25
24
NEW VERSION
20
23
25
27
25
25
26
28
29
Repair Manual and Spare Parts List
ZF 63 A FIG. 1
ZF 63 A
Repair Manual and Spare Parts List
ZF 63 A FIG. 1
Pos.
Part number
Old P/N
Descrizione
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
3312 301 004
0636 301 041
0634 319 132
3312 101 003
451892
442373
442135
500484
0634 304 688
0634 306 204
0630 001 085
0636 101 475
3312 301 007
3312 301 008
3312 199 031
0634 304 688
0634 306 204
3312 301 037
3312 301 005
3312 301 033
17 3312 301 013
18 0636 113 006
442731
105542
167010
320202
438637
439653
463772
442731
105542
Scatola
Tappo
Paraolio uscita
Coperchio filtro completo
. Coperchio filtro
. Guarnizione OR
Guarnizione OR
. Rosetta
. Vite M8x30
Filtro olio
Guarnizione
Filtro olio completo
. Guarnizione OR
. Guarnizione OR
. Filtro olio
Tubo aspirazione
Tubo aspirazione con supporto
Piastra ritegno
Vite T.E.
(ritegno tubo aspirazione)
Vite T.E.
(tubo aspirazione con supporto)
Spina
Coperchio
Coperchio
Asta livello olio
Asta livello olio + OR
. Guarnizione OR
(Asta livello olio)
Valvola di sfiato
Paraolio entrata
Rosetta
Vite T.E.
Vite T.E.
Vite T.E.
Vite T.E.
Vite T.E.
Vite T.E.
Rosetta
Piastra
Piastra
Vite T.E.
Vite T.E.
Rosetta
Piastra
Targhetta di identificazione
Rosetta
Vite M8x30
Housing
Plug
Output shaft seal
Filter cover, assy.
. Filter cover
. O-Ring
O-Ring
. Washer
. Screw M8x30
Oil filter
Sealing washer
Oil filter, assy
. O-Ring
. O-Ring
. Oil filter
Suction pipe
Suction pipe with support
Retaining plate
Hex head screw
(suction pipe retainer)
Hex head screw
(suction pipe with support)
Locator pin
Cover (housing)
Cover (housing)
Oil dipstick
Oil dipstick + OR
. O-Ring
(Oil dipstick)
Breather valve
Input shaft seal
Washer
Hex head screw
Hex head screw
Hex head screw
Hex head screw
Hex head screw
Hex head screw
Washer
Buffle plate
Buffle plate
Hex head screw
Hex head screw
Washer
Buffle plate
Name plate
Washer
Screw M8x30
I
438948
439223
455079
0636 015 020
19 0631 315 520
20 3312 301 002
3312 301 003
21 978.36.701.02
3312 201 002
22 0634 304 405
335817
451889
501352
454913
500989
501211
23
24
25
26
27
28
29
30
442369
413883
442371
442374
442375
442376
452512
455079
31
32
33
34
35
36
37
38
3311 301 002
3312 301 030
0630 302 091
0636 010 550
0636 015 227
0636 010 572
0636 015 386
0636 113 006
0636 015 020
0630 001 046
3312 301 011
3312 301 012
0636 113 006
0636 015 020
0630 001 046
3312 301 006
3312 301 001
0630 001 085
0636 101 475
455053
458290
455079
438963
167010
320202
Q.taÁ
Q.ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
Note
(2) old part number
(2) new part number
2
2
1
1
1
1
1
(1)
1
1
12
4
5
2
1
1
1
1
1 Ratio I=1.2; 1.6; 2.0
1 Ratio I=2.5; 2.7
2
2
2
1
1
1
1
Fino a matricola 10730G - Up to serial number 10730G
Da matricola 10731G - From serial number 10731G
(1) Only Ratio I=2.7 (also PCM) ; Ratio I=2.52 uprated version & ratio I= 2.52 (for PCM only)
(2) Fornito solo incluso nel kit filtro olio p/n 3312 199 031
Supplied only included in the oil filter kit p/n 3312 199 031
41
42
2
3
12
33
10
15
1
7
14
11
6
5
13
8
34
9
35
4
19
32
22
21
16
31
30
17
18
19
20
23
25
27
25
25
18
16
28
29
26
NEW VERSION
25
24
Repair Manual and Spare Parts List
ZF 63 FIG. 1
ZF 63
Repair Manual and Spare Parts List
ZF 63 FIG. 1
Pos.
Part number
Old P/N
Descrizione
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
3312 301 020
0636 301 041
0634 319 132
3312 101 003
455502
442373
442135
500484
0634 304 688
0634 306 204
0630 001 085
0636 101 475
3312 301 007
3312 301 008
3312 199 031
0634 304 688
0634 306 204
3312 301 037
3312 301 022
3312 301 032
17 3312 301 013
18 0636 113 006
442731
105542
167010
320202
438637
439653
463772
442731
105542
Scatola
Tappo
Paraolio uscita
Coperchio filtro completo
. Coperchio filtro
. Guarnizione OR
. Guarnizione OR
. Rosetta
. Vite M8x30
Filtro olio
Guarnizione
Filtro olio completo
. Guarnizione OR
. Guarnizione OR
. Filtro olio
Tubo aspirazione
Tubo aspirazione con supporto
Piastra ritegno
Vite T.E.
(ritegno tubo aspirazione)
Vite T.E. (tubo aspirazione
con supporto)
Spina
Coperchio
Coperchio
Asta livello olio
Asta livello olio + OR
. Guarnizione OR
(Asta livello olio)
Valvola di sfiato
Paraolio entrata
Rosetta
Vite T.E.
Vite T.E.
Vite T.E.
Vite T.E.
Vite T.E.
Vite T.E.
Rosetta
Piastra
Targhetta di identificazione
Rosetta
Vite M8x30
Housing
Plug
Output shaft seal
Filter cover, assy.
. Filter cover
. O-Ring
. O-Ring
. Washer
. Screw M8x30
Oil filter
Gasket
Oil filter, assy
. O-Ring
. O-Ring
. Oil filter
Suction pipe
Suction pipe with support
Retaining plate
Hex head screw
(suction pipe retainer)
Hex head screw (suction pipe
with support)
Locator pin
Cover (housing)
Cover
Oil dipstick
Oil dipstick + OR
. O-Ring
(Oil dipstick)
Breather valve
Input shaft seal
Washer
Hex head screw
Hex head screw
Hex head screw
Hex head screw
Hex head screw
Hex head screw
Washer
Buffle plate
Name plate
Washer
Screw M8x30
I
455499
439223
455079
0636 015 020
19 0631 315 520
20 3312 301 018
3312 301 019
21 978.21.701.01
3312 201 001
22 0634 304 405
335817
455501
501861
468239
500992
501211
23
24
25
26
27
28
29
30
442369
413883
442371
442374
442375
455443
452512
455079
31
32
33
34
35
3311 301 002
3312 301 030
0630 302 091
0636 010 550
0636 015 227
0636 010 569
0636 015 386
0636 113 006
0636 015 020
0630 001 046
3312 301 023
3312 301 001
0630 001 085
0636 101 475
442371
455500
167010
320202
Q.taÁ
Q.ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
Note
(1) old part number
(1) new part number
2
2
1
1
1
1
1
Only Ratio I=1.25
1
1
12
4
5
2
1
2
2
2
1
1
1
1
Fino a matricola 18672F - Up to serial number 18672F
Da matricola 18673F - From serial number 18673F
(1) Fornito solo incluso nel kit filtro olio p/n 3312 199 031
Supplied only included in the oil filter kit p/n 3312 199 031
43
Repair Manual and Spare Parts List
ZF 80 A - ZF 80-1 A FIG. 1
7
10
14
15
11
6
13
29
3
28
1
44
19
2
12
8
30
9
31
5
4
20
25
24
16
17
18
20
22
23
21
26
NEW VERSION
18
27
16
ZF 80 A - ZF 80-1 A
Repair Manual and Spare Parts List
Pos.
Old P/N
Descrizione
Description
1 3313 301 013
3313 301 009
2 0636 301 041
3 0634 319 104
4 3312 101 003
5
6 0634 304 688
7 0634 306 204
8 0630 001 085
9 0636 101 475
10 3312 301 007
11 3312 301 008
12 3312 199 031
13 0634 304 688
14 0634 306 204
15 3312 301 037
16 3313 301 015
3313 301 011
3313 301 022
17 0632 311 398
18 0636 101 411
489412
19
20
21
22
23
462997
335817
413883
442369
489414
Scatola
Scatola
Tappo
Paraolio uscita
Coperchio filtro completo
. Coperchio filtro
. Guarnizione OR
. Guarnizione OR
. Rosetta
. Vite M8x30
Filtro olio
Guarnizione
Filtro olio completo
. Guarnizione OR
. Guarnizione OR
. Filtro olio
Tubo aspirazione
Tubo aspirazione
Tubo aspirazione con supporto
Fascetta
Vite T.E.
(fascetta tubo aspirazione)
Anello centratore
Spina
Paraolio entrata
Valvola di sfiato
Coperchio
Coperchio
Asta livello olio
Asta livello olio + OR
. Guarnizione OR (Asta livello olio)
Rosetta
Vite T.E.
Tappo
Targhetta di identificazione
Rosetta
Vite M8x30
Housing
Housing
Plug
Output shaft seal
Filter cover, assy.
. Filter cover
. O-Ring
. O-Ring
. Washer
. Screw M8x30
Oil filter
Gasket
Oil filter, assy
. O-Ring
. O-Ring
. Oil filter
Suction pipe
Suction pipe
Suction pipe with support
Suction pipe clamp
Hex head screw
(suction pipe clamp)
Centering ring
Locator pin
Input shaft seal
Breather valve
Cover (housing)
Cover (housing)
Oil dipstick
Oil dipstick + OR
. O-Ring (Oil dipstick)
Washer
Hex head screw
Plug
Name plate
Washer
Screw M8x30
24
25
26
27
28
29
30
31
Part number
ZF 80 A - ZF 80-1 A FIG. 1
3313 301 014
0631 315 520
3312 301 030
3311 301 002
3313 301 012
3313 301 010
978.36.701.01
3313 201 001
0634 304 405
0630 302 091
0636 015 227
3312 301 017
3312 301 001
0630 001 085
0636 101 475
442373
448160
500484
442731
105542
167010
320202
438637
439653
463772
442731
105542
439522
479439
102879
439520
500993
501211
442371
442375
469691
167010
320202
Q.taÁ
Q.ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Note
Not available any more
From s/n 21410 L (1)
(4) old part number
(4) new part number
(3)
1
2
1
1
1 Not available any more
1 From s/n 21410 L (2)
1
1
1
14
14
1
1
1
1
(1) Scatola non fornibile con coperchio cod. 3310 301 012. Fornibile solo con coperchio codice 3313 301 010
This housing is not suitable with cover p/n 3313 301 012. But only with the new cover p/n 3313 301 010
(2) Coperchio non fornibile con scatola cod. 3310 301 013. Fornibile solo con scatola codice 3313 301 009
This cover is not suitable with housing p/n 3313 301 013. But only with the new housing p/n 3313 301 009
(3) Adatto solo alla nuova scatola p/n 3313 301 009
Suitable only to new housing p/n 3313 301 009
(4) Fornito solo incluso nel kit filtro olio p/n 3312 199 031
Supplied only included in the oil filter kit p/n 3312 199 031
Fino a matricola 35909E - Up to serial number 35909E
Da matricola 35910E - From serial number 35910E
45
46
13
14
12
17
15
19
16
21
18
4
20
22
11
5
3
6
2
1
7
8
21
20
9
11
19
16
10
17
18
14
25
27
32
9
15
33
31
13
26
30
12
23
28
7
24
29
24
Repair Manual and Spare Parts List
ZF 63 A FIG. 2
ZF 63 A
Repair Manual and Spare Parts List
ZF 63 A FIG. 2
Pos.
Part number
Old P/N
Descrizione
Description
1
2
3
4
5
6
7
8
3312 304 009
0634 306 328
3313 304 017
0636 016 111
3312 302 041
0635 501 940
3312 302 004
3312 302 006
3312 302 007
3312 302 040
0631 501 062
3312 199 051
3312 199 052
0630 513 066
3312 302 012
3312 302 013
3312 302 008
3312 302 009
0630 501 038
3312 302 015
3312 302 038
0634 402 178
3312 302 014
0635 460 006
0634 402 176
3312 199 032
439489
105571
475710
348826
447038
Flangia uscita
Guarnizione OR
Rondella
Vite T.E.
Anello di tenuta
Cuscinetto a rulli conici
Rasamento
Ingranaggio Z3=49
Ingranaggio Z3=50
Cuscinetto a rullini
Chiavetta
Albero di ingresso completo
Albero di ingresso completo
. Anello elastico
. Disco finale
. Disco finale
. Disco frizione esterno
. Disco frizione interno
. Anello di ritegno
. Molla a tazza
. Molla a tazza
. Anello interno
. Pistone
. Sfera
. Anello esterno
. Albero di ingresso +
cilindro frizione
. Albero di ingresso +
cilindro frizione
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Spessore 0,1 mm
Spessore 0,15 mm
Spessore 0,2 mm
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Spessore 0,1 mm
Spessore 0,15 mm
Spessore 0,3 mm
Spessore 0,5 mm
Distanziale
Output flange
O-Ring
Washer
Hex head screw
Piston ring
Tapered roller bearing
Butting ring
Reverse gear Z3=49
Reverse gear Z3=50
Needle bearing
Key
Input shaft, assy.
Input shaft, assy.
. Snap ring
. End disc
. End disc
. Outer clutch disc
. Inner clutch disc
. Retainer ring
. Cup spring
. Cup spring
. Inner clutch piston ring
. Clutch piston
. Ball
. Outer clutch piston ring
. Input shaft &
clutch housing
. Input shaft &
clutch housing
Tapered roller bearing
Tapered roller bearing
Shim 0.1 mm
Shim 0.15 mm
Shim 0.2 mm
Tapered roller bearing
Tapered roller bearing
Tapered roller bearing
Tapered roller bearing
Tapered roller bearing
Shim 0.1 mm
Shim 0.15 mm
Shim 0.3 mm
Shim 0.5 mm
Spacer
9
10
11
12
13
14
15
16
17
18
19
20
21
22
454406
488955
501462
441438
437956
455788
455789
501345
455787
455786
500076
500148
500066
500147
106690
500069
3312 199 033
23 0635 501 937
0635 501 941
24 3312 302 023
3312 302 024
3312 302 025
25 0635 501 942
26 0635 501 941
0735 370 229
27 0635 501 938
28 0635 501 922
29 3312 304 027
3312 304 028
3312 304 029
3312 304 030
30 3312 302 016
447754
277213
277214
277215
501332
333859
166807
442340
154102
154101
501341
Q.taÁ
Q.ty
Note
1
1
1
1
3
1
2
1
1 Only Ratio I=2.04
4
1
1
(1)
1
2
2
(1)
2
10
8
2
6
From s/n 18674 L
6
2
2
2
2
1
1
1
1
2
2
2
1
1
1
1
1
2
2
2
2
1
(1)
(1)
(1)
(1)
(1) Only Ratio I=2.7 (also PCM) ; Ratio I=2.52 uprated version & ratio I= 2.52 (for PCM only)
47
Repair Manual and Spare Parts List
Pos.
