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Repair Manual and Spare Parts List: ZF 63 Iv ZF 80 Iv ZF 80-1 IV ZF 85 Iv
Repair Manual and Spare Parts List: ZF 63 Iv ZF 80 Iv ZF 80-1 IV ZF 85 Iv
and
Spare Parts List
ZF 63 IV
ZF 80 IV
ZF 80-1 IV
ZF 85 IV
FEBRUARY 2006
cod. 310.01.0009h
Repair Manual and Spare Parts List Table of contents
TABLE OF CONTENTS
1
Repair Manual and Spare Parts List Table of contents
2
Repair Manual and Spare Parts List Introduction
INTRODUCTION
This manual gives specific instructions for the proper repair on
ZF 63 IV - ZF 80 IV - ZF 80-1 IV - ZF 85 IV model transmissions.
Please follow the procedures carefully to insure quality service.
ZF-HURTH MARINE recommends to read the manual completely
before starting with repairs, as some of the procedures described
are rather complex.
Along with standard tools, ZF-HURTH MARINE recommends the
use of special tools, necessary to perform repairs correctly. The
special tools are available through your local ZF-HURTH MARINE
dealer.
This manual is based on the technical information at the time of
printing. The manual has been checked carefully in order to avoid
errors. However ZF-HURTH MARINE is not liable, for any misre-
presentations, errors of description or omissions.
Modifications on future manuals may be introduced without prior
notice.
3
4
Repair Manual and Spare Parts List Section 1
1. MAJOR COMPONENTS
1.4 2
2.1 2.3
2.2
1.1
2.4
1
3
1.3
1.2
5
Repair Manual and Spare Parts List Section 1
TORQUE WRENCH
adjustable up to 180 Nm (152 ft.lb.)
ACCURACY OF READING:
SMALL HAND 1 mm (.03937 in)
LARGE HAND
1/100 mm (.0004 in) EXTRACTOR minimum diameter 130 m
MEASURING DEPTH
APPROX. 11 mm (.433 in)
6
Repair Manual and Spare Parts List Section 2
2. SPECIAL TOOLS
It is assumed that all standard tools, such as, torque CLAMPING RING for measuring the bearing clearance
wrenches, open-end wrenches, allen keys and extrac- input shaft P/N 219.354.3 (618582)
tors, are available.
All fixtures for pressing parts in or out should be used in LEVER
DIAL INDICATOR
MANDREL
ADAPTER for basic unit 978.25.0017.0 (454421).
For disassembly and assembly
For bearing input shaft - spline side.
Shaft seal - input side : P/N 224.836.005 (454425)
- P/N 978.25.0018.0 (469686) ZF 63 IV
Shaft seal output propeller side:
- P/N 978.35.0019.0 (500465) ZF 80 IV - ZF 80-1 IV -
- P/N 978.30.0001.0 (500445) ZF 63 IV
ZF 85 IV
- P/N 20.1040.01 ZF 80 IV - ZF 80-1 IV - ZF 85 IV
Output shaft seal control block side:
- P/N 978.30.0003.0 (500447) ZF 63 IV
- P/N 20.1040.02 ZF 80 IV - ZF 80-1 IV - ZF 85 IV
50
A B
ADAPTER FOR
BASIC UNIT BASIC UNIT 454422
Mandrel P/N 20.1072.01 to assemble input shaft seal
ZF 63 IV ZF 80 IV - ZF 80-1 IV - ZF 85 IV Only for model: ZF 85 IV - ZF 80 IV (ZF 85 IV DERIVATE
VERSION)
Ð 978.25.0009.0 (477853)
Ð 978.25.0011.0 (477854)
978.25.0013.0 (477857) Ð
978.30.0014.0 (477858) 978.30.0014.0 (477858)
Ð 978.35.0016.0 (477895)
7
Repair Manual and Spare Parts List Section 2
SHIM PUNCH
To determinate the correct preload of the tapered roller for assembly Seal - suction pipe
bearings. ZF 80 IV - ZF 80-1 IV - ZF 85 IV P/N 20.1021.00
- P/N 20.1017.00 ZF 63 IV ZF 63 IV: P/N 20.1029.00
- P/N 20.1019.00 ZF 80 IV - ZF 80-1 IV - ZF 85 IV
8
Repair Manual and Spare Parts List Section 3
3. DISASSEMBLY
INTRODUCTION
Clean the transmission thoroughly on the outside be- The repair area should be clean and well lighted.
fore disassembly. ZF HURTH MARINE recommends using a swiveling
stand for aiding in assembly and disassembly.
Swiveling stand ZF
Swiveling stand ZF
Output - half side up
Input - half side up
+ | IMPORTANT |
The used oil and the oil filter are to be handled as 2
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.
3
FIG. 1 - 2
9
Repair Manual and Spare Parts List Section 3
FIG. 2 - 1
1
3.3 REMOVAL BREATHER VALVE
Unscrew breather valve (item 1, Fig. 3-1). Wash valve
in a detergent, let dry and dip in oil, then let oil drip off.
FIG. 3 - 1
FIG. 4 - 1
FIG. 4 - 2
10
Repair Manual and Spare Parts List Section 3
4
FIG. 5 - 1
FIG. 5 - 2
11
Repair Manual and Spare Parts List Section 3
3.6 HOUSING
+ | IMPORTANT |
Only transmission type ZF 63 IV, i=2.0 and i=2.5.
FIG. 6 - 1a
1 FIG. 6 - 1b
3.6.2 Removal of shafts and gears
Take the gear set out of the housing
. intermediate shaft (item 1, Fig. 6-2)
. input shaft (item 2, Fig. 6-2)
. output shaft (item 4, Fig. 6-2)
2
. reversal shaft (item 3 Fig. 6-2). 3
2 1
Check all gears, bearings and three piston rings on the
input shaft (item 2, Fig. 6-2) for signs of wear or failure. 4
If any of the gears are damaged or showing signs of ex-
cessive wear ZF-HURTH MARINE recommends repla-
cing the complete gear set.
When taper roller bearings need replacing on the input
shaft, the butting rings and needle bearings should
also be replaced. When replacing inner roller bearings
use the same manufacturer. FIG. 6 - 2
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.
12
Repair Manual and Spare Parts List Section 3
FIG. 6 - 3b
FIG. 6 - 4
13
Repair Manual and Spare Parts List Section 3
+ | IMPORTANT |
Regard location of shims under each outer race for
correct position during reassembling. Shims are lo-
cated under outer races of the cover only.
| WARNING |
Improper use of the extractor when removing the 1
races, could cause damage to the races or slipp off.
Output shaft
For extracting the inner races (item 1 and 2, Fig. 7-2d)
proceed as follows: 3
. cut bearing cage (item 3, Fig. 7-2d) open and re-
move rollers 2
. place gear on a sleeve
. press output shaft off the gear. Pay attention for
pressing-out direction of output shaft Fig. 7-2d.
The bearing inner race (item 1, Fig. 7-2d) will be ex- FIG. 7 - 2d
tracted at the same time.
Extracting force required: approx. 400kN
14
Repair Manual and Spare Parts List Section 3
3
2
FIG. 8 - 1a
2
FIG. 8 - 1b
FIG. 8 - 1c
15
16
Repair Manual and Spare Parts List Section 4
4. ASSEMBLY
INTRODUCTION
A well-lighted work area that is free from dirt and chips, The next assembly procedure requires the following:
will facilitate the work considerably. . An electric oven or heating lamp for heating the
ZF-HURTH MARINE recommends to use a swivelling housing halves will be required when mounting
stand, described in the disassembly section to aid in the bearings.
the assembly.
. A hydraulic or mechanical press
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!
2
2
1 1
FIG. 1 - 1c FIG. 1 - 1d
17
Repair Manual and Spare Parts List Section 4
FIG. 1 - 2
FIG. 1 - 3a
D
FIG. 1 - 3b
18
Repair Manual and Spare Parts List Section 4
| 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. FIG. 1 - 5
Use a feeler gauge to check it.
FIG. 1 - 6
19
Repair Manual and Spare Parts List Section 4
| WARNING |
Handle heated tapered roller bearing inner races
only with protective gloves!
