Repair Manual and Spare Parts List

Repair Manual and Spare Parts List ZF 6 A ZF 6 ZF 80 A ZF 80- A ZF 85 A FEBRUARY 006 cod. 0.0.0054i

Repair Manualand Spare Parts List Table of contents TABLE OF CONTENTS INTRODUCTION...... MAJOR COMPONENTS..... 5. TRANSMISSION SET-UP.... 5. CLEANERS AND SEALANTS......6. MEASURING TOOLS.... 6.4 STANDARD TOOLS AND FIXTURE....6. SPECIAL TOOLS..... 7. DISASSEMBLY... 9 INTRODUCTION...9. FLUID FILTER.....9.. Remove fluid filter......9.. Suction of transmission fluid......9.. Suction of transmission fluid on ZF 80 A, ZF 80- A and ZF 85 A....9. DIPSTICK..... 0. BREATHER VALVE...... 0.4 OUTPUT FLANGE... 0.5 CONTROL BLOCK.......5. NeutralSafety Switch....5. NeutralSafety Switch Check.......6 HOUSING......6. Transmission housing halves.......6. Shafts and gears....6. Radialshaft seals....6.4 Fluid inlet pipe......7 TAPERED ROLLER BEARINGS.... 4.7. Outer races of tapered roller bearing.... 4.7. Inner races of tapered roller bearings... 4.8 CLUTCH PACK.... 5.8. Removalof the clutch discs... 5 4. ASSEMBLY... 7 INTRODUCTION... 7 4. INPUT SHAFT..... 7 4.. Mount discs into reversing clutch... 7 4.. Install needle bearings and gear... 8 4.. Assemble butting rings... 8 4..4 Mounting inner races of tapered roller bearings...... 8 4..5 Assemble shims, support shims and retaining ring... 8 4..5 Assemble piston rings... 9 4. INTERMEDIATE SHAFT...... 9 4.. Mounting inner races of tapered roller bearings...... 9 4. OUTPUT SHAFT... 9 4.. Mounting inner race of tapered roller bearing... 9 4.4 PREASSEMBLY OF HOUSING...0 4.4. Assembly of outer races (tapered roller bearings).... 0 4.4. Installation of fluid suction pipe and baffle.... 0 4.4. Assembling input shaft seal...... 4.4.4 Mounting the breather filter...... 4.5 MEASURING THE BEARING CLEARANCE/ ADJUSTING THE PRETENSION OF BEARINGS.. 4.5. General...... 4.5. Mounting outer races of tapered roller bearings into housing...... 4.5. Inserting gear set into housing... 4.5.4 Measuring bearing clearance on input shaft.... 4.5.5 Measuring bearing clearance at intermediate shaft..... 4.5.6 Measuring the bearing clearance on the output shaft... 4.5.7 Adjusting the pretension/clearance of bearings.....4 4.5.8 Finalassembly of the housing...4 4.6 CONTROL BLOCK.....5 4.6. Mounting the controlblock...... 5 4.7 FLUID FILTER....5 4.7. Mounting the fluid filter.... 5 4.8 OUTPUT FLANGE.....5 4.9 MAKING THE TRANSMISSION READY FOR OPERATION......6 4.9. Filling up with transmission Fluid.... 6 4.9. Check fluid level......6 5. ADJUSTMENT DATA.....7 5. SHIFTING PRESSURE.....7 5. LUBE OIL DELIVERY RATE.....7 6. HYDRAULIC DIAGRAM....8 7. TIGHTENING TORQUES... 9 8. FUNCTION TEST....0 9. TROUBLESHOOTING..... 0. AUTOMATIC TRANSMISSION FLUID... 6. SPARE PARTS LIST ZF6A - ZF6 - ZF80A - ZF80-A...9 Preface.....9 Name plate......9 FIG. ZF 6 A....40 FIG. ZF 6.....4 FIG. ZF 80 A - ZF 80- A.....44

Repair Manualand Spare Parts List Table of contents FIG. ZF 6 A... 46 FIG. ZF 6.... 50 FIG. ZF 80 A - ZF 80- A..... 5 FIG. Mechanical selector valve ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A...... 56 FIG. 4 Old electric selector valve with proportional valves ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A...... 58 FIG. 5 ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A...... 60 FIG. 6 Old electric selector valve ON/OFF V, 6 bar ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A...... 6 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..... 64 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..... 66 ZF 6 A - ZF 6 KIT COMPONENTS...... 68 ZF 80 A - ZF 80- A KIT COMPONENTS... 69. SPARE PARTS LIST ZF 80 A (06, 07, 08, 09, 00, 0 VERSION) ZF 80- A (04, 05, 06, 07, 09, 00 VERSION)... 7 Preface..... 7 Name plate...... 7 FIG. ZF 80 A - ZF 80- A...... 7 FIG. ZF 80 A - ZF 80- A...... 74 FIG. Mechanical selector valve ZF 80 A - ZF 80- A...... 78 FIG. 4 Old electric selector valve ON/OFF V, 6 bar ZF 80 A - ZF 80- A...... 80 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...... 8 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...... 84 KIT COMPONENTS ZF 80 A - ZF 80- A... 86. SPARE PARTS LIST ZF 85 A..... 87 Preface... 87 Name plate..... 87 FIG. ZF 85 A...... 88 FIG. ZF 85 A...... 90 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... 94 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... 96 KIT COMPONENTS ZF 85 A... 98 4. SPARE PARTS LIST ZF 80A (ZF 85 A DERIVATE VERSION)... 99 Preface... 99 Name plate..... 99 FIG. ZF 80 A (ZF 85 A DERIVATE VERSION).... 00 FIG. ZF 80 A (ZF 85 A DERIVATE VERSION).... 0 FIG. Mechanical selector valve ZF 80 A (ZF 85 A DERIVATE VERSION).... 04 FIG. 4 Electric selector valve ON/OFF V - 6 bar Electric selector valve ON/OFF 4V - 6 bar ZF 80 A (ZF 85 A DERIVATE VERSION).... 06 FIG. 5 Electric selector valve ON/OFF V - 6 bar with trolling valve Electric selector valve ON/OFF 4V - 6 bar with trolling valve ZF 80 A (ZF 85 A DERIVATE VERSION).... 08 KIT COMPONENTS ZF 80 A (ZF 85 A DERIVATE VERSION)..... 0

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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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.......4 5

Repair Manualand 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 oilplug 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 6 4.0 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 (8-7 - 9 - mm) (7/8") Measuring gauge from 0-5 mm (0-.0 in.) Accurancy of reading /00 mm (0.0004 in.) ALLEN WRENCH (6 mm) DIAL INDICATOR GAUGE WITH ARM-TYPE SUPPORT HEXAGON SOCKET WRENCH (6-8 - 7-9 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

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 978.5.007.0 (4544) CLAMPING RING for measuring the bearing clearance input shaft P/N 9.54. (6858) LEVER CLAMPING SCREW INPUT SHAFT DIAL INDICATOR ADAPTER for basic unit 978.5.007.0 (4544). For bearing input shaft - spline side. - P/N 978.5.008.0 (469686) ZF 6 A - ZF 6 - P/N 978.5.009.0 (500465) ZF 80 A - ZF 80- A - ZF 85 A MANDREL For disassembly and assembly Shaft seal- input side : P/N 4.86.005 (45445) Shaft seal- output side: - P/N 4.86.006 (45446) ZF 6 A - ZF 6 - P/N 978.5.0005.0 (500449) ZF 80 A - ZF 80- A - ZF 85 A EXTRACTOR SPLIT RING Input shaft. Taper roller bearing inner race - control block side. P/N 4.86.009 D (45670) For assembling input shaft seal on the input spline side Bushing P/N 0.00.0 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 978.5.00.0 (4544) LEGS KIT (composed of three legs) P/N 978.5.0006.0 (477776) MandrelP/N 0.00.0 to assemble input shaft seal Only for models: ZF 6 A - ZF 6 - ZF 80 A - ZF 80- A 50 BASIC UNIT A B ADAPTER FOR BASIC UNIT 4544 Part number ZF 6 ZF 6 A ZF 80A ZF 80- A ZF 85 A ZF 80A ] 978.5.0009.0 (47785) l l 978.5.00.0 (477854) l l l 978.5.00.0 (477856) l 978.5.00.0 (477857) l 978.5.006.0 (477895) l l ] (ZF 85 A DERIVATE VERSION) MandrelP/N 0.07.0 to assemble input shaft seal Only for model: ZF 85 A - ZF 80 A (ZF 85 A DERIVATE VERSION) 7

Repair Manualand Spare Parts List Section SHIM To determinate the correct preload of the tapered roller bearings. - P/N 0.005.00 ZF 6 A - P/N 0.08.00 ZF 6 - P/N 0.06.00 - ZF80 A - ZF 80- A - ZF 85 A PUNCH for assembly Seal - suction pipe - P/N 0.0.00 ZF 80 A - ZF 80- A - ZF 85 A - P/N 0.09.00 ZF 6 A - ZF 6 CENTRE SQUARE PUNCH To position the oilsuction pipe into housing P/N 0.04.00 SPECIAL HEX HEAD BOLT WITH BEARING for measuring the bearing clearance intermediate shaft P/N. 4.86.008 (45805) 8