Part number
Old P/N
Descrizione
ZF 63 A FIG. 2
Description
Q.taÁ
Q.ty
Note
Vers. 21,001,015 (Rapporto I=1,22)
31 3312 302 005
500860
Ingranaggio Z1=37
32 3312 199 023
455731
Albero intermedio Z4=45, Z5=34
33 3312 199 024
455732
Albero di uscita Z2=45
Vers. 21,001,015 (Ratio I=1.22)
Forward gear Z1=37
1
Intermediate shaft Z4=45, Z5=34 1
Output shaft Z2=45
1
]
]
Vers. 22,002,016 (Rapporto I=1,56)
31 3312 202 003
451950
Ingranaggio Z1=32
32 3312 199 025
455733
Albero intermedio Z4=45, Z5=29
33 3312 199 026
455734
Albero di uscita Z2=50
Vers. 22,002,016 (Ratio I=1.56)
Forward gear Z1=32
1
Intermediate shaft Z4=45, Z5=29 1
Output shaft Z2=50
1
]
]
Vers. 24,003,017 (Rapporto I=2,04)
31 3312 202 004
452128
Ingranaggio Z1=27
32 3312 199 027
Albero intermedio Z4=44, Z5=24
33 3312 199 028
455736
Albero di uscita Z2=55
Vers. 24,003,017 (Ratio I=2.04)
Forward gear Z1=27
1
Intermediate shaft Z4=44, Z5=24 1
Output shaft Z2=55
1
]
]
Vers. 25,004,018 (Rapporto I=2,52)
31 3312 202 005
452148
Ingranaggio Z1=23
32 3312 199 029
455737
Albero intermedio Z4=45, Z5=21
33 3312 199 030
455738
Albero di uscita Z2=58
Vers. 25,004,018 (Ratio I=2.52)
Forward gear Z1=23
1
Intermediate shaft Z4=45, Z5=21 1
Output shaft Z2=58
1
]
]
Vers. 012,20,035 (Rapporto I=2,52 uprated)
Vers. 012,20,035 (uprated version I=2,52)
31 3312 202 007
32 3312 199 073
33 3312 199 074
501797
Ingranaggio Z1=23
Forward gear Z1=23
1
Albero intermedio Z4=45, Z5=21 Intermediate shaft Z4=45, Z5=21 1
Albero di uscita Z2=58
Output shaft Z2=58
1
Vers. 30,005,021,034 (Rapporto I=2,7)
31 3312 202 006
501340
Ingranaggio Z1=22
32 3312 199 003
Albero intermedio Z4=45, Z5=20
33 3312 199 056
Albero di uscita Z2=59
Vers. 30,005,021,034 (Ratio I=2.7)
Forward gear Z1=22
1
Intermediate shaft Z4=45, Z5=20 1
Output shaft Z2=59
1
] Cuscinetti a rulli conici giaÁ assemblati - Tapered roller bearings already assembled
48
]
]
]
]
49
50
13
14
12
17
15
19
16
21
18
4
20
22
11
5
3
6
2
1
7
8
21
20
9
11
19
16
10
17
18
14
25
27
31
9
15
32
30
13
26
12
23
28
7
24
29
24
Repair Manual and Spare Parts List
ZF 63 FIG. 2
ZF 63
Repair Manual and Spare Parts List
ZF 63 FIG. 2
Q.taÁ
Q.ty
Pos.
Part number
Old P/N
Descrizione
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
3312 304 009
0634 306 328
3313 304 017
0636 016 111
3312 302 041
0635 501 940
3312 302 004
3312 302 006
3312 302 040
0631 501 062
3312 199 051
0630 513 066
3312 302 012
3312 302 008
3312 302 009
0630 501 038
3312 302 015
3312 302 038
0634 402 178
3312 302 014
0635 460 006
0634 402 176
3312 199 032
439489
105571
475710
348826
447038
Output flange
O-Ring
Washer
Hex head screw
Piston ring
Tapered roller bearing
Butting ring
Reverse gear Z3=49
Needle bearing
Key
Input shaft, assy.
. Snap ring
. End disc
. Outer clutch disc
. Inner clutch disc
. Retainer ring
. Cup spring
. Cup spring
. Inner clutch piston ring
. Clutch piston
. Ball
. Outer clutch piston ring
. Input shaft and clutch housing
1
1
1
1
3
1
2
1
4
1
1
2
2
10
8
2
6
6 From s/n 18854 L
2
2
2
2
1
23 0635 501 937
24 3312 302 023
3312 302 024
3312 302 025
25 0635 501 942
26 0635 501 941
27 0635 501 938
28 0635 501 922
29 3312 304 027
3312 304 028
3312 304 029
3312 304 030
447754
277213
277214
277215
Flangia uscita
Guarnizione OR
Rondella
Vite T.E.
Anello di tenuta
Cuscinetto a rulli conici
Rasamento
Ingranaggio Z3=49
Cuscinetto a rullini
Chiavetta
Albero di ingresso completo
. Anello elastico
. Disco finale
. Disco frizione esterno
. Disco frizione interno
. Anello di ritegno
. Molla a tazza
. Molla a tazza
. Anello interno
. Pistone
. Sfera
. Anello esterno
. Albero di ingresso+
cilindro frizione
Cuscinetto a rulli conici
Spessore 0,1 mm
Spessore 0,15 mm
Spessore 0,2 mm
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Spessore 0,1 mm
Spessore 0,15 mm
Spessore 0,3 mm
Spessore 0,5 mm
Tapered roller bearing
Shim 0.1 mm
Shim 0.15 mm
Shim 0.2 mm
Tapered roller bearing
Tapered roller bearing
Tapered roller bearing
Tapered roller bearing
Shim 0.1 mm
Shim 0.15 mm
Shim 0.3 mm
Shim 0.5 mm
1
2
2
2
1
1
1
1
2
2
2
2
18
19
20
21
22
454406
488955
441438
437956
455788
455789
455787
455786
500076
500148
500066
500147
106690
500069
333859
166807
442340
154102
154101
Note
Vers. 009,010 (Rapporto I=1,25)
30 3312 302 019
500856
Ingranaggio Z1=39
31 3312 199 048
Albero intermedio Z4=45, Z5=36
32 3312 199 049
Albero di uscita Z2=49
Vers. 009,010 (Ratio I=1.25)
Forward gear Z1=39
1
Intermediate shaft Z4=45, Z5=36 1
Output shaft Z2=49
1
]
]
Vers. 01,001,011 (Rapporto I=1,51)
30 3312 202 008
439253
Ingranaggio Z1=35
31 3312 199 040
470065
Albero intermedio Z4=45, Z5=32
32 3312 199 011
Albero di uscita Z2=53
Vers. 01,001,011 (Ratio I=1.51)
Forward gear Z1=35
1
Intermediate shaft Z4=45, Z5=32 1
Output shaft Z2=53
1
]
]
Vers. 02,002,013 (Rapporto I=1,93)
30 3312 202 009
439254
Ingranaggio Z1=30
31 3312 199 042
470068
Albero intermedio Z4=45, Z5=27
32 3312 199 034
Albero di uscita Z2=58
Vers. 02,002,013 (Ratio I=1.93)
Forward gear Z1=30
1
Intermediate shaft Z4=45, Z5=27 1
Output shaft Z2=58
1
]
]
Vers. 03,003,014 (Rapporto I=2,48)
30 3312 202 010
455504
Ingranaggio Z1=25
31 3312 199 035
479681
Albero intermedio Z4=45, Z5=23
32 3312 199 036
479685
Albero di uscita Z2=62
Vers. 03,003,014 (Ratio I=2.48)
Forward gear Z1=25
1
Intermediate shaft Z4=45, Z5=23 1
Output shaft Z2=62
1
]
]
Vers. 04,004,015 (Rapporto I=2,78)
30 3312 202 011
455510
Ingranaggio Z1=23
31 3312 199 012
Albero intermedio Z4=45, Z5=21
32 3312 199 013
Albero di uscita Z2=64
Vers. 04,004,015 (Ratio I=2.78)
Forward gear Z1=23
1
Intermediate shaft Z4=45, Z5=21 1
Output shaft Z2=64
1
]
]
] Cuscinetti a rulli conici giaÁ assemblati - Tapered roller bearings already assembled
51
52
13
14
12
17
15
19
16
21
18
6
4
5
20
22
11
3
2
7
1
8
21
9
20
30
11
19
16
10
17
18
14
25
27
32
9
31
33
15
13
26
30
12
23
28
7
24
29
24
Repair Manual and Spare Parts List
ZF 80 A - ZF 80-1 A FIG. 2
ZF 80 A - ZF 80-1 A
Repair Manual and Spare Parts List
ZF 80 A - ZF 80-1 A FIG. 2
Q.taÁ
Q.ty
Pos.
Part number
Old P/N
Descrizione
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
3313 304 007
0634 303 505
3313 304 026
0636 016 085
3312 302 041
0635 501 937
3313 302 023
3313 302 024
3312 302 040
0631 501 062
3313 199 026
0630 513 066
3312 302 012
3312 302 008
3312 302 009
0630 501 038
3312 302 015
3312 302 038
0634 402 178
3312 302 014
0635 460 006
0634 402 176
3313 199 027
439581
384176
387841
102823
447038
447754
457823
500819
441438
437956
486633
455788
455789
455787
455786
500076
500148
500148
500066
500147
106690
500069
500237
Flangia
Guarnizione OR
Rondella
Vite T.E.
Anello di tenuta
Cuscinetto a rulli conici
Rasamento
Ingranaggio Z3=44
Cuscinetto a rullini
Chiavetta
Albero di ingresso completo
. Anello elastico
. Disco finale
. Disco frizione esterno
. Disco frizione interno
. Anello di ritegno
. Molla a tazza
. Molla a tazza
. Anello interno
. Pistone
. Sfera
. Anello esterno
. Albero di ingresso+
cilindro frizione
Cuscinetto a rulli conici
Spessore 0,1 mm
Spessore 0,15 mm
Spessore 0,2 mm
Spessore 0,5 mm
Spessore 1,0 mm
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Spessore 0,15 mm
Spessore 0,20 mm
Spessore 0,50 mm
Distanziale
Flange
O-Ring
Washer
Hex head screw
Piston ring
Tapered roller bearing
Butting ring
Reverse gear Z3=44
Needle bearing
Key
Input shaft, assy.
. Snap ring
. End disc
. Outer clutch disc
. Inner clutch disc
. Retainer ring
. Cup spring
. Cup spring
. Inner clutch piston ring
. Clutch piston
. Ball
. Outer clutch piston ring
. Input shaft and clutch housing
1
1
1
1
3
1
2
1
4
1
1
2
2
12
10
2
6
6
2
2
2
2
1
Tapered roller bearing
Shim 0.1 mm
Shim 0.15 mm
Shim 0.2 mm
Shim 0.5 mm
Shim 1.0 mm
Tapered roller bearing
Tapered roller bearing
Tapered roller bearing
Tapered roller bearing
Shim 0.15 mm
Shim 0.20 mm
Shim 0.50 mm
Spacer
1
2
2
2
2
2
1
1
1
1
2
2
2
2
18
19
20
21
22
23 0635 501 939
24 3313 302 042
3313 302 043
3313 302 044
3313 302 045
3313 302 046
25 0635 501 937
26 0635 501 938
27 0635 373 008
28 0635 501 914
29 3208 304 023
3208 304 024
3208 304 027
30 3313 302 030
439630
439631
439632
439633
439634
447754
333859
384182
449125
449126
449127
439533
Note
Intermediate shaft
Da matricola 43448L (ZF 80 A) e 43463L (ZF 80-1 A)
From serial number 43448L (ZF 80 A) and 43463L (ZF 80-1 A)
SOLO PER ZF 80 A
Vers. 15,001 (Rapporto I=1,2)
31 3313 302 021
32 3313 199 030
500392
33 3313 199 031
500398
Vers. 16,002 (Rapporto I=1,41)
31 3313 302 026
500850
32 3313 199 032
500393
33 3313 199 033
500399
Vers. 17,003 (Rapporto I=1,57)
31 3313 302 025
500849
32 3313 199 034
500394
33 3313 199 035
500400
Vers. 18,004 (Rapporto I=1,96)
31 3313 202 004
459589
32 3313 199 036
500395
33 3313 199 016
500401
Ingranaggio Z1=35
Albero intermedio Z4=44, Z5=35
Albero di uscita Z2=42
Ingranaggio Z1=32
Albero intermedio Z4=44, Z5=32
Albero di uscita Z2=45
Ingranaggio Z1=30
Albero intermedio Z4=44, Z5=30
Albero di uscita Z2=47
Ingranaggio Z1=26
Albero intermedio Z4=44, Z5=26
Albero di uscita Z2=51
ONLY FOR ZF 80 A
Vers. 15,001 (Ratio I=1.2)
Forward gear Z1=35
Intermediate shaft Z4=44, Z5=35
Output shaft Z2=42
Vers. 16,002 (Ratio I=1.41)
Forward gear Z1=32
Intermediate shaft Z4=44, Z5=32
Output shaft Z2=45
Vers. 17,003 (Ratio I=1.57)
Forward gear Z1=30
Intermediate shaft Z4=44, Z5=30
Output shaft Z2=47
Vers. 18,004 (Ratio I=1.96)
Forward gear Z1=26
Intermediate shaft Z4=44, Z5=26
Output shaft Z2=51
1
1
1
]
]
1
1
1
]
]
1
1
1
]
]
1
1
1
]
]
53
Repair Manual and Spare Parts List
Pos.