When the inner races have cooled down, drive them
carefully against the collar using a brass punch.
NOTE
Apply copper/brass punch on inner race and not on 2 2
the rollers.
FIG. 2 - 1
| CAUTION |
Handle heated tapered roller bearing inner races
only with protective gloves! 2
When the inner races have cooled down, drive them
carefully against the collar using a brass punch.
NOTE
Apply copper/brass punch on inner race and not on
the rollers.
FIG. 3 - 1
4.3.3 Pressing the gear on
| ATTENTION | 4
ONLY ZF 63 IV: with transmission ratio of 1.3 to 2.0
the ring (item 1 Fig. 3-2) must be mounted
. Provide press fit of output shaft with a thin coat of 2
glycerol.
. With a transmission ratio of 1.3 to 2.0, a washer
(item 1, Fig. 3-2) should be inserted. 1
. Press gear (item 2, Fig. 3-2) on shaft (item 3, Fig. 3-
3
2), by means of a hydraulic press.
Pressing force required: 200 kN
After having pressed the gear on, mount second in-
ner race of bearing (item 4, Fig. 3-2) as described
under 3.2. FIG. 3 - 2
20
Repair Manual and Spare Parts List Section 4
1 A
FIG. 4 - 2b
1
A
FIG. 4 - 2c
21
Repair Manual and Spare Parts List Section 4
FIG. 4 - 4
22
Repair Manual and Spare Parts List Section 4
| CAUTION |
Make sure to keep any dirt out of housing.
. Insert gears into housing
. Mount "input" housing half (item 1, Fig. 5-3) with all
bolts, lock washers (item 2 and 3, Fig. 5-3) and par-
allel pins (item 4, Fig. 5-3).
2
Tightening torques of bolts: 40 Nm (30 ft. lb.)
3
FIG. 5 - 3
23
Repair Manual and Spare Parts List Section 4
FIG. 5 - 5b
24
Repair Manual and Spare Parts List Section 4
FIG. 5 - 7b
25
Repair Manual and Spare Parts List Section 4
| 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
half has reached ambiet temperature, drive outer
races of bearings up to the stop, using a copper
punch.
d) Insert gears again.
e) Fill space between seal and dust lips of shaft seal
rings with a high quality bearing grease (KLUEBER
STABURAGS NBU 30).
f) Apply a thin coat of Loctite 518 on mating face of "in-
put" housing half and join both housing halves.
| WARNING |
The necessary time for a complete polymerization is
5 hours: we recommend therefore to clean carefully
the mating surfaces with Loctite 7063 cleaner be-
fore applying the Loctite 518 and wait the requested
time before the spin test.
g) Drive parallel pins into housing to align housing
halves, before tightening.
h) Apply Loctite 243 on to mounting bolts (item 2 and 3,
Fig. 5-7a) and torque them to 40 Nm (30 ft lb).
i) Check pretension of bearings accord-ing to sections
5.4, 5.5 and 5.7.
| CAUTION |
There must be no measurable bearing clearance.
j) Only for transmission size i=2.0 and i=2.5
ZF 63 IV. Press radial shaft seal (item 1, Fig. 4-3b)
with a suitable pipe into the "drive" housing half.
NOTE
The sealing lip on the radial shaft seal show to the
inside of the housing. The radial shaft seal must
be so adjusted that the sealing lip does not bear
on the former running point of the shaft.
k) Mount the output flange again. (see chapter 5.6).
26
Repair Manual and Spare Parts List Section 4
FIG. 8 - 2
27
Repair Manual and Spare Parts List Section 4
+ | IMPORTANT |
Oil check with threaded dipstick (B) must be done in a MAX
MAX
different way compared with the one not threaded (A): MIN MIN
28
Repair Manual and Spare Parts List Section 5
5. ADJUSTMENT DATA
300
20
250
15
200
10 150
100
5
50
0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
DRIVING SPEED (rpm)
5.1.2 ZF 63 IV - ZF 80 IV VERSION; mechanical selector valve 23 bar p/n 3312 108 001
30
SHIFTING PRESSURE (bar)
10 150
100
5
50
0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
DRIVING SPEED (rpm)
29
Repair Manual and Spare Parts List Section 5
5.1.3 ZF 63 IV INDMAR VERSION; mechanical selector valve 21 bar p/n 3312 108 003
30
SHIFTING PRESSURE (bar)
10 150
100
5
50
0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
DRIVING SPEED (rpm)
7.39
6.86
25
6.33
5.80
20 5.28
4.75
4.22
15
3.69
N.
MI 3.17
10 2.64
2.11
1.58
5
1.05
0.53
0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
DRIVING SPEED (rpm)
30
Repair Manual and Spare Parts List Section 5
5.2.2 ZF 63 IV - ZF 80 IV VERSION; mechanical selector valve 23 bar p/n 3312 108 001
30 7.91
7.39
6.86
25
6.33
5.80
20 5.28
4.75
4.22
15
3.69
N.
MI 3.17
10 2.64
2.11
1.58
5
1.05
0.53
0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
DRIVING SPEED (rpm)
5.2.3 ZF 63 IV INDMAR VERSION; mechanical selector valve 21 bar p/n 3312 108 003
30 7.91
7.39
6.86
25
6.33
5.80
20 5.28
4.75
N. 4.22
15 MI
3.69
3.17
10 2.64
2.11
1.58
5
1.05
0.53
0 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
DRIVING SPEED (rpm)
31
32
= Shifting pressure 21.5+2 bar
= Fluid 2+0.5 bar
= Leakage fluid A B
Direction of
water flow
Connection for
temperature probe
indicating at abt.
110°C 3/8” - 18 NPSF
6. HYDRAULIC DIAGRAM
Shifting
Basic lubricating throttle valve pressure
relief valve
Fluid delivery pump
A
B
Fluid filter
Filte grade 60µ
7. TIGHTENING TORQUES
TORQUE TORQUE
PART SIZE LOCTITE
IN lb.ft. IN Nm
Mounting bracket bolts ZF 63 IV M12 min. 55.5 - max. 57 min. 75 - max 77 Ð
Mounting bracket bolts
ZF 80 IV, ZF 80-1 IV, ZF 85 IV M12 min. 55.5 - max. 57 min. 75 - max 77 Ð
33
Repair Manual and Spare Parts List Section 8
8. FUNCTION TEST
When the transmission has been completely assembled Tests to be carried out:
and filled up with transmission fluid, it would be conve- 1. Fluid leaks
nient to make a function test.
2. Noise emission
This test can be carried out on a bench test rig, or in a
boat. If no fluid cooler can be connected, a hydraulic 3. Direction of rotation, LH/RH
hose must be connected between the inlet and outlet 4. Lube oil temperature
of the hydraulic pump. 5. Shifting pressure
Measuring instruments required: 6. Lube oil flow rate
. Pressure gauge 0-40 bar (0-580 psi), with connect-
ing thread M10x1
. Temperature gauge 0-120ëC (0-250ëF), connecting
thread 3/8"-18NPSF
. Flow meter 0-35 liters/min (0-10 gals/min)
Durat.
Motor speed (rpm) Shift lever position Test
minutes
800-1000 neutral 5 1, 2
A<->B
600-800 (idling speed) - 1, 2, 3
position repeatedly
1500-2500 B position - 1, 2, 4
A<->B
600-800 (idling speed) - 1, 2, 3
position repeatedly
idling - max. speed A position - 1, 2, 5] ], 6] ]
600-800 (idling speed) A->B position - 1, 2
idling - max. speed B position - 1, 2, 5] ], 6] ]
]
Until a fluid temperature of 75-80 ëC (167-176ëF) has been reached
]]
At different speeds.
34
Repair Manual and Spare Parts List Section 9
9. TROUBLESHOOTING
In case of trouble, first check whether all recommended mounting and operating instructions have been completed.
The subsequent tables will assist you in troubleshooting and finding solutions.
If any adjustments are necessary on the transmission, please reference the Repair Manual.
Warranty claims will be forfeited if work on the transmision is performed by unauthorized persons during the war-
ranty period.