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

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

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. 5 -.5. 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. 5 -.5. 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 -

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. 6 -.6. 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

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

Repair Manualand 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 specialtool(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 location of shims under each outer race for correct position during reassembling. Shims are located under outer races of the cover only. FIG. 7 -.7. 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 when removing the races, could cause damage to the race or slip off. Input shaft - Control block side The inner race and the gear on the controlblock side can be removed by using the split ring and a standard hydraulic press (fig. 7-b). Input shaft - Control block side ZF 85 A - ZF 80A (ZF 85 A DERIVATE VERSION). 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). INPUT SPLINE SIDE CONTROL BLOCK SIDE FIG. 7 - a FIG. 7 - b FIG. 7 - c 4

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 6 5 4. 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. 7 5 4 6 FIG. 8 - b Control block side (Fig. 8-c) ZF 85 A - ZF 80A (ZF 85 A DERIVATE VERSION). 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. 5 4 6 FIG. 8 - c 5

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. 4 5 6 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). 4 5 6. 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

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

Repair Manualand Spare Parts List Section 4 4.. Install needle bearings and gear Input spline side. Install needle bearing (item, fig. -) onto shaft. ZF 6 A (Ratio=.7 only) ZF 80A - 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. - 4..4 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 manualpress 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. - 4 4..5 Assemble shims, support shims and retaining ring ZF 85 A - ZF 80A (ZF 85 A DERIVATE VERSION). 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

Repair Manualand Spare Parts List Section 4 4..6 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. - 6 4. 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. - 4. 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

Repair Manualand Spare Parts List Section 4 4.4 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. 4.4. Installation of fluid suction pipe and baffle 4.4.. 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 4.4.. 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

Repair Manualand Spare Parts List Section 4 4.4. 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 0.00.0 (item ).. Use mandrelp/n 0.00.0 (item ) to position the input shaft sealin the correct way. For model ZF 85 A - ZF 80A (ZF 85 A DERIVATE VERSION). Smear loctite 574 on the outside diameter of the input shaft seal using a roller.. Lubricate the inside lip with Kluber Staburags NBU0 grease.. Insert the input shaft seal(item ) into input shaft using the appropriate mandrelp/n 0.07.0 (item ).. Position the input shaft sealin the correct way. 4.4.4 Mounting the breather filter Due to the taper thread, the breather (item, Fig. 4-4) need not to be coated with Loctite 4. Apply thin coat of Loctite 574 to the oil breather (item, Fig. 4-4). 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 FIG. 4 - b ZF 85 A ZF 80A (ZF 85 A DERIVATE VERSION) FIG. 4 - c FIG. 4-4

Repair Manualand Spare Parts List Section 4 4.5 MEASURING THE BEARING CLEARANCE/ADJUSTING THE PRETENSION OF BEARINGS 4.5. General The required pretension/play of bearings of the individualshafts 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 (0.0079 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 0.0-0. 0.00-0. 0.00-0. ZF 85 A - ZF 80 A ] 0.0-0. 0.00-0. 0.-0.5 ZF 6 A - ZF 6 0.0-0. 0.00-0. 0.05-0.5 Pretension (inches) Shaft Input Intermediate Output ZF 80 A - ZF 80- A 0.00-0.005 0.000-0.005 0.000-0.005 ZF 85 A - ZF 80 A ] 0.00-0.005 0.000-0.005 0.004-0.006 ZF 6 A - ZF 6 0.00-0.005 0.000-0.005 0.00-0.006 ] (ZF 85 A DERIVATE VERSION) 4.5. 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. 5-4.5. 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 -

Repair Manualand Spare Parts List Section 4 4.5.4 Measuring bearing clearance on input shaft a) Turn input shaft severaltimes to permit bearings to seat. b) Fit clamping ring (tool p/n 9.54. (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. 5-4 4.5.5 Measuring bearing clearance at intermediate shaft a) Unscrew plug (item, Fig. 5-5a) from the housing. b) Screw in specialtool(p/n 4.86.008 (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 4.5.6 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

Repair Manualand Spare Parts List Section 4 4.5.7 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. 4 4 5 FIG. 5-7a 4.5.8 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

Repair Manualand Spare Parts List Section 4 4.6 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. 6-4.7 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. 7-4.8 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

Repair Manualand Spare Parts List Section 4 4.9 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 4.7.. FIG. 9-4.9. 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

Repair Manualand Spare Parts List Section 5 5. ADJUSTMENT DATA 5. SHIFTING PRESSURE SHIFTING PRESSURE (bar) 0 5.5 0 5 MAX. MIN. 400 50 00 50 00 SHIFTING PRESSURE (psi) 0 50 00 5 50 0 0 0 500 000 500 000 500 000 500 4000 4500 5000 DRIVING SPEED (rpm) ZF 6 A - ZF 6 - ZF 80 A; mechanical selector valve bar p/n 08 00 ZF 80- A - ZF 85 A - ZF 80 A (ZF 85 A DERIVATE VERSION); mechanical selector valve 6 bar p/n 08 00 5. LUBE OIL DELIVERY RATE DELIVERY RATE ( /min) 0 5 0 5 0 5 0 0 7.9 7.9 6.86 6. 5.80 5.8 4.75 4..69.7.64..58.05 0.5 0 500 000 500 000 500 000 500 4000 4500 5000 DRIVING SPEED (rpm) ZF 6 A - ZF 6 - ZF 80 A; mechanical selector valve bar p/n 08 00 ZF 80- A - ZF 85 A - ZF 80 A (ZF 85 A DERIVATE VERSION); mechanical selector valve 6 bar p/n 08 00 MIN. ALL MODELS DELIVERY RATE (gal. /min) 7

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

Repair Manualand Spare Parts List Section 7 7. TIGHTENING TORQUES PART Mounting brackets bolts ZF 6 A - ZF 6 Mounting brackets bolts ZF 80 A - ZF 80- A - ZF 85 A Output flange bolt ZF 6 A - ZF 6 SIZE TORQUE IN lb.ft. TORQUE IN Nm LOCTITE M min 55.5 - max 57 min 75 - max 77 - M min 55.5 - max 57 min 75 - max 77 - M6 74 00 4 Housing bolts M0 0 40 - Control block bolts M8 8 4 Shifting lever bolt M8 7 - Output flange bolt ZF 80 A - ZF 80- A - ZF 85 A M6 74 00 4 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 - 0 40 4 Stud bolt M6 6 5 4 Controlblock stop screw - 9 - Controlblock pressure screw M0 9 - Screw ZF 6 A M5 4 5 4 Screw ZF 80 A - ZF 80- A - ZF 85 A M6 7 9 4 Neutralsafety switch - 8.5 5 - Control block guide bolt - 9 - Control block temperature plug - 6 5-9

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 800-000 neutral40ëc/04 ëf 5, 600-800 (idling speed) A<->B position repeatedly 40ëC/04 ëf -,, 500-500 B position 80ëC / 76 ëf -,, 4 600-800 (idling speed) A<->B position repeatedly 80ëC/76 ëf -,, idling - max. speed A position 80ëC/76 ëf -,, 5 ],6 ] 600-800 (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

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..

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.

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 58. 6.4 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.

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 8. 7.6 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 5. 8. 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

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

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-0589. 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 7045. 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 4000. 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. DEUTZ OEL ATF-D KROON OIL BV, ALMELO/NL. ATF DEXRON IID. ALMIROL ATF 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. 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

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 7045. TEXAMATIC 46. TEXAMATIC 7080. 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

8

Repair Manualand 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 80A - ZF 80- 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. Serialnumber. Item no.. Part name. Identification no.. quantity of 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 80A 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

Repair Manualand Spare Parts List ZF 6 A FIG. ZF 6 A 4 5 8 7 6 0 9 8 5 6 7 0 4 9 5 6 4 9 8 7 4 5 0 6 8 NEW VERSION 5 5 7 5 9 6 8 40