Part number
Old P/N
Descrizione
ZF 80 A - ZF 80-1 A FIG. 2
Description
Q.taÁ
Q.ty
Vers. 19,005 (Rapporto I=2,5)
31 3313 202 005
462133
32 3313 199 037
500396
33 3313 199 038
500402
Vers. 20,006 (Rapporto I=2,85)
31 3313 202 006
462134
32 3313 199 039
500397
33 3313 199 040
500403
Vers. 19,005 (Ratio I=2.5)
Ingranaggio Z1=22
Forward gear Z1=22
Albero intermedio Z4=44, Z5=22 Intermediate shaft Z4=44, Z5=22
Albero di uscita Z2=55
Output shaft Z2=55
Vers. 20,006 (Ratio I=2.85)
Ingranaggio Z1=20
Forward gear Z1=20
Albero intermedio Z4=44, Z5=20 Intermediate shaft Z4=44, Z5=20
Albero di uscita Z2=57
Output shaft Z2=57
Note
1
1
1
]
]
1
1
1
]
]
SOLO PER ZF 80-1 A
Vers. 007 (Rapporto I=1,57)
31 3313 302 025
500849
32 3313 199 034
500394
33 3313 199 035
500400
ONLY FOR ZF 80-1 A
Vers. 007 (Ratio I=1.57)
Ingranaggio Z1=30
Forward gear Z1=30
1
Albero intermedio Z4=44, Z5=30 Intermediate shaft Z4=44, Z5=30 1
Albero di uscita Z2=47
Output shaft Z2=47
1
]
]
Vers. 008 (Rapporto I=1,96)
31 3313 202 004
459589
32 3313 199 036
500395
33 3313 199 003
Vers. 008 (Ratio I=1.96)
Ingranaggio Z1=26
Forward gear Z1=26
1
Albero intermedio Z4=44, Z5=26 Intermediate shaft Z4=44, Z5=26 1
Albero di uscita Z2=51
Output shaft Z2=51
1
]
]
Vers. 009 (Rapporto I=1,21)
31 3313 302 021
32 3313 199 030
500392
33 3313 199 031
500398
Vers. 009 (Ratio I=1.21)
Ingranaggio Z1=35
Forward gear Z1=35
1
Albero intermedio Z4=44, Z5=35 Intermediate shaft Z4=44, Z5=35 1
Albero di uscita Z2=42
Output shaft Z2=42
1
]
]
Vers. 010 (Rapporto I=1,41)
31 3313 302 026
500850
32 3313 199 032
500393
33 3313 199 033
500399
Vers. 010 (Ratio I=1.41)
Ingranaggio Z1=32
Forward gear Z1=32
1
Albero intermedio Z4=44, Z5=32 Intermediate shaft Z4=44, Z5=32 1
Albero di uscita Z2=45
Output shaft Z2=45
1
]
]
Vers. 011 (Rapporto I=2,5)
31 3313 202 005
462133
32 3313 199 001
33 3313 199 004
Vers. 011 (Ratio I=2.5)
Ingranaggio Z1=22
Forward gear Z1=22
1
Albero intermedio Z4=44, Z5=22 Intermediate shaft Z4=44, Z5=22 1
Albero di uscita Z2=55
Output shaft Z2=55
1
]
]
Vers. 012 (Rapporto I=2,85)
31 3313 202 007
501739
32 3313 199 002
33 3313 199 005
Vers. 012 (Ratio I=2.85)
Ingranaggio Z1=20
Forward gear Z1=20
1
Albero intermedio Z4=44, Z5=20 Intermediate shaft Z4=44, Z5=20 1
Albero di uscita Z2=57
Output shaft Z2=57
1
]
]
] Cuscinetti a rulli conici giaÁ assemblati - Tapered roller bearings already assembled
54
55
Repair Manual and Spare Parts List
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A FIG. 3
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
2
12
10
13
1
5
6
4
11
9
8
6
13
7
14
15
13
19
16
18
17
16
23
5
6
24
20
22
3
21
MECHANICAL SELECTOR VALVE
56
Repair Manual and Spare Parts List
Pos.
Part number
Old P/N
Descrizione
Description
408388
452963
442377
442372
455785
500065
500026
455756
500107
103465
107410
500028
500044
106695
455764
105527
500030
500083
500029
500032
500097
500027
Valvola di comando completo
23 bar
Valvola di comando alta velocitaÁ
26 bar
. Valvola di comando
. Guarnizione
. Leva
. Vite T.E.
. Rosetta
. Dado
. Guarnizione
. Vite di fermo
. Tappo
. Tappo
. Tappo
. Rosetta
. Vite di guida
. Molla
. Sfera
. Interruttore completo
. Guarnizione OR
. Boccola
. Anello elastico
. Boccola
. Molla per lubrificazione
. Sfera
. Distanziale
Control valve assy.
23 bar
High speed control valve assy.
26 bar
. Control valve
. Gasket
. Lever
. Hex head screw
. Washer
. Nut
. Gasket
. Stop screw
. Plug
. Plug
. Plug
. Washer
. Guide bolt
. Spring
. Ball
. Neutral safety switch assy.
. O-Ring
. Bushing
. Snap ring
. Bushing
. Spring
. Ball
. Spacer
1 3312 108 001
3313 108 001
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
I
3312 308 020
3312 308 025
0636 101 727
0630 302 090
0637 006 157
0634 309 621
3312 308 034
0636 309 007
0631 405 061
0636 302 053
0634 801 302
3312 308 037
3312 308 047
0635 460 014
3312 308 029
001.105.0158
3312 308 039
0630 502 005
3312 308 038
3312 308 042
0635 460 023
3312 308 036
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A FIG. 3
Q.taÁ
Q.ty
Note
1
1
Only for ZF 80-1A
1
1
1
7
8
1
1
1
1
1
1
3
1
1
2
1
1
1
1
1
1
1
1
57
Repair Manual and Spare Parts List
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A FIG. 4
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
11
9
1
4
6
8
5
10
12
27
20
21
11
7
22
13
23
14
15
58
18
10
24
12
19
25
2
10
3
12
26
17
9
16
8
6
7
5
4
15
14
28
13
12
10
27
29
OLD ELECTRIC SELECTOR VALVE WITH PROPORTIONAL VALVES
Repair Manual and Spare Parts List
Pos.
Part number
1 3312 199 004
3312 199 005
3313 108 003
3313 108 004
2
I
3 3312 308 020
4 3312 308 064
3312 308 065
5 0634 304 651
6 0634 304 391
7 0630 502 078
8 3312 308 054
9 3312 308 062
10 0636 302 053
11 3312 308 059
12 0634 801 302
13 0636 101 651
14 0630 001 096
15 1043 326 045
16 3312 308 063
17 0634 306 524
18 0636 101 727
19 0630 302 090
20 0630 532 004
21 0634 304 309
22 3312 308 058
23 3312 308 040
24 3312 308 043
25 3312 308 017
26 3312 302 041
27 3312 117 001
28 0631 501 062
29 978.28.641.01
Old P/N
408388
501634
501635
501724
501524
501528
501502
501533
103465
501516
107410
501525
501527
501562
442377
442372
501529
501523
501515
500031
500038
500040
447038
437956
501751
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A FIG. 4
Descrizione
Description
Distributore elettrico
Distributore elettrico
Distributore elettrico
Distributore elettrico
. Valvola di comando
Guarnizione
Valvola proporzionale 12 V
Valvola proporzionale 24 V
Guarnizione OR
Anello di tenuta
Anello elastico
Pistoncino valvola 2/3 vie
Molla per pistone
Tappo
Grano
Rosetta
Vite
Rondella
Fermo valvola
Tappo
Anello OR
Vite T.E.
Rosetta
Anello elastico
Anello di tenuta OR
Tappo
Molla
Perno guida molla
Pistoncino estraibile
Anello di tenuta
Kit connettori
Chiavetta
Kit guarnizioni
Electric selector valve
Electric selector valve
Electric selector valve
Electric selector valve
. Control valve
Gasket
Electric valve 12 V
Electric valve 24 V
O-Ring
Piston ring
Snap ring
Valve piston
Piston spring
Plug
Drilled plug
Washer
Screw
Washer
Valve lock
Plug
O-Ring
Hex head screw
Washer
Snap ring
O-Ring
Plug
Spring
Spring guide pin
Valve piston
Piston ring
Connectors kit
Key
Seal kit
(1)
Installare con 12 V - to be instelled with 12 V power supply
(2)
Installare con 24 V - to be instelled with 24 V power supply
(3)
Installare con 24 V - 26 bar - to be instelled with 24 V power supply - 26 bar
(4)
Installare con 12 V - 26 bar - to be instelled with 12 V power supply - 26 bar
Q.taÁ
Q.ty
1
1
1
1
1
1
2
2
2
2
2
2
2
4
2
4
2
2
2
1
1
6
6
1
1
1
1
1
1
3
1
1
1
Note
(1)
(2)
(3) Only for ZF 80-1 A
(4) Only for ZF 80-1 A
59
Repair Manual and Spare Parts List
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A FIG. 5
9
8
9
10
13
11
14
12
7
15
16
10
11
12
21
20
18
6
7
19
17
8
4
23
22
5
3
1
2
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
60
Repair Manual and Spare Parts List
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A FIG. 5
Pos.
Part number
Old P/N
Descrizione
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
0630 502 005
3312 308 038
3312 308 042
0635 460 023
3312 308 036
3312 308 052
0634 304 690
3312 308 050
3312 308 056
0634 801 298
4656 306 013
0732 042 539
0631 405 062
3312 308 051
0636 302 068
0634 801 260
0636 302 065
0634 801 281
3312 308 061
3312 308 057
3312 308 053
0636 302 053
0634 801 302
500083
500029
500032
500097
500027
501497
501522
501495
501513
500095
Anello elastico
Boccola
Molla per lubrificazione
Sfera
Distanziale
Vite torna a casa "B"
Anello di tenuta OR
Rondella
Vite
Rosetta
Pistoncino ammortizzatore
Molla ammortizzatore
Tappo
Vite torna a casa "A"
Tappo
Rosetta
Vite
Rosetta
Molla
Perno guida molla
Pistoncino valvola riduzione
Tappo
Rosetta
Snap ring
Bushing
Spring
Ball
Spacer
Come home screw "B"
O-Ring
Washer
Screw
Washer
Piston
Spring
Plug
Come home screw "A"
Plug
Washer
Screw
Washer
Spring
Spring guide pin
Valve piston
Plug
Washer
501530
501496
500744
500897
501520
227851
501532
501514
501498
103465
107410
Q.taÁ
Q.ty
Note
1
1
1
1
1
1
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
61
Repair Manual and Spare Parts List
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A FIG. 6
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
OLD ELECTRIC SELECTOR VALVE ON/OFF 12V, 26 BAR
10
4
9
5
1
6
8
2
3
2
F1420176
7
F1420175
62
Repair Manual and Spare Parts List
Pos.
Part number
1 3312 199 015
2
3
4
5
6
7
8
9
10
[
3312 308 069
0631 405 061
0636 302 053
0634 801 302
0636 309 007
3316 117 001
0636 101 727
0630 302 090
3312 308 020
Old P/N
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A FIG. 6
Descrizione
Description
Distributore elettrico
26 bar ON/OFF
Elettrovalvola ON/OFF 12V
Tappo
Tappo M10x1
Rosetta
Tappo
Assieme connettore
Vite T.E. M8x40
Rosetta
Guarnizione
Electric selector valve
26 bar ON/OFF
Solenoid valve ON/OFF 12V
Dummy plug
Screw plug M10x1
Washer
Screw plug
Connector kit
Cap screw M8x40
Washer
Gasket
Q.taÁ
Q.ty
1
2
1
1
1
1
2
6
6
1
Note
[
Ma= 12 Nm
Ma= 30 Nm
Installare con 12 V - To be installed with 12 V power supply
63
Repair Manual and Spare Parts List
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A FIG. 7
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
NEW ELECTRIC SELECTOR VALVE ON/OFF 12V - 26 BAR
NEW ELECTRIC SELECTOR VALVE ON/OFF 24V - 26 BAR
10
11
4
6
7
5
10
2
1
2
3
8
10
F1420178
64
9
Repair Manual and Spare Parts List
Pos.
Part number
1 3312 199 063
3312 199 064
2 3312 308 069
3312 308 106
3 0631 405 061
4 0636 302 053
5 0634 801 302
6 0636 309 007
7 0636 101 709
8 0636 101 727
9 0630 302 090
10 3316 117 001
11 3312 308 020
Old P/N
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A FIG. 7
Descrizione
Description
Distributore elettrico ON/OFF
12V - 26 bar
Distributore elettrico ON/OFF
24V - 26 bar
Elettrovalvola ON/OFF 12V
Elettrovalvola ON/OFF 24V
Tappo
Tappo M10x1
Rosetta
Tappo
Vite T.E. M8x65
Vite T.E. M8x40
Rosetta elastica
Assieme connettore
Guarnizione
Elecric selector valve ON/OFF
12V - 26 bar
Elecric selector valve ON/OFF
24V - 26 bar
Solenoid valve ON/OFF 12V
Solenoid valve ON/OFF 24V
Dummy plug
Screw plug M10x1
Washer
Screw plug
Cap screw M8x65
Cap screw M8x40
Spring washer
Connector kit
Gasket
Q.taÁ
Q.ty
Note
1
[
1
2
2
1
1
1
1
2
4
6
2
1
[ [
Ma=20 Nm
Ma=20 Nm
Ma=12 Nm
Ma=35 Nm
[ Installare con 12 V - To be installed with 12 V power supply
[ [ Installare con 24 V - To be installed with 24 V power supply
Per convertire la elettrovalvola da 12V a 24V sostituire solo
il solenoide con il ricambio a cod. 3312 199 062.
To transform the solenoid valve from 12V to 24V it will be
enough to replace only the solenoid - available loosen P/N
3312 199 062.
F1420179
La valvola non eÁ disponibile singolarmente ed eÁ un componente comune alla versione 12V e 24V dell'elettrovalvola.
The valve is not available loosen and it is a common component both for 12V and 24V solenoid valve.
F1420180
65
Repair Manual and Spare Parts List
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A FIG. 8
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
NEW ELECTRIC SELECTOR VALVE ON/OFF 12V - 26 BAR
WITH TROLLING VALVE
NEW ELECTRIC SELECTOR VALVE ON/OFF 24V - 26 BAR
WITH TROLLING VALVE
10
12
11
10
13
6
4
5
10
1
2
7
3
10
F1420178
66
8
9
Repair Manual and Spare Parts List
Pos.
Part number
Descrizione
Description
1 3312 199 065
Distributore elettrico ON/OFF
12V, 26 bar con TV
3312 199 066
Distributore elettrico ON/OFF
24V, 26 bar con TV
Electric selector valve ON/OFF
12V, 26 bar
with Trolling valve
Electric selector valve ON/OFF
24V, 26 bar
with Trolling valve
Solenoid valve ON/OFF
12V, 26 bar
Solenoid valve ON/OFF
24V, 26 bar
Dummy plug
Screw plug M10x1
Sealing ring
Screw plug
Cap screw M8x65
Cap screw M8x40
Spring washer
Connector kit
Trolling device
Proportional valve 12V
Proportional valve 24V
Gasket
2 3312 308 069
3312 308 106
3
4
5
6
7
8
9
10
11
12
0631 405 061
0636 302 053
0634 801 302
0636 309 007
0636 101 709
0636 101 727
0630 302 090
3316 117 001
3312 108 027
3312 308 096
3312 308 124
13 3312 308 020
Old P/N
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A FIG. 8
Elettrovalvola ON/OFF
12V, 26 BAR
Elettrovalvola ON/OFF
24V, 26 bar
Tappo
Tappo a vite M10x1
Anello di tenuta
Tappo a vite
Vite TCEI M8x65
Vite TCEI M8x40
Rosetta elastica
Assieme connettore
Trolling valve
Valvola proporzionale 12V
Valvola proporzionale 24V
Guarnizione
Q.taÁ
Q.ty
Note
1
[
1
[[
2
Ma=20 Nm
2
Ma=20 Nm
1
1
1
1
2
4
6
3
1
1
1
1
Ma=12 Nm
Ma=35 Nm
Ma=27 Nm
Ma=27 Nm
[ Installare con 12 V - To be installed with 12 V power supply
[ [ Installare con 24 V - To be installed with 24 V power supply
Per convertire la elettrovalvola da 12V a 24V sostituire solo
il solenoide con il ricambio a cod. 3312 199 062.