1.1 Shifting lever is loose. 1.1 Tighten clamping bolt on shifting lever
1.2 Remote control does not permit lever 1.2 Lift remote control off, if gears can be
1. Transmission cannot be shifted. travel required for testing. shifted by hand, correct remote control.
1.3 Remote control faulty. 1.3 Repair remote control.
1.4 No shifting pressure available. 1.4 Refer to 7.
2.1 Shift linkage time misadjusted; 2.1 Lift remote control off, if gear can be
not allowing full engagement. shifted by hand, correct remote con-
2. Delayed shift. trol. If the transmission cannot be
shifted correctly by hand, replace
the control block.
3.1 Inadmissible fluid used. 3.1 Drain fluid, refill with prescribed fluid,
flush transmission while engine runs
in neutral position, drain fluid, refill
transmission.
3. Clutch is slipping, i.e. 3.2 Fluid contains water. 3.2 Refer to 9.
propeller speed too low as 3.3 Shifting pressure too low. 3.3 Refer to 6.
compared to engine speed.
3.4 Wear on clutch discs. 3.4 Disassemble transmission, replace
clutch discs.
3.5 Piston rings in clutch are damaged. 3.5 Disassemble transmission,
replace clutch.
35
Repair Manual and Spare Parts List Section 9
7.1 Direction of engine rotation does not 7.1 Replace with engine of correct of rota-
agree with arrow on transmission. tion.
7.2 No fluid in the transmission. 7.2 Refill with fluid.
7.3 Fine filter is dirty. 7.3 Replace fine filter.
7.4 Fluid level in transmission is too low.
7.4 Top-up with fluid. In case of loss of
fluid check transmission, cooler and
7. No shifting pressure available. pipelines for leakage and remedy
same, also refer to 10. through 13.
7.5 Fluid pump worn out. 7.5 Replace control block.
7.6 Fitting key in input shaft for fluid 7.6 Remove control block.
pump drive is broken.
7.7 Spring of shifting pressure Replace 7.7 Replace fitting key, replace any other
control block relief valve is broken. faulty parts.
8.1 Fluid cooler is too small. 8.1 Use a larger fluid cooler.
8.2 Excessive fluid in transmission. 8.2 Remove excessive fluid with commer-
cial suction pump.
8.3 Fluid cooler is dirty on water side. 8.3 Detach coolant water lines and clean
fluid cooler on water side.
8.4 Worn fluid pump in control block. 8.4 Replace control block containing fluid
pump.
8.5 Faulty piston rings in control block. 8.5 Remove control block, replace piston
rings. In case of wear in the control
8. Excessive fluid temperature. block due to faulty piston rings re-
place control block as well.
8.6 Clutch is slipping. 8.6 Refer to 3.
8.7 Clutch does not open completely due 8.7 Dismount transmission and coupling,
to worn disc support. replace all faulty parts.
8.8 Clutch does not open completely due 8.8 Dismount transmission, replace inner
to worn disc support. disc support and/or clutch.
8.9 With fluid cooler in bypass and unfa- 8.9 Correct bypass pipeline.
vorable arrangement of pipelines too
little coolant water flows through by-
pass to cooler.
11. Fluid leakage at breather. 11.1 Excessive fluid in transmission. 11.1 Pump excessive fluid out with com-
mercial hand pump.
12.1 Bolts are not tight. 12.1 Tighten bolts with prescri-bed torque.
12.2 Replace seals, tighten bolts with
12.2 Seals on bolts have been used sev- prescribed torque.
eral times.
12. Fluid leakage at joints. 12.3 Unscrew housing half, finish mating
12.3 Mating faces are contaminated, no faces with oilstone or finishing file,
surface seal applied. apply surface seal.
Assemble trans-mission, tighten
bolts with correct torque.
36
Repair Manual and Spare Parts List Section 9
13.1 Fluid level too low so that pump 13.1 Top up with fluid to marking on dip-
sucks in air. stick.
13.2 Damage starting on flexible coupling 13.2 Replace flexible coupling.
due to wear or fatigue, possible due Check alignment between engine
to misalignment between engine and transmission.
and transmission.
13.3 Beginning damage of bearings in 13.3 Disassemble transmission, replace
13. Transmission noise becomes lou- transmission, e.g. due to torsional vi- bearings concerned and other faulty
der. brations, running without fluid, over- parts. Find causes and remedy.
load, wrong alignment of transmis-
sion excessive engine output.
13.4 Beginning damage of gearings, e.g. 13.4 Disassemble transmission, remove
due to torsional vibrations, running faulty parts.
without fluid, overload.
13.5 Fluid suction pipe in transmission 13.5 Disassemble transmission, fix fluid
has come Ioose. suction pipe.
14.1 The engine or propeller generate tor- 14.1 Mount a flexible coupling with another
sional vibrations in the drive unit stiffness factor between enging and
which produce a "chattering" noise transmission; a coupling with a higher
in the transmission. stiffness factor might be sufficient.
14. Chattering transmission noise Otherwise analyse the torsional vibra-
mainly at low engine. tions to find out the required stiffness
for the coupling.
14.2 Misaligned cardan shafts on input or 14.2 Mount and align cardan shaft strictly
output. according to instructions issued by
cardan shaft manufacture.
37
Repair Manual and Spare Parts List Section 9
17.1 Excessive fluid in transmission. 17.1 Remove excessive fluid with com-
mercial suction pump.
17.2 Oil cooler is dirty. 17.2 Replace the cooler and check the
water circuit.
17.3 No water in circuit. 17.3 Check the cooling circuit.
17.4 Undersized cooler. 17.4 Replace the cooler with a proper one
17. High oil temperature.
17.5 Clutch is slipping. 17.5 Refer to 18.
17.6 Excessive friction of the 17.6 Check the clutch play and the cor-
reverse clutch. rect position of the piston.
17.7 Possible bypass in the cooling 17.7 Reduce the bypass.
circuit.
- hydraulic
19.1 Oil filter is dirty. 19.1 Replace oil filter.
19.2 Fluid level in transmission is low. 19.2 Refill with fluid.
19.3 Oil suction hose not properly 19.3 Replace the seal and adjust
adjusted. correctly the suction hose.
19.4 Defective cover filter : air suction. 19.4 Replace cover filter.
19. Noise. - at idle speed
19.5 Coupling. 19.5 Replace.
- under load
19.6 Wrong shimming. 19.6 Re-shim.
19.7 Defective gears. 19.7 Replace defective gears.
22.1 Regulate.
22.1 Shift lever.
22. Hard shifting. 22.2 Disassemble the control valve and
22.2 Control block is dirty. clean.
38
Repair Manual and Spare Parts List Section 9
23.1 Warped discs due to overheating. 23.1 Replace discs, replace any other
faulty parts.
23.2 Needle bearings on input shaft are 23.2 Disassemble transmission, replace
23. Transmission is dragging in faulty. needle bearings.
neutral. 23.3 Intermediate gear moved from the 23.3 Replace the intermediate gear.
shaft and touching the clutch drum.
23.4 Discs of the reverse clutch radially 23.4 Replace the discs and change the
broken due to torsional vibration. damper with a proper one.