Repair Manualand Spare Parts List ZF 6 A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 0 004 4589 Scatola Housing 066 0 04 447 Tappo Plug 064 9 445 Paraolio uscita Output shaft seal 4 0 00 500484 Coperchio filtro completo Filter cover, assy. 5 I. Coperchio filtro. Filter cover 6 064 04 688 447. Guarnizione OR. O-Ring 7 064 06 04 0554 Guarnizione OR O-Ring 8 060 00 085 6700. Rosetta. Washer 9 066 0 475 00. Vite M8x0. Screw M8x0 0 0 007 4867 Filtro olio Oilfilter () old part number 0 008 4965 Guarnizione Sealing washer 99 0 4677 Filtro olio completo Oilfilter, assy 064 04 688 447. Guarnizione OR. O-Ring 4 064 06 04 0554. Guarnizione OR. O-Ring 5 0 07. Filtro olio. Oilfilter () new part number 6 0 005 48948 Tubo aspirazione Suction pipe 0 0 Tubo aspirazione con supporto Suction pipe with support 7 0 0 49 Piastra ritegno Retaining plate 8 066 006 455079 Vite T.E. Hex head screw (ritegno tubo aspirazione) (suction pipe retainer) 066 05 00 Vite T.E. Hex head screw (tubo aspirazione con supporto) (suction pipe with support) 9 06 5 50 587 Spina Locator pin 0 0 00 45889 Coperchio Cover (housing) 0 00 505 Coperchio Cover (housing) () 978.6.70.0 4549 Asta livello olio Oildipstick 0 00 500989 Asta livello olio + OR Oildipstick + OR 064 04 405 50. Guarnizione OR. O-Ring (Asta livello olio) (Oildipstick) 0 00 4469 Valvola di sfiato Breather valve 4 0 00 488 Paraolio entrata Input shaft seal 5 060 0 09 447 Rosetta Washer 6 066 00 550 4474 Vite T.E. Hex head screw 4 7 066 05 7 4475 Vite T.E. Hex head screw 5 8 066 00 57 4476 Vite T.E. Hex head screw 9 066 05 86 455 Vite T.E. Hex head screw 0 066 006 455079 Vite T.E. Hex head screw 066 05 00 Vite T.E. Hex head screw 060 00 046 Rosetta Washer 0 0 45505 Piastra Buffle plate Ratio I=.;.6;.0 0 0 45890 Piastra Buffle plate Ratio I=.5;.7 066 006 455079 Vite T.E. Hex head screw 066 05 00 Vite T.E. Hex head screw 4 060 00 046 Rosetta Washer 5 0 006 4896 Piastra Buffle plate 6 0 00 Targhetta di identificazione Name plate 7 060 00 085 6700 Rosetta Washer 8 066 0 475 00 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 (for PCM only) () Fornito solo incluso nel kit filtro olio p/n 99 0 Supplied only included in the oil filter kit p/n 99 0 4

Repair Manualand Spare Parts List ZF 6 FIG. ZF 6 4 5 8 4 9 5 5 6 7 0 4 9 6 0 9 8 7 0 4 5 5 6 5 7 5 NEW VERSION 9 8 6 8 4

Repair Manualand Spare Parts List ZF 6 FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 0 00 45550 Scatola Housing 066 0 04 447 Tappo Plug 064 9 445 Paraolio uscita Output shaft seal 4 0 00 500484 Coperchio filtro completo Filter cover, assy. 5 I. Coperchio filtro. Filter cover 6 064 04 688 447. Guarnizione OR. O-Ring 7 064 06 04 0554. Guarnizione OR. O-Ring 8 060 00 085 6700. Rosetta. Washer 9 066 0 475 00. Vite M8x0. Screw M8x0 0 0 007 4867 Filtro olio Oilfilter () old part number 0 008 4965 Guarnizione Gasket 99 0 4677 Filtro olio completo Oilfilter, assy 064 04 688 447. Guarnizione OR. O-Ring 4 064 06 04 0554. Guarnizione OR. O-Ring 5 0 07. Filtro olio. Oilfilter () new part number 6 0 0 455499 Tubo aspirazione Suction pipe 0 0 Tubo aspirazione con supporto Suction pipe with support 7 0 0 49 Piastra ritegno Retaining plate 8 066 006 455079 Vite T.E. Hex head screw (ritegno tubo aspirazione) (suction pipe retainer) 066 05 00 Vite T.E. (tubo aspirazione Hex head screw (suction pipe con supporto) with support) 9 06 5 50 587 Spina Locator pin 0 0 08 45550 Coperchio Cover (housing) 0 09 5086 Coperchio Cover Only Ratio I=.5 978..70.0 4689 Asta livello olio Oildipstick 0 00 50099 Asta livello olio + OR Oildipstick + OR 064 04 405 50. Guarnizione OR. O-Ring (Asta livello olio) (Oildipstick) 0 00 4469 Valvola di sfiato Breather valve 4 0 00 488 Paraolio entrata Input shaft seal 5 060 0 09 447 Rosetta Washer 6 066 00 550 4474 Vite T.E. Hex head screw 4 7 066 05 7 4475 Vite T.E. Hex head screw 5 8 066 00 569 45544 Vite T.E. Hex head screw 9 066 05 86 455 Vite T.E. Hex head screw 0 066 006 455079 Vite T.E. Hex head screw 066 05 00 Vite T.E. Hex head screw 060 00 046 447 Rosetta Washer 0 0 455500 Piastra Buffle plate 0 00 Targhetta di identificazione Name plate 4 060 00 085 6700 Rosetta Washer 5 066 0 475 00 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 99 0 4

Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. ZF 80A - ZF 80- A 9 4 5 8 8 0 9 9 5 6 7 0 4 0 4 5 6 0 7 8 6 NEW VERSION 7 6 8 44

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 0 0 4894 Scatola Housing Not available any more 0 009 Scatola Housing From s/n 40 L () 066 0 04 447 Tappo Plug 064 9 04 44860 Paraolio uscita Output shaft seal 4 0 00 500484 Coperchio filtro completo Filter cover, assy. 5. Coperchio filtro. Filter cover 6 064 04 688 447. Guarnizione OR. O-Ring 7 064 06 04 0554. Guarnizione OR. O-Ring 8 060 00 085 6700. Rosetta. Washer 9 066 0 475 00. Vite M8x0. Screw M8x0 0 0 007 4867 Filtro olio Oilfilter (4) old part number 0 008 4965 Guarnizione Gasket 99 0 4677 Filtro olio completo Oilfilter, assy 064 04 688 447. Guarnizione OR. O-Ring 4 064 06 04 0554. Guarnizione OR. O-Ring 5 0 07. Filtro olio. Oilfilter (4) new part number 6 0 05 495 Tubo aspirazione Suction pipe 0 0 Tubo aspirazione Suction pipe () 0 0 Tubo aspirazione con supporto Suction pipe with support 7 06 98 47949 Fascetta Suction pipe clamp 8 066 0 4 0879 Vite T.E. Hex head screw (fascetta tubo aspirazione) (suction pipe clamp) 9 0 04 46997 Anello centratore Centering ring 0 06 5 50 587 Spina Locator pin 0 00 488 Paraolio entrata Input shaft seal 0 00 4469 Valvola di sfiato Breather valve 0 0 48944 Coperchio Cover (housing) Not available any more 0 00 Coperchio Cover (housing) From s/n 40 L () 4 978.6.70.0 4950 Asta livello olio Oildipstick 0 00 50099 Asta livello olio + OR Oildipstick + OR 5 064 04 405 50. Guarnizione OR (Asta livello olio). O-Ring (Oildipstick) 6 060 0 09 447 Rosetta Washer 4 7 066 05 7 4475 Vite T.E. Hex head screw 4 8 0 07 46969 Tappo Plug 9 0 00 Targhetta di identificazione Name plate 0 060 00 085 6700 Rosetta Washer 066 0 475 00 Vite M8x0 Screw M8x0 () Scatola non fornibile con coperchio cod. 0 0 0. 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. 0 0 0. Fornibile solo con scatola codice 0 009 This cover is not suitable with housing p/n 0 0. But only with the new housing p/n 0 009 () Adatto solo alla nuova scatola p/n 0 009 Suitable only to new housing p/n 0 009 (4) Fornito solo incluso nel kit filtro olio p/n 99 0 Supplied only included in the oil filter kit p/n 99 0 Fino a matricola 5909E - Up to serial number 5909E Da matricola 590E - From serial number 590E 45

Repair Manualand Spare Parts List ZF 6 A FIG. ZF 6 A 4 7 9 5 6 8 0 4 5 6 7 8 0 9 7 6 9 0 4 8 5 7 5 9 0 6 7 8 4 4 9 46

Repair Manualand Spare Parts List ZF 6 A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 04 009 49489 Flangia uscita Output flange 064 06 8 0557 Guarnizione OR O-Ring 04 07 47570 Rondella Washer 4 066 06 4886 Vite T.E. Hex head screw 5 0 04 44708 Anello di tenuta Piston ring 6 065 50 940 Cuscinetto a rulli conici Tapered roller bearing 7 0 004 454406 Rasamento Butting ring 8 0 006 488955 Ingranaggio Z=49 Reverse gear Z=49 0 007 5046 Ingranaggio Z=50 Reverse gear Z=50 Only Ratio I=.04 9 0 040 4448 Cuscinetto a rullini Needle bearing 4 0 06 50 06 47956 Chiavetta Key 99 05 Albero di ingresso completo Input shaft, assy. 99 05 Albero di ingresso completo Input shaft, assy. () 060 5 066 455788. Anello elastico. Snap ring 0 0 455789. Disco finale. End disc 0 0 5045. Disco finale. End disc () 4 0 008 455787. Disco frizione esterno. Outer clutch disc 0 5 0 009 455786. Disco frizione interno. Inner clutch disc 8 6 060 50 08 500076. Anello di ritegno. Retainer ring 7 0 05 50048. Molla a tazza. Cup spring 6 0 08. Molla a tazza. Cup spring 6 From s/n 8674 L 8 064 40 78 500066. Anello interno. Inner clutch piston ring 9 0 04 50047. Pistone. Clutch piston 0 065 460 006 06690. Sfera. Ball 064 40 76 500069. Anello esterno. Outer clutch piston ring 99 0. Albero di ingresso +. Input shaft & cilindro frizione clutch housing 99 0. Albero di ingresso +. Input shaft & () cilindro frizione clutch housing 065 50 97 447754 Cuscinetto a rulli conici Tapered roller bearing 065 50 94 Cuscinetto a rulli conici Tapered roller bearing () 4 0 0 77 Spessore 0, mm Shim 0. mm 0 04 774 Spessore 0,5 mm Shim 0.5 mm 0 05 775 Spessore 0, mm Shim 0. mm 5 065 50 94 Cuscinetto a rulli conici Tapered roller bearing 6 065 50 94 Cuscinetto a rulli conici Tapered roller bearing 075 70 9 50 Cuscinetto a rulli conici Tapered roller bearing () 7 065 50 98 859 Cuscinetto a rulli conici Tapered roller bearing 8 065 50 9 Cuscinetto a rulli conici Tapered roller bearing 9 04 07 66807 Spessore 0, mm Shim 0. mm 04 08 4440 Spessore 0,5 mm Shim 0.5 mm 04 09 540 Spessore 0, mm Shim 0. mm 04 00 540 Spessore 0,5 mm Shim 0.5 mm 0 0 06 504 Distanziale Spacer () () Only Ratio I=.7 (also PCM) ; Ratio I=.5 uprated version & ratio I=.5 (for PCM only) 47

