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ZF Transmission ZF 63 IV ZF 80 IV ZF 80-1 IV ZF 85 IV Spare parts Manual & Repair Manual – PDF DOWNLOAD
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ZF Transmission ZF 63 IV ZF 80 IV ZF 80-1 IV ZF 85 IV Spare parts Manual & Repair Manual – PDF DOWNLOAD
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Description
ZF Transmission ZF 63 IV ZF 80 IV ZF 80-1 IV ZF 85 IV Spare parts Manual & Repair Manual – PDF DOWNLOAD
FILE DETAILS:
ZF Transmission ZF 63 IV ZF 80 IV ZF 80-1 IV ZF 85 IV Spare parts Manual & Repair Manual – PDF DOWNLOAD
Language : English
Pages : 110
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
ZF Transmission ZF 63 IV ZF 80 IV ZF 80-1 IV ZF 85 IV Spare parts Manual & Repair Manual – PDF DOWNLOAD
INTRODUCTION:
This manual gives specific instructions for the proper repair on ZF863IV – ZF 801V – ZF 80-11V – 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
TABLE OF CONTENTS:
ZF Transmission ZF 63 IV ZF 80 IV ZF 80-1 IV ZF 85 IV Spare parts Manual & Repair Manual – PDF DOWNLOAD
Repair Manual and Spare Parts List
Table of contents
TABLE OF CONTENTS
INTRODUCTION
1 MAJOR COMPONENTS
1 1 MAJOR TRANSMISSIONS COMPONENTS
1 2 CLEANERS AND SEALANTS
1 3 MEASURING TOOLS
1 4 STANDARD TOOLS AND FIXTURE
1 1 MAJOR TRANSMISSIONS COMPONENTS
1 2 CLEANERS AND SEALANTS
1 3 MEASURING TOOLS
1 4 STANDARD TOOLS AND FIXTURE
2, SPECIALTOOLS
3 DISASSEMBLY
INTRODUCTION
INTRODUCTION
3A FLUID FILTER
3 1 1 Remove fluid filter
3 1 2 Suction of transmission fluid
3 1 3 Suction of transmission fluid on
3 1 1 Remove fluid filter
3 1 2 Suction of transmission fluid
3 1 3 Suction of transmission fluid on
ZF631V, ZF 801V, ZF80-11V and ZF851V
3 2REMOVALDIPSTICK
3 3 REMOVAL BREATHER VALVE
34 0UTPUT FLANGE
3 3 REMOVAL BREATHER VALVE
34 0UTPUT FLANGE
3 5 REMOVAL CONTROL BLOCK
3 5 1 Neutral Safety Switch
3 5 2 Neutral Safety Switch Check
3 5 1 Neutral Safety Switch
3 5 2 Neutral Safety Switch Check
BBHOUSING oo
3 6 1 Disassemble the transmission housing
halves
3 6 1 Disassemble the transmission housing
halves
3 6 2 Removal of shafts and gears
3 6 3 Removal of radial shaftseals
3 6 4 Removal of fluid inlet pipe
3 6 3 Removal of radial shaftseals
3 6 4 Removal of fluid inlet pipe
3 7 TAPERED ROLLER BEARINGS
3 7 1 Disassembling the outer races of
taper roller bearing
taper roller bearing
3 7 2 Removal of inner races of
taper roller bearings
taper roller bearings
3 8 REVERSING CLUTCHPACK
3 8 1 Removal of the clutch discs
3 8 1 Removal of the clutch discs
4, ASSEMBLY cci iii i
INTRODUCTION
INTRODUCTION
41 INPUT SHAFT
4 1 1 Mount discs into reversing clutch
4 1 2 Install needle bearings and gear
4 1 3 Assemble butting rings
4 1 1 Mount discs into reversing clutch
4 1 2 Install needle bearings and gear
4 1 3 Assemble butting rings
4 1 4 Mounting inner races of tapered
roller bearings
4 1 5 Assemble piston rings
roller bearings
4 1 5 Assemble piston rings
4 2 INTERMEDIATE AND REVERSAL SHAFT
4 2 1 Mounting inner races of tapered
roller bearings
roller bearings
43 0UTPUT SHAFT 20
4 3 1 Preparations for assembly 20
4 3 2 Mounting inner race of
4 3 1 Preparations for assembly 20
4 3 2 Mounting inner race of
tapered roller bearing 20
4 3 3 Pressing the gearon 20
4 3 3 Pressing the gearon 20
4 4 PREASSEMBLY OF HOUSING 21
4 4 1 Assembly of outer races
(tapered roller bearings) 21
4 4 2 Installation of fluid suction pipe 21