39
Repair Manual and Spare Parts List Section 10
ADDINOL MINERALOÈL . ADDINOL ATF D IID ENGEN PETROLEUM, . ENGEN ATF 22D
GMBH, KRUMPA/D . ADDINOL ATF D III CAPE TOWN/ZA
. AGIP ATF II D . TRANSMISIONES AUTOMATICAS
ERTOIL SA, MADRID/E
. AGIP ATF D 309 D2
AGIP PETROLI SPA, ROM/I . AGIP ATF PLUS . ESSO ATF D (21611)
. AGIP DEXRON III ESSO AG, HAMBURG/D . ESSO ATF F-30320
AGIP SCHMIERTECHNIK, È L ATF-D
. AUTOL GETRIEBEO . ESSO ATF D (21065)
WUÈRZBURG/D È L ATF III D
. AUTOL GETRIEBEO
FIAT LUBRIFICANTI, . TUTELA GI/A
ARAL LUBRICANTS GMBH, . ARAL GETRIEBEO È L ATF 22 VILLASTELLONE/I
BOCHUM/D È L ATF 55 F-30589
. ARAL GETR.O
FINA EUROPE SA, . FINAMATIC II-D
AVIA MINERALOÈL-AG, . AVIA FLUID ATF 86 BRUÈSSEL/B
MUÈNCHEN/D FUCHS LUBRICANTS (UK), . SILKTRAN MP-ATF
BLASER SWISSLUBE, . BLASOL 229 DERBY/GB . SILKTRAN PSV ATF
HASLE-RUÈEGSAU/CH FUCHS MINERALOÈLWERKE, . TITAN ATF 4000
BP OIL DEUTSCHLAND, . FRONTOL UNIVERSAL-ATF 100
MANNHEIM/D
HAMBURG/D GINOUVES GEORGES SA, . YORK LT 785
. AUTRAN DX II LA FARLEDE/F
BP OIL INTERNATIONAL, . AUTRAN MBX GULF OIL (GB) LTD, . UNIFLUID
LONDON/GB . AUTRAN DX III (F-30370) CHELTENHAM/GB . ATF 2
. AUTRAN DX III (F-30381)
HANDELSMIJ NOVIOL B.V., . KENDALL ATF DEXRON IID
BUCHER+CIE AG, . MOTOREX ATF SUPER D-22656
NIJMEGEN/NL
LANGENTHAL/CH . MOTOREX ATF DEXRON III MC
HOMBERG GMBH+CO KG, . HOMBERG-GETRIEBE-FLUID D
CALPAM GMBH, . PAMATIC FLUID 289
WUPPERTAL/D
ASCHAFFENBURG/D . CALPAMATIC FLUID III F
IGOL FRANCE, PARIS/F . IGOL ATF 420
. CALTEX ATF-HDA
. CALTEX ATF-HDM INA RAFINERIJA . INA-ATF SUPER
CALTEX PETROLEUM ZAGREB/CROATIA
. CALTEX TEXAMATIC 1278
CORP., LONDON/GB . CALTEX TEXAMATIC 7045 ITALIANA PETROLI, . TRANSMISSION FLUID DX
. CALTEX TEXAMATIC 1205A GENOVA/I
. CASTROL TQ-D (22765) JAPAN ENERGY CORP., . JOMO ATF K
. CASTROL TQ DEXRON III F-30520 TOKYO/JAPAN
CASTROL LTD, . CASTROL TRANSMAX S (F-30319) È L IID 23
KAÈPPLER K., STUTTGART/D . SELECTOL FLUID GETR.O
SWINDON/GB . CASTROL TRANSMAX T (F-30359)
. CASTROL TQ-D (21289) KLOÈCKNER ENERGIEHANDEL . DEUTZ OEL ATF-D
. CASTROL ATF 21293 GMBH, KOÈLN/D
CEPSA, MADRID/E . CEPSA ATF-70 . ATF DEXRON IID
KROON OIL BV, ALMELO/NL . ALMIROL ATF
CHEVRON PRODUCTS CO., . CHEVRON ATF F-30108
RICHMOND/USA . Q8 AUTO 15
KUWAIT PETROLEUM, . Q8 AUTO 14 (IID-21677)
CITGO PETROLEUM CORP., . CITGO ATF DEXRON III F-30167 HOOGVLIET/NL . Q8 AUTO 14 (IID)
TULSA/USA . Q8 AUTO 14 (IID-21883)
C.J.DIEDERICHS SOÈHNE, . CIDISOL-HYDR.-FLUID LEPRINCE+SIVEKE GMBH,
WUPPERTAL/D DEXRON IID . LEPRINXOL FLUID CN
HERFORD/D
DE OLIEBRON B.V., . ATF DMM LIQUI MOLY / MEGUIN, . ATF IIE
ZWIJNDRECHT/NL . ATF 289 ULM/D . MEGOL ATF IID
LUBRICATION ENGIN., . AUTOMATIC TRANSMISSION
. DEAMATIC
DEA MINERALOÈL AG, . DEAFLUID 4011
FORT WORTH/USA FLUID
HAMBURG/D . DEAFLUID 3003 MAURAN SA, ODARS/F . INTER OIL INTER MATIC ATF D2
40
Repair Manual and Spare Parts List Section 10
41
42
Repair Manual and Spare Parts List Section 11 : Spare parts list
ZF63 IV - ZF80 IV - ZF80-1 IV
Preface
The spare parts list is only valid for the type and ver- When ordering parts, please state:
sions of transmission, as shown below. . Transmission type
You will find the transmission type and version on your . Serial number
transmission name plate.
. Item no.
If the type and version indicated differs from that
. Part name
printed in this Manual, the relative Spare Parts List
should be ordered from ZF HURTH MARINE. . Identification no.
The indicated dimensions and standards are as such . quantity of parts required.
not enough for ordering parts.
Name plate
The name plate is mounted to the transmission
Transmission type
Serial number
XXXXX L 3312 003 (014)
43
44
14
13 33
32 10 25
9 21
26 ZF 63 IV
17 11
24 27 29
26
16 18 12
15
19 22 26
28
20
2 27
31 26
Repair Manual and Spare Parts List
1 26
25 30
26
3
25
26
23
24
7 6
4
8
8 6
5 NEW VERSION
ZF 63 IV FIG. 1
Repair Manual and Spare Parts List ZF 63 IV FIG. 1
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
] Fornito solamento incluso nel Kit filtro olio p/n 3312 199 031
Supplied only included in the oil filter Kit p/n 3312 199 031
45
46
15
14 33
32 22
11 27 26
10
18 12 25 26 29
27
17 19 13
20 27
16 23
ZF 80 IV - ZF 80-1 IV
26
21
2
26
31
27
Repair Manual and Spare Parts List
3 1 27
26
30
27
4
28
27
24
25
8
7
5
9
9 7
6
ZF 80 IV - ZF 80-1 IV FIG. 1
NEW VERSION
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 1
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
] Fornito solamento incluso nel Kit filtro olio p/n 3312 199 031
Supplied only included in the oil filter Kit p/n 3312 199 031
47
48
13
15 11
19 16 ZF 63 IV
12
20
10 14 23
21
17
18
20
18 8 22
16 6
10
13 31
19 9
Repair Manual and Spare Parts List
11 23
17 32 25
8
15 7
14 5 27
24
12 4
28
6 26
33
34
28
1
29
2
34a
3
30
ZF 63 IV FIG. 2
Repair Manual and Spare Parts List ZF 63 IV FIG. 2
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
] Cuscinetti a rulli conici giaÁ assemblati - Tapered roller bearings already assembled
49
50
15
17 13
21 18
14
22
12 16 25
23
19
20
22
20
ZF 80 IV - ZF 80-1 IV
9 24
18 7
12
15 10 34
13 21 11 25
Repair Manual and Spare Parts List
19 35 27
9
17 8
16 5 26 29
10
14 4
30
7 28
6
36
32
33 31
1
2
37
3
ZF 80 IV - ZF 80-1 IV FIG. 2
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 2
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
l Solo per ZF 80 IV e ZF 80-1 IV - Rapporto I=2.49 - Only for ZF 80 IV and ZF 80-1 IV - Ratio I=2.49
l l Solo per ZF 80-1 IV - Escluso rapporto I=2.49 - Only for ZF 80-1 IV - No ratio I=2.49
Da matricola From s/n's: 43513L (ZF 80 IV)
43511L (ZF 80-1 IV)
51
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 2
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
] Cuscinetti a rulli conici giaÁ assemblati - Tapered roller bearings already assembled
52
53
Repair Manual and Spare Parts List ZF 63 IV - ZF 80 IV - ZF 80-1 IV FIG. 3
ZF 63 IV - ZF 80 IV - ZF 80-1 IV
4
17 20
7
6 18
16 23
21
6 19 22
5 24
1 13
9
10
15 3
11 2
12 16
13
13
14 6
5
54
Repair Manual and Spare Parts List ZF 63 IV - ZF 80 IV - ZF 80-1 IV FIG. 3
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
55
