Repair Manual and Spare Parts List

Transcription

1 Repair Manual and Spare Parts List ZF 6 A ZF 6 ZF 80 A ZF 80- A ZF 80 A NEW VERSION ZF 80- A NEW VERSION ZF 85 A NOVEMBER 005 cod h

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3 Repair Manualand Spare Parts List Table of contents TABLE OF CONTENTS INTRODUCTION MAJOR COMPONENTS TRANSMISSION SET-UP CLEANERS AND SEALANTS MEASURING TOOLS STANDARD TOOLS AND FIXTURE SPECIAL TOOLS DISASSEMBLY... 9 INTRODUCTION...9. FLUID FILTER Remove fluid filter Suction of transmission fluid Suction of transmission fluid on ZF 80 A, ZF 80- A and ZF 85 A DIPSTICK BREATHER VALVE OUTPUT FLANGE CONTROL BLOCK NeutralSafety Switch NeutralSafety Switch Check HOUSING Transmission housing halves Shafts and gears Radialshaft seals Fluid inlet pipe TAPERED ROLLER BEARINGS Outer races of tapered roller bearing Inner races of tapered roller bearings CLUTCH PACK Removalof the clutch discs ASSEMBLY... 7 INTRODUCTION INPUT SHAFT Mount discs into reversing clutch Install needle bearings and gear Assemble butting rings Mounting inner races of tapered roller bearings Assemble piston rings INTERMEDIATE SHAFT Mounting inner races of tapered roller bearings OUTPUT SHAFT Mounting inner race of tapered roller bearing PREASSEMBLY OF HOUSING Assembly of outer races (tapered roller bearings) Installation of fluid suction pipe and baffle Assembling input shaft seal Mounting the breather filter MEASURING THE BEARING CLEARANCE/ ADJUSTING THE PRETENSION OF BEARINGS General Mounting outer races of tapered roller bearings into housing Inserting gear set into housing Measuring bearing clearance on input shaft Measuring bearing clearance at intermediate shaft Measuring the bearing clearance on the output shaft Adjusting the pretension/clearance of bearings Finalassembly of the housing CONTROL BLOCK Mounting the controlblock FLUID FILTER Mounting the fluid filter OUTPUT FLANGE MAKING THE TRANSMISSION READY FOR OPERATION Filling up with transmission Fluid Check fluid level ADJUSTMENT DATA SHIFTING PRESSURE LUBE OIL DELIVERY RATE HYDRAULIC DIAGRAM TIGHTENING TORQUES FUNCTION TEST TROUBLESHOOTING AUTOMATIC TRANSMISSION FLUID SPARE PARTS LIST ZF6A - ZF6 - ZF80A - ZF80-A...9 Preface Name plate FIG. ZF 6 A FIG. ZF FIG. ZF 80 A - ZF 80- A

4 Repair Manualand Spare Parts List Table of contents FIG. ZF 6 A FIG. ZF FIG. ZF 80 A - ZF 80- A FIG. Mechanical selector valve ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 4 Old electric selector valve with proportional valves ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 5 ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 6 Old electric selector valve ON/OFF V, 6 bar ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 7 New electric selector valve ON/OFF V - 6 bar New electric selector valve ON/OFF 4V - 6 bar ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 8 New electric selector valve ON/OFF V - 6 bar with trolling valve New electric selector valve ON/OFF 4V - 6 bar with trolling valve ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A ZF 6 A - ZF 6 KIT COMPONENTS ZF 80 A - ZF 80- A KIT COMPONENTS SPARE PARTS LIST ZF 85 A Preface Name plate FIG. ZF 85 A FIG. ZF 85 A FIG. Mechanical selector valve ZF85A... 9 FIG. 4 Electric selector valve ON/OFF V - 6 bar Electric selector valve ON/OFF 4V - 6 bar ZF85A FIG. 5 Electric selector valve ON/OFF V - 6 bar with trolling valve Electric selector valve ON/OFF 4V - 6 bar with trolling valve ZF85A KIT COMPONENTS ZF 85 A SPARE PARTS LIST ZF 80A - ZF 80- A NEW VERSION Preface Name plate FIG. ZF 80 A - ZF 80- A FIG. ZF 80 A - ZF 80- A FIG. Mechanical selector valve ZF 80 A - ZF 80- A FIG. 4 Old electric selector valve ON/OFF V, 6 bar ZF 80 A - ZF 80- A FIG. 5 New electric selector valve ON/OFF V - 6 bar New electric selector valve ON/OFF 4V - 6 bar ZF 80 A - ZF 80- A FIG. 6 New electric selector valve ON/OFF V - 6 bar with trolling valve New electric selector valve ON/OFF 4V - 6 bar with trolling valve ZF 80 A - ZF 80- A KIT COMPONENTS ZF 80 A - ZF 80- A... 86

5 Repair Manualand Spare Parts List Introduction INTRODUCTION This manualgives specific instructions for the proper repair on ZF 6 - ZF 6 A - ZF 80 A - ZF 80- A - ZF 85 A transmissions. Please follow the procedures carefully to insure quality service. ZF HURTH MARINE recommends to read the manualcompletely 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 manualis based on the technicalinformation 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.

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7 Repair Manualand Spare Parts List Section. MAJOR COMPONENTS. TRANSMISSION SET-UP The main components of the ZF Marine Transmissions are: ITEM DESCRIPTION ITEM DESCRIPTION Two-piece aluminum die cast Gears. Oilfilter. Input shaft with reversing clutch pack assembly. Oildipstick. Intermediate shaft. Breather valve. Output shaft.4 Oildrain plug (ZF 80A, ZF 80-A, ZF 85A) Controlblock

8 Repair Manual and Spare Parts List Section. CLEANERS AND SEALANTS For cleaning: Cold cleaner such as benzene, thrichloroethane or Loctite fast cleaner No.706. 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 4 medium-hard for securing oil plug on ZF 80 A - ZF 80- A - ZF 85 A.. MEASURING TOOLS MICROMETER. Loctite 45 for securing output flange on spline.. Loctite 58 for housing surfaces.. Loctite 574 for outer diameter sealing rings.. Grease: Staburags NBU 0, Klueber Co.for radial shaft seals.. ATF FLUID:.8 litres (.0 US.gallons) for ZF litres (.05 US.gallons) for ZF 6 A 5.5 litres (.5 US.gallons) for ZF 80 A - ZF 80- A 5.5 litres (.5 US.gallons) for ZF 85 A.4. STANDARD TOOLS AND FIXTURE WRENCH for hexagon bolts ( mm) (7/8") Measuring gauge from 0-5 mm (0-.0 in.) Accurancy of reading /00 mm ( in.) ALLEN WRENCH (6 mm) DIAL INDICATOR GAUGE WITH ARM-TYPE SUPPORT HEXAGON SOCKET WRENCH ( mm) TORQUE WRENCH adjustable up to 80 Nm (5 ft.lb.) DIAL GAUGE INCREMENTS DIAL FACE CAN BE TURNED TO ZERO POSITION PLASTIC HAMMER (000 g) and sturdy screwdriver ACCURACY OF READING: SMALL HAND mm (.097 in) LARGE HAND /00 mm (.0004 in) EXTRACTOR minimum diameter 0 m MEASURING DEPTH APPROX. mm (.4 in) FEELER GAUGE PLIER 6

9 Repair Manualand Spare Parts List Section. 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 (4544) CLAMPING RING for measuring the bearing clearance input shaft P/N (6858) LEVER CLAMPING SCREW INPUT SHAFT DIAL INDICATOR ADAPTER for basic unit (4544). For bearing input shaft - spline side. - P/N (469686) ZF 6 A - ZF 6 - P/N (500465) ZF 80 A - ZF 80- A - ZF 85 A MANDREL For disassembly and assembly Shaft seal- input side : P/N (45445) Shaft seal- output side: - P/N (45446) ZF 6 A - ZF 6 - P/N (500449) ZF 80 A - ZF 80- A - ZF 85 A EXTRACTOR SPLIT RING Input shaft. Taper roller bearing inner race - control D block side. P/N (45670) For assembling input shaft seal on the input spline side Bushing P/N to insert input shaft seal Only for models: ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A EXTRACTOR Tapered roller bearing outer races basic unit P/N (4544) MandrelP/N to assemble input shaft seal Only for models: ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A LEGS KIT (composed of three legs) P/N (477776) 50 BASIC UNIT Part number ZF 6 ZF 6 A A B ADAPTER FOR BASIC UNIT 4544 ZF 80A ZF 80- A ZF 85 A (47785) l l (477854) l l l (477856) l (477857) l (477895) l l MandrelP/N to assemble input shaft seal Only for model: ZF 85 A 7

10 Repair Manualand Spare Parts List Section SHIM To determinate the correct preload of the tapered roller bearings. - P/N ZF 6 A - P/N ZF 6 - P/N ZF80 A - ZF 80- A - ZF 85 A PUNCH for assembly Seal - suction pipe - P/N ZF 80 A - ZF 80- A - ZF 85 A - P/N ZF 6 A - ZF 6 CENTRE SQUARE PUNCH To position the oilsuction pipe into housing P/N SPECIAL HEX HEAD BOLT WITH BEARING for measuring the bearing clearance intermediate shaft P/N (45805) 8

11 Repair Manualand Spare Parts List Section. 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. FLUID FILTER.. Remove fluid filter Turn the screw that fixes the oilfilter cover in a counterclockwise direction and remove the filter from its housing (item, fig. -). Use a 6 mm Allen wrench. Pull filter element off (item, fig.-). Check O-rings (item and 4, fig. -) for wear, replace if necessary. 4 FIG. -.. Suction of transmission fluid Push hose of suction pump (item, Fig. -) through the suction pipe (item, Fig. -) down to the bottom of the housing and suck the fluid off... Suction of transmission fluid on ZF 80A, ZF 80- A and ZF 85 A Remove the plug (item, Fig. -) 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. FIG. - 9

12 Repair Manualand Spare Parts List Section. DIPSTICK Unscrew dipstick (item, Fig. -) (counterclockwise) and pull out of housing. Replace O-Ring if present (check parts list section ). FIG. -. BREATHER VALVE Unscrew breather valve (item, Fig. -). Wash valve in a detergent, let dry and dip in oil, then let oil drip off. FIG. -.4 OUTPUT FLANGE Lock output flange in swivel frame. Unscrew hex head bolt (item, Fig. 4-). Remove disc (item, Fig. 4-) and O-ring (item, Fig. 4- ). Screw hex bolt (item, Fig. 4-) in again. Place extractor on the transmission and pull output flange (item, Fig. 4-) off. 4 FIG. 4 - FIG. 4-0

13 Repair Manualand Spare Parts List Section.5 CONTROL BLOCK Unscrew allen head bolts (item, Fig. 5-) Pull control block (item, Fig. 5-) together with seal (item, Fig. 5-) off the input shaft. Remove key (item 4, Fig. 5-) from input shaft (item 5, Fig. 5-). 4 FIG Neutral Safety Switch Unscrew neutralsafety switch (item, Fig. 5-). Note: Use 7/8 inch wrench for hex bolts. To reassemble switch: tightening torque: 5 Nm (8.5 ft.lb.) FIG 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 a Fig. 5-) extended you should get a reading, indicating a good switch. Compressing the pin (item b Fig. 5-) you should have «O» reading, B: volt light Connect the neutralsafety switch with a light in series to a volt battery. The switch is good when the light goes out when the center pin (item b Fig. 5-) is compressed. Battery V DC Battery V DC Lamp 8.4 A Lamp 8.4 A Neutral position a AorB position b FIG. 5 -

14 Repair Manualand Spare Parts List Section.6 HOUSING.6. Transmission housing halves Using an adequate drift punch, top the locating pins (item, Fig. 6-a and 6-b) out of the housing. Loosen and remove all hex head bolts and lock washers (item and, Fig. 6-b). 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. FIG. 6 - a FIG. 6 - b.6. Shafts and gears Take the gear set out of the housing. Intermediate shaft (item, Fig. 6-).. Input shaft (item, Fig. 6-).. Output shaft (item, Fig. 6-). Check all gears, bearings and three piston rings on the input shaft (item 4, Fig. 6-) 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 FIG Radial shaft seals Input shaft seal Using a sealmandrelinside the housing top the input shaft sealout. Discard sealand replace with a new one. (Fig. 6-a). FIG. 6 - a

