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ZF 63 User Manual

ZF 63
112 pages
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ZF 63 A
ZF 63
ZF 80 A
ZF 80-1 A
ZF 85 A
FEBRUARY 2006
cod.
310.01.0054i
Repair Manual
and
Spare Parts List
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ZF 63 Specifications

General IconGeneral
Max Input Speed3000 rpm
TypeMarine Transmission
Direction of RotationClockwise or Counter-Clockwise
ApplicationCommercial and Recreational Marine
LubricationOil Bath

Summary

Introduction to ZF Marine Transmissions

Major Components of ZF Transmissions

Transmission Set-Up Overview

Details the main components of the transmission.

Cleaners and Sealants for Maintenance

Lists recommended cleaners and sealants for maintenance.

Essential Measuring Tools for Repair

Describes essential measuring tools for repairs.

Standard Tools and Fixtures

Lists standard tools and fixtures required for service.

Special Tools for ZF Transmission Repair

Disassembly Procedures for ZF Transmissions

Fluid Filter Removal

Procedure for removing the fluid filter assembly.

Dipstick Removal

Steps for removing the transmission dipstick.

Breather Valve Removal

Instructions for removing and cleaning the breather valve.

Output Flange Removal

Procedure for removing the output flange.

Control Block Disassembly

Disassembly of the control block, including safety switch checks.

Housing Disassembly

Steps for disassembling the transmission housing components.

Tapered Roller Bearing Removal

Procedures for removing tapered roller bearings.

Clutch Pack Disassembly

Steps for disassembling the clutch pack.

Assembly Procedures for ZF Transmissions

Input Shaft Assembly

Instructions for assembling the input shaft.

Intermediate Shaft Assembly

Procedures for assembling the intermediate shaft.

Output Shaft Assembly

Steps for assembling the output shaft.

Preassembly of Housing

Steps for the preliminary assembly of housing parts.

Bearing Clearance Measurement and Adjustment

Procedures for bearing clearance measurement and adjustment.

Adjustment Data and Specifications

Shifting Pressure Chart

Graph showing shifting pressure versus driving speed.

Lube Oil Delivery Rate Chart

Graph showing lube oil delivery rate versus speed.

Hydraulic System Diagram

Tightening Torques Specification

Function Test Procedures

Troubleshooting Common Transmission Issues

Transmission Cannot Be Shifted

Possible causes and remedies for shifting failure.

Delayed Shift Time

Causes and solutions for slow gear shifting.

Clutch Slippage Diagnosis

Diagnosing and fixing clutch slippage issues.

Transmission Locked in Gear

Troubleshooting a transmission stuck in gear.

Output Shafts in Neutral Position

Addressing issues with output shafts in neutral.

Low Shifting Pressure

Diagnosing low shifting pressure.

No Shifting Pressure Available

Remedies for absent shifting pressure.

Excessive Fluid Temperature

Causes and fixes for high fluid temperature.

Water or Milky Fluid Contamination

Identifying and resolving fluid contamination.

Fluid Leakage at Shafts

Troubleshooting fluid leaks from shafts.

Fluid Leakage at Breather

Addressing fluid leaks from the breather.

Fluid Leakage at Joints and Connections

Fixing fluid leaks at connection points.

Increasing Transmission Noise

Diagnosing increasing transmission noise.

Chattering Noise at Low Speed

Resolving specific chattering noise issues.

General Low Pressure Issues

Troubleshooting general low pressure conditions.

General Oil Leakage

General causes and fixes for oil leaks.

High Oil Temperature Issues

Addressing issues causing high oil temperature.

Clutch Slippage Diagnosis

Diagnosing and rectifying clutch slippage.

Transmission Noise Troubleshooting

General troubleshooting for transmission noise.

Engagement Not Possible

Resolving issues preventing gear engagement.

Slow Gear Engagement

Diagnosing and fixing slow gear engagement.

Hard Shifting Diagnosis

Solutions for difficult gear shifting.

Transmission Dragging in Neutral

Addressing transmission drag in neutral.

Water in Oil Contamination

Identifying and fixing water contamination in oil.

Automatic Transmission Fluid Information

Spare Parts List for ZF 63A, 63, 80A, 80-1A

Spare Parts List for ZF 80A and 80-1A

Spare Parts List for ZF 85A

Spare Parts List for ZF 80A (ZF 85A Derivate Version)

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