Repair Manual and Spare Parts List ZF 63 IV - ZF 80 IV - ZF 80-1 IV FIG. 4
ZF 63 IV - ZF 80 IV - ZF 80-1 IV
26
10
12
13
11
14
15
4
5
7
6
8
16
9
17
12
3
10
2
25
19
18
10
12
24
15
14
23
27
13
9
22
11
7
21
12
20
5
10
8
26
6
4
1
56
Repair Manual and Spare Parts List ZF 63 IV - ZF 80 IV - ZF 80-1 IV FIG. 4
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
57
Repair Manual and Spare Parts List ZF 63 IV - ZF 80 IV - ZF 80-1 IV FIG. 5
ZF 63 IV - ZF 80 IV - ZF 80-1 IV
17
18
19
22
20 10 1
21
4
2
3
5
12
11
10
9 16
15
8
7
14
12
13 11
10
9
8
7
6
58
Repair Manual and Spare Parts List ZF 63 IV - ZF 80 IV - ZF 80-1 IV FIG. 5
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
59
Repair Manual and Spare Parts List ZF 63 IV - ZF 80 IV - ZF 80-1 IV FIG. 6
ZF 63 IV - ZF 80 IV - ZF 80-1 IV
10
9
4
5
1
6
3
2
F1420176
F1420175
60
Repair Manual and Spare Parts List ZF 63 IV - ZF 80 IV - ZF 80-1 IV FIG. 6
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
61
Repair Manual and Spare Parts List ZF 63 IV - ZF 80 IV - ZF 80-1 IV FIG. 7
ZF 63 IV - ZF 80 IV - ZF 80-1 IV
10
5 7 10
4
6
11
3 9
8
10
F1420178
62
Repair Manual and Spare Parts List ZF 63 IV - ZF 80 IV - ZF 80-1 IV FIG. 7
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
1 3312 199 063 Distributore elettrico ON/OFF Elecric selector valve ON/OFF
12V - 26 bar 12V - 26 bar 1 [
3312 199 064 Distributore elettrico ON/OFF Elecric selector valve ON/OFF
24V - 26 bar 24V - 26 bar 1 [ [
2 3312 308 069 Elettrovalvola ON/OFF 12V Solenoid valve ON/OFF 12V 2 Ma=20 Nm
3312 308 106 Elettrovalvola ON/OFF 24V Solenoid valve ON/OFF 24V 2 Ma=20 Nm
3 0631 405 061 Tappo Dummy plug 1
4 0636 302 053 Tappo M10x1 Screw plug M10x1 1 Ma=12 Nm
5 0634 801 302 Rosetta Washer 1
6 0636 309 007 Tappo Screw plug 1 Ma=35 Nm
7 0636 101 709 Vite T.E. M8x65 Cap screw M8x65 2
8 0636 101 727 Vite T.E. M8x40 Cap screw M8x40 4
9 0630 302 090 Rosetta elastica Spring washer 6
10 3316 117 001 Assieme connettore Connector kit 2
11 3312 308 020 Guarnizione Gasket 1
F1420179
F1420180
63
Repair Manual and Spare Parts List ZF 63 IV - ZF 80 IV - ZF 80-1 IV FIG. 8
ZF 63 IV - ZF 80 IV - ZF 80-1 IV
12
11
10 6 4
13 5
10
2
7
9
3 8
10
F1420178
64
Repair Manual and Spare Parts List ZF 63 IV - ZF 80 IV - ZF 80-1 IV FIG. 8
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
1 3312 199 065 Distributore elettrico ON/OFF Electric selector valve ON/OFF 1 [
12V, 26 bar con TV 12V, 26 bar
with Trolling valve
3312 199 066 Distributore elettrico ON/OFF Electric selector valve ON/OFF 1 [[
24V, 26 bar con TV 24V, 26 bar
with Trolling valve
2 3312 308 069 Elettrovalvola ON/OFF Solenoid valve ON/OFF 2 Ma=20 Nm
12V, 26 BAR 12V, 26 bar
3312 308 106 Elettrovalvola ON/OFF Solenoid valve ON/OFF 2 Ma=20 Nm
24V, 26 bar 24V, 26 bar
3 0631 405 061 Tappo Dummy plug 1
4 0636 302 053 Tappo a vite M10x1 Screw plug M10x1 1 Ma=12 Nm
5 0634 801 302 Anello di tenuta Sealing ring 1
6 0636 309 007 Tappo a vite Screw plug 1 Ma=35 Nm
7 0636 101 709 Vite TCEI M8x65 Cap screw M8x65 2
8 0636 101 727 Vite TCEI M8x40 Cap screw M8x40 4
9 0630 302 090 Rosetta elastica Spring washer 6
10 3316 117 001 Assieme connettore Connector kit 3
11 3312 108 027 Trolling valve Trolling device 1
12 3312 308 096 Valvola proporzionale 12V Proportional valve 12V 1 Ma=27 Nm
3312 308 124 Valvola proporzionale 24V Proportional valve 24V 1 Ma=27 Nm
13 3312 308 020 Guarnizione Gasket 1
F1420179
F1420180
65
Repair Manual and Spare Parts List ZF 63 IV
± ± 3312 199 020 500423 Kit guarnizioni e anelli elastici Seal kit & piston rings 1
1 29 3312 301 030 413883 . Paraolio entrata . Input shaft seal 1
1 4 0634 319 133 444070 . Paraolio uscita . Output shaft seal 1
1 30 0634 319 134 444071 . Paraolio uscita . Output shaft seal 1
3 3 3312 308 020 408388 . Guarnizione . Gasket 1
3 8 0634 309 621 500065 . Anello di tenuta . Seal 1
2 4 3312 302 041 447038 . Anello elastico . Piston ring 3
1 22 0634 304 405 501211 . Guarnizione OR . O-Ring 1
1 11 0634 304 688 442731 . Guarnizione OR . O-Ring 1
1 12 0634 306 204 105542 . Guarnizione OR . O-Ring 1
1 20 3312 301 008 439653 . Guarnizione . Gasket 1
± ± 3312 199 021 500433 Kit guarnizioni e frizioni Seal kit & clutch kit 1
± ± 3312 199 020 504230 . Kit guarnizioni e anelli elastici . Seal kit & piston rings 1
2 14 3312 302 009 455786 . Disco frizione interno . Inner clutch disc 8
2 13 3312 302 008 455787 . Disco frizione esterno . Outer clutch disc 10
66
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV
± ± 3313 199 023 500425 Kit guarnizioni e anelli elastici Seal kit & piston rings 1
1 29 3312 301 030 413883 . Paraolio entrata . Input shaft seal 1
1 5 0634 309 631 105113 . Paraolio uscita . Output shaft seal 1
1 30 0634 309 619 480762 . Paraolio uscita . Output shaft seal 1
3 3 3312 308 020 408388 . Guarnizione . Gasket 1
3 8 0634 309 621 500065 . Anello di tenuta . Seal 1
2 4 3312 302 041 447038 . Anello elastico . Piston ring 3
1 23 0634 304 405 501211 . Guarnizione OR . O-Ring 1
1 12 0634 304 688 442731 . Guarnizione OR . O-Ring 1
1 13 0634 306 204 105542 . Guarnizione OR . O-Ring 1
1 21 3312 301 008 439653 . Guarnizione . Gasket 1
± ± 3313 199 024 500435 Kit guarnizioni e frizioni Seal kit & clutch kit 1
± ± 3313 199 023 500425 . Kit guarnizioni e anelli elastici . Seal kit & piston rings 1
2 16 3312 302 009 455786 . Disco frizione interno . Inner clutch disc 10
2 15 3312 302 008 455787 . Disco frizione esterno . Outer clutch disc 12
67
68
Repair Manual and Spare Parts List Section 12 : Spare parts list
ZF 80 IV, ZF 80 - 1 IV
Preface
The spare parts list is only valid for the type and ver- When ordering parts, please state:
sions of transmission, as shown below. . Transmission type
You will find the transmission type and version on your . Transmission version
transmission name plate.
. Serial number
If the type and version indicated differs from that printed
. Item no.
in this Manual, the relative Spare Parts List should be
ordered from ZF HURTH MARINE. . Part name
The indicated dimensions and standards are as such . Identification no.
not enough for ordering parts. . quantity of parts required.