Repair Manualand 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=.) 0 005 500860 Ingranaggio Z=7 Forward gear Z=7 99 0 4557 Albero intermedio Z4=45, Z5=4 Intermediate shaft Z4=45, Z5=4 ] 99 04 4557 Albero di uscita Z=45 Output shaft Z=45 ] Vers.,00,06 (Rapporto I=,56) Vers.,00,06 (Ratio I=.56) 0 00 45950 Ingranaggio Z= Forward gear Z= 99 05 4557 Albero intermedio Z4=45, Z5=9 Intermediate shaft Z4=45, Z5=9 ] 99 06 45574 Albero di uscita Z=50 Output shaft Z=50 ] Vers. 4,00,07 (Rapporto I=,04) Vers. 4,00,07 (Ratio I=.04) 0 004 458 Ingranaggio Z=7 Forward gear Z=7 99 07 Albero intermedio Z4=44, Z5=4 Intermediate shaft Z4=44, Z5=4 ] 99 08 45576 Albero di uscita Z=55 Output shaft Z=55 ] Vers. 5,004,08 (Rapporto I=,5) Vers. 5,004,08 (Ratio I=.5) 0 005 4548 Ingranaggio Z= Forward gear Z= 99 09 45577 Albero intermedio Z4=45, Z5= Intermediate shaft Z4=45, Z5= ] 99 00 45578 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) 0 007 50797 Ingranaggio Z= Forward gear Z= 99 07 Albero intermedio Z4=45, Z5= Intermediate shaft Z4=45, Z5= ] 99 074 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) 0 006 5040 Ingranaggio Z= Forward gear Z= 99 00 Albero intermedio Z4=45, Z5=0 Intermediate shaft Z4=45, Z5=0 ] 99 056 Albero di uscita Z=59 Output shaft Z=59 ] ] Cuscinetti a rulli conici giaá assemblati - Tapered roller bearings already assembled 48

49

Repair Manualand Spare Parts List ZF 6 FIG. ZF 6 4 7 9 5 6 8 0 4 5 6 7 8 0 9 7 6 9 0 4 8 5 7 5 9 0 6 7 8 4 4 9 50

Repair Manualand Spare Parts List ZF 6 FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 04 009 49489 Flangia uscita Output flange 064 06 8 0557 Guarnizione OR O-Ring 04 07 47570 Rondella Washer 4 066 06 4886 Vite T.E. Hex head screw 5 0 04 44708 Anello di tenuta Piston ring 6 065 50 940 Cuscinetto a rulli conici Tapered roller bearing 7 0 004 454406 Rasamento Butting ring 8 0 006 488955 Ingranaggio Z=49 Reverse gear Z=49 9 0 040 4448 Cuscinetto a rullini Needle bearing 4 0 06 50 06 47956 Chiavetta Key 99 05 Albero di ingresso completo Input shaft, assy. 060 5 066 455788. Anello elastico. Snap ring 0 0 455789. Disco finale. End disc 4 0 008 455787. Disco frizione esterno. Outer clutch disc 0 5 0 009 455786. Disco frizione interno. Inner clutch disc 8 6 060 50 08 500076. Anello di ritegno. Retainer ring 7 0 05 50048. Molla a tazza. Cup spring 6 0 08. Molla a tazza. Cup spring 6 From s/n 8854 L 8 064 40 78 500066. Anello interno. Inner clutch piston ring 9 0 04 50047. Pistone. Clutch piston 0 065 460 006 06690. Sfera. Ball 064 40 76 500069. Anello esterno. Outer clutch piston ring 99 0. Albero di ingresso+. Input shaft and clutch housing cilindro frizione 065 50 97 447754 Cuscinetto a rulli conici Tapered roller bearing 4 0 0 77 Spessore 0, mm Shim 0. mm 0 04 774 Spessore 0,5 mm Shim 0.5 mm 0 05 775 Spessore 0, mm Shim 0. mm 5 065 50 94 Cuscinetto a rulli conici Tapered roller bearing 6 065 50 94 Cuscinetto a rulli conici Tapered roller bearing 7 065 50 98 859 Cuscinetto a rulli conici Tapered roller bearing 8 065 50 9 Cuscinetto a rulli conici Tapered roller bearing 9 04 07 66807 Spessore 0, mm Shim 0. mm 04 08 4440 Spessore 0,5 mm Shim 0.5 mm 04 09 540 Spessore 0, mm Shim 0. mm 04 00 540 Spessore 0,5 mm Shim 0.5 mm Vers. 009,00 (Rapporto I=,5) Vers. 009,00 (Ratio I=.5) 0 0 09 500856 Ingranaggio Z=9 Forward gear Z=9 99 048 Albero intermedio Z4=45, Z5=6 Intermediate shaft Z4=45, Z5=6 ] 99 049 Albero di uscita Z=49 Output shaft Z=49 ] Vers. 0,00,0 (Rapporto I=,5) Vers. 0,00,0 (Ratio I=.5) 0 0 008 495 Ingranaggio Z=5 Forward gear Z=5 99 040 470065 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) 0 0 009 4954 Ingranaggio Z=0 Forward gear Z=0 99 04 470068 Albero intermedio Z4=45, Z5=7 Intermediate shaft Z4=45, Z5=7 ] 99 04 Albero di uscita Z=58 Output shaft Z=58 ] Vers. 0,00,04 (Rapporto I=,48) Vers. 0,00,04 (Ratio I=.48) 0 0 00 455504 Ingranaggio Z=5 Forward gear Z=5 99 05 47968 Albero intermedio Z4=45, Z5= Intermediate shaft Z4=45, Z5= ] 99 06 479685 Albero di uscita Z=6 Output shaft Z=6 ] Vers. 04,004,05 (Rapporto I=,78) Vers. 04,004,05 (Ratio I=.78) 0 0 0 45550 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

Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. ZF 80A - ZF 80- A 4 7 9 5 6 8 0 5 4 6 7 8 0 9 7 6 9 0 0 4 8 5 7 5 9 0 6 7 8 4 4 9 5

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 04 007 4958 Flangia Flange 064 0 505 8476 Guarnizione OR O-Ring 04 06 8784 Rondella Washer 4 066 06 085 08 Vite T.E. Hex head screw 5 0 04 44708 Anello di tenuta Piston ring 6 065 50 97 447754 Cuscinetto a rulli conici Tapered roller bearing 7 0 0 4578 Rasamento Butting ring 8 0 04 50089 Ingranaggio Z=44 Reverse gear Z=44 9 0 040 4448 Cuscinetto a rullini Needle bearing 4 0 06 50 06 47956 Chiavetta Key 99 06 4866 Albero di ingresso completo Input shaft, assy. 060 5 066 455788. Anello elastico. Snap ring 0 0 455789. Disco finale. End disc 4 0 008 455787. Disco frizione esterno. Outer clutch disc 5 0 009 455786. Disco frizione interno. Inner clutch disc 0 6 060 50 08 500076. Anello di ritegno. Retainer ring 7 0 05 50048. Molla a tazza. Cup spring 6 0 08 50048. Molla a tazza. Cup spring 6 8 064 40 78 500066. Anello interno. Inner clutch piston ring 9 0 04 50047. Pistone. Clutch piston 0 065 460 006 06690. Sfera. Ball 064 40 76 500069. Anello esterno. Outer clutch piston ring 99 07 5007. Albero di ingresso+. Input shaft and clutch housing cilindro frizione 065 50 99 Cuscinetto a rulli conici Tapered roller bearing 4 0 04 4960 Spessore 0, mm Shim 0. mm 0 04 496 Spessore 0,5 mm Shim 0.5 mm 0 044 496 Spessore 0, mm Shim 0. mm 0 045 496 Spessore 0,5 mm Shim 0.5 mm 0 046 4964 Spessore,0 mm Shim.0 mm Intermediate shaft 5 065 50 97 447754 Cuscinetto a rulli conici Tapered roller bearing 6 065 50 98 859 Cuscinetto a rulli conici Tapered roller bearing 7 065 7 008 848 Cuscinetto a rulli conici Tapered roller bearing 8 065 50 94 Cuscinetto a rulli conici Tapered roller bearing 9 08 04 0 4495 Spessore 0,5 mm Shim 0.5 mm 08 04 04 4496 Spessore 0,0 mm Shim 0.0 mm 08 04 07 4497 Spessore 0,50 mm Shim 0.50 mm 0 0 00 495 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=5 99 00 5009 Albero intermedio Z4=44, Z5=5 Intermediate shaft Z4=44, Z5=5 ] 99 0 50098 Albero di uscita Z=4 Output shaft Z=4 ] Vers. 6,00 (Rapporto I=,4) Vers. 6,00 (Ratio I=.4) 0 06 500850 Ingranaggio Z= Forward gear Z= 99 0 5009 Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] 99 0 50099 Albero di uscita Z=45 Output shaft Z=45 ] Vers. 7,00 (Rapporto I=,57) Vers. 7,00 (Ratio I=.57) 0 05 500849 Ingranaggio Z=0 Forward gear Z=0 99 04 50094 Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] 99 05 500400 Albero di uscita Z=47 Output shaft Z=47 ] Vers. 8,004 (Rapporto I=,96) Vers. 8,004 (Ratio I=.96) 0 004 459589 Ingranaggio Z=6 Forward gear Z=6 99 06 50095 Albero intermedio Z4=44, Z5=6 Intermediate shaft Z4=44, Z5=6 ] 99 06 50040 Albero di uscita Z=5 Output shaft Z=5 ] 5