15 Repair Manualand Spare Parts List Section Output shaft seal Using a mandrelpunch top the output flange sealout from the other side of the housing. Discard sealand replace with a new one. (Fig. 6-b). FIG. 6 - b.6.4 Fluid inlet pipe Replacing the seal: ZF 6 A - ZF 6 (Fig. 6-4a). Remove baffle plate (item ).. Remove suction pipe (item ).. Drive out seal(item ). OLD VERSION NEW VERSION FIG. 6-4a ZF 80A - ZF 80- A - ZF 85 A (Fig. 6-4b). Remove suction pipe (item ).. Drive out seal(item ). FIG. 6-4b

16 Repair Manual and Spare Parts List Section.7 TAPERED ROLLER BEARINGS Check for failed bearings or excessive bearing wear..7. Outer races of tapered roller bearing Remove the outer races out of the housing halves by means of the special tool (Fig. 7-)or by heating the housing halves in an oven to approx. 0 ëc (48 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 locationof shims under each outer race for correct position during reassembling. Shims are located under outer races of the cover only. FIG Inner races of tapered roller bearings NOTE. Input shaft - spline side. The extractor (Fig. 7-a) is required for pulling the inner races off. For extracting the inner races proceed as follows:. Screw in adapter onto the puller (item ).. Place adapter onto the roller cage.. Tighten collar to rollers by means of cap nut (item ).. Screw spindle (item )against shaft and pull bearing evenly and carefully off. WARNING Improper use of the extractor whenremoving 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-b). INPUT SPLINE SIDE CONTROL BLOCK SIDE FIG. 7 - a FIG. 7 - b Input shaft - Control block side ZF 85 A. Remove the retaining ring (item, Fig. 7-c)using a plier.. Scrap the retaining ring.. Remove the washer (item, Fig. 7-c).. Remove the shims (item, Fig. 7-c). FIG. 7 - c 4

17 Repair Manualand Spare Parts List Section.8 CLUTCH PACK.8. Removal of the clutch discs Control block side (Fig. 8-a) ZF 6 A - ZF Remove thrust washer () off using two screwdrivers.. Take off gear () and, needle bearings ().. Removalof 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. 6 FIG. 8 - a Control block side (Fig. 8-b) ZF 80A - ZF 80- A. Remove thrust washer () off using screwdrivers.. Take off gear (), needle bearings (), and spacer (7).. Removalof 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 FIG. 8 - b Control block side (Fig. 8-c) ZF 85 A. Remove thrust washer () off using two screwdrivers.. Take off gear () and needle bearing ().. Removalof 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 FIG. 8 - c 5

18 Repair Manualand Spare Parts List Section Input spline side (fig. 8-a) ZF 6 A (no ratio.7) - ZF 6. Remove thrust washer () off using two screwdrivers.. Take off gear () and needle bearings ().. 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 FIG. 8 - a Input spline side (fig. 8-b) ZF 80A - ZF 80- A ZF 6 A (only ratio.7) ZF 85 A. Remove thrust washer () off using two screwdrivers.. Take off gear (), needle bearings () and spacer (4) Remove pressure plate (6). Press snap ring (5) against periphery of pressure plate by means of screwdrivers. Extract them together. The discs (7) can now be removed from the clutch housing. 7 FIG. 8 - b 6

19 Repair Manualand 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 Cleaners and solvents can be toxic and potentially harmful without proper ventilation. Use caution when using such cleaners. Always wear protective gloves and glasses! The next assembly procedure requires the following:. An electric oven or heating lamp for heating the housing halves will be required when mounting the bearings.. A hydraulic or mechanical press 4. INPUT SHAFT 4.. Mount discs into reversing clutch Equip both sides coupling with new outer disc (item, Fig. -a) and new inner disc (item, Fig. -a). NOTE. For exact quantity of inner (item, Fig. -a) and outer discs (item, Fig. -a), 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. -b. 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. -b. Install snap ring into groove of clutch housing securing the pressure plate. Place end disc (item, Fig. -c) and snap ring (item, Fig. -c) engaging it into clutch housing groove. Check correct position of end disc (item, Fig. -c). Repeat same procedure on opposite side of clutch (Fig. -d). FIG. - a FIG. - b FIG. - c FIG. - d 7

20 Repair Manual and Spare Parts List Section Install needle bearings and gear Input spline side. Install needle bearing (item, fig. -) onto shaft. ZF 6 A (Ratio=.7 only) ZF 80 A - ZF 80- A - ZF 85 A ZF 6 A (no Ratio=.7) ZF 6. Slide spacer (item, fig. -) where required.. Align splines on clutch discs previously installed and install gear (item, fig. -). Make sure clutch gear is fully installed, engaging all clutch discs. Control block side. Repeat same procedure of input sline. Spacer is only in ZF 80 A and ZF 80- A. 4.. Assemble butting rings NOTE. Make sure thrust washer is fully pressed on and gear is free to rotate.. Thrust washer must not be bent. Position shaft assembly on suitable holding fixture. Using a tube with a bore dia. of 5 mm (.8 inch) in and a plastic hammer gently drive thrust washer in position. (item, Fig. -). Repeat same procedure on opposite side. FIG Mounting inner races of tapered roller bearings Heat inner race of tapered roller bearing (item, Fig. - 4) to approx. 0 ë(48 ëf) and push onto input shaft. After cooling down, press bearing carefully against button ring (item, Fig. -4) by means of a sleeve and a manual press or a copper brass punch. 0 C 48 F D FIG. - CAUTION Handle heated tapered roller bearing inner race only with special gloves! NOTE For pressing, apply sleeve to inner race but not to rollers. FIG Assemble shims, support shims and retaining ring (ZF 85 A). Place the shims (item, Fig. -5).. Install the washer (item, Fig. -5).. Put the retaining ring (item, Fig. -5) in the groove of the input shaft using a plier. WARNING!. Correct the shim thickness: check that there is no slack between washer and the retaining ring.. Maximum permissible clearance should be 0.05 mm. Use a feeler gauge to check it. 8 FIG. - 5

21 Repair Manual and Spare Parts List Section Assemble piston rings Mount piston ring seals (item, Fig. -6) onto input shaft. + IMPORTANT Make sure the interlocking position of the piston rings are staggered on the shaft. FIG INTERMEDIATE SHAFT 0 C 48 F 4.. Mounting inner races of tapered roller bearings Heat inner races of tapered roller bearings (item and, Fig. -) to approx. 0 ëc (48 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. 0 C 48 F FIG OUTPUT SHAFT 0 C 48 F 4.. Mounting inner race of tapered roller bearing Heat inner races of taper roller bearings (item and, Fig. -) to approx. 0 ëc (48ëF) 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. 0 C 48 F FIG. - 9

22 Repair Manualand Spare Parts List Section PREASSEMBLY OF HOUSING 4.4. Assembly of outer races (tapered roller bearings) Heat output half of the housing (item, Fig. 4-) in an oven to approx. 0 ëc (48 ëf). Insert outer races (item, Fig.4-) 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 Installation of fluid suction pipe and baffle Installation of fluid suction pipe. Position oilsuction pipe (item, Fig. 4-a) in the housing.. Put one drop of Loctite 4 into screw threaded hole.. Lightly tighten the screw (item, Fig. 4-a).. Insert centre square punch and tighten definitely the screw.. Adjust oilsuction pipe to measure "A" (A=6 mm) (Fig. 4-b).. Put some ATF fluid on the seal seat and on the oil suction pipe using a brush.. Press into housing over the oilsuction pipe the seal (item, fig. 4-c) using the appropriate punch (Fig. 4-c). FIG. 4 - a OLD VERSION 4 OLD VERSION 4 ZF80 A - ZF80- A ZF6A - ZF6 ZF85 A NEW VERSION FIG. 4 - NEW VERSION A A FIG. 4 - b FIG. 4 - c Installation of baffle (Fig. 4-d) (ZF 6 A - ZF 6) Put one drop of Loctite 4 on the screw thread (item ) and screw baffle plate (item ) into the housing. After tightening the screws bend plate lugs when present over the hexagon of screws (see fig. 4-d). FIG. 4 - d 0

23 Repair Manualand Spare Parts List Section Assembling input shaft seal Apply thin coat of Loctite 574 on periphery of new radial shaft sealrings (item, Fig. 4-a and Fig. 4-b) and grease lips with KLUEBER STABURAGS NBU 0. Put it onto the mounting mandrel. Drive shaft sealuniformly into the housing by tapping slightly onto the mounting mandrel. NOTE The sealing lip (A) on the shaft seal should point into the inside of the housing. The radial shaft seal must be adjusted so that the sealing lip runs on the grounded surface of the shaft. mm A mm FIG. 4 - a A ALTERNATIVELY (Fig. 4-c): For models ZF 6 A - ZF 6 - ZF 80A - ZF 80- A. Smear loctite 574 on the outside diameter of the input shaft seal using a roller.. Lubricate the inside lip with Kluber Staburags NBU0 grease.. Insert the input shaft seal(item ) into input shaft using the appropriate bushing p/n (item ).. Use mandrelp/n (item ) to position the input shaft sealin the correct way. For model ZF 85 A. Smear loctite 574 on the outside diameter of the input shaft seal using a roller.. Lubricate the inside lip with Kluber Staburags NBU0 grease.. Insert the input shaft seal(item ) into input shaft using the appropriate mandrelp/n (item ).. Position the input shaft sealin the correct way Mounting the breather filter Due to the taper thread, the breather (item, Fig. 4-4) need not to be coated with Loctite 574. Tighten carefully during assembly (hand-tight). Cheek leakage during a later test run. Retighten slightly if it leaks. ZF 6 - ZF 6 A ZF 80A - ZF 80- A ZF 85 A FIG. 4 - b FIG. 4 - c FIG. 4-4

24 Repair Manual and Spare Parts List Section MEASURING THE BEARING CLEARANCE/ADJUSTING THE PRETENSION OF BEARINGS 4.5. 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-) at least shims of 0. mm ( in.) thickness from the shims packages which were removed during disassembly. Adjustment values Pretension (mm) FIG. 5 - Shaft Input Intermediate Output ZF 80 A - ZF 80- A ZF 85A ZF 6 A - ZF Pretension (inches) Shaft Input Intermediate Output ZF 80 A - ZF 80- A ZF 85A ZF 6 A - ZF Mounting outer races of tapered roller bearings into housing Heat input half housing (item, Fig. 5-) in an oven to approx. 0 ëc (48 ëf) and insert shims (item ) and outer races (item ) of bearings into it. WARNING Handle heated housing half only with protective gloves! When half housing has cooled down to ambient temperature, press outer races carefully down using a copper/brass punch. FIG Inserting gear set into housing Finish housing mating face halves with an oilstone. CAUTION Make sure to keep any dirt out of housing.. Holding the half housing on a swiveling stand, insert gears into it.. Mount input housing half (item, Fig. 5-) with all bolts, lock washers (item and, Fig. 5-) and parallel pins (item 4, Fig. 5-).. Tightening torque of bolts: 40 Nm (0 ft.lb.). 4 FIG. 5 -

25 Repair Manualand Spare Parts List Section Measuring bearing clearance on input shaft a) Turn input shaft severaltimes to permit bearings to seat. b) Fit clamping ring (tool p/n (6858)) to the spline of the input shaft (item, Fig. 5-4). c) Adjust to «O», dialindicator 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) severaltimes. f) The bearing clearance measured plus the pretension required in section 5. determine the required thickness of shims. FIG Measuring bearing clearance at intermediate shaft a) Unscrew plug (item, Fig. 5-5a) from the housing. b) Screw in specialtool(p/n (45805)) (item, Fig. 5-5a) into intermediate shaft hole. c) Mount dialgauge support securely onto housing. d) Turn intermediate shaft severaltimes to permit bearings to seat. e) Adjust the dial indicator needle on top of the bolt head and «O» to dialindicator (Fig. 5-5b). f) Screw hexagon nut carefully against housing (intermediate shaft moves up) untilbearing clearance is overcome (Fig. 5-5b). NOTE This step should be done very carefully to obtain the actual bearing clearance. g) Carry out steps d) and f) severaltimes. h) The clearance measured plus the pretension required in section 5. determine the required thickness of shims. FIG. 5-5a Measuring the bearing clearance on the output shaft a) Insert output flange onto the output shaft and screw in nut ring. b) Install bolt and spacer on input shaft. c) Turn output shaft repeatedly to permit bearings to seat. d) Mount dialgauge 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 severaltimes. h) The bearing clearance measured plus the pretension required in section 5. will determine the required thickness of shims. FIG. 5-5b FIG. 5-6