To transform the solenoid valve from 12V to 24V it will be
enough to replace only the solenoid - available loosen P/N
3312 199 062.
F1420179
La valvola non eÁ disponibile singolarmente ed eÁ un componente comune alla versione 12V e 24V dell'elettrovalvola.
The valve is not available loosen and it is a common component both for 12V and 24V solenoid valve.
F1420180
67
Repair Manual and Spare Parts List
COMPOSIZIONE KIT ZF 63 A - ZF 63
ZF 63 A - ZF 63
±
ZF 63 A - ZF 63 KIT COMPONENTS
Fig.
Pos.
Part number
Old P/N
Descrizione
Description
±
2
1
1
3
1
2
3
1
1
1
±
2
24
3
3
22
5
8
6
7
11
3312 199 017
0634 306 328
3312 301 030
0634 319 132
3312 308 020
0634 304 405
3312 302 041
0634 309 621
0634 304 688
0634 306 204
3312 301 008
501175
105571
413883
442135
408388
501211
447038
500065
442731
105542
439653
Kit guarnizioni e anelli elastici
. Anello OR
. Paraolio entrata
. Paraolio uscita
. Guarnizione
. Guarnizione OR
. Anello elastico
. Anello di tenuta
. Guarnizione OR
. Guarnizione OR
. Guarnizione
Seal kit & piston rings
. O-ring
. Input shaft seal
. Output shaft seal
. Gasket
. O-Ring
. Piston ring
. Seal
. O-Ring
. O-Ring
. Gasket
±
±
2
2
±
±
15
14
3312 199 018
3312 199 017
3312 302 009
3312 302 008
500432
501175
455786
455787
Kit guarnizioni e frizioni
. Kit guarnizioni e anelli elastici
. Disco frizione interno
. Disco frizione esterno
Seal kit & clutch kit
. Seal kit & piston rings
. Inner disc
. Outer disc
1
8
10
±
2
2
2
2
2
2
2
2
2
2
2
2
2
2
±
9
25
26
6
23
27
28
24
24
24
29
29
29
29
3312 199 019
3312 302 040
0635 501 942
0635 501 941
0635 501 940
0635 501 937
0635 501 938
0635 501 922
3312 302 023
3312 302 024
3312 302 025
3312 304 027
3312 304 028
3312 304 029
3312 304 030
501216
441438
Kit cuscinetti
. Cuscinetto a rullini
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Spessore 0,1 mm
. Spessore 0,15 mm
. Spessore 0,2 mm
. Spessore 0,1 mm
. Spessore 0,15 mm
. Spessore 0,3 mm
. Spessore 0,5 mm
Bearing kit
. Needle bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Shim 0.1 mm
. Shim 0.15 mm
. Shim 0.2 mm
. Shim 0.1 mm
. Shim 0.15 mm
. Shim 0.3 mm
. Shim 0.5 mm
4
1
1
1
1
1
1
2
2
2
2
2
2
2
447754
333859
277213
277214
277215
166807
442340
154102
154101
Q.ty
1
1
1
1
1
3
1
1
1
1
COMPOSIZIONE KIT CUSCINETTI ZF 63 A, R. 2,52 (uprated version), R. 2,7
ZF 63 A BEARINGS KIT, RATIO I = 2.52 (uprated version), Ratio I=2.7
Fig.
±
2
2
2
2
2
2
2
2
2
2
2
2
2
2
68
Pos.
Part number
±
9
25
23
6
26
27
28
24
24
24
29
29
29
29
3312 199 053
3312 302 040
0635 501 942
0635 501 941
0635 501 940
0735 370 229
0635 501 938
0635 501 922
3312 302 023
3312 302 024
3312 302 025
3312 304 027
3312 304 028
3312 304 029
3312 304 030
Old P/N
441438
501332
333859
277213
277214
277215
166807
442340
154102
154101
Descrizione
Description
Kit cuscinetti
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Spessore 0,1 mm
. Spessore 0,15 mm
. Spessore 0,2 mm
. Spessore 0,1 mm
. Spessore 0,15 mm
. Spessore 0,3 mm
. Spessore 0,5 mm
Bearing kit
. Needle bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Shim 0.1 mm
. Shim 0.15 mm
. Shim 0.2 mm
. Shim 0.1 mm
. Shim 0.15 mm
. Shim 0.3 mm
. Shim 0.5 mm
Q.ty
4
1
1
1
1
1
1
2
2
2
2
2
2
2
Repair Manual and Spare Parts List
ZF 80 A - ZF 80-1 A
COMPOSIZIONE KIT ZF 80 A - ZF 80-1 A
Fig.
±
ZF 80 A - ZF 80-1 A KIT COMPONENTS
Pos.
Part number
Old P/N
Descrizione
Description
±
2
1
1
3
1
2
3
1
1
1
±
2
21
3
3
25
5
8
6
7
11
3313 199 020
0634 303 505
3312 301 030
0634 319 104
3312 308 020
0634 304 405
3312 302 041
0634 309 621
0634 304 688
0634 306 204
3312 301 008
501171
384176
413883
448160
408388
501211
447038
500065
442731
105542
439653
Kit guarnizioni e anelli elastici
. Anello OR
. Paraolio entrata
. Paraolio uscita
. Guarnizione
. Guarnizione OR
. Anello elastico
. Anello di tenuta
. Guarnizione OR
. Guarnizione OR
. Guarnizione
Seal kit & piston rings
. O-ring
. Input shaft seal
. Output shaft seal
. Gasket
. O-Ring
. Piston ring
. Seal
. O-Ring
. O-Ring
. Gasket
±
±
2
2
±
±
15
14
3313 199 021
3313 199 020
3312 302 009
3312 302 008
500434
501171
455786
455787
Kit guarnizioni e frizioni
. Kit guarnizioni e anelli elastici
. Disco frizione interno
. Disco frizione esterno
Seal kit & clutch kit
. Seal kit & piston rings
. Inner disc
. Outer disc
1
10
12
±
2
2
2
2
2
2
2
2
2
2
2
2
2
2
±
9
23
6,25
26
27
28
24
24
24
24
24
29
29
29
3313 199 022
3312 302 040
0635 501 939
0635 501 937
0635 501 938
0635 373 008
0635 501 914
3313 302 042
3313 302 043
3313 302 044
3313 302 045
3313 302 046
3208 304 023
3208 304 024
3208 304 027
501218
441438
Kit cuscinetti
. Cuscinetto a rullini
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Spessore 0,1 mm
. Spessore 0,15 mm
. Spessore 0,2 mm
. Spessore 0,5 mm
. Spessore 1,0 mm
. Spessore 0,15 mm
. Spessore 0,2 mm
. Spessore 0,5 mm
Bearing kit
. Needle bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Shim 0.1 mm
. Shim 0.15 mm
. Shim 0.2 mm
. Shim 0.5 mm
. Shim 1.0 mm
. Shim 0.15 mm
. Shim 0.2 mm
. Shim 0.5 mm
4
1
2
1
1
1
2
2
2
2
2
2
2
2
447754
333859
384182
439630
439631
439632
439633
439634
449125
449126
449127
Q.ty
1
1
1
1
1
3
1
1
1
1
69
70
Section 12 : Spare parts list
ZF 80 A - ZF 80-1 A
Repair Manual and Spare Parts List
12. SPARE PARTS LIST
ZF 80 A (016, 017, 018, 019, 020, 021 VERSION)
ZF 80-1 A (024, 025, 026, 027, 029, 030 VERSION)
Preface
The spare parts list is only valid for the type and versions of transmission, as shown below.
You will find the transmission type and version on your
transmission name plate.
If 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 referring to the following versions:
ZF 80 A
ZF 80-1 A
versions 016
versions 024
(1.20 R);
(1.21 R);
017 (1.41 R); 018 (1.57 R); 019 (1.96 R); 020 (2.50 R); 021 (2.85 R).
025 (1.41 R); 026 (1.57 R); 027 (1.96 R); 029 (2.50 R); 030 (2.85 R).
Name plate
The name plate is mounted to the transmission
71
Repair Manual and Spare Parts List
ZF 80 A - ZF 80-1 A FIG. 1
7
10
14
15
17
11
6
13
27
3
1
72
18
2
12
8
30
28
9
31
5
4
19
24
23
16
19
21
22
20
25
26
ZF 80 A versions 016 - 017 - 018 - 019 - 020 - 021
ZF 80-1 A versions 024 - 025 - 026 - 027 - 029 - 030
Repair Manual and Spare Parts List
Pos.
Part number
1 3313 199 078
3313 199 114
3313 301 009
3313 201 003
3313 301 022
0636 101 411
3312 301 008
2 0636 301 041
3 0634 319 104
4 3312 101 003
5
6 0634 304 688
7 0634 306 204
8 0630 001 085
9 0636 101 475
10 3312 301 007
11 3312 301 008
12 3312 199 031
13 0634 304 688
14 0634 306 204
15 3312 301 037
16 3313 301 022
17 0636 101 411
18
19
20
21
22
23
24
25
26
27
28
30
31
3313 301 014
0631 315 520
3312 301 030
3311 301 002
3313 301 010
3313 201 001
0634 304 405
0630 302 091
0636 015 227
3312 301 017
3312 301 001
0630 001 085
0636 101 475
Old P/N
442373
448160
500484
442731
105542
167010
320202
438637
439653
463772
442731
105542
102879
462997
335817
413883
442369
500993
501211
442371
442375
469691
167010
320202
ZF 80 A - ZF 80-1 A FIG. 1
Descrizione
Description
Assieme scatola
Assieme scatola
. Scatola
. Scatola con boccola flangiata
. Tubo aspirazione con supporto
. Vite
. Guarnizione
Tappo M16x1,5
Paraolio uscita
Coperchio filtro completo
. Coperchio filtro
. Guarnizione OR
. Guarnizione OR
. Rosetta
. Vite M8x30
Filtro olio
Guarnizione
Filtro olio completo
. Guarnizione OR
. Guarnizione OR
. Filtro olio
Tubo aspirazione con supporto
Vite T.E. M6x16
(fascetta tubo aspirazione)
Anello centratore
Spina
Paraolio entrata
Valvola di sfiato
Coperchio
Asta livello olio + OR
. Guarnizione OR (Asta livello olio)
Rosetta
Vite T.E. M10x35
Tappo
Targhetta di identificazione
Rosetta
Vite M8x30
Housing, assy.
Housing, assy.
. Housing
. Housing with flanged bushing
. Suction pipe with support
. Screw
. Gasket
Plug M16x1.5
Output shaft seal
Filter cover, assy.
. Filter cover
. O-Ring
. O-Ring
. Washer
. Screw M8x30
Oil filter
Gasket
Oil filter, assy
. O-Ring
. O-Ring
. Oil filter
Suction pipe with support
Hex head screw M6x16
(suction pipe clamp)
Centering ring
Locator pin
Input shaft seal
Breather valve
Cover (housing)
Oil dipstick + OR
. O-Ring (Oil dipstick)
Washer
Hex head screw M10x35
Plug
Name plate
Washer
Screw M8x30
Q.taÁ
Q.ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Note
up to s/n XXXXXR
from s/n XXXXXR
up to s/n XXXXXR
from s/n XXXXXR
(1) old part number
(1) new part number
1 up to s/n XXXXXR
2
1
1
1
1
1
14
14
1
1
1
1
(1) Fornito solo incluso nel kit filtro olio p/n 3312 199 031
Supplied only included in the oil filter kit p/n 3312 199 031
73
Repair Manual and Spare Parts List
ZF 80 A - ZF 80-1 A FIG. 2
26
13
14
74
4
5
12
17
15
19
16
21
18
20
22
11
6
3
7
2
1
8
21
20
9
17
10
30
11
16
19
18
14
25
27
32
9
15
33
31
13
12
30
7
28
23
24
29
24
ZF 80 A versions 016 - 017 - 018 - 019 - 020 - 021
ZF 80-1 A versions 024 - 025 - 026 - 027 - 029 - 030
Repair Manual and Spare Parts List
ZF 80 A - ZF 80-1 A FIG. 2
Pos.
Part number
Old P/N
Descrizione
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
3313 304 007
0634 303 505
3313 304 026
0636 016 085
3312 302 041
0635 501 937
3313 302 023
3313 302 024
3312 302 040
0631 501 062
3313 199 075
0630 513 065
3319 302 003
3319 302 001
3319 302 006
0630 501 038
3313 302 059
0634 402 178
3319 302 004
0635 460 006
0634 402 177
3313 199 076
0635 501 939
3313 302 042
3313 302 043
3313 302 044
3313 302 045
3313 302 046
0635 501 937
0635 501 938
0635 373 008
0635 501 914
3208 304 023
3208 304 024
3208 304 027
3313 302 030
439581
384176
387841
102823
447038
447754
457823
500819
441438
437956
Flangia
Flange
Guarnizione OR
O-Ring
Rondella
Washer
Vite T.E.
Hex head screw
Anello di tenuta
Piston ring
Cuscinetto a rulli conici
Tapered roller bearing
Rasamento
Butting ring
Ingranaggio Z3=44
Reverse gear Z3=44
Cuscinetto a rullini
Needle bearing
Chiavetta
Key
Albero di ingresso completo
Input shaft, assy.