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) 0 005 46 Ingranaggio Z= Forward gear Z= 99 07 50096 Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] 99 08 50040 Albero di uscita Z=55 Output shaft Z=55 ] Vers. 0,006 (Rapporto I=,85) Vers. 0,006 (Ratio I=.85) 0 006 464 Ingranaggio Z=0 Forward gear Z=0 99 09 50097 Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] 99 040 50040 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) 0 05 500849 Ingranaggio Z=0 Forward gear Z=0 99 04 50094 Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] 99 05 500400 Albero di uscita Z=47 Output shaft Z=47 ] Vers. 008 (Rapporto I=,96) Vers. 008 (Ratio I=.96) 0 004 459589 Ingranaggio Z=6 Forward gear Z=6 99 06 50095 Albero intermedio Z4=44, Z5=6 Intermediate shaft Z4=44, Z5=6 ] 99 00 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=5 99 00 5009 Albero intermedio Z4=44, Z5=5 Intermediate shaft Z4=44, Z5=5 ] 99 0 50098 Albero di uscita Z=4 Output shaft Z=4 ] Vers. 00 (Rapporto I=,4) Vers. 00 (Ratio I=.4) 0 06 500850 Ingranaggio Z= Forward gear Z= 99 0 5009 Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] 99 0 50099 Albero di uscita Z=45 Output shaft Z=45 ] Vers. 0 (Rapporto I=,5) Vers. 0 (Ratio I=.5) 0 005 46 Ingranaggio Z= Forward gear Z= 99 00 Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] 99 004 Albero di uscita Z=55 Output shaft Z=55 ] Vers. 0 (Rapporto I=,85) Vers. 0 (Ratio I=.85) 0 007 5079 Ingranaggio Z=0 Forward gear Z=0 99 00 Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] 99 005 Albero di uscita Z=57 Output shaft Z=57 ] ] Cuscinetti a rulli conici giaá assemblati - Tapered roller bearings already assembled 54

55

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 5 6 4 9 8 0 6 7 4 5 7 8 6 9 6 5 4 6 0 56

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 08 00 Valvola di comando completo Controlvalve assy. bar bar 08 00 Valvola di comando alta velocitaá High speed controlvalve assy. Only for ZF 80-A 6 bar 6 bar I. Valvola di comando. Controlvalve 08 00 40888. Guarnizione. Gasket 4 08 05 4596. Leva. Lever 5 066 0 77 4477. Vite T.E.. Hex head screw 7 6 060 0 090 447. Rosetta. Washer 8 7 067 006 57 455785. Dado. Nut 8 064 09 6 500065. Guarnizione. Gasket 9 08 04 50006. Vite di fermo. Stop screw 0 066 09 007 455756. Tappo. Plug 06 405 06 50007. Tappo. Plug 066 0 05 0465. Tappo. Plug 064 80 0 0740. Rosetta. Washer 4 08 07 50008. Vite di guida. Guide bolt 5 08 047 500044. Molla. Spring 6 065 460 04 06695. Sfera. Ball 7 08 09 455764. Interruttore completo. Neutralsafety switch assy. 8 00.05.058 0557. Guarnizione OR. O-Ring 9 08 09 50000. Boccola. Bushing 0 060 50 005 50008. Anello elastico. Snap ring 08 08 50009. Boccola. Bushing 08 04 5000. Molla per lubrificazione. Spring 065 460 0 500097. Sfera. Ball 4 08 06 50007. Distanziale. Spacer 57

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 4 7 6 0 0 45 5 7 8 9 4 0 8 9 5 0 6 7 9 6 8 6 7 5 4 8 5 4 0 7 9 58

Repair Manualand 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 99 004 Distributore elettrico Electric selector valve () 99 005 Distributore elettrico Electric selector valve () 08 00 Distributore elettrico Electric selector valve () Only for ZF 80- A 08 004 Distributore elettrico Electric selector valve (4) Only for ZF 80- A I. Valvola di comando. Controlvalve 08 00 40888 Guarnizione Gasket 4 08 064 5064 Valvola proporzionale V Electric valve V 08 065 5065 Valvola proporzionale 4 V Electric valve 4 V 5 064 04 65 5074 Guarnizione OR O-Ring 6 064 04 9 5054 Anello di tenuta Piston ring 7 060 50 078 5058 Anello elastico Snap ring 8 08 054 5050 Pistoncino valvola / vie Valve piston 9 08 06 505 Molla per pistone Piston spring 0 066 0 05 0465 Tappo Plug 4 08 059 5056 Grano Drilled plug 064 80 0 0740 Rosetta Washer 4 066 0 65 5055 Vite Screw 4 060 00 096 5057 Rondella Washer 5 04 6 045 Fermo valvola Valve lock 6 08 06 5056 Tappo Plug 7 064 06 54 Anello OR O-Ring 8 066 0 77 4477 Vite T.E. Hex head screw 6 9 060 0 090 447 Rosetta Washer 6 0 060 5 004 5059 Anello elastico Snap ring 064 04 09 505 Anello di tenuta OR O-Ring 08 058 5055 Tappo Plug 08 040 5000 Molla Spring 4 08 04 50008 Perno guida molla Spring guide pin 5 08 07 500040 Pistoncino estraibile Valve piston 6 0 04 44708 Anello di tenuta Piston ring 7 7 00 Kit connettori Connectors kit 8 06 50 06 47956 Chiavetta Key 9 978.8.64.0 5075 Kit guarnizioni Sealkit () 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

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 9 0 4 5 7 8 9 6 0 8 0 6 7 9 7 8 4 5 60

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 060 50 005 50008 Anello elastico Snap ring 08 08 50009 Boccola Bushing 08 04 5000 Molla per lubrificazione Spring 4 065 460 0 500097 Sfera Ball 5 08 06 50007 Distanziale Spacer 6 08 05 50497 Vite torna a casa "B" Come home screw "B" 7 064 04 690 505 Anello di tenuta OR O-Ring 8 08 050 50495 Rondella Washer 9 08 056 505 Vite Screw 0 064 80 98 500095 Rosetta Washer 4656 06 0 Pistoncino ammortizzatore Piston 07 04 59 Molla ammortizzatore Spring 06 405 06 5050 Tappo Plug 4 08 05 50496 Vite torna a casa "A" Come home screw "A" 5 066 0 068 500744 Tappo Plug 6 064 80 60 500897 Rosetta Washer 7 066 0 065 5050 Vite Screw 8 064 80 8 785 Rosetta Washer 9 08 06 505 Molla Spring 0 08 057 5054 Perno guida molla Spring guide pin 08 05 50498 Pistoncino valvola riduzione Valve piston 066 0 05 0465 Tappo Plug 064 80 0 0740 Rosetta Washer 6

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 0 6 5 4 9 8 F4076 7 F4075 6

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 99 05 Distributore elettrico Electric selector valve [ 6 bar ON/OFF 6 bar ON/OFF 08 069 Elettrovalvola ON/OFF V Solenoid valve ON/OFF V 06 405 06 Tappo Dummy plug 4 066 0 05 Tappo M0x Screw plug M0x Ma= Nm 5 064 80 0 Rosetta Washer 6 066 09 007 Tappo Screw plug Ma= 0 Nm 7 6 7 00 Assieme connettore Connector kit 8 066 0 77 Vite T.E. M8x40 Cap screw M8x40 6 9 060 0 090 Rosetta Washer 6 0 08 00 Guarnizione Gasket [ Installare con V - To be installed with V power supply 6