26 Repair Manualand Spare Parts List Section Adjusting the pretension/clearance of bearings When the thickness of shims has been determined, the transmission must be disassembled again. a) Using a adequate drift punch, drive the parallel pins (item, Fig. 5-7a) with slight blows, out of the housing. b) Loosen hex bolts (item and, 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. 0ëC (48ëF) and remove the outer races of bearings together with shims. WARNING Handle heated housing half and outer race only with protective gloves! NOTE Make sure to keep the shims with each outer race and not mix them together FIG. 5-7a Final assembly of the housing a) Heat input side of the housing in an oven to approx. 0ëC (48 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 0). f) Apply a thin coat of Loctite 58 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 and, Fig. 5-7a) and torque them to 40 Nm (0 ft.lb.). NOTE There must be not measurable bearing clearance. WARNING 50 A B ADAPTER FOR BASIC UNIT 4544 BASIC UNIT FIG. 5-7b The necessary time for a complete polymerization is 5 hours: we recommend therefore to clean carefully the mating surfaces with Loctite 706 cleaner before applying the Loctite 58 and wait the requested time before the spin test. 4

27 Repair Manualand Spare Parts List Section CONTROL BLOCK 4.6. Mounting the control block NOTE Piston rings (item, Fig. 6-) have to be replaced, if thickness is less than.9 mm (0.094in). a) Insert key (item, Fig. 6-) into groove of shaft. b) Place new seal (item, Fig. 6-) 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-) on socket head bolts (item 5, Fig. 6-) and provide screw threads each with a drop of Loctite 4. f) Tight control block bolts. Tightening torque: 8 Nm (4 ft.lb.). 5 4 FIG FLUID FILTER 4.7. Mounting the fluid filter. Wet O-rings (item and, Fig. 7-) with some ATF fluid and mount them.. Install filter element (item, Fig. 7-) into the transmission.. Lock cover (item 4 Fig. 7-) to the transmission using an allen wrench. Tightening torque: min. 5 Nm - max 8 Nm (min. 4 ft.lb. - max 6 ft.lb.) 4 FIG OUTPUT FLANGE Provide spline (X) of output shaft with a thin coat of Loctite 45 and sealing lip (Z) of shaft seal with a thin coat of ATF fluid. (Fig. 8-) Fit output flange (item, Fig. 8-). Provide O-ring (item, Fig. 8-) with ATF fluid and insert into output flange. Tight output flange down on output shaft with bolt (item, Fig 8-) and washer (4). Tightening torque: ZF 6 A - ZF 6 : 00 Nm (74 ft.lb.) ZF 80 A - ZF 80- A : 00 Nm (74 ft.lb.) ZF 85 A : 00 Nm (74 ft.lb.) Z X 4 FIG. 8-5

28 Repair Manualand Spare Parts List Section MAKING THE TRANSMISSION READY FOR OPERATION 4.9. Filling up with transmission Fluid Filling with ATF fluid into the fluid filter opening. (Fig. 9- ) Quantity: ZF 6 : 4.0 US-qts (.8 liters) ZF 6 A : 4. US-qts (4.0 liters) ZF 80 A - ZF 80- 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 FIG 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, figure 9-) 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- item A) B) It is threaded (Fig. 9- item B). + IMPORTANT Oil check with threaded dipstick (B) must be done in a different way compared with the one not threaded (A): A) Oildipstick and housing hole not threaded: dipstick completely inserted into hole. B) Oildipstick and housing hole threaded: dipstick not inserted into the housing hole (not screw in). A MAX MIN Housing B MAX MIN O-RING Housing FIG. 9-6

29 Repair Manualand Spare Parts List Section 5 5. ADJUSTMENT DATA 5. SHIFTING PRESSURE SHIFTING PRESSURE (bar) MAX. MIN SHIFTING PRESSURE (psi) DRIVING SPEED (rpm) = ZF 6 A - ZF 6 - ZF 80 A = ZF 80- A - ZF 85 A 5. LUBE OIL DELIVERY RATE DELIVERY RATE ( /min) MIN. ALL MODELS DRIVING SPEED (rpm) DELIVERY RATE (gal. /min) 7

30 Repair Manualand Spare Parts List Section 6 6. HYDRAULIC DIAGRAM oil cooler = Shifting pressure.5 + bar = Fluid +0.5 bar = Leakage fluid Measuring point for shift pressure M0x Lube pressure relief valve Basic lubricating throttle valve Fluid delivery pump Fluid filter Filte grade 60µ Fluid sump A B A 0 B Shifting valve for A-0-B position Illustration shows shifting pos. «B» Direction of water flow Connection for temperature probe indicating at abt. 0 C /8-8 NPSF Shifting pressure relief valve Neutral position switch indication by electric signal 8

31 Repair Manualand Spare Parts List Section 7 7. TIGHTENING TORQUES PART SIZE TORQUE IN lb.ft. TORQUE IN Nm LOCTITE Mounting brackets bolts ZF 6 A - ZF 6 M min 0 - max 04 min 75 - max 77 - Mounting brackets bolts ZF 80 A - ZF 80- A - ZF 85 A M min 0 - max 04 min 75 - max 77 - Output flange bolt ZF 6 A - ZF 6 M Housing bolts M Control block bolts M8 8 4 Shifting lever bolt M8 7 - Output flange bolt ZF 80 A - ZF 80- A - ZF 85 A M Fluid filter bolt M8 min 4 - max 6 min 5 - max 8 - Oilbreather - Hand tight Hand tight 574 Fluid dipstick - Hand tight Hand tight - Oildrain plug Stud bolt M Controlblock stop screw Controlblock pressure screw M0 9 - Screw ZF 6 A M Screw ZF 80 A - ZF 80- A - ZF 85 A M Neutralsafety switch Control block guide bolt Control block temperature plug

32 Repair Manualand 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 M0x.. Temperature gauge 0-0ëC (0-50ëF) connecting thread /8«-8NPSF.. Flow meter 0-5 liters/min (0-0 gals/min). Tests to be carried out:. Fluid leaks. Noise emission. Output direction of rotation, LH/RH 4. Lube oiltemperature 5. Shifting pressure 6. Lube oilflow rate The function test should be carried out follows: Motor speed rpm Shift lever position Temperature Durat. minutes Test neutral40ëc/04 ëf 5, (idling speed) A<->B position repeatedly 40ëC/04 ëf -,, B position 80ëC / 76 ëf -,, (idling speed) A<->B position repeatedly 80ëC/76 ëf -,, idling - max. speed A position 80ëC/76 ëf -,, 5 ],6 ] (idling speed) A->B position 80ëC/76 ëf - -, idling - max. speed B position 80ëC/76 ëf -,, 5 ],6 ] ] At different speeds. 80ëC/76 ëf - 0

33 Repair Manualand 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 Remedy. Transmission cannot be shifted.. Delayed shift time.. Clutch is slipping, i.e. propeller speed too low as compared to engine speed.. Shifting lever is loose.. Remote controldoes not permit lever travel required.. Remote controlfaulty..4 No shifting pressure available.. Shift linkage misadjust not allowing full engagement.. Inadmissible fluid used.. Fluid contains water.. Shifting pressure too low..4 Wear on clutch discs..5 Piston rings are damaged.. Tighten clamping bolt on shifting lever.. Lift remote controloff, if gears can be shifted by hand, adjust remote control. Repair remote control..4 Refer to 7.. Lift remote controloff, if gear can be. shifted by hand, adjust remote control. If the transmission cannot be shifted correctly by hand, replace the control block.. Drain fluid, refill with prescribed fluid, flush transmission while engine runs in neutral position drain fluid, refill transmission.. Refer to 9.. Refer to 6..4 Disassemble transmission, replace clutch discs..5 Disassemble transmission, replace piston rings. 4. Transmission locked in gear. 5. Output shaft turns in neutralposition. 6. Shifting pressure too low. 4. Medium piston ring in input shaft in control block is faulty. 4. Warped discs due to overheating of slipping clutch. 4. Needle bearings on input shaft are worn out. 5. Rotary slide valve in control block is worn. 5. Faulty needle bearing on input shaft. 5. Warped discs due to overheating of slipping clutch. 6. Fluid filter clogged. 6. Fluid level in transmission too low. 6. Fluid pump is worn out. 6.4 Spring in shifting pressure relief valve is broken. 6.5 Piston rings on input shaft are faulty. 6.6 Piston rings in clutch are faulty. 4. Remove control block, replace piston ring, if control block is worn, replace likewise. 4. Refer to. 4. Disassemble transmission, replace needle bearing and check for damage input shaft and gears. 5. Replace control block. 5. Disassemble transmission and input shaft, replace bearing concerned and other damaged parts. 5. Refer to. 6. Replace fine filter. 6. Top-up with fluid; in case of fluid loss check transmission, cooler and pipelines for leakage also refer to 0 through. 6. Replace control block containing fluid pump. 6.4 Replace control block. 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. 6.6 Disassemble transmission, replace piston rings..

34 Repair Manualand Spare Parts List Section 9 Symptom Possible cause Remedy 7. No shifting pressure available. 8. Excessive fluid temperature. 9. Water in the fluid, fluid looks milky. 7. Direction of engine rotation does not agree with arrow on transmission front cover. 7. No fluid in the transmission. 7. Fine filter is dirty. 7.4 Fluid level in transmission is too low. 7.5 Fluid pump worn out. 7.6 Pump key in input shaft for fluid pump drive is broken. 7.7 Spring of shifting pressure relief valve is broken. 8. Fluid cooler is too small. 8. Excessive fluid in transmission. 8. Fluid cooler is dirty on water side. 8.4 Worn fluid pump in control block. 8.5 Faulty piston rings in control block. 8.6 Clutch is slipping. 8.7 Clutch does not open completely due to worn disc support. 8.8 Clutch does not open completely due to broken cup springs. 8.9 With fluid cooler in bypass and unfavorable arrangement of pipelines too little coolant water flows through bypass to cooler. 9. Fluid cooler faulty. 9. High water level in engine compartment, water entering at output shaft seal. 7. Replace with suitable rotation engine. 7. Refill with fluid. 7. 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 0 through. 7.5 Replace control block. 7.6 Remove control block. Replace pump key, and any other faulty parts. 7.7 Replace control block. 8. Use a larger fluid cooler. 8. Remove excessive fluid with commercialsuction pump. 8. Detach coolant water lines and clean fluid cooler on water side. 8.4 Replace control block containing fluid pump. 8.5 Remove control block, replace piston rings. In case of wear in the control block due to faulty piston rings replace control block as well. 8.6 Refer to. 8.7 Dismount transmission and clutch, replace all faulty parts. 8.8 Dismount transmission and clutch, replace all faulty parts. 8.9 Correct bypass pipeline. 9. Repair leakage at cooler or replace cooler. Change transmission fluid. 9. Remedy cause for water level in engine compartment. Change transmission fluid. 0. Fluid leakage at input or output shaft 0. Breather clogged with paint or dirt 0. Shaft sealfaulty 0. Excessive fluid in transmission 0. Remove paint or dirt from breather Replace seal. If seal location on shaft is worn, regrind. 0. Remove excessive fluid with commercialsuction pump.. Fluid leakage at breather.. Excessive fluid in transmission.. Pump excessive fluid out with commercialhand pump.. Fluid leakage at joints or screw connections.. Bolts are not tight at the prescribed torque.. Loctite not properly spread onto sealing surface.. Gasket has been used several times.. Tighten bolts to prescribed torque.. Resealafter removing old Loctite and cleaning. Finish mating faces with oilstone.. Replace gasket.