ZF 80 IV versions 029 (1.21 R); 030 (1.40 R); 031 (1.64 R); 032 (2.01 R); 033 (2.49 R)
ZF 80-1 IV versions 034 (1.21 R); 035 (1.40 R); 036 (1.64 R); 037 (2.01 R); 038 (2.49 R);
Name plate
The name plate is mounted to the transmission.
69
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 1
30
29
26
26
26
27
28
27
26
27
27
27
24
27
26
25
7
27
25
9
22
10
23
13
11
12
16
6
14
31
8
21
15
32
19
20
18
1
17
5
4
3
70
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 1
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
] Fornito solamento incluso nel Kit filtro olio p/n 3312 199 031
Supplied only included in the oil filter Kit p/n 3312 199 031
71
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 2
31
30
32
24
37
36
29
13
25
25
14
34
16
27
3
33
10
35
28
26
9
19
20
15
17
18
10
12
21
11
22
1
21
6
23
2
19
16 5
4
12
17
22
20
18
14
15
13
72
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 2
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
l Solo per ZF 80 IV (tutti i rapporti) e ZF 80-1 IV Rapporto I=2.49 - Only for ZF 80 IV (all ratios) and ZF 80-1 IV Ratio I=2.49
l l Solo per ZF 80-1 IV - Escluso rapporto I=2.49 - Only for ZF 80-1 IV - No ratio I=2.49
73
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 2
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
] Cuscinetti a rulli conici giaÁ assemblati - Tapered roller bearings already assembled
74
75
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 3
4
17 20
7
6 18
16 23
21
6 19 22
5 24
1 13
9
10
15 3
11 2
12 16
13
13
14 6
5
76
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 3
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
1 3312 108 001 Valvola di comando completa Mechanical selector valve 23 bar 1
3313 108 001 Valvola di comando alta velocitaÁ Mechanical selector valve 26 bar 1 Only for ZF 80-1 IV
2 I . Valvola di comando . Control valve 1
3 3312 308 020 408388 . Guarnizione . Gasket 1
4 3312 308 025 452963 . Leva . Lever 1
5 0636 101 727 442377 . Vite T.E. . Hex head screw 7
6 0630 302 090 442372 . Rosetta . Washer 8
7 0637 006 157 455785 . Dado . Nut 1
8 0634 309 621 500065 . Guarnizione . Gasket 1
9 3312 308 034 500026 . Vite di fermo . Stop screw 1
10 0636 309 007 455756 . Tappo . Plug 1
11 0631 405 061 500107 . Tappo . Plug 1
12 0636 302 053 103465 . Tappo . Plug 1
13 0634 801 302 107410 . Rosetta . Washer 3
14 3312 308 037 500028 . Vite di guida . Guide bolt 1
15 3312 308 047 500044 . Molla . Spring 1
16 0635 460 014 106695 . Sfera . Ball 2
17 3312 308 029 455764 . Interruttore completo . Neutral safety switch assy. 1
18 001.105.0158 105527 . Guarnizione OR . O-Ring 1
19 3312 308 039 500030 . Boccola . Bushing 1
20 0630 502 005 500083 . Anello elastico . Snap ring 1
21 3312 308 038 500029 . Boccola . Bushing 1
22 3312 308 042 500032 . Molla per lubrificazione . Spring 1
23 0635 460 023 500097 . Sfera . Ball 1
24 3312 308 036 500027 . Distanziale . Spacer 1
77
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 4
10
9
4
5
1
6
3
2
F1420176
F1420175
78
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 4
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
79
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 5
10
5 7 10
4
6
11
3 9
8
10
F1420178
80
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 5
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
1 3312 199 063 Distributore elettrico ON/OFF Elecric selector valve ON/OFF
12V - 26 bar 12V - 26 bar 1 [
3312 199 064 Distributore elettrico ON/OFF Elecric selector valve ON/OFF
24V - 26 bar 24V - 26 bar 1 [ [
2 3312 308 069 Elettrovalvola ON/OFF 12V Solenoid valve ON/OFF 12V 2 Ma=20 Nm
3312 308 106 Elettrovalvola ON/OFF 24V Solenoid valve ON/OFF 24V 2 Ma=20 Nm
3 0631 405 061 Tappo Dummy plug 1
4 0636 302 053 Tappo M10x1 Screw plug M10x1 1 Ma=12 Nm
5 0634 801 302 Rosetta Washer 1
6 0636 309 007 Tappo Screw plug 1 Ma=35 Nm
7 0636 101 709 Vite T.E. M8x65 Cap screw M8x65 2
8 0636 101 727 Vite T.E. M8x40 Cap screw M8x40 4
9 0630 302 090 Rosetta elastica Spring washer 6
10 3316 117 001 Assieme connettore Connector kit 2
11 3312 308 020 Guarnizione Gasket 1
F1420179
F1420180
81
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 6
12
11
10 6 4
13 5
10
2
7
9
3 8
10
F1420178
82
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV FIG. 6
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
1 3312 199 065 Distributore elettrico ON/OFF Electric selector valve ON/OFF 1 [
12V, 26 bar con TV 12V, 26 bar
with Trolling valve
3312 199 066 Distributore elettrico ON/OFF Electric selector valve ON/OFF 1 [[
24V, 26 bar con TV 24V, 26 bar
with Trolling valve
2 3312 308 069 Elettrovalvola ON/OFF Solenoid valve ON/OFF 2 Ma=20 Nm
12V, 26 BAR 12V, 26 bar
3312 308 106 Elettrovalvola ON/OFF Solenoid valve ON/OFF 2 Ma=20 Nm
24V, 26 bar 24V, 26 bar
3 0631 405 061 Tappo Dummy plug 1
4 0636 302 053 Tappo a vite M10x1 Screw plug M10x1 1 Ma=12 Nm
5 0634 801 302 Anello di tenuta Sealing ring 1
6 0636 309 007 Tappo a vite Screw plug 1 Ma=35 Nm
7 0636 101 709 Vite TCEI M8x65 Cap screw M8x65 2
8 0636 101 727 Vite TCEI M8x40 Cap screw M8x40 4
9 0630 302 090 Rosetta elastica Spring washer 6
10 3316 117 001 Assieme connettore Connector kit 3
11 3312 108 027 Trolling valve Trolling device 1
12 3312 308 096 Valvola proporzionale 12V Proportional valve 12V 1 Ma=27 Nm
3312 308 124 Valvola proporzionale 24V Proportional valve 24V 1 Ma=27 Nm
13 3312 308 020 Guarnizione Gasket 1
F1420179
F1420180
83
Repair Manual and Spare Parts List ZF 80 IV - ZF 80-1 IV
± ± 3313 199 023 500425 Kit guarnizioni e anelli elastici Seal kit & piston rings 1
1 29 3312 301 030 413883 . Paraolio entrata . Input shaft seal 1
1 5 0634 309 631 105113 . Paraolio uscita . Output shaft seal 1
1 30 0634 309 619 480762 . Paraolio uscita . Output shaft seal 1
3 3 3312 308 020 408388 . Guarnizione . Gasket 1
3 8 0634 309 621 500065 . Anello di tenuta . Seal 1
2 4 3312 302 041 447038 . Anello elastico . Piston ring 3
1 23 0634 304 405 501211 . Guarnizione OR . O-Ring 1
1 12 0634 304 688 442731 . Guarnizione OR . O-Ring 1
1 13 0634 306 204 105542 . Guarnizione OR . O-Ring 1
1 21 3312 301 008 439653 . Guarnizione . Gasket 1
± ± 3313 199 079 Kit guarnizioni e frizioni Seal kit & clutch kit 1
± ± 3313 199 023 500425 . Kit guarnizioni e anelli elastici . Seal kit & piston rings 1
2 16 3319 302 006 . Disco frizione interno . Inner clutch disc 8
2 15 3319 302 001 . Disco frizione esterno . Outer clutch disc 10
84
Repair Manual and Spare Parts List Section 13 : Spare parts list ZF 85 IV
Preface
The spare parts list is only valid for the type and ver- When ordering parts, please state:
sions of transmission, as shown below. . Transmission type
You will find the transmission type and version on your . Transmission version
transmission name plate.