. Anello elastico
. Snap ring
. Disco finale
. End disc
. Disco frizione esterno
. Outer clutch disc
. Disco frizione interno
. Inner clutch disc
. Anello di ritegno
. Retainer ring
. Molla a tazza
. Cup spring
. Anello interno
. Inner clutch piston ring
. Pistone
. Clutch piston
. Sfera
. Ball
. Anello esterno
. Outer clutch piston ring
. Albero di ingresso+cilindro frizione. Input shaft and clutch housing
Cuscinetto a rulli conici
Tapered roller bearing
Spessore 0,1 mm
Shim 0.1 mm
Spessore 0,15 mm
Shim 0.15 mm
Spessore 0,2 mm
Shim 0.2 mm
Spessore 0,5 mm
Shim 0.5 mm
Spessore 1,0 mm
Shim 1.0 mm
Cuscinetto a rulli conici
Tapered roller bearing
Cuscinetto a rulli conici
Tapered roller bearing
Cuscinetto a rulli conici
Tapered roller bearing
Cuscinetto a rulli conici
Tapered roller bearing
Spessore 0,15 mm
Shim 0.15 mm
Spessore 0,2 mm
Shim 0.2 mm
Spessore 0,5 mm
Shim 0.5 mm
Distanziale
Spacer
25
26
27
28
29
30
500076
500066
106690
439630
439631
439632
439633
439634
447754
333859
384182
449125
449126
449127
439533
SOLO PER ZF 80 A
Vers. 016 (Rapporto I=1,2)
31 3313 302 021
32 3313 199 030
500392
33 3313 199 031
500398
Vers. 017 (Rapporto I=1,41)
31 3313 302 026
500850
32 3313 199 032
500393
33 3313 199 033
500399
Vers. 018 (Rapporto I=1,57)
31 3313 302 025
500849
32 3313 199 034
500394
33 3313 199 035
500400
Vers. 019 (Rapporto I=1,96)
31 3313 202 004
459589
32 3313 199 036
500395
33 3313 199 016
500401
Vers. 020 (Rapporto I=2,5)
31 3313 202 005
462133
32 3313 199 037
500396
33 3313 199 038
500402
Ingranaggio Z1=35
Albero intermedio Z4=44, Z5=35
Albero di uscita Z2=42
Ingranaggio Z1=32
Albero intermedio Z4=44, Z5=32
Albero di uscita Z2=45
Ingranaggio Z1=30
Albero intermedio Z4=44, Z5=30
Albero di uscita Z2=47
Ingranaggio Z1=26
Albero intermedio Z4=44, Z5=26
Albero di uscita Z2=51
Ingranaggio Z1=22
Albero intermedio Z4=44, Z5=22
Albero di uscita Z2=55
Description
Q.taÁ
Q.ty
ONLY FOR ZF 80 A
Vers. 016 (Ratio I=1.2)
Forward gear Z1=35
Intermediate shaft Z4=44, Z5=35
Output shaft Z2=42
Vers. 017 (Ratio I=1.41)
Forward gear Z1=32
Intermediate shaft Z4=44, Z5=32
Output shaft Z2=45
Vers. 018 (Ratio I=1.57)
Forward gear Z1=30
Intermediate shaft Z4=44, Z5=30
Output shaft Z2=47
Vers. 019 (Ratio I=1.96)
Forward gear Z1=26
Intermediate shaft Z4=44, Z5=26
Output shaft Z2=51
Vers. 020 (Ratio I=2.5)
Forward gear Z1=22
Intermediate shaft Z4=44, Z5=22
Output shaft Z2=55
Note
1
1
1
1
3
1
2
1
4
1
1
2
2
10
8
2
6
2
2
2
2
1
1
2
2
2
2
2 Intermediate shaft
1
1
1
1
2
2
2
2
1
1
1
]
]
1
1
1
]
]
1
1
1
]
]
1
1
1
]
]
1
1
1
]
]
75
Repair Manual and Spare Parts List
Pos.
Part number
Old P/N
Descrizione
ZF 80 A - ZF 80-1 A FIG. 2
Description
Q.taÁ
Q.ty
Note
Vers. 021 (Rapporto I=2,85)
31 3313 202 006
462134
32 3313 199 039
500397
33 3313 199 040
500403
Vers. 021 (Ratio I=2.85)
Ingranaggio Z1=20
Forward gear Z1=20
1
Albero intermedio Z4=44, Z5=20 Intermediate shaft Z4=44, Z5=20 1
Albero di uscita Z2=57
Output shaft Z2=57
1
]
]
SOLO PER ZF 80-1 A
Vers. 024 (Rapporto I=1,21)
31 3313 302 021
32 3313 199 030
500392
33 3313 199 031
500398
ONLY FOR ZF 80-1 A
Vers. 024 (Ratio I=1.21)
Ingranaggio Z1=35
Forward gear Z1=35
1
Albero intermedio Z4=44, Z5=35 Intermediate shaft Z4=44, Z5=35 1
Albero di uscita Z2=42
Output shaft Z2=42
1
]
]
Vers. 025 (Rapporto I=1,41)
31 3313 302 026
500850
32 3313 199 032
500393
33 3313 199 033
500399
Vers. 025 (Ratio I=1.41)
Ingranaggio Z1=32
Forward gear Z1=32
1
Albero intermedio Z4=44, Z5=32 Intermediate shaft Z4=44, Z5=32 1
Albero di uscita Z2=45
Output shaft Z2=45
1
]
]
Vers. 026 (Rapporto I=1,57)
31 3313 302 025
500849
32 3313 199 034
500394
33 3313 199 035
500400
Vers. 026 (Ratio I=1.57)
Ingranaggio Z1=30
Forward gear Z1=30
1
Albero intermedio Z4=44, Z5=30 Intermediate shaft Z4=44, Z5=30 1
Albero di uscita Z2=47
Output shaft Z2=47
1
]
]
Vers. 027 (Rapporto I=1,96)
31 3313 202 004
459589
32 3313 199 036
500395
33 3313 199 003
Vers. 027 (Ratio I=1.96)
Ingranaggio Z1=26
Forward gear Z1=26
1
Albero intermedio Z4=44, Z5=26 Intermediate shaft Z4=44, Z5=26 1
Albero di uscita Z2=51
Output shaft Z2=51
1
]
]
Vers. 029 (Rapporto I=2,5)
31 3313 202 005
462133
32 3313 199 001
33 3313 199 004
Vers. 029 (Ratio I=2.5)
Ingranaggio Z1=22
Forward gear Z1=22
1
Albero intermedio Z4=44, Z5=22 Intermediate shaft Z4=44, Z5=22 1
Albero di uscita Z2=55
Output shaft Z2=55
1
]
]
Vers. 030 (Rapporto I=2,85)
31 3313 202 007
501739
32 3313 199 002
33 3313 199 005
Vers. 030 (Ratio I=2.85)
Ingranaggio Z1=20
Forward gear Z1=20
1
Albero intermedio Z4=44, Z5=20 Intermediate shaft Z4=44, Z5=20 1
Albero di uscita Z2=57
Output shaft Z2=57
1
]
]
] Cuscinetti a rulli conici giaÁ assemblati - Tapered roller bearings already assembled
76
77
Repair Manual and Spare Parts List
ZF 80 A - ZF 80-1 A FIG. 3
ZF 80 A versions 016 - 017 - 018 - 019 - 020 - 021
ZF 80-1 A versions 024 - 025 - 026 - 027 - 029 - 030
2
12
10
13
1
5
6
4
11
9
8
6
13
7
14
15
13
19
16
18
17
16
23
5
6
24
20
22
3
21
MECHANICAL SELECTOR VALVE
78
Repair Manual and Spare Parts List
Pos.
Part number
Old P/N
Descrizione
Description
408388
452963
442377
442372
455785
500065
500026
455756
500107
103465
107410
500028
500044
106695
455764
105527
500030
500083
500029
500032
500097
500027
Valvola di comando
completo 23 bar
Valvola di comando
alta velocitaÁ 26 bar
. Valvola di comando
. Guarnizione
. Leva
. Vite T.E.
. Rosetta
. Dado
. Guarnizione
. Vite di fermo
. Tappo
. Tappo
. Tappo
. Rosetta
. Vite di guida
. Molla
. Sfera
. Interruttore completo
. Guarnizione OR
. Boccola
. Anello elastico
. Boccola
. Molla per lubrificazione
. Sfera
. Distanziale
Mechanical selector
valve 23 bar
Mechanical selector
valve 26 bar
. Control valve
. Gasket
. Lever
. Hex head screw
. Washer
. Nut
. Gasket
. Stop screw
. Plug
. Plug
. Plug
. Washer
. Guide bolt
. Spring
. Ball
. Neutral safety switch assy.
. O-Ring
. Bushing
. Snap ring
. Bushing
. Spring
. Ball
. Spacer
1 3312 108 001
1 3313 108 001
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
I
3312 308 020
3312 308 025
0636 101 727
0630 302 090
0637 006 157
0634 309 621
3312 308 034
0636 309 007
0631 405 061
0636 302 053
0634 801 302
3312 308 037
3312 308 047
0635 460 014
3312 308 029
001.105.0158
3312 308 039
0630 502 005
3312 308 038
3312 308 042
0635 460 023
3312 308 036
ZF 80 A - ZF 80-1 A FIG. 3
Q.taÁ
Q.ty
Note
1
1
Only for ZF 80-1A
1
1
1
7
8
1
1
1
1
1
1
3
1
1
2
1
1
1
1
1
1
1
1
79
Repair Manual and Spare Parts List
ZF 80 A - ZF 80-1 A FIG. 4
ZF 80 A versions 016 - 017 - 018 - 019 - 020 - 021
ZF 80-1 A versions 024 - 025 - 026 - 027 - 029 - 030
OLD ELECTRIC SELECTOR VALVE ON/OFF 12V, 26 BAR
10
4
9
5
1
6
8
2
3
2
F1420176
7
F1420175
80
Repair Manual and Spare Parts List
Pos.
Part number
1 3312 199 015
2
3
4
5
6
7
8
9
10
[
3312 308 069
0631 405 061
0636 302 053
0634 801 302
0636 309 007
3316 117 001
0636 101 727
0630 302 090
3312 308 020
Old P/N
ZF 80 A - ZF 80-1 A FIG. 4
Descrizione
Description
Distributore elettrico
26 bar ON/OFF
Elettrovalvola ON/OFF 12V
Tappo
Tappo M10x1
Rosetta
Tappo
Assieme connettore
Vite T.E. M8x40
Rosetta
Guarnizione
Electric selector valve
26 bar ON/OFF
Solenoid valve ON/OFF 12V
Dummy plug
Screw plug M10x1
Washer
Screw plug
Connector kit
Cap screw M8x40
Spring washer
Gasket
Q.taÁ
Q.ty
1
2
1
1
1
1
2
6
6
1
Note
[
Ma= 12 Nm
Ma= 30 Nm
Installare con 12 V - To be installed with 12 V power supply
81
Repair Manual and Spare Parts List
ZF 80 A - ZF 80-1 A FIG. 5
ZF 80 A versions 016 - 017 - 018 - 019 - 020 - 021
ZF 80-1 A versions 024 - 025 - 026 - 027 - 029 - 030
NEW ELECTRIC SELECTOR VALVE ON/OFF 12V - 26 BAR
NEW ELECTRIC SELECTOR VALVE ON/OFF 24V - 26 BAR
10
11
4
6
7
5
10
2
1
2
3
8
10
F1420178
82
9
Repair Manual and Spare Parts List
Pos.
Part number
1 3312 199 063
3312 199 064
2 3312 308 069
3312 308 106
3 0631 405 061
4 0636 302 053
5 0634 801 302
6 0636 309 007
7 0636 101 709
8 0636 101 727
9 0630 302 090
10 3316 117 001
11 3312 308 020
Old P/N
ZF 80 A - ZF 80-1 A FIG. 5
Descrizione
Description
Distributore elettrico ON/OFF
12V - 26 bar
Distributore elettrico ON/OFF
24V - 26 bar
Elettrovalvola ON/OFF 12V
Elettrovalvola ON/OFF 24V
Tappo
Tappo M10x1
Rosetta
Tappo
Vite T.E. M8x65
Vite T.E. M8x40
Rosetta elastica
Assieme connettore
Guarnizione
Elecric selector valve ON/OFF
12V - 26 bar
Elecric selector valve ON/OFF
24V - 26 bar
Solenoid valve ON/OFF 12V
Solenoid valve ON/OFF 24V
Dummy plug
Screw plug M10x1
Washer
Screw plug
Cap screw M8x65
Cap screw M8x40
Spring washer
Connector kit
Gasket
Q.taÁ
Q.ty
Note
1
[
1
2
2
1
1
1
1
2
4
6
2
1
[ [
Ma=20 Nm
Ma=20 Nm
Ma=12 Nm
Ma=35 Nm
[ Installare con 12 V - To be installed with 12 V power supply
[ [ Installare con 24 V - To be installed with 24 V power supply
Per convertire la elettrovalvola da 12V a 24V sostituire solo
il solenoide con il ricambio a cod. 3312 199 062.
To transform the solenoid valve from 12V to 24V it will be
enough to replace only the solenoid - available loosen P/N
3312 199 062.
F1420179
La valvola non eÁ disponibile singolarmente ed eÁ un componente comune alla versione 12V e 24V dell'elettrovalvola.
The valve is not available loosen and it is a common component both for 12V and 24V solenoid valve.
F1420180
83
Repair Manual and Spare Parts List
ZF 80 A - ZF 80-1 A FIG. 6
ZF 80 A versions 016 - 017 - 018 - 019 - 020 - 021
ZF 80-1 A versions 024 - 025 - 026 - 027 - 029 - 030
NEW ELECTRIC SELECTOR VALVE ON/OFF 12V - 26 BAR
WITH TROLLING VALVE
NEW ELECTRIC SELECTOR VALVE ON/OFF 24V - 26 BAR
WITH TROLLING VALVE
10
12
11
10
13
6
4
5
10
1
2
7
3
10
F1420178
84
8
9
Repair Manual and Spare Parts List
Pos.
Part number
Descrizione
Description
1 3312 199 065
Distributore elettrico ON/OFF
12V, 26 bar con TV
3312 199 066
Distributore elettrico ON/OFF
24V, 26 bar con TV
Electric selector valve ON/OFF
12V, 26 bar
with Trolling valve
Electric selector valve ON/OFF
24V, 26 bar
with Trolling valve
Solenoid valve ON/OFF
12V, 26 bar
Solenoid valve ON/OFF
24V, 26 bar
Dummy plug
Screw plug M10x1
Sealing ring
Screw plug
Cap screw M8x65
Cap screw M8x40
Spring washer
Connector kit
Trolling device
Proportional valve 12V
Proportional valve 24V
Gasket
2 3312 308 069
3312 308 106
3
4
5
6
7
8
9
10
11
12
0631 405 061
0636 302 053
0634 801 302
0636 309 007
0636 101 709
0636 101 727
0630 302 090
3316 117 001
3312 108 027
3312 308 096
3312 308 124
13 3312 308 020
Old P/N
ZF 80 A - ZF 80-1 A FIG. 6
Elettrovalvola ON/OFF
12V, 26 BAR
Elettrovalvola ON/OFF
24V, 26 bar
Tappo
Tappo a vite M10x1
Anello di tenuta
Tappo a vite
Vite TCEI M8x65
Vite TCEI M8x40
Rosetta elastica
Assieme connettore
Trolling valve
Valvola proporzionale 12V
Valvola proporzionale 24V
Guarnizione
Q.taÁ
Q.ty
Note
1
[
1
[[
2
Ma=20 Nm
2
Ma=20 Nm
1
1
1
1
2
4
6
3
1
1
1
1
Ma=12 Nm
Ma=35 Nm
Ma=27 Nm
Ma=27 Nm
[ Installare con 12 V - To be installed with 12 V power supply
[ [ Installare con 24 V - To be installed with 24 V power supply
Per convertire la elettrovalvola da 12V a 24V sostituire solo
il solenoide con il ricambio a cod. 3312 199 062.