35 Repair Manualand Spare Parts List Section 9 Symptom Possible cause Remedy. Transmission noise becomes louder. 4. Chattering transmission noise mainly at low engine speed. 5. Low pressure. 6. Oilleakage.. Fluid level too low so that pump sucks in air.. Damage starting on flexible coupling due to wear or fatigue probably due to misalignment between engine and transmission.. Beginning damage of bearings in transmission, e.g. due to torsional vibration, running without fluid, overload, wrong alignment of transmission..4 Beginning damage of gearing, e.g. due to torsionalvibrations, running without fluid, overload..5 Fluid suction pipe in transmission has come loose. 4. The engine or propeller generates torsionalvibrations in the drive unit which produces a hammering noise in the transmission. 4. Misaligned cardan shafts on input or output. 5. Fine filter is dirty. 5. Fluid level in transmission is low. 5. Controlblock is broken. 5.4 Problem at control valve. 5.5 Piston rings on input shaft are faulty. 5.6 Piston rings inside the clutch are faulty. 5.7 Defective cover filter : air suction. 5.8 Oilsuction hose not properly adjusted. 5.9 Fitting key in input shaft for fluid pump drive is broken. 5.0 Possible wear of the piston ring grooves. 6. Porosity. 6. Seals. 6. Joints. 6.4 Bracket with flatness error. 6.5 Bolts are not tight. 6.6 Fittings loosen. 6.7 Dipstick is not tight. 6.8 Filter is not tight. 6.9 Excessive fluid in transmission. 6.0 Breather clogged with paint or dirt (fluid leakage at output shaft). 6. Aluminium washers used more times.. Top up with fluid to marking on dipstick.. Replace flexible coupling. Cheek alignment between engine and transmission.. Disassemble transmission, replace bearings concerned and other faulty parts. Find causes and remedy..4 Disassemble transmission, replace faulty parts..5 Disassemble transmission fix fluid suction pipe. 4. Mount a flexible coupling with a different stiffness factor between engine and transmission; a coupling with a higher stiffness factor might be sufficient. Otherwise analyze the torsionalvibrations to find out the required stiffness for the coupling. 4. Mount and align cardan shaft strictly according to instructions issued by cardan shaft manufacturer. 5. Replace fine filter. 5. Refill with fluid. 5. Replace control block. 5.4 Replace control block. 5.5 Remove control block and replace piston rings. 5.6 Disassemble transmission, replace piston rings. 5.7 Replace cover filter. 5.8 Replace the seal and adjust correctly the suction hose. 5.9 Remove control block replace fitting key, replace any other faulty parts. 5.0 Replace the input shaft. 6. Replace faulty parts. 6. Replace seals. 6. Check if bolts are tighten with the correct torque. Clean the surface and resealwith Loctite Replace bracket. 6.5 Resealand tighten bolts with prescribed torque. 6.6 Tighten or replace. 6.7 Tighten dipstick or replace o-ring dipstick. 6.8 Tighten filter or replace o-ring filter 6.9 Remove excessive fluid with commercialsuction pump. 6.0 Remove paint or dirty from breather. 6. Replace aluminium washers.

36 Repair Manualand Spare Parts List Section 9 Symptom Possible cause Remedy 7. High oiltemperature. 7. Excessive fluid in transmission. 7. Oilcooler is dirty. 7. No water in circuit. 7.4 Undersized cooler. 7.5 Clutch is slipping. 7.6 Excessive friction of the reverse clutch. 7.7 Possible bypass in the cooling circuit. 7. Remove excessive fluid with commercialsuction pump. 7. Replace the cooler and check the water circuit. 7. Check the cooling circuit. 7.4 Replace the cooler with a proper one. 7.5 Refer to Check the clutch play and the correct position of the piston. 7.7 Reduce the bypass. 8. Slipping clutch 8. Low pressure. 8. Fluid level in transmission is low. 8. Shift lever not properly adjusted. 8.4 Trolling lever not in the detent position. 8.5 Wear on clutch discs. 8.6 Piston rings in clutch are faulty. 8.7 Inadmissible fluid used. 8.8 Water in the fluid. 8.9 Piston rings on input shaft are faulty. 8. Refer to Refill with fluid. 8. Regulate at the end of the way. 8.4 Ajust the lever at the detent position. 8.5 Disassemble transmission, replace clutch discs. 8.6 Disassemble transmission, replace piston rings. 8.7 Drain fluid, refill with prescribed fluid. 8.8 Repair leakage at cooler or replace cooler. Change transmission fluid. 8.9 Remove control block and replace piston rings. 9. Noise. - hydraulic 9. Oilfilter is dirty. 9. Fluid level in transmission is low. 9. Oilsuction hose not properly adjusted. 9.4 Defective cover filter : air suction. - at idle speed 9.5 Coupling. - under load 9.6 Wrong shimming. 9.7 Defective gears. 9. Replace oil filter. 9. Refill with fluid. 9. Replace the seal and adjust correctly the suction hose. 9.4 Replace cover filter. 9.5 Replace. 9.6 Re-shim. 9.7 Replace defective gears. 0. Engagement not possible.. Slow engagement.. Hard shifting. 0. Fluid level in transmission is low. 0. Fine filter is dirty. 0. Incorrect shift lever position. 0.4 Coupling is damaged. 0.5 Controlblock. 0.6 Shifting lever is loose. 0.7 Low pressure.. Fluid level in transmission is low.. Shift lever.. Regulate.. Shift lever.. Controlblock is dirty. 0. Refill with fluid. 0. Replace fine filter. 0. Regulate at the end of the way. 0.4 Replace coupling. 0.5 Replace control block. 0.6 Tighten clamping bolt on shifting lever. 0.7 Refer to 5.. Refill with fluid.. Low pressure.. Refer to 5.. Regulate.. Disassemble the control valve and clean. 4

37 Repair Manualand Spare Parts List Section 9 Symptom Possible cause Remedy. Transmission is dragging in neutral.. Warped discs due to overheating.. Needle bearings on input shaft are faulty.. Intermediate gear moved from the shaft and touching the clutch drum..4 Discs of the reverse clutch radially broken due to torsionalvibration.. Replace discs, replace any other faulty parts.. Disassemble transmission, replace needle bearings.. Replace the intermediate gear..4 Replace the discs and change the damper with a proper one. 4. Water in the oil. 4. Fluid cooler faulty. 4. Water in bilge. 4. Repair leakage at cooler or replace cooler. 4. Remove water from the bilge and check the oilseal. 5

38 Repair Manualand Spare Parts List Section 0 0. AUTOMATIC TRANSMISSION FLUID MANUFACTURER PRODUCT MANUFACTURER PRODUCT ADDINOL MINERALOÈ L GMBH, KRUMPA/D AGIP PETROLI SPA, ROM/I AGIP SCHMIERTECHNIK, WUÈ RZBURG/D ARAL LUBRICANTS GMBH, BOCHUM/D AVIA MINERALOÈ L-AG, MUÈ NCHEN/D BLASER SWISSLUBE, HASLE-RUÈ EGSAU/CH BP OIL DEUTSCHLAND, HAMBURG/D BP OIL INTERNATIONAL, LONDON/GB BUCHER+CIE AG, LANGENTHAL/CH CALPAM GMBH, ASCHAFFENBURG/D CALTEX PETROLEUM CORP., LONDON/GB CASTROL LTD, SWINDON/GB CEPSA, MADRID/E CHEVRON PRODUCTS CO., RICHMOND/USA CITGO PETROLEUM CORP., TULSA/USA C.J.DIEDERICHS SOÈ HNE, WUPPERTAL/D DE OLIEBRON B.V., ZWIJNDRECHT/NL DEA MINERALOÈ L AG, HAMBURG/D DEUTSCHE SHELL AG, HAMBURG/D DUCKHAMS OIL, BROMLEY/GB ELF LUBRIFIANTS, PARIS/F ELFMATIC G ELLER-MONTAN-COMP., DUISBURG/D. ADDINOL ATF D IID. ADDINOL ATF D III. AGIP ATF II D. AGIP ATF D 09. AGIP ATF PLUS. AGIP DEXRON III. AUTOL GETRIEBEOÈ L ATF-D. AUTOL GETRIEBEOÈ L ATF III D. ARAL GETRIEBEOÈ L ATF. ARAL GETR.OÈ L ATF 55 F AVIA FLUID ATF 86. BLASOL 9. FRONTOL UNIVERSAL-ATF 00. AUTRAN DX II. AUTRAN MBX. AUTRAN DX III (F-070). AUTRAN DX III (F-08). MOTOREX ATF SUPER D-656. MOTOREX ATF DEXRON III MC. PAMATIC FLUID 89. CALPAMATIC FLUID III F. CALTEX ATF-HDA. CALTEX ATF-HDM. CALTEX TEXAMATIC 78. CALTEX TEXAMATIC CALTEX TEXAMATIC 05A. CASTROL TQ-D (765). CASTROL TQ DEXRON III F-050. CASTROL TRANSMAX S (F-09). CASTROL TRANSMAX T (F-059). CASTROL TQ-D (89). CASTROL ATF 9. CEPSA ATF-70. CHEVRON ATF F-008. CITGO ATF DEXRON III F-067. CIDISOL-HYDR.-FLUID DEXRON IID. ATF DMM. ATF 89. DEAMATIC. DEAFLUID 40. DEAFLUID 00. MAC ATF D-666. UNIMATIC. TRANSANTAR DF. ANTAR 9. ELFMATIC G 9. HUILE RENAULT DIESEL. STARMATIC. TRANSANTAR DF. ELLMO-AUTOMATIK-FLUID ENGEN PETROLEUM, CAPE TOWN/ZA ERTOIL SA, MADRID/E ESSO AG, HAMBURG/D FIAT LUBRIFICANTI, VILLASTELLONE/I FINA EUROPE SA, BRUÈ SSEL/B FUCHS LUBRICANTS (UK), DERBY/GB FUCHS MINERALOÈ LWERKE, MANNHEIM/D GINOUVES GEORGES SA, LA FARLEDE/F GULF OIL (GB) LTD, CHELTENHAM/GB HANDELSMIJ NOVIOL B.V., NIJMEGEN/NL HOMBERG GMBH+CO KG, WUPPERTAL/D. ENGEN ATF D. TRANSMISIONES AUTOMATICAS D. ESSO ATF D (6). ESSO ATF F-00. ESSO ATF D (065). TUTELA GI/A. FINAMATIC II-D. SILKTRAN MP-ATF. SILKTRAN PSV ATF. TITAN ATF YORK LT 785. UNIFLUID. ATF. KENDALL ATF DEXRON IID. HOMBERG-GETRIEBE-FLUID D IGOL FRANCE, PARIS/F. IGOL ATF 40 INA RAFINERIJA ZAGREB/CROATIA. INA-ATF SUPER ITALIANA PETROLI, GENOVA/I. TRANSMISSION FLUID DX JAPAN ENERGY CORP., TOKYO/JAPAN. JOMO ATF K KAÈ PPLER K., STUTTGART/D. SELECTOL FLUID GETR.OÈ L IID KLOÈ CKNER ENERGIEHANDEL GMBH, KOÈ LN/D KROON OIL BV, ALMELO/NL KUWAIT PETROLEUM, HOOGVLIET/NL LEPRINCE+SIVEKE GMBH, HERFORD/D LIQUI MOLY / MEGUIN, ULM/D LUBRICATION ENGIN., FORT WORTH/USA MAURAN SA, ODARS/F MIN.OÈ L-RAFFIN. DOLLBERGEN, UETZE/D MOBIL OIL, WEDEL/D MOBIL SEKIYU KABUS. KAISHA, TOKYO/J MOL HUNGARIAN OIL, KOMARON/H MORRIS LUBRICANTS, SHREWSBURY/GB NAFTEC, ALGIER/DZ. DEUTZ OEL ATF-D. ATF DEXRON IID. ALMIROL ATF. Q8 AUTO 5. Q8 AUTO 4 (IID-677). Q8 AUTO 4 (IID). Q8 AUTO 4 (IID-88). LEPRINXOL FLUID CN. ATF IIE. MEGOL ATF IID. AUTOMATIC TRANSMISSION FLUID. INTER OIL INTER MATIC ATF D. PENNASOL FLUID-GETR.OÈ L TYP PCN. MOBIL ATF 0 D004 / D685. MOBIL ATF F-007. MOBIL ATF 0 D4 / D87. MOBIL ATF 0Y (D-4). CARRIER ATF. LIQUIMATIC DII. TASSILIA 6