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 0 6 4 5 7 0 8 9 0 F4078 64

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 99 06 Distributore elettrico ON/OFF Elecric selector valve ON/OFF V - 6 bar V - 6 bar [ 99 064 Distributore elettrico ON/OFF Elecric selector valve ON/OFF 4V - 6 bar 4V - 6 bar [[ 08 069 Elettrovalvola ON/OFF V Solenoid valve ON/OFF V Ma=0 Nm 08 06 Elettrovalvola ON/OFF 4V Solenoid valve ON/OFF 4V Ma=0 Nm 06 405 06 Tappo Dummy plug 4 066 0 05 Tappo M0x Screw plug M0x Ma= Nm 5 064 80 0 Rosetta Washer 6 066 09 007 Tappo Screw plug Ma=5 Nm 7 066 0 709 Vite T.E. M8x65 Cap screw M8x65 8 066 0 77 Vite T.E. M8x40 Cap screw M8x40 4 9 060 0 090 Rosetta elastica Spring washer 6 0 6 7 00 Assieme connettore Connector kit 08 00 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. 99 06. To transform the solenoid valve from V to 4V it will be enough to replace only the solenoid - available loosen P/N 99 06. 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 65

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 0 0 6 4 5 0 7 8 9 0 F4078 66

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 99 065 Distributore elettrico ON/OFF Electric selector valve ON/OFF [ V, 6 bar con TV V, 6 bar with Trolling valve 99 066 Distributore elettrico ON/OFF Electric selector valve ON/OFF [ [ 4V, 6 bar con TV 4V, 6 bar with Trolling valve 08 069 Elettrovalvola ON/OFF Solenoid valve ON/OFF Ma=0 Nm V, 6 BAR V, 6 bar 08 06 Elettrovalvola ON/OFF Solenoid valve ON/OFF Ma=0 Nm 4V, 6 bar 4V, 6 bar 06 405 06 Tappo Dummy plug 4 066 0 05 Tappo a vite M0x Screw plug M0x Ma= Nm 5 064 80 0 Anello di tenuta Sealing ring 6 066 09 007 Tappo a vite Screw plug Ma=5 Nm 7 066 0 709 Vite TCEI M8x65 Cap screw M8x65 8 066 0 77 Vite TCEI M8x40 Cap screw M8x40 4 9 060 0 090 Rosetta elastica Spring washer 6 0 6 7 00 Assieme connettore Connector kit 08 07 Trolling valve Trolling device 08 096 Valvola proporzionale V Proportionalvalve V Ma=7 Nm 08 4 Valvola proporzionale 4V Proportionalvalve 4V Ma=7 Nm 08 00 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. 99 06. To transform the solenoid valve from V to 4V it will be enough to replace only the solenoid - available loosen P/N 99 06. 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 67

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 ± ± 4 5 8 6 7 99 07 064 06 8 0 00 064 9 08 00 064 04 405 0 04 064 09 6 064 04 688 064 06 04 0 008 5075 0557 488 445 40888 50 44708 500065 447 0554 4965 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 ± ± ± ± 5 4 99 08 99 07 0 009 0 008 5004 5075 455786 455787 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 5 6 6 7 8 4 4 4 9 9 9 9 99 09 0 040 065 50 94 065 50 94 065 50 940 065 50 97 065 50 98 065 50 9 0 0 0 04 0 05 04 07 04 08 04 09 04 00 506 4448 447754 859 77 774 775 66807 4440 540 540 Kit cuscinetti. Cuscinetto a rullini. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Spessore 0, 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 ± ± 9 5 6 6 7 8 4 4 4 9 9 9 9 99 05 0 040 065 50 94 065 50 94 065 50 940 075 70 9 065 50 98 065 50 9 0 0 0 04 0 05 04 07 04 08 04 09 04 00 4448 50 859 77 774 775 66807 4440 540 540 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

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 ± ± 5 5 8 6 7 99 00 064 0 505 0 00 064 9 04 08 00 064 04 405 0 04 064 09 6 064 04 688 064 06 04 0 008 507 8476 488 44860 40888 50 44708 500065 447 0554 4965 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 ± ± ± ± 5 4 99 0 99 00 0 009 0 008 50044 507 455786 455787 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 6,5 6 7 8 4 4 4 4 4 9 9 9 99 0 0 040 065 50 99 065 50 97 065 50 98 065 7 008 065 50 94 0 04 0 04 0 044 0 045 0 046 08 04 0 08 04 04 08 04 07 508 4448 447754 859 848 4960 496 496 496 4964 4495 4496 4497 Kit cuscinetti. Cuscinetto a rullini. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Spessore 0, 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

70

Repair Manualand Spare Parts List Section : Spare parts list ZF 80 A - ZF 80- A. SPARE PARTS LIST ZF 80 A (06, 07, 08, 09, 00, 0 VERSION) ZF 80- A (04, 05, 06, 07, 09, 00 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

Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. ZF 80A versions 06-07 - 08-09 - 00-0 ZF 80- A versions 04-05 - 06-07 - 09-00 8 4 5 7 8 0 8 9 5 6 7 0 4 9 4 6 7 9 0 5 6 7

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 99 078 Assieme scatola Housing, assy. up to s/n XXXXXR 99 4 Assieme scatola Housing, assy. from s/n XXXXXR 0 009. Scatola. Housing up to s/n XXXXXR 0 00. Scatola con boccola flangiata. Housing with flanged bushing from s/n XXXXXR 0 0. Tubo aspirazione con supporto. Suction pipe with support 066 0 4. Vite. Screw 0 008. Guarnizione. Gasket 066 0 04 447 Tappo M6x,5 Plug M6x.5 064 9 04 44860 Paraolio uscita Output shaft seal 4 0 00 500484 Coperchio filtro completo Filter cover, assy. 5. Coperchio filtro. Filter cover 6 064 04 688 447. Guarnizione OR. O-Ring 7 064 06 04 0554. Guarnizione OR. O-Ring 8 060 00 085 6700. Rosetta. Washer 9 066 0 475 00. Vite M8x0. Screw M8x0 0 0 007 4867 Filtro olio Oilfilter () old part number 0 008 4965 Guarnizione Gasket 99 0 4677 Filtro olio completo Oilfilter, assy 064 04 688 447. Guarnizione OR. O-Ring 4 064 06 04 0554. Guarnizione OR. O-Ring 5 0 07. Filtro olio. Oilfilter () new part number 6 0 0 Tubo aspirazione con supporto Suction pipe with support 7 066 0 4 0879 Vite T.E. M6x6 Hex head screw M6x6 (fascetta tubo aspirazione) (suction pipe clamp) 8 0 04 46997 Anello centratore Centering ring up to s/n XXXXXR 9 06 5 50 587 Spina Locator pin 0 0 00 488 Paraolio entrata Input shaft seal 0 00 4469 Valvola di sfiato Breather valve 0 00 Coperchio Cover (housing) 0 00 50099 Asta livello olio + OR Oildipstick + OR 4 064 04 405 50. Guarnizione OR (Asta livello olio). O-Ring (Oildipstick) 5 060 0 09 447 Rosetta Washer 4 6 066 05 7 4475 Vite T.E. M0x5 Hex head screw M0x5 4 7 0 07 46969 Tappo Plug 8 0 00 Targhetta di identificazione Name plate 0 060 00 085 6700 Rosetta Washer 066 0 475 00 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 99 0 7

Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. ZF 80A versions 06-07 - 08-09 - 00-0 ZF 80- A versions 04-05 - 06-07 - 09-00 4 7 9 5 6 8 0 5 4 6 7 8 0 9 7 6 9 0 0 4 8 5 7 5 9 0 6 7 8 4 4 9 74

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 04 007 4958 Flangia Flange 064 0 505 8476 Guarnizione OR O-Ring 04 06 8784 Rondella Washer 4 066 06 085 08 Vite T.E. Hex head screw 5 0 04 44708 Anello di tenuta Piston ring 6 065 50 97 447754 Cuscinetto a rulli conici Tapered roller bearing 7 0 0 4578 Rasamento Butting ring 8 0 04 50089 Ingranaggio Z=44 Reverse gear Z=44 9 0 040 4448 Cuscinetto a rullini Needle bearing 4 0 06 50 06 47956 Chiavetta Key 99 075 Albero di ingresso completo Input shaft, assy. 060 5 065. Anello elastico. Snap ring 9 0 00. Disco finale. End disc 4 9 0 00. Disco frizione esterno. Outer clutch disc 0 5 9 0 006. Disco frizione interno. Inner clutch disc 8 6 060 50 08 500076. Anello di ritegno. Retainer ring 7 0 059. Molla a tazza. Cup spring 6 8 064 40 78 500066. Anello interno. Inner clutch piston ring 9 9 0 004. Pistone. Clutch piston 0 065 460 006 06690. Sfera. Ball 064 40 77. Anello esterno. Outer clutch piston ring 99 076. Albero di ingresso+cilindro frizione. Input shaft and clutch housing 065 50 99 Cuscinetto a rulli conici Tapered roller bearing 4 0 04 4960 Spessore 0, mm Shim 0. mm 0 04 496 Spessore 0,5 mm Shim 0.5 mm 0 044 496 Spessore 0, mm Shim 0. mm 0 045 496 Spessore 0,5 mm Shim 0.5 mm 0 046 4964 Spessore,0 mm Shim.0 mm Intermediate shaft 5 065 50 97 447754 Cuscinetto a rulli conici Tapered roller bearing 6 065 50 98 859 Cuscinetto a rulli conici Tapered roller bearing 7 065 7 008 848 Cuscinetto a rulli conici Tapered roller bearing 8 065 50 94 Cuscinetto a rulli conici Tapered roller bearing 9 08 04 0 4495 Spessore 0,5 mm Shim 0.5 mm 08 04 04 4496 Spessore 0, mm Shim 0. mm 08 04 07 4497 Spessore 0,5 mm Shim 0.5 mm 0 0 00 495 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=5 99 00 5009 Albero intermedio Z4=44, Z5=5 Intermediate shaft Z4=44, Z5=5 ] 99 0 50098 Albero di uscita Z=4 Output shaft Z=4 ] Vers. 07 (Rapporto I=,4) Vers. 07 (Ratio I=.4) 0 06 500850 Ingranaggio Z= Forward gear Z= 99 0 5009 Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] 99 0 50099 Albero di uscita Z=45 Output shaft Z=45 ] Vers. 08 (Rapporto I=,57) Vers. 08 (Ratio I=.57) 0 05 500849 Ingranaggio Z=0 Forward gear Z=0 99 04 50094 Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] 99 05 500400 Albero di uscita Z=47 Output shaft Z=47 ] Vers. 09 (Rapporto I=,96) Vers. 09 (Ratio I=.96) 0 004 459589 Ingranaggio Z=6 Forward gear Z=6 99 06 50095 Albero intermedio Z4=44, Z5=6 Intermediate shaft Z4=44, Z5=6 ] 99 06 50040 Albero di uscita Z=5 Output shaft Z=5 ] Vers. 00 (Rapporto I=,5) Vers. 00 (Ratio I=.5) 0 005 46 Ingranaggio Z= Forward gear Z= 99 07 50096 Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] 99 08 50040 Albero di uscita Z=55 Output shaft Z=55 ] 75