4 4 3 Assembling input shaft seal 22
4 4 2 Installation of fluid suction pipe 21
4 4 3 Assembling input shaft seal 22
4 4 4 Mounting the breather filter 22
4 5 MEASURING THE BEARING CLEARANCE/
ADJUSTING THE PRETENSION OF BEARINGS 23
ADJUSTING THE PRETENSION OF BEARINGS 23
451 General 23
4 5 2 Mounting outer races of tapered roller
bearings into housing 23
4 5 3 Inserting gear set into housing 23
4 5 4 Measuring bearing clearance
oninputshaft 24
4 5 5 Measuring bearing clearance at
intermediate and reversal shafts 24
4 5 6 Measuring the bearing clearance
on the output shaft 25
4 5 7 Adjusting the pretension clearance
ofbearings oo 25
4 5 8 Final assembly of the housing 26
4 6 CONTROLBLOCK 27
4 6 1 Mounting the control block 27
47FLUDFILTER o oo 27
4 7 1 Mounting the fluid filter 27
4 8 MAKING THE TRANSMISSION
READY FOR OPERATION es 27
4 8 1 Filling up with Transmission Fluid 27
4 8 2 Inserting fluid filter into housing 27
4 8 3 Check fluid level 28
5 ADJUSTMENT DATA 29
5 1 SHIFTING PRESSURE ccovviat 29
5 1 1 ZF80-1IV VERSION – ZF85IV 29
51 2 ZF63IV-ZF80IVVERSION 29
5 1 3 ZF 63 IVINDMAR VERSION 30
5 2 LUBE OIL DELIVERY RATE 30
5 2 1 ZF80-1IV VERSION – ZF85IV 30
4 5 2 Mounting outer races of tapered roller
bearings into housing 23
4 5 3 Inserting gear set into housing 23
4 5 4 Measuring bearing clearance
oninputshaft 24
4 5 5 Measuring bearing clearance at
intermediate and reversal shafts 24
4 5 6 Measuring the bearing clearance
on the output shaft 25
4 5 7 Adjusting the pretension clearance
ofbearings oo 25
4 5 8 Final assembly of the housing 26
4 6 CONTROLBLOCK 27
4 6 1 Mounting the control block 27
47FLUDFILTER o oo 27
4 7 1 Mounting the fluid filter 27
4 8 MAKING THE TRANSMISSION
READY FOR OPERATION es 27
4 8 1 Filling up with Transmission Fluid 27
4 8 2 Inserting fluid filter into housing 27
4 8 3 Check fluid level 28
5 ADJUSTMENT DATA 29
5 1 SHIFTING PRESSURE ccovviat 29
5 1 1 ZF80-1IV VERSION – ZF85IV 29
51 2 ZF63IV-ZF80IVVERSION 29
5 1 3 ZF 63 IVINDMAR VERSION 30
5 2 LUBE OIL DELIVERY RATE 30
5 2 1 ZF80-1IV VERSION – ZF85IV 30
5 2 2 ZF63IV – ZF80IV VERSION
5 2 3 ZF 63 IV INDMAR VERSION
5 2 3 ZF 63 IV INDMAR VERSION
6 HYDRAULIC DIAGRAM 32
7 TIGHTENING TORQUES 33
8 FUNCTION TEST 34
| Repair Manual and Spare Parts List
7 TIGHTENING TORQUES 33
8 FUNCTION TEST 34
| Repair Manual and Spare Parts List
Table of contents
9 TROUBLESHOOTING 35
10 AUTOMATIC TRANSMISSION FLUID 40
10 AUTOMATIC TRANSMISSION FLUID 40
11 SPARE PARTS LIST ZF631V – ZF801V – ZF80-11V 43
Preface
Name plate
FIG 1 ZF 63 IV
FIG 1 ZF80IV-ZF80-1IV 46
FIG 2 ZF B3 IV otis 48
FIG 2 ZFB0IV-ZF80-1IV 50
FIG 3 Mechanical selector valve
ZF63IV-ZF80IV-ZF80-1IV 54
ZF63IV-ZF80IV-ZF80-1IV 54
FIG 4 Old electric selector valve with
proportional valves
ZF63IV-ZF80IV-ZF80-1IV 56
FIG 5 ZF63IV-ZF80IV-ZF80-1IV 58
FIG 8 Old electric selector valve
ON/OFF 12V, 26 BAR
ZF63IV-ZF80IV-ZF80-1IV 60
FIG 7 New electric selector valve ON/OFF 12V – 26 bar
proportional valves
ZF63IV-ZF80IV-ZF80-1IV 56
FIG 5 ZF63IV-ZF80IV-ZF80-1IV 58
FIG 8 Old electric selector valve
ON/OFF 12V, 26 BAR
ZF63IV-ZF80IV-ZF80-1IV 60
FIG 7 New electric selector valve ON/OFF 12V – 26 bar
New electric selector valve ON/OFF 24V – 26 bar
ZF63IV-ZF80IV-ZF80-1IV 62
ZF63IV-ZF80IV-ZF80-1IV 62
FIG 8 New electric selector valve on/off 12v – 26 bar
with trolling valve
New electric selector valve on/off 24v – 26 bar
with trolling valve
with trolling valve