39 Repair Manualand Spare Parts List Section 0 MANUFACTURER PRODUCT MANUFACTURER PRODUCT NANHAI SUPERIOR LUB-OIL, CHINA NIS-RAFINERIJA NAFTE BEOGRAD/YU OEST G. MIN.OÈ LWERK, FREUDENSTADT/D OMEX PETROLEUM PTY, BELLEVUE/AUS OMV AG, SCHWECHAT/A OPTIMOL OÈ LWERKE, HAMBURG/D OSWALD KLUTH, BARGFELD-STEGEN/D PAKELO MOTOR OIL, SAN BONIFACIO/I PANOLIN AG, MADETSWIL/CH PARS OIL CO., TEHRAN/IR PAZ LUBRICANTS & CHEMICALS, HAIFA/IL PENNZOIL PRODUCT COMP., HOUSTON/USA PETRO-CANADA, MISSISSAUGA/CDN PETROL OFISI A.S., BAKANLIKLAR/TR PETROLEX, KWIDZYN/PL PRINZ-SCHULTE, FRECHEN/D REPSOL DISTRIBUCION SA, MADRID/E. NANHAI ATF (D). GALAX MATIC DAC. ATF T 40. OMEX ATF DEXRON II. OMV ATF D II (D47). OMV ATF III (F-0580). OPTIMOL ATF T 40. UNIVERSAL ATF-D. MULTIPURPOSE TRANSM. FLUID IID. PANOLIN ATF MULTI 996. PANOLIN ATF DEXRON III. PARS ENTEGHAL-E AUTOMATIC OIL. PAZBO EZF. PENNZOIL ATF F-00. DEXRON III/MERC.ATF (F-095). PETROL OFISI ATF II. VECO MATIC IID. AERO-LINE ATF-. AERO-LINE ATF-D. REPSOL MATIC ATF S.A.E.L, ALCOBENDAS/E. GULF ATF DII D- SASOL OIL, RANDBURG/ZA. SASOL ATF DXII SCHMIERSTOFFRAFFINERIE SALZBERGEN/D. WINTERSHALL ATF D SHELL ASEOL AG, BERN/CH. ASEOL ATF DB UNIVERSAL SHELL INTERNATIONAL, LONDON/GB SLOVNAFT JS CO, BRATISLAVA/SLO SONOL ISRAEL LTD, HAIFA/IL. SHELL DONAX TA (D-666). SHELL DONAX TG (F-058). MADIT AUTOMATIC. DEXRON D SOPROGRASA SA, MADRID/E. SOPRAL 64 STATOIL STAVANGER/N. TRANSWAY DX III (F-07). TRANSWAY DX II STL TECNOL, ESCALQUENS/F. TECNOL TECMATIC D SUN OIL COMPANY, AARTSELAAR/B SUOMEN PETROOLI OY, HAMINA/SF SVENSKA STATOIL AB, NYNAÈ SHAMN/S TAMOIL LUBES, GENEVA/CH TEXACO LUBRICANTS COMP., BEACON/USA TEXACO SERVICES LTD, BRUÈ SSEL/B TOTAL RAFFINAGE DISTR., PARIS/F TOTAL SOUTH AFRICA, JOHANNESBURG/ZA TURBOTANK BOÈ SCHE BOÈ DEKER, BREMEN/D UFANEFTECHIM REFINERY, UFA/RUS UNIL DEUTSCHLAND GMBH, BREMEN/D VALVOLINE INC., LEXINGTON/USA VALVOLINE INTERNAT., DORDRECHT/NL VEBA OEL AG, GELSENKIRCHEN/D VEEDOL INTERNATIONAL, SWINDON/GB YACCO SA, ST PIERRE-LES-ELBEUF/F ZELLER+GMELIN GMBH&CO, EISLINGEN/D. SUNAMATIC 49. SUNAMATIC 5. TEBOIL FLUID E (F-00). TEBOIL FLUID D. TRANSWAY DX III (F-07). TAMOIL ATF II D. ATF MERCON / DEXRON III. TEXAMATIC TEXAMATIC 46. TEXAMATIC TEXTRAN PSM. TEXAMATIC 40. TEXAMATIC 49. TEXAMATIC 96. TOTAL FLUIDE ATX. TOTAL FLUIDE IID. TOTAL FLUIDE AT 4. TOTAL FLUIDE ATD. TURBO UNIV. ATF MERCON 40. UFALUB ATF. UNIL MATIC CN T 40. VALVOLINE MULTI-PURPOSE ATF. VALVOLINE ATF TYPE D. MOVARA ATF-GETRIEBEOÈ L DIID. VEEDOL ATF-M (764). VEEDOL ATF DEXRON III F-05. VEEDOL UNITRANS S PLUS. YACCO ATF D DIVINOL FLUID 666 7

40 8

41 Repair Manual and Spare Parts List Section : Spare parts list ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A. SPARE PARTS LIST ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A Preface The spare parts list is onlyvalid 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.. quantityof parts required. The spare parts list is referring to the following versions: ZF 6 A versions (. R); (.56 R); 4 (.04 R); 5 (.5 R); 0 (.70 R); versions 00 (. R); 00 (.56 R); 00 (.04 R); 004 (.5 R); 0 (.5 R uprated); 005 (.70 R); versions 05 (. R); 06 (.56 R); 07 (.04 R); 08 (.5 R); 05 (.5 R); 00 (.5 R uprated); 0 (.70 R); 04 (.70 R); ZF 6 versions 0 (.5 R); 0 (.9 R); 0 (.48 R); 04 (.78 R); versions 009 (.5 R); 00 (.5 R); 00 (.9 R); 00 (.48 R); 004 (.78 R); versions 00 (.5 R); 0 (.5 R); 0 (.9 R); 04 (.48 R); 05 (.78 R); ZF 80 A versions 5 (.0 R); 6 (.4 R); 7 (.57 R); 8 (.96 R); 9 (.50 R); 0 (.85 R); versions 00 (.0 R); 00 (.4 R); 00 (.57 R); 004 (.96 R); 005 (.50 R); 006 (.85 R); ZF 80- A versions 009 (. R); 00 (.4 R); 007 (.57 R); 008 (.96 R); 0 (.50 R); 0 (.85 R); Name plate The name plate is mounted to the transmission 9

42 Repair Manual and Spare Parts List ZF 6 A FIG. ZF 6 A NEW VERSION

43 Repair Manual and Spare Parts List ZF 6 A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Scatola Housing Tappo Plug Paraolio uscita Output shaft seal Coperchio filtro completo Filter cover, assy. 5 I. Coperchio filtro. Filter cover Guarnizione OR. O-Ring Guarnizione OR O-Ring Rosetta. Washer Vite M8x0. Screw M8x Filtro olio Oil filter () old part number Guarnizione Sealing washer Filtro olio completo Oil filter, assy Guarnizione OR. O-Ring Guarnizione OR. O-Ring Filtro olio. Oil filter () new part number Tubo aspirazione Suction pipe 0 0 Tubo aspirazione con supporto Suction pipe with support Piastra ritegno Retaining plate Vite T.E. Hex head screw (ritegno tubo aspirazione) (suction pipe retainer) Vite T.E. Hex head screw (tubo aspirazione con supporto) (suction pipe with support) Spina Locator pin Coperchio Cover (housing) Coperchio Cover (housing) () Asta livello olio Oil dipstick Asta livello olio + OR Oil dipstick + OR Guarnizione OR. O-Ring (Asta livello olio) (Oil dipstick) Valvola di sfiato Breather valve Paraolio entrata Input shaft seal Rosetta Washer Vite T.E. Hex head screw Vite T.E. Hex head screw Vite T.E. Hex head screw Vite T.E. Hex head screw Vite T.E. Hex head screw Vite T.E. Hex head screw Rosetta Washer Piastra Buffle plate Ratio I=.;.6; Piastra Buffle plate Ratio I=.5; Vite T.E. Hex head screw Vite T.E. Hex head screw Rosetta Washer Piastra Buffle plate Targhetta di identificazione Name plate Rosetta Washer Vite M8x0 Screw M8x0 Fino a matricola 070G - Up to serial number 070G Da matricola 07G - From serial number 07G () Only Ratio I=.7 (also PCM) ; Ratio I=.5 uprated version & ratio I=.5 (also PCM) () Fornito solo incluso nel kit filtro olio p/n 99 0 Supplied only included in the oil filter kit p/n

44 Repair Manual and Spare Parts List ZF 6 FIG. ZF NEW VERSION

45 Repair Manual and Spare Parts List ZF 6 FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Scatola Housing Tappo Plug Paraolio uscita Output shaft seal Coperchio filtro completo Filter cover, assy. 5 I. Coperchio filtro. Filter cover Guarnizione OR. O-Ring Guarnizione OR. O-Ring Rosetta. Washer Vite M8x0. Screw M8x Filtro olio Oil filter () old part number Guarnizione Gasket Filtro olio completo Oil filter, assy Guarnizione OR. O-Ring Guarnizione OR. O-Ring Filtro olio. Oil filter () new part number Tubo aspirazione Suction pipe 0 0 Tubo aspirazione con supporto Suction pipe with support Piastra ritegno Retainingplate Vite T.E. Hex head screw (ritegno tubo aspirazione) (suction pipe retainer) Vite T.E. (tubo aspirazione Hex head screw (suction pipe con supporto) with support) Spina Locator pin Coperchio Cover (housing) Coperchio Cover Only Ratio I= Asta livello olio Oil dipstick Asta livello olio + OR Oil dipstick + OR Guarnizione OR. O-Ring (Asta livello olio) (Oil dipstick) Valvola di sfiato Breather valve Paraolio entrata Input shaft seal Rosetta Washer Vite T.E. Hex head screw Vite T.E. Hex head screw Vite T.E. Hex head screw Vite T.E. Hex head screw Vite T.E. Hex head screw Vite T.E. Hex head screw Rosetta Washer Piastra Buffle plate 0 00 Targhetta di identificazione Name plate Rosetta Washer Vite M8x0 Screw M8x0 Fino a matricola 867F - Up to serial number 867F Da matricola 867F - From serial number 867F () Fornito solo incluso nel kit filtro olio p/n 99 0 Supplied only included in the oil filter kit p/n

46 Repair Manual and Spare Parts List ZF 80 A - ZF 80- A FIG. ZF 80 A - ZF 80- A NEW VERSION

47 Repair Manual and Spare Parts List ZF 80 A - ZF 80- A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Scatola Housing Not available any more Scatola Housing From s/n 40 L () Tappo Plug Paraolio uscita Output shaft seal Coperchio filtro completo Filter cover, assy. 5. Coperchio filtro. Filter cover Guarnizione OR. O-Ring Guarnizione OR. O-Ring Rosetta. Washer Vite M8x0. Screw M8x Filtroolio Oil filter (4) old part number Guarnizione Gasket Filtro olio completo Oil filter, assy Guarnizione OR. O-Ring Guarnizione OR. O-Ring Filtroolio. Oil filter (4) new part number Tuboaspirazione Suction pipe 0 0 Tuboaspirazione Suction pipe () 0 0 Tubo aspirazione con supporto Suction pipe with support Fascetta Suction pipe clamp Vite T.E. Hex head screw (fascetta tuboaspirazione) (suction pipe clamp) Anellocentratore Centering ring Spina Locator pin Paraolio entrata Input shaft seal Valvola di sfiato Breather valve Coperchio Cover (housing) Not available any more 0 00 Coperchio Cover (housing) From s/n 40 L () Asta livelloolio Oil dipstick Asta livelloolio+ OR Oil dipstick + OR Guarnizione OR (Asta livello olio). O-Ring (Oil dipstick) Rosetta Washer Vite T.E. Hex head screw Tappo Plug Targhetta di identificazione Name plate Rosetta Washer Vite M8x0 Screw M8x0 () Scatola non fornibile con coperchio cod Fornibile solo con coperchio codice 0 00 This housing is not suitable with cover p/n 0 0. But only with the new cover p/n 0 00 () Coperchio non fornibile con scatola cod Fornibile solo con scatola codice This cover is not suitable with housing p/n 0 0. But only with the new housing p/n () Adatto solo alla nuova scatola p/n Suitable only to new housing p/n (4) Fornito solo incluso nel kit filtro olio p/n 99 0 Supplied only included in the oil filter kit p/n 99 0 Finoa matricola 5909E - Up toserial number 5909E Da matricola 590E - From serial number 590E 45

48 Repair Manualand Spare Parts List ZF 6 A FIG. ZF 6 A

49 Repair Manual and Spare Parts List ZF 6 A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Flangia uscita Output 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 Z=49 Reverse gear Z= Ingranaggio Z=50 Reverse gear Z=50 Only Ratio I= Cuscinetto a rullini Needle bearing Chiavetta Key Albero di ingresso completo Input shaft, assy Albero di ingresso completo Input shaft, assy. () Anello elastico. Snap ring Disco finale. End disc 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 Molla a tazza. Cup spring 6 From s/n 8674 L Anello interno. Inner clutch piston ring Pistone. Clutch piston Sfera. Ball Anello esterno. Outer clutch piston ring Albero di ingresso +. Input shaft & cilindro frizione clutch housing Albero di ingresso +. Input shaft & () cilindro frizione clutch housing Cuscinetto a rulli conici Tapered roller bearing Cuscinetto a rulli conici Tapered roller bearing () Spessore 0, mm Shim 0. mm Spessore 0,5 mm Shim 0.5 mm Spessore 0, mm Shim 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 Cuscinetto a rulli conici Tapered roller bearing Spessore 0, mm Shim 0. mm Spessore 0,5 mm Shim 0.5 mm Spessore 0, mm Shim 0. mm Spessore 0,5 mm Shim 0.5 mm Distanziale Spacer () () Only Ratio I=.7 (also PCM) ; Ratio I=.5 uprated version & ratio I=.5 (also PCM) 47