To transform the solenoid valve from 12V to 24V it will be
enough to replace only the solenoid - available loosen P/N
3312 199 062.
F1420179
La valvola non eÁ disponibile singolarmente ed eÁ un componente comune alla versione 12V e 24V dell'elettrovalvola.
The valve is not available loosen and it is a common component both for 12V and 24V solenoid valve.
F1420180
85
Repair Manual and Spare Parts List
ZF 80 A - ZF 80-1 A
COMPOSIZIONE KIT - KIT COMPONENTS
versions 016 - 017 - 018 - 019 - 020 - 021
ZF 80 A
ZF 80-1 A versions 024 - 025 - 026 - 027 - 029 - 030
Fig.
Pos.
Part number
Old P/N
Descrizione
Description
±
2
1
1
3
1
2
3
1
1
1
±
2
20
3
3
24
5
8
6
7
11
3313 199 020
0634 303 505
3312 301 030
0634 319 104
3312 308 020
0634 304 405
3312 302 041
0634 309 621
0634 304 688
0634 306 204
3312 301 008
501171
384176
413883
448160
408388
501211
447038
500065
442731
105542
439653
Kit guarnizioni e anelli elastici
. Anello OR
. Paraolio entrata
. Paraolio uscita
. Guarnizione
. Guarnizione OR
. Anello elastico
. Anello di tenuta
. Guarnizione OR
. Guarnizione OR
. Guarnizione
Seal kit & piston rings
. O-ring
. Input shaft seal
. Output shaft seal
. Gasket
. O-Ring
. Piston ring
. Seal
. O-Ring
. O-Ring
. Gasket
±
±
2
2
±
±
15
14
3313 199 077
3313 199 020
3319 302 006
3319 302 001
Kit guarnizioni e frizioni
. Kit guarnizioni e anelli elastici
. Disco frizione interno
. Disco frizione esterno
Seal kit & clutch kit
. Seal kit & piston rings
. Inner disc
. Outer disc
1
8
10
±
2
2
2
2
2
2
2
2
2
2
2
2
2
2
±
9
23
6,25
26
27
28
24
24
24
24
24
29
29
29
3313 199 022
3312 302 040
0635 501 939
0635 501 937
0635 501 938
0635 373 008
0635 501 914
3313 302 042
3313 302 043
3313 302 044
3313 302 045
3313 302 046
3208 304 023
3208 304 024
3208 304 027
Kit cuscinetti
. Cuscinetto a rullini
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Spessore 0,1 mm
. Spessore 0,15 mm
. Spessore 0,2 mm
. Spessore 0,5 mm
. Spessore 1,0 mm
. Spessore 0,15 mm
. Spessore 0,2 mm
. Spessore 0,5 mm
Bearing kit
. Needle bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Shim 0.1 mm
. Shim 0.15 mm
. Shim 0.2 mm
. Shim 0.5 mm
. Shim 1.0 mm
. Shim 0.15 mm
. Shim 0.2 mm
. Shim 0.5 mm
4
1
2
1
1
1
2
2
2
2
2
2
2
2
86
501171
501218
441438
447754
333859
384182
439630
439631
439632
439633
439634
449125
449126
449127
Q.ty
1
1
1
1
1
3
1
1
1
1
Repair Manual and Spare Parts List
Section 13 : Spare parts list ZF 85 A
13. SPARE PARTS LIST ZF 85 A
Preface
The spare parts list is only valid for the type and versions of transmission, as shown below.
You will find the transmission type and version on your
transmission name plate.
If 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 referring to the following versions:
ZF 85 A
versions 004
(1.57 R);
007
(1.75 R);
003
(1.96 R);
002
(2.50 R)
Name plate
The name plate is mounted to the transmission
Tipo della trasmissione
Transmission type
Rapporto della trasmissione
Transmission ratio
Posizione della leva "A"
Shifting position "A"
Posizione della leva "B"
Shifting position "B"
Versione della trasmissione
Transmission version
Numero di serie
Serial number
Ogni anno è assegnata
una diversa lettera progressiva
Every year a new progressive
letter is assigned
Codice della trasmissione
Transmission part number
87
Repair Manual and Spare Parts List
ZF 85 A
ZF 85 A FIG. 1
17
11
7
12 14
10
6
13
88
15
8
28
2
9
29
5
4
20
3
26
27
18
1
23
22
16
18
21
19
24
25
versions 004 - 007 - 003 - 002
Repair Manual and Spare Parts List
Pos.
Part number
1 3323 199 001
3323 301 002
3313 301 022
0636 101 411
3312 301 008
2 0636 301 041
3 0634 319 104
4 3312 101 003
5
6 0634 304 688
7 0634 306 204
8 0630 001 085
9 0636 101 475
10 3312 301 007
11 3312 301 008
12 3312 199 031
13 0634 304 688
14 0634 306 204
15 3312 301 037
16 3313 301 022
17 0636 101 411
18
19
20
21
22
23
24
25
26
27
28
29
0631 315 520
0634 301 846
3311 301 002
3323 301 001
3313 201 001
0634 304 405
0630 302 091
0636 015 227
3312 301 017
3312 301 001
0630 001 085
0636 101 475
Old P/N
442373
448160
500484
442731
105542
167010
320202
438637
439653
463772
442731
105542
438637
102879
335817
442369
500993
501211
442371
442375
469691
167010
320202
ZF 85 A FIG. 1
Descrizione
Description
Assieme scatola
. Scatola
. Tubo aspirazione con supporto
. Vite TCEI M6x16
. Guarnizione
Tappo M16x1,5
Paraolio uscita
Coperchio filtro completo
. Coperchio filtro
. Guarnizione OR
. Guarnizione OR
. Rosetta
. Vite M8x30
Filtro olio
Guarnizione
Filtro olio completo
. Guarnizione OR
. Guarnizione OR
. Filtro olio
Tubo aspirazione con supporto
Vite T.E. M6x16
(fascetta tubo aspirazione)
Spina
Paraolio entrata
Valvola di sfiato
Coperchio
Asta livello olio + OR
. Guarnizione OR (Asta livello olio)
Rosetta
Vite T.E. M10x35
Tappo scarico olio
Targhetta di identificazione
Rosetta
Vite M8x30
Housing, assy.
. Housing
. Suction pipe with support
. Cap screw M6x16
. Gasket
Plug M16x1.5
Output shaft seal
Filter cover, assy.
. Filter cover
. O-Ring
. O-Ring
. Washer
. Screw M8x30
Oil filter
Gasket
Oil filter, assy
. O-Ring
. O-Ring
. Oil filter
Suction pipe with support
Hex head screw M6x16
(suction pipe clamp)
Locator pin
Input shaft seal
Breather valve
Cover (housing)
Oil dipstick + OR
. O-Ring (Oil dipstick)
Washer
Hex head screw M10x35
Oil drain plug
Name plate
Washer
Screw M8x30
Q.taÁ
Q.ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Note
(1) old part number
(1) new part number
2
1
1
1
1
1
14
14
1
1
1
1
(1) Fornito solo incluso nel kit filtro olio p/n 3312 199 031
Supplied only included in the oil filter kit p/n 3312 199 031
89
13
14
12
17
90
16
22
5
35
19
36
4
21
3
34
6
2
7
1
8
9
10
18
11
20
16
19
26
28
38
39
32
15
31
27
37
13
12
29
7
33
24
30
25
ZF 85 A
15
18
20
11
23
22
21
14
Repair Manual and Spare Parts List
ZF 85 A FIG. 2
versions 004 - 007 - 003 - 002
Repair Manual and Spare Parts List
ZF 85 A FIG. 2
Q.taÁ
Q.ty
Pos.
Part number
Old P/N
Descrizione
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
3313 304 007
0634 303 505
3313 304 026
0636 016 085
3312 302 041
0635 501 952
3323 302 008
3323 302 004
0735 321 606
0631 501 062
3323 199 004
0630 513 065
3323 302 017
3323 302 012
3323 302 011
3323 302 009
3323 302 030
3323 302 018
0634 402 178
3323 302 006
0635 460 006
0634 402 177
3323 199 003
439581
384176
387841
102823
447038
Flangia
Guarnizione OR
Rondella
Vite T.E. M16x45
Anello di tenuta
Cuscinetto a rulli conici
Rasamento
Ingranaggio Z3=44
Cuscinetto a rullini
Chiavetta
Albero di ingresso completo
. Anello elastico
. Disco finale
. Disco frizione esterno
. Disco frizione interno
. Anello di ritegno
. Ralla
. Molla a tazza
. Anello interno
. Pistone
. Sfera
. Anello esterno
. Albero di ingresso+
cilindro frizione
Cuscinetto a rulli conici
Spessore 0,1 mm
Spessore 0,15 mm
Spessore 0,2 mm
Spessore 0,5 mm
Spessore 1,0 mm
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Spessore 0,15 mm
Spessore 0,20 mm
Spessore 0,25 mm
Spessore 0,30 mm
Spessore 0,50 mm
Distanziale
Cuscinetto a rullini
Spessore 0,10 mm
Spessore 0,15 mm
Spessore 0,20 mm
Spessore 0,50 mm
Anello di sicurezza
Disco appoggio
Spessore 40x50x0,10
Spessore 40x50x0,15
Spessore 40x50x0,20
Flange
O-Ring
Washer
Hex head screw M16x45
Piston ring
Tapered roller bearing
Butting ring
Reverse gear Z3=44
Needle bearing
Key
Input shaft, assy.
. Snap ring
. End disc
. Outer clutch disc
. Inner clutch disc
. Retainer ring
. Thrust washer
. Cup spring
. Inner clutch piston ring
. Clutch piston
. Ball
. Outer clutch piston ring
. Input shaft and
clutch housing
Tapered roller bearing
Shim 0.1 mm
Shim 0.15 mm
Shim 0.2 mm
Shim 0.5 mm
Shim 1.0 mm
Tapered roller bearing
Tapered roller bearing
Tapered roller bearing
Tapered roller bearing
Shim 0.15 mm
Shim 0.20 mm
Shim 0.25 mm
Shim 0.30 mm
Shim 0.50 mm
Spacer
Needle bearing
Shim 0.10 mm
Shim 0.15 mm
Shim 0.20 mm
Shim 0.50 mm
Retaining ring
Support shim
Shim 40x50x0.10
Shim 40x50x0.15
Shim 40x50x0.20
Vers. 004 (Ratio I=1.57)
Forward gear Z1=30
Intermediate shaft Z4=44, Z5=30
Output shaft Z2=47
Vers. 007 (Ratio I=1.75)
Forward gear Z1=28
Intermediate shaft Z4=44, Z5=28
Output shaft Z2=49
Vers. 003 (Ratio I=1.96)
Forward gear Z1=26
Intermediate shaft Z4=44, Z5=26
Output shaft Z2=51
Vers. 002 (Ratio I=2.5)
Forward gear Z1=22
Intermediate shaft Z4=44, Z5=22
Output shaft Z2=55
437956
500066
106690
24 0635 501 951
25 3313 302 042
439630
3313 302 043
439631
3313 302 044
439632
3313 302 045
439633
3313 302 046
439634
26 0635 501 937
447754
27 0635 372 018
28 0635 373 008
384182
29 0635 501 914
30 3208 304 023
449125
3208 304 024
449126
3208 304 025
3208 304 026
3208 304 027
449127
31 3323 302 013
32 0735 321 607
33 3323 303 008
3323 303 009
3323 303 010
3323 303 011
34 0630 501 031
35 0630 100 010
36 0630 000 193
0630 000 298
0630 000 274
Vers. 004 (Rapporto I=1,57)
37 3323 302 038
38 3323 199 005
39 3323 199 009
Vers. 007 (Rapporto I=1,75)
37 3323 202 009
38 3323 199 006
39 3323 199 010
Vers. 003 (Rapporto I=1,96)
37 3323 202 003
38 3323 199 007
39 3323 199 011
Vers. 002 (Rapporto I=2,5)
37 3323 202 002
38 3323 199 008
39 3323 199 012
Ingranaggio Z1=30
Albero intermedio Z4=44, Z5=30
Albero di uscita Z2=47
Ingranaggio Z1=28
Albero intermedio Z4=44, Z5=28
Albero di uscita Z2=49
Ingranaggio Z1=26
Albero intermedio Z4=44, Z5=26
Albero di uscita Z2=51
Ingranaggio Z1=22
Albero intermedio Z4=44, Z5=22
Albero di uscita Z2=55
] Cuscinetti a rulli conici giaÁ assemblati - Tapered roller bearings already assembled
Note
1
1
1
1
3
1
2
1
1
1
1
2
2
10
8
2
1
6
2
2
2
2
1
1
2
2
2
2
2
1
1
1
1
2
2
2
2
2
1
2
2
2
2
2
1
1
1
1
1
1
1
1
]
]
1
1
1
]
]
1
1
1
]
]
1
1
1
]
]
91
Repair Manual and Spare Parts List
ZF 85 A
ZF 85 A FIG. 3
versions 004 - 007 - 003 - 002
2
12
10
13
1
5
6
4
11
9
8
6
13
7
14
15
13
19
16
18
17
16
23
5
6
24
20
22
3
21
MECHANICAL SELECTOR VALVE
92
Repair Manual and Spare Parts List
Pos.
Part number
Old P/N
Descrizione
Description
408388
452963
442377
442372
455785
500065
500026
455756
500107
103465
107410
500028
500044
106695
455764
105527
500030
500083
500029
500032
500097
500027
Valvola di comando
alta velocitaÁ 26 bar
. Valvola di comando
. Guarnizione
. Leva
. Vite T.E.
. Rosetta
. Dado
. Guarnizione
. Vite di fermo
. Tappo
. Tappo
. Tappo
. Rosetta
. Vite di guida
. Molla
. Sfera
. Interruttore completo
. Guarnizione OR
. Boccola
. Anello elastico
. Boccola
. Molla per lubrificazione
. Sfera
. Distanziale
Mechanical selector
valve 26 bar
. Control valve
. Gasket
. Lever
. Hex head screw
. Washer
. Nut
. Gasket
. Stop screw
. Plug
. Plug
. Plug
. Washer
. Guide bolt
. Spring
. Ball
. Neutral safety switch assy.