. Serial number
If the type and version indicated differs from that printed
. Item no.
in this Manual, the relative Spare Parts List should be
ordered from ZF HURTH MARINE. . Part name
The indicated dimensions and standards are as such . Identification no.
not enough for ordering parts. . quantity of parts required.
Name plate
The name plate is mounted to the transmission.
85
Repair Manual and Spare Parts List ZF 85 IV FIG. 1
3
29
26
26
26
27
28
27
26
27
27
27
24
27
26
25
7
27
25
9
22 10
23
13
11
12
16
6
15
31
8
21
14
30
19
20
18
1
17
5
4
86
Repair Manual and Spare Parts List ZF 85 IV FIG. 1
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
] Fornito solamento incluso nel Kit filtro olio p/n 3312 199 031
Supplied only included in the oil filter Kit p/n 3312 199 031
87
88
15
17 13
22 19 ZF 85 IV
14
23
12 16 26
24
20
21
23
21 6 25
19 7
12
15 18 38
10
22 11 26
Repair Manual and Spare Parts List
13
20 9 39 28
17 8
5
27 30
16 37
36
14 31
4 7
29
35
40
33
34 32
1
2
41
3
ZF 85 IV FIG. 2
Repair Manual and Spare Parts List ZF 85 IV FIG. 2
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
4
17 20
7
6 18
16 23
21
6 19 22
5 24
1 13
9
10
15 3
11 2
12 16
13
13
14 6
5
90
Repair Manual and Spare Parts List ZF 85 IV FIG. 3
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
1 3313 108 001 Valvola di comando alta velocitaÁ Mechanical selector valve 26 bar 1
2 I . Valvola di comando . Control valve 1
3 3312 308 020 408388 . Guarnizione . Gasket 1
4 3312 308 025 452963 . Leva . Lever 1
5 0636 101 727 442377 . Vite T.E. . Hex head screw 7
6 0630 302 090 442372 . Rosetta . Washer 8
7 0637 006 157 455785 . Dado . Nut 1
8 0634 309 621 500065 . Guarnizione . Gasket 1
9 3312 308 034 500026 . Vite di fermo . Stop screw 1
10 0636 309 007 455756 . Tappo . Plug 1
11 0631 405 061 500107 . Tappo . Plug 1
12 0636 302 053 103465 . Tappo . Plug 1
13 0634 801 302 107410 . Rosetta . Washer 3
14 3312 308 037 500028 . Vite di guida . Guide bolt 1
15 3312 308 047 500044 . Molla . Spring 1
16 0635 460 014 106695 . Sfera . Ball 2
17 3312 308 029 455764 . Interruttore completo . Neutral safety switch assy. 1
18 001.105.0158 105527 . Guarnizione OR . O-Ring 1
19 3312 308 039 500030 . Boccola . Bushing 1
20 0630 502 005 500083 . Anello elastico . Snap ring 1
21 3312 308 038 500029 . Boccola . Bushing 1
22 3312 308 042 500032 . Molla per lubrificazione . Spring 1
23 0635 460 023 500097 . Sfera . Ball 1
24 3312 308 036 500027 . Distanziale . Spacer 1
91
Repair Manual and Spare Parts List ZF 85 IV FIG. 4
10
5 7 10
4
6
11
3 9
8
10
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92
Repair Manual and Spare Parts List ZF 85 IV FIG. 4
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
1 3312 199 063 Distributore elettrico ON/OFF Elecric selector valve ON/OFF
12V - 26 bar 12V - 26 bar 1 [
3312 199 064 Distributore elettrico ON/OFF Elecric selector valve ON/OFF
24V - 26 bar 24V - 26 bar 1 [ [
2 3312 308 069 Elettrovalvola ON/OFF 12V Solenoid valve ON/OFF 12V 2 Ma=20 Nm
3312 308 106 Elettrovalvola ON/OFF 24V Solenoid valve ON/OFF 24V 2 Ma=20 Nm
3 0631 405 061 Tappo Dummy plug 1
4 0636 302 053 Tappo M10x1 Screw plug M10x1 1 Ma=12 Nm
5 0634 801 302 Rosetta Washer 1
6 0636 309 007 Tappo Screw plug 1 Ma=35 Nm
7 0636 101 709 Vite T.E. M8x65 Cap screw M8x65 2
8 0636 101 727 Vite T.E. M8x40 Cap screw M8x40 4
9 0630 302 090 Rosetta elastica Spring washer 6
10 3316 117 001 Assieme connettore Connector kit 2
11 3312 308 020 Guarnizione Gasket 1
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93
Repair Manual and Spare Parts List ZF 85 IV FIG. 5
10
12
11
10 6 4
13 5
10
2
7
9
3 8
10
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94
Repair Manual and Spare Parts List ZF 85 IV FIG. 5
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
1 3312 199 065 Distributore elettrico ON/OFF Electric selector valve ON/OFF 1 [
12V, 26 bar con TV 12V, 26 bar
with Trolling valve
3312 199 066 Distributore elettrico ON/OFF Electric selector valve ON/OFF 1 [[
24V, 26 bar con TV 24V, 26 bar
with Trolling valve
2 3312 308 069 Elettrovalvola ON/OFF Solenoid valve ON/OFF 2 Ma=20 Nm
12V, 26 BAR 12V, 26 bar
3312 308 106 Elettrovalvola ON/OFF Solenoid valve ON/OFF 2 Ma=20 Nm
24V, 26 bar 24V, 26 bar
3 0631 405 061 Tappo Dummy plug 1
4 0636 302 053 Tappo a vite M10x1 Screw plug M10x1 1 Ma=12 Nm
5 0634 801 302 Anello di tenuta Sealing ring 1
6 0636 309 007 Tappo a vite Screw plug 1 Ma=35 Nm
7 0636 101 709 Vite TCEI M8x65 Cap screw M8x65 2
8 0636 101 727 Vite TCEI M8x40 Cap screw M8x40 4
9 0630 302 090 Rosetta elastica Spring washer 6
10 3316 117 001 Assieme connettore Connector kit 3
11 3312 108 027 Trolling valve Trolling device 1
12 3312 308 096 Valvola proporzionale 12V Proportional valve 12V 1 Ma=27 Nm
3312 308 124 Valvola proporzionale 24V Proportional valve 24V 1 Ma=27 Nm
13 3312 308 020 Guarnizione Gasket 1
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95
Repair Manual and Spare Parts List ZF 85 IV
± ± 3323 199 022 Kit guarnizioni e anelli elastici Seal kit & piston rings 1
1 29 0634 301 846 . Paraolio entrata . Input shaft seal 1
1 5 0634 309 631 105113 . Paraolio uscita . Output shaft seal 1
1 3 0634 309 619 480762 . Paraolio uscita . Output shaft seal 1
3 3 3312 308 020 408388 . Guarnizione . Gasket 1
3 8 0634 309 621 500065 . Anello di tenuta . Seal 1
2 4 3312 302 041 447038 . Anello elastico . Piston ring 3
1 23 0634 304 405 501211 . Guarnizione OR . O-Ring 1
1 12 0634 304 688 442731 . Guarnizione OR . O-Ring 1
1 13 0634 306 204 105542 . Guarnizione OR . O-Ring 1
1 21 3312 301 008 439653 . Guarnizione . Gasket 1
± ± 3323 199 023 Kit guarnizioni e frizioni Seal kit & clutch kit 1
± ± 3323 199 022 . Kit guarnizioni e anelli elastici . Seal kit & piston rings 1
2 16 3323 302 011 . Disco frizione interno . Inner clutch disc 8
2 15 3323 302 012 . Disco frizione esterno . Outer clutch disc 10
96
Repair Manual and Spare Parts List Section 14: Spare parts list ZF 80 IV (ZF 85 IV Derivate version)
Preface
The spare parts list is only valid for the type and ver- When ordering parts, please state:
sions of transmission, as shown below. . Transmission type
You will find the transmission type and version on your . Transmission version
transmission name plate.