50 Repair Manual and Spare Parts List ZF 6 A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Vers.,00,05 (Rapporto I=,) Vers.,00,05 (Ratio I=.) Ingranaggio Z=7 Forward gear Z= Albero intermedio Z4=45, Z5=4 Intermediate shaft Z4=45, Z5=4 ] Albero di uscita Z=45 Output shaft Z=45 ] Vers.,00,06 (Rapporto I=,56) Vers.,00,06 (Ratio I=.56) Ingranaggio Z= Forward gear Z= Albero intermedio Z4=45, Z5=9 Intermediate shaft Z4=45, Z5=9 ] Albero di uscita Z=50 Output shaft Z=50 ] Vers. 4,00,07 (Rapporto I=,04) Vers. 4,00,07 (Ratio I=.04) Ingranaggio Z=7 Forward gear Z= Albero intermedio Z4=44, Z5=4 Intermediate shaft Z4=44, Z5=4 ] Albero di uscita Z=55 Output shaft Z=55 ] Vers. 5,004,08 (Rapporto I=,5) Vers. 5,004,08 (Ratio I=.5) Ingranaggio Z= Forward gear Z= Albero intermedio Z4=45, Z5= Intermediate shaft Z4=45, Z5= ] Albero di uscita Z=58 Output shaft Z=58 ] Vers. 0,0,05 (Rapporto I=,5 uprated) Vers. 0,0,05 (uprated version I=,5) Ingranaggio Z= Forward gear Z= Albero intermedio Z4=45, Z5= Intermediate shaft Z4=45, Z5= ] Albero di uscita Z=58 Output shaft Z=58 ] Vers. 0,005,0,04 (Rapporto I=,7) Vers. 0,005,0,04 (Ratio I=.7) Ingranaggio Z= Forward gear Z= Albero intermedio Z4=45, Z5=0 Intermediate shaft Z4=45, Z5=0 ] Albero di uscita Z=59 Output shaft Z=59 ] ] Cuscinetti a rulli conici giaá assemblati - Tapered roller bearings already assembled 48

51 49

52 Repair Manualand Spare Parts List ZF 6 FIG. ZF

53 Repair Manualand Spare Parts List ZF 6 FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Flangia uscita Output 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 Z=49 Reverse gear Z= 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 Molla a tazza. Cup spring 6 From s/n 8854 L Anello interno. Inner clutch piston ring Pistone. Clutch piston Sfera. Ball Anello esterno. Outer clutch piston ring Albero di ingresso+. Input shaft and clutch housing cilindro frizione Cuscinetto a rulli conici Tapered roller bearing Spessore 0, mm Shim 0. mm Spessore 0,5 mm Shim 0.5 mm Spessore 0, mm Shim 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, mm Shim 0. mm Spessore 0,5 mm Shim 0.5 mm Spessore 0, mm Shim 0. mm Spessore 0,5 mm Shim 0.5 mm Vers. 009,00 (Rapporto I=,5) Vers. 009,00 (Ratio I=.5) Ingranaggio Z=9 Forward gear Z= Albero intermedio Z4=45, Z5=6 Intermediate shaft Z4=45, Z5=6 ] Albero di uscita Z=49 Output shaft Z=49 ] Vers. 0,00,0 (Rapporto I=,5) Vers. 0,00,0 (Ratio I=.5) Ingranaggio Z=5 Forward gear Z= Albero intermedio Z4=45, Z5= Intermediate shaft Z4=45, Z5= ] 99 0 Albero di uscita Z=5 Output shaft Z=5 ] Vers. 0,00,0 (Rapporto I=,9) Vers. 0,00,0 (Ratio I=.9) Ingranaggio Z=0 Forward gear Z= Albero intermedio Z4=45, Z5=7 Intermediate shaft Z4=45, Z5=7 ] Albero di uscita Z=58 Output shaft Z=58 ] Vers. 0,00,04 (Rapporto I=,48) Vers. 0,00,04 (Ratio I=.48) Ingranaggio Z=5 Forward gear Z= Albero intermedio Z4=45, Z5= Intermediate shaft Z4=45, Z5= ] Albero di uscita Z=6 Output shaft Z=6 ] Vers. 04,004,05 (Rapporto I=,78) Vers. 04,004,05 (Ratio I=.78) Ingranaggio Z= Forward gear Z= 99 0 Albero intermedio Z4=45, Z5= Intermediate shaft Z4=45, Z5= ] 99 0 Albero di uscita Z=64 Output shaft Z=64 ] ] Cuscinetti a rulli conici giaá assemblati - Tapered roller bearings already assembled 5

54 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. ZF 80A - ZF 80- A

55 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 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 Z=44 Reverse gear Z= 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 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+. Input shaft and clutch housing cilindro frizione Cuscinetto a rulli conici Tapered roller bearing Spessore 0, mm Shim 0. mm Spessore 0,5 mm Shim 0.5 mm Spessore 0, mm Shim 0. mm Spessore 0,5 mm Shim 0.5 mm Spessore,0 mm Shim.0 mm Intermediate shaft 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 0,5 mm Shim 0.5 mm Spessore 0,0 mm Shim 0.0 mm Spessore 0,50 mm Shim 0.50 mm Distanziale Spacer Da matricola 4448L (ZF 80 A) e 446L (ZF 80- A) From serial number 4448L (ZF 80 A) and 446L (ZF 80- A) SOLO PER ZF 80A ONLY FOR ZF 80A Vers. 5,00 (Rapporto I=,) Vers. 5,00 (Ratio I=.) 0 0 Ingranaggio Z=5 Forward gear Z= Albero intermedio Z4=44, Z5=5 Intermediate shaft Z4=44, Z5=5 ] Albero di uscita Z=4 Output shaft Z=4 ] Vers. 6,00 (Rapporto I=,4) Vers. 6,00 (Ratio I=.4) Ingranaggio Z= Forward gear Z= Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] Albero di uscita Z=45 Output shaft Z=45 ] Vers. 7,00 (Rapporto I=,57) Vers. 7,00 (Ratio I=.57) Ingranaggio Z=0 Forward gear Z= Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] Albero di uscita Z=47 Output shaft Z=47 ] Vers. 8,004 (Rapporto I=,96) Vers. 8,004 (Ratio I=.96) Ingranaggio Z=6 Forward gear Z= Albero intermedio Z4=44, Z5=6 Intermediate shaft Z4=44, Z5=6 ] Albero di uscita Z=5 Output shaft Z=5 ] 5

56 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Vers. 9,005 (Rapporto I=,5) Vers. 9,005 (Ratio I=.5) Ingranaggio Z= Forward gear Z= Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] Albero di uscita Z=55 Output shaft Z=55 ] Vers. 0,006 (Rapporto I=,85) Vers. 0,006 (Ratio I=.85) Ingranaggio Z=0 Forward gear Z= Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] Albero di uscita Z=57 Output shaft Z=57 ] SOLO PER ZF 80- A ONLY FOR ZF 80- A Vers. 007 (Rapporto I=,57) Vers. 007 (Ratio I=.57) Ingranaggio Z=0 Forward gear Z= Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] Albero di uscita Z=47 Output shaft Z=47 ] Vers. 008 (Rapporto I=,96) Vers. 008 (Ratio I=.96) Ingranaggio Z=6 Forward gear Z= Albero intermedio Z4=44, Z5=6 Intermediate shaft Z4=44, Z5=6 ] Albero di uscita Z=5 Output shaft Z=5 ] Vers. 009 (Rapporto I=,) Vers. 009 (Ratio I=.) 0 0 Ingranaggio Z=5 Forward gear Z= Albero intermedio Z4=44, Z5=5 Intermediate shaft Z4=44, Z5=5 ] Albero di uscita Z=4 Output shaft Z=4 ] Vers. 00 (Rapporto I=,4) Vers. 00 (Ratio I=.4) Ingranaggio Z= Forward gear Z= Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] Albero di uscita Z=45 Output shaft Z=45 ] Vers. 0 (Rapporto I=,5) Vers. 0 (Ratio I=.5) Ingranaggio Z= Forward gear Z= Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] Albero di uscita Z=55 Output shaft Z=55 ] Vers. 0 (Rapporto I=,85) Vers. 0 (Ratio I=.85) Ingranaggio Z=0 Forward gear Z= Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] Albero di uscita Z=57 Output shaft Z=57 ] ] Cuscinetti a rulli conici giaá assemblati - Tapered roller bearings already assembled 54

57 55

58 Repair Manualand Spare Parts List ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. ZF 6 A - ZF 6 - ZF 80A - ZF 80- A MECHANICAL SELECTOR VALVE

59 Repair Manualand Spare Parts List ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Valvola di comando completo Controlvalve assy. bar bar Valvola di comando alta velocitaá High speed controlvalve assy. Only for ZF 80-A 6 bar 6 bar I. Valvola di comando. Controlvalve Guarnizione. Gasket Leva. Lever Vite T.E.. Hex head screw Rosetta. Washer Dado. Nut Guarnizione. Gasket Vite di fermo. Stop screw Tappo. Plug Tappo. Plug Tappo. Plug Rosetta. Washer Vite di guida. Guide bolt Molla. Spring Sfera. Ball Interruttore completo. Neutralsafety switch assy Guarnizione OR. O-Ring Boccola. Bushing Anello elastico. Snap ring Boccola. Bushing Molla per lubrificazione. Spring Sfera. Ball Distanziale. Spacer 57

60 Repair Manualand Spare Parts List ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 4 ZF 6 A - ZF 6 - ZF 80A - ZF 80- A OLD ELECTRIC SELECTOR VALVE WITH PROPORTIONAL VALVES

61 Repair Manual and Spare Parts List ZF 6 A- ZF 6 - ZF 80 A- ZF 80- A FIG. 4 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Distributore elettrico Electric selector valve () Distributore elettrico Electric selector valve () Distributore elettrico Electric selector valve () Only for ZF 80- A Distributore elettrico Electric selector valve (4) Only for ZF 80- A I. Valvola di comando. Control valve Guarnizione Gasket Valvola proporzionale V Electric valve V Valvola proporzionale 4 V Electric valve 4 V Guarnizione OR O-Ring Anello di tenuta Piston ring Anello elastico Snap ring Pistoncino valvola / vie Valve piston Molla per pistone Piston spring Tappo Plug Grano Drilled plug Rosetta Washer Vite Screw Rondella Washer Fermo valvola Valve lock Tappo Plug Anello OR O-Ring Vite T.E. Hex head screw Rosetta Washer Anello elastico Snap ring Anello di tenuta OR O-Ring Tappo Plug Molla Spring Perno guida molla Spring guide pin Pistoncino estraibile Valve piston Anello di tenuta Piston ring Kit connettori Connectors kit Chiavetta Key Kit guarnizioni Seal kit () Installare con V - to be instelled with V power supply () Installare con 4 V - to be instelled with 4 V power supply () Installare con 4 V - 6 bar - to be instelled with 4 V power supply - 6 bar (4) Installare con V - 6 bar - to be instelled with V power supply - 6 bar 59

62 Repair Manualand Spare Parts List ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 5 ZF 6 A - ZF 6 - ZF 80A - ZF 80- A

63 Repair Manualand Spare Parts List ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 5 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Anello elastico Snap ring Boccola Bushing Molla per lubrificazione Spring Sfera Ball Distanziale Spacer Vite torna a casa "B" Come home screw "B" Anello di tenuta OR O-Ring Rondella Washer Vite Screw Rosetta Washer Pistoncino ammortizzatore Piston Molla ammortizzatore Spring Tappo Plug Vite torna a casa "A" Come home screw "A" Tappo Plug Rosetta Washer Vite Screw Rosetta Washer Molla Spring Perno guida molla Spring guide pin Pistoncino valvola riduzione Valve piston Tappo Plug Rosetta Washer 6