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. 0 (Rapporto I=,85) Vers. 0 (Ratio I=.85) 0 006 464 Ingranaggio Z=0 Forward gear Z=0 99 09 50097 Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] 99 040 50040 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=5 99 00 5009 Albero intermedio Z4=44, Z5=5 Intermediate shaft Z4=44, Z5=5 ] 99 0 50098 Albero di uscita Z=4 Output shaft Z=4 ] Vers. 05 (Rapporto I=,4) Vers. 05 (Ratio I=.4) 0 06 500850 Ingranaggio Z= Forward gear Z= 99 0 5009 Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] 99 0 50099 Albero di uscita Z=45 Output shaft Z=45 ] Vers. 06 (Rapporto I=,57) Vers. 06 (Ratio I=.57) 0 05 500849 Ingranaggio Z=0 Forward gear Z=0 99 04 50094 Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] 99 05 500400 Albero di uscita Z=47 Output shaft Z=47 ] Vers. 07 (Rapporto I=,96) Vers. 07 (Ratio I=.96) 0 004 459589 Ingranaggio Z=6 Forward gear Z=6 99 06 50095 Albero intermedio Z4=44, Z5=6 Intermediate shaft Z4=44, Z5=6 ] 99 00 Albero di uscita Z=5 Output shaft Z=5 ] Vers. 09 (Rapporto I=,5) Vers. 09 (Ratio I=.5) 0 005 46 Ingranaggio Z= Forward gear Z= 99 00 Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] 99 004 Albero di uscita Z=55 Output shaft Z=55 ] Vers. 00 (Rapporto I=,85) Vers. 00 (Ratio I=.85) 0 007 5079 Ingranaggio Z=0 Forward gear Z=0 99 00 Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] 99 005 Albero di uscita Z=57 Output shaft Z=57 ] ] Cuscinetti a rulli conici giaá assemblati - Tapered roller bearings already assembled 76

77

Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. ZF 80A versions 06-07 - 08-09 - 00-0 ZF 80- A versions 04-05 - 06-07 - 09-00 MECHANICAL SELECTOR VALVE 5 6 4 9 8 0 6 7 4 5 7 8 6 9 6 5 4 6 0 78

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 08 00 Valvola di comando Mechanicalselector completo bar valve bar 08 00 Valvola di comando Mechanicalselector Only for ZF 80-A alta velocitaá 6 bar valve 6 bar I. Valvola di comando. Controlvalve 08 00 40888. Guarnizione. Gasket 4 08 05 4596. Leva. Lever 5 066 0 77 4477. Vite T.E.. Hex head screw 7 6 060 0 090 447. Rosetta. Washer 8 7 067 006 57 455785. Dado. Nut 8 064 09 6 500065. Guarnizione. Gasket 9 08 04 50006. Vite di fermo. Stop screw 0 066 09 007 455756. Tappo. Plug 06 405 06 50007. Tappo. Plug 066 0 05 0465. Tappo. Plug 064 80 0 0740. Rosetta. Washer 4 08 07 50008. Vite di guida. Guide bolt 5 08 047 500044. Molla. Spring 6 065 460 04 06695. Sfera. Ball 7 08 09 455764. Interruttore completo. Neutralsafety switch assy. 8 00.05.058 0557. Guarnizione OR. O-Ring 9 08 09 50000. Boccola. Bushing 0 060 50 005 50008. Anello elastico. Snap ring 08 08 50009. Boccola. Bushing 08 04 5000. Molla per lubrificazione. Spring 065 460 0 500097. Sfera. Ball 4 08 06 50007. Distanziale. Spacer 79

Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. 4 ZF 80A versions 06-07 - 08-09 - 00-0 ZF 80- A versions 04-05 - 06-07 - 09-00 OLD ELECTRIC SELECTOR VALVE ON/OFF V, 6 BAR 0 6 5 4 9 8 F4076 7 F4075 80

Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. 4 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 99 05 Distributore elettrico Electric selector valve [ 6 bar ON/OFF 6 bar ON/OFF 08 069 Elettrovalvola ON/OFF V Solenoid valve ON/OFF V 06 405 06 Tappo Dummy plug 4 066 0 05 Tappo M0x Screw plug M0x Ma= Nm 5 064 80 0 Rosetta Washer 6 066 09 007 Tappo Screw plug Ma= 0 Nm 7 6 7 00 Assieme connettore Connector kit 8 066 0 77 Vite T.E. M8x40 Cap screw M8x40 6 9 060 0 090 Rosetta Spring washer 6 0 08 00 Guarnizione Gasket [ Installare con V - To be installed with V power supply 8

Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. 5 ZF 80A versions 06-07 - 08-09 - 00-0 ZF 80- A versions 04-05 - 06-07 - 09-00 NEW ELECTRIC SELECTOR VALVE ON/OFF V - 6 BAR NEW ELECTRIC SELECTOR VALVE ON/OFF 4V - 6 BAR 0 6 4 5 7 0 8 9 0 F4078 8

Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. 5 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 99 06 Distributore elettrico ON/OFF Elecric selector valve ON/OFF V - 6 bar V - 6 bar [ 99 064 Distributore elettrico ON/OFF Elecric selector valve ON/OFF 4V - 6 bar 4V - 6 bar [[ 08 069 Elettrovalvola ON/OFF V Solenoid valve ON/OFF V Ma=0 Nm 08 06 Elettrovalvola ON/OFF 4V Solenoid valve ON/OFF 4V Ma=0 Nm 06 405 06 Tappo Dummy plug 4 066 0 05 Tappo M0x Screw plug M0x Ma= Nm 5 064 80 0 Rosetta Washer 6 066 09 007 Tappo Screw plug Ma=5 Nm 7 066 0 709 Vite T.E. M8x65 Cap screw M8x65 8 066 0 77 Vite T.E. M8x40 Cap screw M8x40 4 9 060 0 090 Rosetta elastica Spring washer 6 0 6 7 00 Assieme connettore Connector kit 08 00 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. 99 06. To transform the solenoid valve from V to 4V it will be enough to replace only the solenoid - available loosen P/N 99 06. 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

Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. 6 ZF 80A versions 06-07 - 08-09 - 00-0 ZF 80- A versions 04-05 - 06-07 - 09-00 NEW ELECTRIC SELECTOR VALVE ON/OFF V - 6 BAR WITH TROLLING VALVE NEW ELECTRIC SELECTOR VALVE ON/OFF 4V - 6 BAR WITH TROLLING VALVE 0 0 6 4 5 0 7 8 9 0 F4078 84

Repair Manualand Spare Parts List ZF 80 A - ZF 80- A FIG. 6 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 99 065 Distributore elettrico ON/OFF Electric selector valve ON/OFF [ V, 6 bar con TV V, 6 bar with Trolling valve 99 066 Distributore elettrico ON/OFF Electric selector valve ON/OFF [ [ 4V, 6 bar con TV 4V, 6 bar with Trolling valve 08 069 Elettrovalvola ON/OFF Solenoid valve ON/OFF Ma=0 Nm V, 6 BAR V, 6 bar 08 06 Elettrovalvola ON/OFF Solenoid valve ON/OFF Ma=0 Nm 4V, 6 bar 4V, 6 bar 06 405 06 Tappo Dummy plug 4 066 0 05 Tappo a vite M0x Screw plug M0x Ma= Nm 5 064 80 0 Anello di tenuta Sealing ring 6 066 09 007 Tappo a vite Screw plug Ma=5 Nm 7 066 0 709 Vite TCEI M8x65 Cap screw M8x65 8 066 0 77 Vite TCEI M8x40 Cap screw M8x40 4 9 060 0 090 Rosetta elastica Spring washer 6 0 6 7 00 Assieme connettore Connector kit 08 07 Trolling valve Trolling device 08 096 Valvola proporzionale V Proportionalvalve V Ma=7 Nm 08 4 Valvola proporzionale 4V Proportionalvalve 4V Ma=7 Nm 08 00 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. 99 06. To transform the solenoid valve from V to 4V it will be enough to replace only the solenoid - available loosen P/N 99 06. 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 85