. Serial number
If the type and version indicated differs from that printed
. Item no.
in this Manual, the relative Spare Parts List should be
ordered from ZF HURTH MARINE. . Part name
The indicated dimensions and standards are as such . Identification no.
not enough for ordering parts. . quantity of parts required.
Name plate
The name plate is mounted to the transmission.
97
Repair Manual and Spare Parts List ZF 80 IV (ZF 85 IV Derivate version) FIG. 1
3
29
26
26
26
27
28
27
26
27
27
27
24
27
26
25
7
27
25
9
22 10
23
13
11
12
16
6
15
31
8
21
14
30
19
20
18
1
17
5
4
98
Repair Manual and Spare Parts List ZF 80 IV (ZF 85 IV Derivate version) FIG. 1
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
] Fornito solamento incluso nel Kit filtro olio p/n 3312 199 031
Supplied only included in the oil filter Kit p/n 3312 199 031
99
Repair Manual and Spare Parts List ZF 80 IV (ZF 85 IV Derivate version) FIG. 2
32
31
33
25
41
40
30
13
26
26
14
38
16
28
3
10
34
39
29
27
6
20
21
15
17
19
12
22
11
23
7
9
1
22
35
8
24
2
37
20
12
36
17
4
23
16
21
19
14
18
15
13
100
Repair Manual and Spare Parts List ZF 80 IV (ZF 85 IV Derivate version) FIG. 2
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
4
17 20
7
6 18
16 23
21
6 19 22
5 24
1 13
9
10
15 3
11 2
12 16
13
13
14 6
5
102
Repair Manual and Spare Parts List ZF 80 IV (ZF 85 IV Derivate version) FIG. 3
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
1 3313 108 001 Valvola di comando alta velocitaÁ Mechanical selector valve 26 bar 1
2 I . Valvola di comando . Control valve 1
3 3312 308 020 408388 . Guarnizione . Gasket 1
4 3312 308 025 452963 . Leva . Lever 1
5 0636 101 727 442377 . Vite T.E. . Hex head screw 7
6 0630 302 090 442372 . Rosetta . Washer 8
7 0637 006 157 455785 . Dado . Nut 1
8 0634 309 621 500065 . Guarnizione . Gasket 1
9 3312 308 034 500026 . Vite di fermo . Stop screw 1
10 0636 309 007 455756 . Tappo . Plug 1
11 0631 405 061 500107 . Tappo . Plug 1
12 0636 302 053 103465 . Tappo . Plug 1
13 0634 801 302 107410 . Rosetta . Washer 3
14 3312 308 037 500028 . Vite di guida . Guide bolt 1
15 3312 308 047 500044 . Molla . Spring 1
16 0635 460 014 106695 . Sfera . Ball 2
17 3312 308 029 455764 . Interruttore completo . Neutral safety switch assy. 1
18 001.105.0158 105527 . Guarnizione OR . O-Ring 1
19 3312 308 039 500030 . Boccola . Bushing 1
20 0630 502 005 500083 . Anello elastico . Snap ring 1
21 3312 308 038 500029 . Boccola . Bushing 1
22 3312 308 042 500032 . Molla per lubrificazione . Spring 1
23 0635 460 023 500097 . Sfera . Ball 1
24 3312 308 036 500027 . Distanziale . Spacer 1
103
Repair Manual and Spare Parts List ZF 80 IV (ZF 85 IV Derivate version) FIG. 4
10
5 7 10
4
6
11
3 9
8
10
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104
Repair Manual and Spare Parts List ZF 80 IV (ZF 85 IV Derivate version) FIG. 4
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
1 3312 199 063 Distributore elettrico ON/OFF Elecric selector valve ON/OFF
12V - 26 bar 12V - 26 bar 1 [
3312 199 064 Distributore elettrico ON/OFF Elecric selector valve ON/OFF
24V - 26 bar 24V - 26 bar 1 [ [
2 3312 308 069 Elettrovalvola ON/OFF 12V Solenoid valve ON/OFF 12V 2 Ma=20 Nm
3312 308 106 Elettrovalvola ON/OFF 24V Solenoid valve ON/OFF 24V 2 Ma=20 Nm
3 0631 405 061 Tappo Dummy plug 1
4 0636 302 053 Tappo M10x1 Screw plug M10x1 1 Ma=12 Nm
5 0634 801 302 Rosetta Washer 1
6 0636 309 007 Tappo Screw plug 1 Ma=35 Nm
7 0636 101 709 Vite T.E. M8x65 Cap screw M8x65 2
8 0636 101 727 Vite T.E. M8x40 Cap screw M8x40 4
9 0630 302 090 Rosetta elastica Spring washer 6
10 3316 117 001 Assieme connettore Connector kit 2
11 3312 308 020 Guarnizione Gasket 1
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105
Repair Manual and Spare Parts List ZF 80 IV (ZF 85 IV Derivate version) FIG. 5
10
12
11
10 6 4
13 5
10
2
7
9
3 8
10
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106
Repair Manual and Spare Parts List ZF 80 IV (ZF 85 IV Derivate version) FIG. 5
Q.taÁ
Pos. Part number Old P/N Descrizione Description Q.ty Note
1 3312 199 065 Distributore elettrico ON/OFF Electric selector valve ON/OFF 1 [
12V, 26 bar con TV 12V, 26 bar
with Trolling valve
3312 199 066 Distributore elettrico ON/OFF Electric selector valve ON/OFF 1 [[
24V, 26 bar con TV 24V, 26 bar
with Trolling valve
2 3312 308 069 Elettrovalvola ON/OFF Solenoid valve ON/OFF 2 Ma=20 Nm
12V, 26 BAR 12V, 26 bar
3312 308 106 Elettrovalvola ON/OFF Solenoid valve ON/OFF 2 Ma=20 Nm
24V, 26 bar 24V, 26 bar
3 0631 405 061 Tappo Dummy plug 1
4 0636 302 053 Tappo a vite M10x1 Screw plug M10x1 1 Ma=12 Nm
5 0634 801 302 Anello di tenuta Sealing ring 1
6 0636 309 007 Tappo a vite Screw plug 1 Ma=35 Nm
7 0636 101 709 Vite TCEI M8x65 Cap screw M8x65 2
8 0636 101 727 Vite TCEI M8x40 Cap screw M8x40 4
9 0630 302 090 Rosetta elastica Spring washer 6
10 3316 117 001 Assieme connettore Connector kit 3
11 3312 108 027 Trolling valve Trolling device 1
12 3312 308 096 Valvola proporzionale 12V Proportional valve 12V 1 Ma=27 Nm
3312 308 124 Valvola proporzionale 24V Proportional valve 24V 1 Ma=27 Nm
13 3312 308 020 Guarnizione Gasket 1
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107
Repair Manual and Spare Parts List ZF 80 IV (ZF 85 IV Derivate version)
± ± 3323 199 022 Kit guarnizioni e anelli elastici Seal kit & piston rings 1
1 29 0634 301 846 . Paraolio entrata . Input shaft seal 1
1 5 0634 309 631 105113 . Paraolio uscita . Output shaft seal 1
1 3 0634 309 619 480762 . Paraolio uscita . Output shaft seal 1
3 3 3312 308 020 408388 . Guarnizione . Gasket 1
3 8 0634 309 621 500065 . Anello di tenuta . Seal 1
2 4 3312 302 041 447038 . Anello elastico . Piston ring 3
1 23 0634 304 405 501211 . Guarnizione OR . O-Ring 1
1 12 0634 304 688 442731 . Guarnizione OR . O-Ring 1
1 13 0634 306 204 105542 . Guarnizione OR . O-Ring 1
1 21 3312 301 008 439653 . Guarnizione . Gasket 1
± ± 3323 199 023 Kit guarnizioni e frizioni Seal kit & clutch kit 1
± ± 3323 199 022 . Kit guarnizioni e anelli elastici . Seal kit & piston rings 1
2 16 3323 302 011 . Disco frizione interno . Inner clutch disc 8
2 15 3323 302 012 . Disco frizione esterno . Outer clutch disc 10
108