64 Repair Manualand Spare Parts List ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 6 ZF 6 A - ZF 6 - ZF 80A - ZF 80- A OLD ELECTRIC SELECTOR VALVE ON/OFF V, 6 BAR F F4075 6

65 Repair Manualand Spare Parts List ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 6 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Distributore elettrico Electric selector valve [ 6 bar ON/OFF 6 bar ON/OFF Elettrovalvola ON/OFF V Solenoid valve ON/OFF V Tappo Dummy plug Tappo M0x Screw plug M0x Ma= Nm Rosetta Washer Tappo Screw plug Ma= 0 Nm Assieme connettore Connector kit Vite T.E. M8x40 Cap screw M8x Rosetta Washer Guarnizione Gasket [ Installare con V - To be installed with V power supply 6

66 Repair Manualand Spare Parts List ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 7 ZF 6 A - ZF 6 - ZF 80A - ZF 80- A NEW ELECTRIC SELECTOR VALVE ON/OFF V - 6 BAR NEW ELECTRIC SELECTOR VALVE ON/OFF 4V - 6 BAR F

67 Repair Manualand Spare Parts List ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 7 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Distributore elettrico ON/OFF Elecric selector valve ON/OFF V - 6 bar V - 6 bar [ Distributore elettrico ON/OFF Elecric selector valve ON/OFF 4V - 6 bar 4V - 6 bar [[ Elettrovalvola ON/OFF V Solenoid valve ON/OFF V Ma=0 Nm Elettrovalvola ON/OFF 4V Solenoid valve ON/OFF 4V Ma=0 Nm Tappo Dummy plug Tappo M0x Screw plug M0x Ma= Nm Rosetta Washer Tappo Screw plug Ma=5 Nm Vite T.E. M8x65 Cap screw M8x Vite T.E. M8x40 Cap screw M8x Rosetta elastica Spring washer Assieme connettore Connector kit Guarnizione Gasket [ Installare con V - To be installed with V power supply [ [ Installare con 4 V - To be installed with 4 V power supply Per convertire la elettrovalvola da V a 4V sostituire solo ilsolenoide con ilricambio a cod To transform the solenoid valve from V to 4V will be enough to replace only the solenoid - available loosen P/N F4079 La valvola non eá disponibile singolarmente ed eá un componente comune alla versione V e 4V dell'elettrovalvola. The valve is not available loosen and it is a common component both for V and 4V solenoid valve. F

68 Repair Manualand Spare Parts List ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 8 ZF 6 A - ZF 6 - ZF 80A - ZF 80- A NEW ELECTRIC SELECTOR VALVE ON/OFF V - 6 BAR WITH TROLLING VALVE NEW ELECTRIC SELECTOR VALVE ON/OFF 4V - 6 BAR WITH TROLLING VALVE F

69 Repair Manualand Spare Parts List ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A FIG. 8 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Distributore elettrico ON/OFF Electric selector valve ON/OFF [ V, 6 bar con TV V, 6 bar with Trolling valve Distributore elettrico ON/OFF Electric selector valve ON/OFF [ [ 4V, 6 bar con TV 4V, 6 bar with Trolling valve Elettrovalvola ON/OFF Solenoid valve ON/OFF Ma=0 Nm V, 6 BAR V, 6 bar Elettrovalvola ON/OFF Solenoid valve ON/OFF Ma=0 Nm 4V, 6 bar 4V, 6 bar Tappo Dummy plug Tappo a vite M0x Screw plug M0x Ma= Nm Anello di tenuta Sealing ring Tappo a vite Screw plug Ma=5 Nm Vite TCEI M8x65 Cap screw M8x Vite TCEI M8x40 Cap screw M8x Rosetta elastica Spring washer Assieme connettore Connector kit Trolling valve Trolling device Valvola proporzionale V Proportionalvalve V Ma=7 Nm 08 4 Valvola proporzionale 4V Proportionalvalve 4V Ma=7 Nm Guarnizione Gasket [ Installare con V - To be installed with V power supply [ [ Installare con 4 V - To be installed with 4 V power supply 67

70 Repair Manualand Spare Parts List ZF 6 A - ZF 6 COMPOSIZIONE KIT ZF 6 A - ZF 6 ± ZF 6 A - ZF 6 KIT COMPONENTS Fig. Pos. Part number Old P/N Descrizione Description Q.ty ± ± 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 ± ± ± ± Kit guarnizioni e frizioni. Kit guarnizioni e anelli elastici. Disco frizione interno. Disco frizione esterno Seal kit & clutch kit. Sealkit & piston rings. Inner disc. Outer disc 8 0 ± ± 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, mm. Spessore 0,5 mm. Spessore 0, mm. Spessore 0, mm. Spessore 0,5 mm. Spessore 0, 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. mm. Shim 0.5 mm. Shim 0. mm. Shim 0. mm. Shim 0.5 mm. Shim 0. mm. Shim 0.5 mm 4 COMPOSIZIONE KIT CUSCINETTI ZF 6 A, R.,5 (uprated version), R.,7 ZF 6 A BEARINGS KIT, RATIO I =.5 (upratedversion), Ratio I=.7 Fig. Pos. Part number Old P/N Descrizione Description Q.ty ± ± 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, mm. Spessore 0,5 mm. Spessore 0, mm. Spessore 0, mm. Spessore 0,5 mm. Spessore 0, 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. mm. Shim 0.5 mm. Shim 0. mm. Shim 0. mm. Shim 0.5 mm. Shim 0. mm. Shim 0.5 mm 4 68

71 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A COMPOSIZIONE KIT ZF 80A - ZF 80- A ± ZF 80 A - ZF 80- A KIT COMPONENTS Fig. Pos. Part number Old P/N Descrizione Description Q.ty ± ± 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 ± ± ± ± Kit guarnizioni e frizioni. Kit guarnizioni e anelli elastici. Disco frizione interno. Disco frizione esterno Seal kit & clutch kit. Sealkit & piston rings. Inner disc. Outer disc 0 ± ± 9 6, 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. Spessore 0, mm. Spessore 0,5 mm. Spessore 0, mm. Spessore 0,5 mm. Spessore,0 mm. Spessore 0,5 mm. Spessore 0, 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. mm. Shim 0.5 mm. Shim 0. mm. Shim 0.5 mm. Shim.0 mm. Shim 0.5 mm. Shim 0. mm. Shim 0.5 mm 4 69

72 70

73 Repair Manualand Spare Parts List Section : Spare parts list ZF 80 A - ZF 80- A NEW VERSION. SPARE PARTS LIST ZF 80A - ZF 80- A NEW 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. Serialnumber. Item no.. Part name. Identification no.. quantity of parts required. The spare parts list is referring to the following versions: ZF 80A versions 06 (.0 R); 07 (.4 R); 08 (.57 R); 09 (.96 R); 00 (.50 R); 0 (.85 R). ZF 80- A versions 04 (. R); 05 (.4 R); 06 (.57 R); 07 (.96 R); 09 (.50 R); 00 (.85 R). Name plate The name plate is mounted to the transmission 7

74 Repair Manual and Spare Parts List ZF 80 A - ZF 80- A NEW VERSION FIG. ZF 80 A versions ZF 80- A versions

75 Repair Manual and Spare Parts List ZF 80 A - ZF 80- A NEW VERSION FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Assieme scatola Housing, assy Scatola. Housing 0 0. Tubo aspirazione con supporto. Suction pipe with support Vite. Screw Guarnizione. Gasket Tappo M6x,5 Plug M6x Paraolio uscita Output shaft seal Coperchio filtro completo Filter cover, assy. 5. Coperchio filtro. Filter cover Guarnizione OR. O-Ring Guarnizione OR. O-Ring Rosetta. Washer Vite M8x0. Screw M8x Filtro olio Oil filter () old part number Guarnizione Gasket Filtro olio completo Oil filter, assy Guarnizione OR. O-Ring Guarnizione OR. O-Ring Filtro olio. Oil filter () new part number Tubo aspirazione con supporto Suction pipe with support Vite T.E. M6x6 Hex head screw M6x6 (fascetta tubo aspirazione) (suction pipe clamp) Anello centratore Centering ring Spina Locator pin Paraolio entrata Input shaft seal Valvola di sfiato Breather valve 0 00 Coperchio Cover (housing) Asta livello olio + OR Oil dipstick + OR Guarnizione OR (Asta livello olio). O-Ring (Oil dipstick) Rosetta Washer Vite T.E. M0x5 Hex head screw M0x Tappo Plug Targhetta di identificazione Name plate Rosetta Washer Vite M8x0 Screw M8x0 () Fornito solo incluso nel kit filtro olio p/n 99 0 Supplied only included in the oil filter kit p/n

76 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A NEW VERSION FIG. ZF 80A versions ZF 80- A versions

77 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A NEW VERSION FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 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 Z=44 Reverse gear Z= 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, mm Shim 0. mm Spessore 0,5 mm Shim 0.5 mm Spessore 0, mm Shim 0. mm Spessore 0,5 mm Shim 0.5 mm Spessore,0 mm Shim.0 mm Intermediate shaft 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 0,5 mm Shim 0.5 mm Spessore 0, mm Shim 0. mm Spessore 0,5 mm Shim 0.5 mm Distanziale Spacer SOLO PER ZF 80A ONLY FOR ZF 80A Vers. 06 (Rapporto I=,) Vers. 06 (Ratio I=.) 0 0 Ingranaggio Z=5 Forward gear Z= Albero intermedio Z4=44, Z5=5 Intermediate shaft Z4=44, Z5=5 ] Albero di uscita Z=4 Output shaft Z=4 ] Vers. 07 (Rapporto I=,4) Vers. 07 (Ratio I=.4) Ingranaggio Z= Forward gear Z= Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] Albero di uscita Z=45 Output shaft Z=45 ] Vers. 08 (Rapporto I=,57) Vers. 08 (Ratio I=.57) Ingranaggio Z=0 Forward gear Z= Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] Albero di uscita Z=47 Output shaft Z=47 ] Vers. 09 (Rapporto I=,96) Vers. 09 (Ratio I=.96) Ingranaggio Z=6 Forward gear Z= Albero intermedio Z4=44, Z5=6 Intermediate shaft Z4=44, Z5=6 ] Albero di uscita Z=5 Output shaft Z=5 ] Vers. 00 (Rapporto I=,5) Vers. 00 (Ratio I=.5) Ingranaggio Z= Forward gear Z= Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] Albero di uscita Z=55 Output shaft Z=55 ] 75

78 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A NEW VERSION FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Vers. 0 (Rapporto I=,85) Vers. 0 (Ratio I=.85) Ingranaggio Z=0 Forward gear Z= Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] Albero di uscita Z=57 Output shaft Z=57 ] SOLO PER ZF 80- A ONLY FOR ZF 80- A Vers. 04 (Rapporto I=,) Vers. 04 (Ratio I=.) 0 0 Ingranaggio Z=5 Forward gear Z= Albero intermedio Z4=44, Z5=5 Intermediate shaft Z4=44, Z5=5 ] Albero di uscita Z=4 Output shaft Z=4 ] Vers. 05 (Rapporto I=,4) Vers. 05 (Ratio I=.4) Ingranaggio Z= Forward gear Z= Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] Albero di uscita Z=45 Output shaft Z=45 ] Vers. 06 (Rapporto I=,57) Vers. 06 (Ratio I=.57) Ingranaggio Z=0 Forward gear Z= Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] Albero di uscita Z=47 Output shaft Z=47 ] Vers. 07 (Rapporto I=,96) Vers. 07 (Ratio I=.96) Ingranaggio Z=6 Forward gear Z= Albero intermedio Z4=44, Z5=6 Intermediate shaft Z4=44, Z5=6 ] Albero di uscita Z=5 Output shaft Z=5 ] Vers. 09 (Rapporto I=,5) Vers. 09 (Ratio I=.5) Ingranaggio Z= Forward gear Z= Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] Albero di uscita Z=55 Output shaft Z=55 ] Vers. 00 (Rapporto I=,85) Vers. 00 (Ratio I=.85) Ingranaggio Z=0 Forward gear Z= Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] Albero di uscita Z=57 Output shaft Z=57 ] ] Cuscinetti a rulli conici giaá assemblati - Tapered roller bearings already assembled 76

79 77

80 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A NEW VERSION FIG. ZF 80A versions ZF 80- A versions MECHANICAL SELECTOR VALVE