. O-Ring
. Bushing
. Snap ring
. Bushing
. Spring
. Ball
. Spacer
1 3313 108 001
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
I
3312 308 020
3312 308 025
0636 101 727
0630 302 090
0637 006 157
0634 309 621
3312 308 034
0636 309 007
0631 405 061
0636 302 053
0634 801 302
3312 308 037
3312 308 047
0635 460 014
3312 308 029
001.105.0158
3312 308 039
0630 502 005
3312 308 038
3312 308 042
0635 460 023
3312 308 036
ZF 85 A FIG. 3
Q.taÁ
Q.ty
Note
1
1
1
1
7
8
1
1
1
1
1
1
3
1
1
2
1
1
1
1
1
1
1
1
93
Repair Manual and Spare Parts List
ZF 85 A
ZF 85 A FIG. 4
versions 004 - 007 - 003 - 002
ELECTRIC SELECTOR VALVE ON/OFF 12V - 26 BAR
ELECTRIC SELECTOR VALVE ON/OFF 24V - 26 BAR
10
11
4
6
7
5
10
2
1
2
3
8
10
F1420178
94
9
Repair Manual and Spare Parts List
Pos.
Part number
1 3312 199 063
3312 199 064
2 3312 308 069
3312 308 106
3 0631 405 061
4 0636 302 053
5 0634 801 302
6 0636 309 007
7 0636 101 709
8 0636 101 727
9 0630 302 090
10 3316 117 001
11 3312 308 020
Old P/N
ZF 85 A FIG. 4
Descrizione
Description
Distributore elettrico ON/OFF
12V - 26 bar
Distributore elettrico ON/OFF
24V - 26 bar
Elettrovalvola ON/OFF 12V
Elettrovalvola ON/OFF 24V
Tappo
Tappo M10x1
Rosetta
Tappo
Vite T.E. M8x65
Vite T.E. M8x40
Rosetta elastica
Assieme connettore
Guarnizione
Elecric selector valve ON/OFF
12V - 26 bar
Elecric selector valve ON/OFF
24V - 26 bar
Solenoid valve ON/OFF 12V
Solenoid valve ON/OFF 24V
Dummy plug
Screw plug M10x1
Washer
Screw plug
Cap screw M8x65
Cap screw M8x40
Spring washer
Connector kit
Gasket
Q.taÁ
Q.ty
Note
1
[
1
2
2
1
1
1
1
2
4
6
2
1
[ [
Ma=20 Nm
Ma=20 Nm
Ma=12 Nm
Ma=35 Nm
[ Installare con 12 V - To be installed with 12 V power supply
[ [ Installare con 24 V - To be installed with 24 V power supply
Per convertire la elettrovalvola da 12V a 24V sostituire solo
il solenoide con il ricambio a cod. 3312 199 062.
To transform the solenoid valve from 12V to 24V it will be
enough to replace only the solenoid - available loosen P/N
3312 199 062.
F1420179
La valvola non eÁ disponibile singolarmente ed eÁ un componente comune alla versione 12V e 24V dell'elettrovalvola.
The valve is not available loosen and it is a common component both for 12V and 24V solenoid valve.
F1420180
95
Repair Manual and Spare Parts List
ZF 85 A
ZF 85 A FIG. 5
versions 004 - 007 - 003 - 002
ELECTRIC SELECTOR VALVE ON/OFF 12V - 26 BAR
WITH TROLLING VALVE
ELECTRIC SELECTOR VALVE ON/OFF 24V - 26 BAR
WITH TROLLING VALVE
10
12
11
10
13
6
4
5
10
1
2
7
3
10
F1420178
96
8
9
Repair Manual and Spare Parts List
Pos.
Part number
Descrizione
Description
1 3312 199 065
Distributore elettrico ON/OFF
12V, 26 bar con TV
3312 199 066
Distributore elettrico ON/OFF
24V, 26 bar con TV
Electric selector valve ON/OFF
12V, 26 bar
with Trolling valve
Electric selector valve ON/OFF
24V, 26 bar
with Trolling valve
Solenoid valve ON/OFF
12V, 26 bar
Solenoid valve ON/OFF
24V, 26 bar
Dummy plug
Screw plug M10x1
Sealing ring
Screw plug
Cap screw M8x65
Cap screw M8x40
Spring washer
Connector kit
Trolling device
Proportional valve 12V
Proportional valve 24V
Gasket
2 3312 308 069
3312 308 106
3
4
5
6
7
8
9
10
11
12
0631 405 061
0636 302 053
0634 801 302
0636 309 007
0636 101 709
0636 101 727
0630 302 090
3316 117 001
3312 108 027
3312 308 096
3312 308 124
13 3312 308 020
Old P/N
ZF 85 A FIG. 5
Elettrovalvola ON/OFF
12V, 26 BAR
Elettrovalvola ON/OFF
24V, 26 bar
Tappo
Tappo a vite M10x1
Anello di tenuta
Tappo a vite
Vite TCEI M8x65
Vite TCEI M8x40
Rosetta elastica
Assieme connettore
Trolling valve
Valvola proporzionale 12V
Valvola proporzionale 24V
Guarnizione
Q.taÁ
Q.ty
Note
1
[
1
[[
2
Ma=20 Nm
2
Ma=20 Nm
1
1
1
1
2
4
6
3
1
1
1
1
Ma=12 Nm
Ma=35 Nm
Ma=27 Nm
Ma=27 Nm
[ Installare con 12 V - To be installed with 12 V power supply
[ [ Installare con 24 V - To be installed with 24 V power supply
Per convertire la elettrovalvola da 12V a 24V sostituire solo
il solenoide con il ricambio a cod. 3312 199 062.
To transform the solenoid valve from 12V to 24V it will be
enough to replace only the solenoid - available loosen P/N
3312 199 062.
F1420179
La valvola non eÁ disponibile singolarmente ed eÁ un componente comune alla versione 12V e 24V dell'elettrovalvola.
The valve is not available loosen and it is a common component both for 12V and 24V solenoid valve.
F1420180
97
Repair Manual and Spare Parts List
ZF 85 A
COMPOSIZIONE KIT - KIT COMPONENTS
ZF 85 A versions 004 - 007 - 003 - 002
Fig.
Pos.
Part number
±
2
1
1
3
1
2
3
1
1
1
±
2
19
3
3
23
5
8
6
7
11
3323 199 019
0634 303 505
0634 301 846
0634 319 104
3312 308 020
0634 304 405
3312 302 041
0634 309 621
0634 304 688
0634 306 204
3312 301 008
±
±
2
2
±
±
15
14
±
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
±
6
9
24
26
27
28
29
32
25
25
25
25
25
30
30
30
33
33
33
33
36
36
36
98
Old P/N
Descrizione
Description
Kit guarnizioni e anelli elastici
. Anello OR
. Paraolio entrata
. Paraolio uscita
. Guarnizione
. Guarnizione OR
. Anello elastico
. Anello di tenuta
. Guarnizione OR
. Guarnizione OR
. Guarnizione
Seal kit & piston rings
. O-ring
. Input shaft seal
. Output shaft seal
. Gasket
. O-Ring
. Piston ring
. Seal
. O-Ring
. O-Ring
. Gasket
3323 199 020
3323 199 019
3323 302 011
3323 302 012
Kit guarnizioni e frizioni
. Kit guarnizioni e anelli elastici
. Disco frizione interno
. Disco frizione esterno
Seal kit & clutch kit
. Seal kit & piston rings
. Inner disc
. Outer disc
1
8
10
3323 199 021
0635 501 952
0735 321 606
0635 501 951
0635 501 937
0635 372 018
0635 373 008
0635 501 914
0735 321 607
3313 302 042
3313 302 043
3313 302 044
3313 302 045
3313 302 046
3208 304 023
3208 304 024
3208 304 027
3323 303 008
3323 303 009
3323 303 010
3323 303 011
0630 000 193
0630 000 298
0630 000 274
Kit cuscinetti
. Cuscinetto a rullini conici
. Cuscinetto a rullini
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini
. Spessore 0,1 mm
. Spessore 0,15 mm
. Spessore 0,20 mm
. Spessore 0,50 mm
. Spessore 1,00 mm
. Spessore 0,15 mm
. Spessore 0,20 mm
. Spessore 0,50 mm
. Spessore 0,10 mm
. Spessore 0,15 mm
. Spessore 0,20 mm
. Spessore 0,50 mm
. Spessore 40x50x0,10
. Spessore 40x50x0,15
. Spessore 40x50x0,20
Bearing kit
. Tapered roller bearing
. Needle bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Needle bearing
. Shim 0.10 mm
. Shim 0.15 mm
. Shim 0.20 mm
. Shim 0.50 mm
. Shim 1.00 mm
. Shim 0.15 mm
. Shim 0.20 mm
. Shim 0.50 mm
. Shim 0.10 mm
. Shim 0.15 mm
. Shim 0.20 mm
. Shim 0.50 mm
. Shim 40x50x0.10
. Shim 40x50x0.15
. Shim 40x50x0.20
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
384176
448160
408388
501211
447038
500065
442731
105542
439653
447754
384182
439630
439631
439632
439633
439634
449125
449126
449127
Q.ty
1
1
1
1
1
3
1
1
1
1
Repair Manual and Spare Parts List Section 14 : Spare parts list ZF 80 A (ZF 85 A Derivate version)
14. SPARE PARTS LIST ZF 80 A (ZF 85 A DERIVATE VERSION)
Preface
The spare parts list is only valid for the type and versions of transmission, as shown below.
You will find the transmission type and version on your
transmission name plate.
If 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 referring to the following versions:
ZF 85 A
versions 038
(1.57 R);
039
(1.75 R);
040
(1.96 R);
041
(2.50 R)
Name plate
The name plate is mounted to the transmission
Tipo della trasmissione
Transmission type
Rapporto della trasmissione
Transmission ratio
Posizione della leva "A"
Shifting position "A"
Posizione della leva "B"
Shifting position "B"
Versione della trasmissione
Transmission version
Numero di serie
Serial number
Ogni anno è assegnata
una diversa lettera progressiva
Every year a new progressive
letter is assigned
Codice della trasmissione
Transmission part number
99
Repair Manual and Spare Parts List
ZF 80 A
ZF 80 A (ZF 85 A Derivate version) FIG. 1
17
11
7
12 14
10
6
13
100
15
8
28
2
9
29
5
4
20
3
26
27
18
1
23
22
16
18
21
19
24
25
versions 038 - 039 - 040 - 041
Repair Manual and Spare Parts List
Pos.
Part number
1 3323 199 001
3323 301 002
3313 301 022
0636 101 411
3312 301 008
2 0636 301 041
3 0634 319 104
4 3312 101 003
5
6 0634 304 688
7 0634 306 204
8 0630 001 085
9 0636 101 475
10 3312 301 007
11 3312 301 008
12 3312 199 031
13 0634 304 688
14 0634 306 204
15 3312 301 037
16 3313 301 022
17 0636 101 411
18
19
20
21
22
23
24
25
26
27
28
29
0631 315 520
0634 301 846
3311 301 002
3323 301 001
3313 201 001
0634 304 405
0630 302 091
0636 015 227
3312 301 017
3312 301 001
0630 001 085
0636 101 475
Old P/N
442373
448160
500484
442731
105542
167010
320202
438637
439653
463772
442731
105542
438637
102879
335817
442369
500993
501211
442371
442375
469691
167010
320202
ZF 80 A (ZF 85 A Derivate version) FIG. 1
Descrizione
Description
Assieme scatola
. Scatola
. Tubo aspirazione con supporto
. Vite TCEI M6x16
. Guarnizione
Tappo M16x1,5
Paraolio uscita
Coperchio filtro completo
. Coperchio filtro
. Guarnizione OR
. Guarnizione OR
. Rosetta
. Vite M8x30
Filtro olio
Guarnizione
Filtro olio completo
. Guarnizione OR
. Guarnizione OR
. Filtro olio
Tubo aspirazione con supporto
Vite T.E. M6x16
(fascetta tubo aspirazione)
Spina
Paraolio entrata
Valvola di sfiato
Coperchio
Asta livello olio + OR
. Guarnizione OR (Asta livello olio)
Rosetta
Vite T.E. M10x35
Tappo scarico olio
Targhetta di identificazione
Rosetta
Vite M8x30
Housing, assy.
. Housing
. Suction pipe with support
. Cap screw M6x16
. Gasket
Plug M16x1.5
Output shaft seal
Filter cover, assy.
. Filter cover
. O-Ring
. O-Ring
. Washer
. Screw M8x30
Oil filter
Gasket
Oil filter, assy
. O-Ring
. O-Ring
. Oil filter
Suction pipe with support
Hex head screw M6x16
(suction pipe clamp)
Locator pin
Input shaft seal
Breather valve
Cover (housing)
Oil dipstick + OR
. O-Ring (Oil dipstick)
Washer
Hex head screw M10x35
Oil drain plug
Name plate
Washer
Screw M8x30
Q.taÁ
Q.ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Note
(1) old part number
(1) new part number
2
1
1
1
1
1
14
14
1
1
1
1
(1) Fornito solo incluso nel kit filtro olio p/n 3312 199 031
Supplied only included in the oil filter kit p/n 3312 199 031
101
Repair Manual and Spare Parts List
ZF 80 A
ZF 80 A (ZF 85 A Derivate version) FIG. 2
27
11
12
13
14
102
3
4
5
36
35
17
18
15
20
16
22
19
11
23
21
6
34
7
2
1
8
22
21
9
10
18
16
20
19
14
26
28
38
39
32
37
15
13
31
12
29
7
24
33
30
25
versions 038 - 039 - 040 - 041
Repair Manual and Spare Parts List
ZF 80 A (ZF 85 A Derivate version) FIG. 2
Q.taÁ
Q.ty
Pos.
Part number
Old P/N
Descrizione
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
3313 304 007
0634 303 505
3313 304 026
0636 016 085
3312 302 041
0635 501 952
3323 302 008
3313 302 063
0735 321 606
0631 501 062
3313 199 109
0630 513 065
3323 302 017
3323 302 012
3323 302 011
3323 302 009
3323 302 030
3323 302 018
0634 402 178
3313 302 062
0635 460 006
0634 402 181
3313 199 108
439581
384176
387841
102823
447038
Flangia
Guarnizione OR
Rondella
Vite T.E. M16x45
Anello di tenuta
Cuscinetto a rulli conici
Rasamento
Ingranaggio Z3=44
Cuscinetto a rullini
Chiavetta
Albero di ingresso completo
. Anello elastico
. Disco finale
. Disco frizione esterno
. Disco frizione interno
. Anello di ritegno
. Ralla
. Molla a tazza
. Anello interno
. Pistone
. Sfera
. Anello esterno
. Albero di ingresso+
cilindro frizione
Cuscinetto a rulli conici
Spessore 0,1 mm
Spessore 0,15 mm
Spessore 0,2 mm
Spessore 0,5 mm
Spessore 1,0 mm
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Cuscinetto a rulli conici
Spessore 0,15 mm
Spessore 0,20 mm
Spessore 0,25 mm
Spessore 0,30 mm
Spessore 0,50 mm
Distanziale
Cuscinetto a rullini
Spessore 0,10 mm
Spessore 0,15 mm
Spessore 0,20 mm
Spessore 0,50 mm
Anello di sicurezza
Disco appoggio
Spessore 40x50x0,10
Spessore 40x50x0,15
Spessore 40x50x0,20
Flange
O-Ring
Washer
Hex head screw M16x45
Piston ring
Tapered roller bearing
Butting ring
Reverse gear Z3=44
Needle bearing
Key
Input shaft, assy.