New electric selector valve on/off 24v – 26 bar
with trolling valve
ZFB3IV-ZF80IV-ZF801IV 64
KIT COMPONENTS ZF 63 IV ocee 66
KIT COMPONENTS ZF 80 IV-ZF 80-1 IV 67
KIT COMPONENTS ZF 63 IV ocee 66
KIT COMPONENTS ZF 80 IV-ZF 80-1 IV 67
12 SPARE PARTS LIST
ZF 801V (029 – 030 – 031 – 032 – 033 VERSION)
ZF 80-11V (034 – 035 – 036 – 037 – 038 VERSION) 69
ZF 80-11V (034 – 035 – 036 – 037 – 038 VERSION) 69
Preface ii 69
Name plate ooii 69
FIG 1 ZF80IV, ZF80-1IV ccovivint, 70
FIG 2 ZF80IV, ZF80-1IV cvoeivnnt 72
FIG 3 Mechanical selector valve
Name plate ooii 69
FIG 1 ZF80IV, ZF80-1IV ccovivint, 70
FIG 2 ZF80IV, ZF80-1IV cvoeivnnt 72
FIG 3 Mechanical selector valve
ZF80IV, ZF80-1IV coven 76
FIG 4 Old electric selector valve
ON/OFF 12V, 26 bar ZF80IV, ZF80-1IV 78
FIG 5 New electric selector valve ON/OFF 12V – 26 bar
New electric selector valve ON/OFF 24V – 26 bar
ZF80IV,ZF80-1IV ccoveens 80
FIG 6 New electric selector valve on/off 12v – 26 bar
with trolling valve
New electric selector valve on/off 24v – 26 bar
with trolling valve
ZF80IV,ZF80-1IV ccoveens 82
KIT COMPONENTS
ZFB80IV, ZF80-1IV oi 84
ON/OFF 12V, 26 bar ZF80IV, ZF80-1IV 78
FIG 5 New electric selector valve ON/OFF 12V – 26 bar
New electric selector valve ON/OFF 24V – 26 bar
ZF80IV,ZF80-1IV ccoveens 80
FIG 6 New electric selector valve on/off 12v – 26 bar
with trolling valve
New electric selector valve on/off 24v – 26 bar
with trolling valve
ZF80IV,ZF80-1IV ccoveens 82
KIT COMPONENTS
ZFB80IV, ZF80-1IV oi 84
13 SPARE PARTS LIST ZF85IV 85
Preface 85
Name plate ooo 85
FIG 1 ZF85IV Looe 86
FIG 2 ZF85IV Looe 88
FIG 3 Mechanical selector valve ZF85IV 20
Preface 85
Name plate ooo 85
FIG 1 ZF85IV Looe 86
FIG 2 ZF85IV Looe 88
FIG 3 Mechanical selector valve ZF85IV 20
FIG 4 Electric selector valve ON/OFF 12V – 26 bar
Electric selector valve ON/OFF 24V – 26 bar
ZFB5IV 92
Electric selector valve ON/OFF 24V – 26 bar
ZFB5IV 92
FIG 5 Electric selector valve ON/OFF 12V – 26 bar
with trolling valve
Electric selector valve ON/OFF 24V – 26 bar
with trolling valve
with trolling valve
Electric selector valve ON/OFF 24V – 26 bar
with trolling valve
ZFB5IV oe 94
KIT COMPONENTS ZF851V cooivnnns 96
14 SPARE PARTS LIST ZF801V
(ZF85IV DERIVATE VERSION) 97
Preface 97
Name plate 97
FIG 1 ZF80IV (ZF 851V DERIVATE VERSION) 98
FIG 2 ZF80IV (ZF 851V DERIVATE VERSION) 100
FIG 3 Mechanical selector valve
ZF 801V (ZF 851V DERIVATE VERSION) 102
KIT COMPONENTS ZF851V cooivnnns 96
14 SPARE PARTS LIST ZF801V
(ZF85IV DERIVATE VERSION) 97
Preface 97
Name plate 97
FIG 1 ZF80IV (ZF 851V DERIVATE VERSION) 98
FIG 2 ZF80IV (ZF 851V DERIVATE VERSION) 100
FIG 3 Mechanical selector valve
ZF 801V (ZF 851V DERIVATE VERSION) 102
FIG 4 Electric selector valve ON/OFF 12V – 26 bar
Electric selector valve ON/OFF 24V – 26 bar
ZF801V (ZF 851V DERIVATE VERSION) 104
Electric selector valve ON/OFF 24V – 26 bar
ZF801V (ZF 851V DERIVATE VERSION) 104
FIG 5 Electric selector valve ON/OFF 12V – 26 bar
with trolling valve
Electric selector valve ON/OFF 24V – 26 bar
with trolling valve
with trolling valve
Electric selector valve ON/OFF 24V – 26 bar
with trolling valve
ZF801V (ZF 851V DERIVATE VERSION) 106
KIT COMPONENTS ZF 801V
(ZF85IV DERIVATE VERSION) 108
KIT COMPONENTS ZF 801V
(ZF85IV DERIVATE VERSION) 108
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PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
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