81 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A NEW VERSION FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Valvola di comando Mechanicalselector completo bar valve bar Valvola di comando Mechanicalselector Only for ZF 80-A alta velocitaá 6 bar valve 6 bar I. Valvola di comando. Controlvalve Guarnizione. Gasket Leva. Lever Vite T.E.. Hex head screw Rosetta. Washer Dado. Nut Guarnizione. Gasket Vite di fermo. Stop screw Tappo. Plug Tappo. Plug Tappo. Plug Rosetta. Washer Vite di guida. Guide bolt Molla. Spring Sfera. Ball Interruttore completo. Neutralsafety switch assy Guarnizione OR. O-Ring Boccola. Bushing Anello elastico. Snap ring Boccola. Bushing Molla per lubrificazione. Spring Sfera. Ball Distanziale. Spacer 79

82 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A NEW VERSION FIG. 4 ZF 80A versions ZF 80- A versions OLD ELECTRIC SELECTOR VALVE ON/OFF V, 6 BAR F F

83 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A NEW VERSION FIG. 4 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Distributore elettrico Electric selector valve [ 6 bar ON/OFF 6 bar ON/OFF Elettrovalvola ON/OFF V Solenoid valve ON/OFF V Tappo Dummy plug Tappo M0x Screw plug M0x Ma= Nm Rosetta Washer Tappo Screw plug Ma= 0 Nm Assieme connettore Connector kit Vite T.E. M8x40 Cap screw M8x Rosetta Spring washer Guarnizione Gasket [ Installare con V - To be installed with V power supply 8

84 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A NEW VERSION FIG. 5 ZF 80A versions ZF 80- A versions NEW ELECTRIC SELECTOR VALVE ON/OFF V - 6 BAR NEW ELECTRIC SELECTOR VALVE ON/OFF 4V - 6 BAR F4078 8

85 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A NEW VERSION FIG. 5 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Distributore elettrico ON/OFF Elecric selector valve ON/OFF V - 6 bar V - 6 bar [ Distributore elettrico ON/OFF Elecric selector valve ON/OFF 4V - 6 bar 4V - 6 bar [[ Elettrovalvola ON/OFF V Solenoid valve ON/OFF V Ma=0 Nm Elettrovalvola ON/OFF 4V Solenoid valve ON/OFF 4V Ma=0 Nm Tappo Dummy plug Tappo M0x Screw plug M0x Ma= Nm Rosetta Washer Tappo Screw plug Ma=5 Nm Vite T.E. M8x65 Cap screw M8x Vite T.E. M8x40 Cap screw M8x Rosetta elastica Spring washer Assieme connettore Connector kit Guarnizione Gasket [ Installare con V - To be installed with V power supply [ [ Installare con 4 V - To be installed with 4 V power supply Per convertire la elettrovalvola da V a 4V sostituire solo ilsolenoide con ilricambio a cod To transform the solenoid valve from V to 4V will be enough to replace only the solenoid - available loosen P/N F4079 La valvola non eá disponibile singolarmente ed eá un componente comune alla versione V e 4V dell'elettrovalvola. The valve is not available loosen and it is a common component both for V and 4V solenoid valve. F4080 8

86 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A NEW VERSION FIG. 6 ZF 80A versions ZF 80- A versions NEW ELECTRIC SELECTOR VALVE ON/OFF V - 6 BAR WITH TROLLING VALVE NEW ELECTRIC SELECTOR VALVE ON/OFF 4V - 6 BAR WITH TROLLING VALVE F

87 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A NEW VERSION FIG. 6 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Distributore elettrico ON/OFF Electric selector valve ON/OFF [ V, 6 bar con TV V, 6 bar with Trolling valve Distributore elettrico ON/OFF Electric selector valve ON/OFF [ [ 4V, 6 bar con TV 4V, 6 bar with Trolling valve Elettrovalvola ON/OFF Solenoid valve ON/OFF Ma=0 Nm V, 6 BAR V, 6 bar Elettrovalvola ON/OFF Solenoid valve ON/OFF Ma=0 Nm 4V, 6 bar 4V, 6 bar Tappo Dummy plug Tappo a vite M0x Screw plug M0x Ma= Nm Anello di tenuta Sealing ring Tappo a vite Screw plug Ma=5 Nm Vite TCEI M8x65 Cap screw M8x Vite TCEI M8x40 Cap screw M8x Rosetta elastica Spring washer Assieme connettore Connector kit Trolling valve Trolling device Valvola proporzionale V Proportionalvalve V Ma=7 Nm 08 4 Valvola proporzionale 4V Proportionalvalve 4V Ma=7 Nm Guarnizione Gasket [ Installare con V - To be installed with V power supply [ [ Installare con 4 V - To be installed with 4 V power supply 85

88 Repair Manualand Spare Parts List ZF 80 A - ZF 80- A NEW VERSION COMPOSIZIONE KIT - KIT COMPONENTS ZF 80A versions ZF 80- A versions Fig. Pos. Part number Old P/N Descrizione Description Q.ty ± ± 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 ± ± ± ± Kit guarnizioni e frizioni. Kit guarnizioni e anelli elastici. Disco frizione interno. Disco frizione esterno Seal kit & clutch kit. Sealkit & piston rings. Inner disc. Outer disc 8 0 ± ± 9 6, 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. Spessore 0, mm. Spessore 0,5 mm. Spessore 0, mm. Spessore 0,5 mm. Spessore,0 mm. Spessore 0,5 mm. Spessore 0, 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. mm. Shim 0.5 mm. Shim 0. mm. Shim 0.5 mm. Shim.0 mm. Shim 0.5 mm. Shim 0. mm. Shim 0.5 mm 4 86

89 Repair Manualand Spare Parts List Section : Spare parts list ZF 85 A. 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. Serialnumber. 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 (.57 R); 007 (.75 R); 00 (.96 R); 00 (.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 "B" Shifting position "B" Posizione della leva "A" Shifting position "A" 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 Versione della trasmissione Transmission version 87

90 Repair Manual and Spare Parts List ZF 85 A FIG. ZF 85 A versions

91 Repair Manual and Spare Parts List ZF 85 A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Assieme scatola Housing, assy Scatola. Housing 0 0. Tubo aspirazione con supporto. Suction pipe with support Vite TCEI M6x6. Cap screw M6x Guarnizione. Gasket TappoM6x,5 Plug M6x Paraolio uscita Output shaft seal Coperchio filtro completo Filter cover, assy. 5. Coperchio filtro. Filter cover Guarnizione OR. O-Ring Guarnizione OR. O-Ring Rosetta. Washer Vite M8x0. Screw M8x Filtroolio Oil filter () old part number Guarnizione Gasket Filtro olio completo Oil filter, assy Guarnizione OR. O-Ring Guarnizione OR. O-Ring Filtroolio. Oil filter () new part number Tubo aspirazione con supporto Suction pipe with support Vite T.E. M6x6 Hex head screw M6x6 (fascetta tuboaspirazione) (suction pipe clamp) Spina Locator pin Paraolio entrata Input shaft seal Valvola di sfiato Breather valve 0 00 Coperchio Cover (housing) Asta livelloolio+ OR Oil dipstick + OR Guarnizione OR (Asta livello olio). O-Ring (Oil dipstick) Rosetta Washer Vite T.E. M0x5 Hex head screw M0x Tapposcaricoolio Oil drain plug Targhetta di identificazione Name plate Rosetta Washer Vite M8x0 Screw M8x0 () Fornito solo incluso nel kit filtro olio p/n 99 0 Supplied only included in the oil filter kit p/n

92 Repair Manual and Spare Parts List ZF 85 A FIG. ZF 85 A versions

93 Repair Manual and Spare Parts List ZF 85 A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Flangia Flange Guarnizione OR O-Ring Rondella Washer Vite T.E. M6x45 Hex head screw M6x Anello di tenuta Piston ring Cuscinetto a rulli conici Tapered roller bearing Rasamento Buttingring Ingranaggio Z=44 Reverse gear Z= 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 Ralla. Thrust washer 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+. Input shaft and cilindro frizione clutch housing Cuscinetto a rulli conici Tapered roller bearing Spessore 0, mm Shim 0. mm Spessore 0,5 mm Shim 0.5 mm Spessore 0, mm Shim 0. mm Spessore 0,5 mm Shim 0.5 mm Spessore,0 mm Shim.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 0,5 mm Shim 0.5 mm Spessore 0,0 mm Shim 0.0 mm Spessore 0,5 mm Shim 0.5 mm Spessore 0,0 mm Shim 0.0 mm Spessore 0,50 mm Shim 0.50 mm 0 0 Distanziale Spacer Cuscinetto a rulli conici Tapered roller bearing Spessore 0,0 mm Shim 0.0 mm Spessore 0,5 mm Shim 0.5 mm 0 00 Spessore 0,0 mm Shim 0.0 mm 0 0 Spessore 0,50 mm Shim 0.50 mm Anello di sicurezza Retainingring Disco appoggio Support shim Spessore 40x50x0,0 Shim 40x50x Spessore 40x50x0,5 Shim 40x50x Spessore 40x50x0,0 Shim 40x50x0.0 Vers. 004 (Rapporto I=,57) Vers. 004 (Ratio I=.57) Ingranaggio Z=0 Forward gear Z= Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] Albero di uscita Z=47 Output shaft Z=47 ] Vers. 007 (Rapporto I=,75) Vers. 007 (Ratio I=.75) Ingranaggio Z=8 Forward gear Z= Albero intermedio Z4=44, Z5=8 Intermediate shaft Z4=44, Z5=8 ] Albero di uscita Z=49 Output shaft Z=49 ] Vers. 00 (Rapporto I=,96) Vers. 00 (Ratio I=.96) Ingranaggio Z=6 Forward gear Z= Albero intermedio Z4=44, Z5=6 Intermediate shaft Z4=44, Z5=6 ] Albero di uscita Z=5 Output shaft Z=5 ] Vers. 00 (Rapporto I=,5) Vers. 00 (Ratio I=.5) Ingranaggio Z= Forward gear Z= Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] Albero di uscita Z=55 Output shaft Z=55 ] ] Cuscinetti a rulli conici giaá assemblati - Tapered roller bearings already assembled 9

94 Repair Manualand Spare Parts List ZF 85 A FIG. ZF 85 A versions MECHANICAL SELECTOR VALVE

95 Repair Manualand Spare Parts List ZF 85 A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Valvola di comando Mechanicalselector alta velocitaá 6 bar valve 6 bar I. Valvola di comando. Controlvalve Guarnizione. Gasket Leva. Lever Vite T.E.. Hex head screw Rosetta. Washer Dado. Nut Guarnizione. Gasket Vite di fermo. Stop screw Tappo. Plug Tappo. Plug Tappo. Plug Rosetta. Washer Vite di guida. Guide bolt Molla. Spring Sfera. Ball Interruttore completo. Neutralsafety switch assy Guarnizione OR. O-Ring Boccola. Bushing Anello elastico. Snap ring Boccola. Bushing Molla per lubrificazione. Spring Sfera. Ball Distanziale. Spacer 9

96 Repair Manualand Spare Parts List ZF 85 A FIG. 4 ZF 85 A versions ELECTRIC SELECTOR VALVE ON/OFF V - 6 BAR ELECTRIC SELECTOR VALVE ON/OFF 4V - 6 BAR F

97 Repair Manualand Spare Parts List ZF 85 A FIG. 4 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note Distributore elettrico ON/OFF Elecric selector valve ON/OFF V - 6 bar V - 6 bar [ Distributore elettrico ON/OFF Elecric selector valve ON/OFF 4V - 6 bar 4V - 6 bar [[ Elettrovalvola ON/OFF V Solenoid valve ON/OFF V Ma=0 Nm Elettrovalvola ON/OFF 4V Solenoid valve ON/OFF 4V Ma=0 Nm Tappo Dummy plug Tappo M0x Screw plug M0x Ma= Nm Rosetta Washer Tappo Screw plug Ma=5 Nm Vite T.E. M8x65 Cap screw M8x Vite T.E. M8x40 Cap screw M8x Rosetta elastica Spring washer Assieme connettore Connector kit Guarnizione Gasket [ Installare con V - To be installed with V power supply [ [ Installare con 4 V - To be installed with 4 V power supply Per convertire la elettrovalvola da V a 4V sostituire solo ilsolenoide con ilricambio a cod To transform the solenoid valve from V to 4V will be enough to replace only the solenoid - available loosen P/N F4079 La valvola non eá disponibile singolarmente ed eá un componente comune alla versione V e 4V dell'elettrovalvola. The valve is not available loosen and it is a common component both for V and 4V solenoid valve. F