. Snap ring
. End disc
. Outer clutch disc
. Inner clutch disc
. Retainer ring
. Thrust washer
. Cup spring
. Inner clutch piston ring
. Clutch piston
. Ball
. Outer clutch piston ring
. Input shaft and
clutch housing
Tapered roller bearing
Shim 0.1 mm
Shim 0.15 mm
Shim 0.2 mm
Shim 0.5 mm
Shim 1.0 mm
Tapered roller bearing
Tapered roller bearing
Tapered roller bearing
Tapered roller bearing
Shim 0.15 mm
Shim 0.20 mm
Shim 0.25 mm
Shim 0.30 mm
Shim 0.50 mm
Spacer
Needle bearing
Shim 0.10 mm
Shim 0.15 mm
Shim 0.20 mm
Shim 0.50 mm
Retaining ring
Support shim
Shim 40x50x0.10
Shim 40x50x0.15
Shim 40x50x0.20
Vers. 038 (Ratio I=1.57)
Forward gear Z1=30
Intermediate shaft Z4=44, Z5=30
Output shaft Z2=47
Vers. 039 (Ratio I=1.75)
Forward gear Z1=28
Intermediate shaft Z4=44, Z5=28
Output shaft Z2=49
Vers. 040 (Ratio I=1.96)
Forward gear Z1=26
Intermediate shaft Z4=44, Z5=26
Output shaft Z2=51
Vers. 041 (Ratio I=2.5)
Forward gear Z1=22
Intermediate shaft Z4=44, Z5=22
Output shaft Z2=55
437956
500066
106690
24 0635 501 951
25 3313 302 042
439630
3313 302 043
439631
3313 302 044
439632
3313 302 045
439633
3313 302 046
439634
26 0635 501 937
447754
27 0635 372 018
28 0635 373 008
384182
29 0635 501 914
30 3208 304 023
449125
3208 304 024
449126
3208 304 025
3208 304 026
3208 304 027
449127
31 3323 302 013
32 0735 321 607
33 3323 303 008
3323 303 009
3323 303 010
3323 303 011
34 0630 501 031
35 0630 100 010
36 0630 000 193
0630 000 298
0630 000 274
Vers. 038 (Rapporto I=1,57)
37 3323 302 015
38 3313 199 110
39 3323 199 009
Vers. 039 (Rapporto I=1,75)
37 3323 202 009
38 3313 199 111
39 3323 199 010
Vers. 040 (Rapporto I=1,96)
37 3323 202 003
38 3313 199 112
39 3323 199 011
Vers. 041 (Rapporto I=2,5)
37 3323 202 002
38 3313 199 113
39 3323 199 012
Ingranaggio Z1=30
Albero intermedio Z4=44, Z5=30
Albero di uscita Z2=47
Ingranaggio Z1=28
Albero intermedio Z4=44, Z5=28
Albero di uscita Z2=49
Ingranaggio Z1=26
Albero intermedio Z4=44, Z5=26
Albero di uscita Z2=51
Ingranaggio Z1=22
Albero intermedio Z4=44, Z5=22
Albero di uscita Z2=55
] Cuscinetti a rulli conici giaÁ assemblati - Tapered roller bearings already assembled
Note
1
1
1
1
3
1
2
1
1
1
1
2
2
10
8
2
1
6
2
2
2
2
1
1
2
2
2
2
2
1
1
1
1
2
2
2
2
2
1
2
2
2
2
2
1
1
1
1
1
1
1
1
]
]
1
1
1
]
]
1
1
1
]
]
1
1
1
]
]
103
Repair Manual and Spare Parts List
ZF 80 A
ZF 80 A (ZF 85 A Derivate version) FIG. 3
versions 038 - 039 - 040 - 041
2
12
10
13
1
5
6
4
11
9
8
6
13
7
14
15
13
19
16
18
17
16
23
5
6
24
20
22
3
21
MECHANICAL SELECTOR VALVE
104
Repair Manual and Spare Parts List
Pos.
Part number
Old P/N
Descrizione
Description
408388
452963
442377
442372
455785
500065
500026
455756
500107
103465
107410
500028
500044
106695
455764
105527
500030
500083
500029
500032
500097
500027
Valvola di comando
alta velocitaÁ 26 bar
. Valvola di comando
. Guarnizione
. Leva
. Vite T.E.
. Rosetta
. Dado
. Guarnizione
. Vite di fermo
. Tappo
. Tappo
. Tappo
. Rosetta
. Vite di guida
. Molla
. Sfera
. Interruttore completo
. Guarnizione OR
. Boccola
. Anello elastico
. Boccola
. Molla per lubrificazione
. Sfera
. Distanziale
Mechanical selector
valve 26 bar
. Control valve
. Gasket
. Lever
. Hex head screw
. Washer
. Nut
. Gasket
. Stop screw
. Plug
. Plug
. Plug
. Washer
. Guide bolt
. Spring
. Ball
. Neutral safety switch assy.
. O-Ring
. Bushing
. Snap ring
. Bushing
. Spring
. Ball
. Spacer
1 3313 108 001
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
I
3312 308 020
3312 308 025
0636 101 727
0630 302 090
0637 006 157
0634 309 621
3312 308 034
0636 309 007
0631 405 061
0636 302 053
0634 801 302
3312 308 037
3312 308 047
0635 460 014
3312 308 029
001.105.0158
3312 308 039
0630 502 005
3312 308 038
3312 308 042
0635 460 023
3312 308 036
ZF 80 A (ZF 85 A Derivate version) FIG. 3
Q.taÁ
Q.ty
Note
1
1
1
1
7
8
1
1
1
1
1
1
3
1
1
2
1
1
1
1
1
1
1
1
105
Repair Manual and Spare Parts List
ZF 80 A
ZF 80 A (ZF 85 A Derivate version) FIG. 4
versions 038 - 039 - 040 - 041
ELECTRIC SELECTOR VALVE ON/OFF 12V - 26 BAR
ELECTRIC SELECTOR VALVE ON/OFF 24V - 26 BAR
10
11
4
6
7
5
10
2
1
2
3
8
10
F1420178
106
9
Repair Manual and Spare Parts List
Pos.
Part number
1 3312 199 063
3312 199 064
2 3312 308 069
3312 308 106
3 0631 405 061
4 0636 302 053
5 0634 801 302
6 0636 309 007
7 0636 101 709
8 0636 101 727
9 0630 302 090
10 3316 117 001
11 3312 308 020
Old P/N
ZF 80 A (ZF 85 A Derivate version) FIG. 4
Descrizione
Description
Distributore elettrico ON/OFF
12V - 26 bar
Distributore elettrico ON/OFF
24V - 26 bar
Elettrovalvola ON/OFF 12V
Elettrovalvola ON/OFF 24V
Tappo
Tappo M10x1
Rosetta
Tappo
Vite T.E. M8x65
Vite T.E. M8x40
Rosetta elastica
Assieme connettore
Guarnizione
Elecric selector valve ON/OFF
12V - 26 bar
Elecric selector valve ON/OFF
24V - 26 bar
Solenoid valve ON/OFF 12V
Solenoid valve ON/OFF 24V
Dummy plug
Screw plug M10x1
Washer
Screw plug
Cap screw M8x65
Cap screw M8x40
Spring washer
Connector kit
Gasket
Q.taÁ
Q.ty
Note
1
[
1
2
2
1
1
1
1
2
4
6
2
1
[ [
Ma=20 Nm
Ma=20 Nm
Ma=12 Nm
Ma=35 Nm
[ Installare con 12 V - To be installed with 12 V power supply
[ [ Installare con 24 V - To be installed with 24 V power supply
Per convertire la elettrovalvola da 12V a 24V sostituire solo
il solenoide con il ricambio a cod. 3312 199 062.
To transform the solenoid valve from 12V to 24V it will be
enough to replace only the solenoid - available loosen P/N
3312 199 062.
F1420179
La valvola non eÁ disponibile singolarmente ed eÁ un componente comune alla versione 12V e 24V dell'elettrovalvola.
The valve is not available loosen and it is a common component both for 12V and 24V solenoid valve.
F1420180
107
Repair Manual and Spare Parts List
ZF 80 A
ZF 80 A (ZF 85 A Derivate version) FIG. 5
versions 038 - 039 - 040 - 041
ELECTRIC SELECTOR VALVE ON/OFF 12V - 26 BAR
WITH TROLLING VALVE
ELECTRIC SELECTOR VALVE ON/OFF 24V - 26 BAR
WITH TROLLING VALVE
10
12
11
10
13
6
4
5
10
1
2
7
3
10
F1420178
108
8
9
Repair Manual and Spare Parts List
Pos.
Part number
Descrizione
Description
1 3312 199 065
Distributore elettrico ON/OFF
12V, 26 bar con TV
3312 199 066
Distributore elettrico ON/OFF
24V, 26 bar con TV
Electric selector valve ON/OFF
12V, 26 bar
with Trolling valve
Electric selector valve ON/OFF
24V, 26 bar
with Trolling valve
Solenoid valve ON/OFF
12V, 26 bar
Solenoid valve ON/OFF
24V, 26 bar
Dummy plug
Screw plug M10x1
Sealing ring
Screw plug
Cap screw M8x65
Cap screw M8x40
Spring washer
Connector kit
Trolling device
Proportional valve 12V
Proportional valve 24V
Gasket
2 3312 308 069
3312 308 106
3
4
5
6
7
8
9
10
11
12
0631 405 061
0636 302 053
0634 801 302
0636 309 007
0636 101 709
0636 101 727
0630 302 090
3316 117 001
3312 108 027
3312 308 096
3312 308 124
13 3312 308 020
Old P/N
ZF 80 A (ZF 85 A Derivate version) FIG. 5
Elettrovalvola ON/OFF
12V, 26 BAR
Elettrovalvola ON/OFF
24V, 26 bar
Tappo
Tappo a vite M10x1
Anello di tenuta
Tappo a vite
Vite TCEI M8x65
Vite TCEI M8x40
Rosetta elastica
Assieme connettore
Trolling valve
Valvola proporzionale 12V
Valvola proporzionale 24V
Guarnizione
Q.taÁ
Q.ty
Note
1
[
1
[[
2
Ma=20 Nm
2
Ma=20 Nm
1
1
1
1
2
4
6
3
1
1
1
1
Ma=12 Nm
Ma=35 Nm
Ma=27 Nm
Ma=27 Nm
[ Installare con 12 V - To be installed with 12 V power supply
[ [ Installare con 24 V - To be installed with 24 V power supply
Per convertire la elettrovalvola da 12V a 24V sostituire solo
il solenoide con il ricambio a cod. 3312 199 062.
To transform the solenoid valve from 12V to 24V it will be
enough to replace only the solenoid - available loosen P/N
3312 199 062.
F1420179
La valvola non eÁ disponibile singolarmente ed eÁ un componente comune alla versione 12V e 24V dell'elettrovalvola.
The valve is not available loosen and it is a common component both for 12V and 24V solenoid valve.
F1420180
109
Repair Manual and Spare Parts List
ZF 80 A (ZF 85 A Derivate version)
COMPOSIZIONE KIT - KIT COMPONENTS
ZF 80 A versions 038 - 039 - 040 - 041
Fig.
Pos.
Part number
±
2
1
1
3
1
2
3
1
1
1
±
2
19
3
3
23
5
8
6
7
11
3323 199 019
0634 303 505
0634 301 846
0634 319 104
3312 308 020
0634 304 405
3312 302 041
0634 309 621
0634 304 688
0634 306 204
3312 301 008
±
±
2
2
±
±
15
14
±
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
±
6
9
24
26
27
28
29
32
25
25
25
25
25
30
30
30
33
33
33
33
36
36
36
110
Old P/N
Descrizione
Description
Kit guarnizioni e anelli elastici
. Anello OR
. Paraolio entrata
. Paraolio uscita
. Guarnizione
. Guarnizione OR
. Anello elastico
. Anello di tenuta
. Guarnizione OR
. Guarnizione OR
. Guarnizione
Seal kit & piston rings
. O-ring
. Input shaft seal
. Output shaft seal
. Gasket
. O-Ring
. Piston ring
. Seal
. O-Ring
. O-Ring
. Gasket
3323 199 020
3323 199 019
3323 302 011
3323 302 012
Kit guarnizioni e frizioni
. Kit guarnizioni e anelli elastici
. Disco frizione interno
. Disco frizione esterno
Seal kit & clutch kit
. Seal kit & piston rings
. Inner disc
. Outer disc
1
8
10
3323 199 021
0635 501 952
0735 321 606
0635 501 951
0635 501 937
0635 372 018
0635 373 008
0635 501 914
0735 321 607
3313 302 042
3313 302 043
3313 302 044
3313 302 045
3313 302 046
3208 304 023
3208 304 024
3208 304 027
3323 303 008
3323 303 009
3323 303 010
3323 303 011
0630 000 193
0630 000 298
0630 000 274
Kit cuscinetti
. Cuscinetto a rullini conici
. Cuscinetto a rullini
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini conici
. Cuscinetto a rullini
. Spessore 0,1 mm
. Spessore 0,15 mm
. Spessore 0,20 mm
. Spessore 0,50 mm
. Spessore 1,00 mm
. Spessore 0,15 mm
. Spessore 0,20 mm
. Spessore 0,50 mm
. Spessore 0,10 mm
. Spessore 0,15 mm
. Spessore 0,20 mm
. Spessore 0,50 mm
. Spessore 40x50x0,10
. Spessore 40x50x0,15
. Spessore 40x50x0,20
Bearing kit
. Tapered roller bearing
. Needle bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Tapered roller bearing
. Needle bearing
. Shim 0.10 mm
. Shim 0.15 mm
. Shim 0.20 mm
. Shim 0.50 mm
. Shim 1.00 mm
. Shim 0.15 mm
. Shim 0.20 mm
. Shim 0.50 mm
. Shim 0.10 mm
. Shim 0.15 mm
. Shim 0.20 mm
. Shim 0.50 mm
. Shim 40x50x0.10
. Shim 40x50x0.15
. Shim 40x50x0.20
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
384176
448160
408388
501211
447038
500065
442731
105542
439653
447754
384182
439630
439631
439632
439633
439634
449125
449126
449127
Q.ty
1
1
1
1
1
3
1
1
1
1
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