Repair Manualand Spare Parts List ZF 80 A - ZF 80- A COMPOSIZIONE KIT - KIT COMPONENTS ZF 80A versions 06-07 - 08-09 - 00-0 ZF 80- A versions 04-05 - 06-07 - 09-00 Fig. Pos. Part number Old P/N Descrizione Description Q.ty ± ± 0 4 5 8 6 7 99 00 064 0 505 0 00 064 9 04 08 00 064 04 405 0 04 064 09 6 064 04 688 064 06 04 0 008 507 8476 488 44860 40888 50 44708 500065 447 0554 4965 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 ± ± ± ± 5 4 99 077 99 00 9 0 006 9 0 00 507 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 6,5 6 7 8 4 4 4 4 4 9 9 9 99 0 0 040 065 50 99 065 50 97 065 50 98 065 7 008 065 50 94 0 04 0 04 0 044 0 045 0 046 08 04 0 08 04 04 08 04 07 508 4448 447754 859 848 4960 496 496 496 4964 4495 4496 4497 Kit cuscinetti. Cuscinetto a rullini. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Spessore 0, 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

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

Repair Manualand Spare Parts List ZF 85 A FIG. ZF 85 A versions 004-007 - 00-00 4 5 8 8 9 9 5 6 7 0 4 0 7 6 8 6 7 8 9 4 5 88

Repair Manualand Spare Parts List ZF 85 A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 99 00 Assieme scatola Housing, assy. 0 00. Scatola. Housing 0 0. Tubo aspirazione con supporto. Suction pipe with support 066 0 4. Vite TCEI M6x6. Cap screw M6x6 0 008. Guarnizione. Gasket 066 0 04 447 Tappo M6x,5 Plug M6x.5 064 9 04 44860 Paraolio uscita Output shaft seal 4 0 00 500484 Coperchio filtro completo Filter cover, assy. 5. Coperchio filtro. Filter cover 6 064 04 688 447. Guarnizione OR. O-Ring 7 064 06 04 0554. Guarnizione OR. O-Ring 8 060 00 085 6700. Rosetta. Washer 9 066 0 475 00. Vite M8x0. Screw M8x0 0 0 007 4867 Filtro olio Oilfilter () old part number 0 008 4965 Guarnizione Gasket 99 0 4677 Filtro olio completo Oilfilter, assy 064 04 688 447. Guarnizione OR. O-Ring 4 064 06 04 0554. Guarnizione OR. O-Ring 5 0 07 4867. Filtro olio. Oilfilter () new part number 6 0 0 Tubo aspirazione con supporto Suction pipe with support 7 066 0 4 0879 Vite T.E. M6x6 Hex head screw M6x6 (fascetta tubo aspirazione) (suction pipe clamp) 8 06 5 50 587 Spina Locator pin 9 064 0 846 Paraolio entrata Input shaft seal 0 0 00 4469 Valvola di sfiato Breather valve 0 00 Coperchio Cover (housing) 0 00 50099 Asta livello olio + OR Oildipstick + OR 064 04 405 50. Guarnizione OR (Asta livello olio). O-Ring (Oildipstick) 4 060 0 09 447 Rosetta Washer 4 5 066 05 7 4475 Vite T.E. M0x5 Hex head screw M0x5 4 6 0 07 46969 Tappo scarico olio Oildrain plug 7 0 00 Targhetta di identificazione Name plate 8 060 00 085 6700 Rosetta Washer 9 066 0 475 00 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 99 0 89

Repair Manualand Spare Parts List ZF 85 A FIG. ZF 85 A versions 004-007 - 00-00 4 7 8 5 0 6 9 5 5 6 4 6 7 4 8 9 8 0 6 0 4 9 6 8 8 5 9 7 7 9 7 4 0 5 90

Repair Manualand Spare Parts List ZF 85 A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 04 007 4958 Flangia Flange 064 0 505 8476 Guarnizione OR O-Ring 04 06 8784 Rondella Washer 4 066 06 085 08 Vite T.E. M6x45 Hex head screw M6x45 5 0 04 44708 Anello di tenuta Piston ring 6 065 50 95 Cuscinetto a rulli conici Tapered roller bearing 7 0 008 Rasamento Butting ring 8 0 004 Ingranaggio Z=44 Reverse gear Z=44 9 075 606 Cuscinetto a rullini Needle bearing 0 06 50 06 47956 Chiavetta Key 99 004 Albero di ingresso completo Input shaft, assy. 060 5 065. Anello elastico. Snap ring 0 07. Disco finale. End disc 4 0 0. Disco frizione esterno. Outer clutch disc 0 5 0 0. Disco frizione interno. Inner clutch disc 8 6 0 009. Anello di ritegno. Retainer ring 7 0 00. Ralla. Thrust washer 8 0 08. Molla a tazza. Cup spring 6 9 064 40 78 500066. Anello interno. Inner clutch piston ring 0 0 006. Pistone. Clutch piston 065 460 006 06690. Sfera. Ball 064 40 77. Anello esterno. Outer clutch piston ring 99 00. Albero di ingresso+. Input shaft and cilindro frizione clutch housing 4 065 50 95 Cuscinetto a rulli conici Tapered roller bearing 5 0 04 4960 Spessore 0, mm Shim 0. mm 0 04 496 Spessore 0,5 mm Shim 0.5 mm 0 044 496 Spessore 0, mm Shim 0. mm 0 045 496 Spessore 0,5 mm Shim 0.5 mm 0 046 4964 Spessore,0 mm Shim.0 mm 6 065 50 97 447754 Cuscinetto a rulli conici Tapered roller bearing 7 065 7 08 Cuscinetto a rulli conici Tapered roller bearing 8 065 7 008 848 Cuscinetto a rulli conici Tapered roller bearing 9 065 50 94 Cuscinetto a rulli conici Tapered roller bearing 0 08 04 0 4495 Spessore 0,5 mm Shim 0.5 mm 08 04 04 4496 Spessore 0,0 mm Shim 0.0 mm 08 04 05 Spessore 0,5 mm Shim 0.5 mm 08 04 06 Spessore 0,0 mm Shim 0.0 mm 08 04 07 4497 Spessore 0,50 mm Shim 0.50 mm 0 0 Distanziale Spacer 075 607 Cuscinetto a rullini Needle bearing 0 008 Spessore 0,0 mm Shim 0.0 mm 0 009 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 4 060 50 0 Anello di sicurezza Retaining ring 5 060 00 00 Disco appoggio Support shim 6 060 000 9 Spessore 40x50x0,0 Shim 40x50x0.0 060 000 98 Spessore 40x50x0,5 Shim 40x50x0.5 060 000 74 Spessore 40x50x0,0 Shim 40x50x0.0 Vers. 004 (Rapporto I=,57) Vers. 004 (Ratio I=.57) 7 0 08 Ingranaggio Z=0 Forward gear Z=0 8 99 005 Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] 9 99 009 Albero di uscita Z=47 Output shaft Z=47 ] Vers. 007 (Rapporto I=,75) Vers. 007 (Ratio I=.75) 7 0 009 Ingranaggio Z=8 Forward gear Z=8 8 99 006 Albero intermedio Z4=44, Z5=8 Intermediate shaft Z4=44, Z5=8 ] 9 99 00 Albero di uscita Z=49 Output shaft Z=49 ] Vers. 00 (Rapporto I=,96) Vers. 00 (Ratio I=.96) 7 0 00 Ingranaggio Z=6 Forward gear Z=6 8 99 007 Albero intermedio Z4=44, Z5=6 Intermediate shaft Z4=44, Z5=6 ] 9 99 0 Albero di uscita Z=5 Output shaft Z=5 ] Vers. 00 (Rapporto I=,5) Vers. 00 (Ratio I=.5) 7 0 00 Ingranaggio Z= Forward gear Z= 8 99 008 Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] 9 99 0 Albero di uscita Z=55 Output shaft Z=55 ] ] Cuscinetti a rulli conici giaá assemblati - Tapered roller bearings already assembled 9

Repair Manualand Spare Parts List ZF 85 A FIG. ZF 85 A versions 004-007 - 00-00 MECHANICAL SELECTOR VALVE 5 6 4 9 8 0 6 7 4 5 7 8 6 9 6 5 4 6 0 9

Repair Manualand Spare Parts List ZF 85 A FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 08 00 Valvola di comando Mechanicalselector alta velocitaá 6 bar valve 6 bar I. Valvola di comando. Controlvalve 08 00 40888. Guarnizione. Gasket 4 08 05 4596. Leva. Lever 5 066 0 77 4477. Vite T.E.. Hex head screw 7 6 060 0 090 447. Rosetta. Washer 8 7 067 006 57 455785. Dado. Nut 8 064 09 6 500065. Guarnizione. Gasket 9 08 04 50006. Vite di fermo. Stop screw 0 066 09 007 455756. Tappo. Plug 06 405 06 50007. Tappo. Plug 066 0 05 0465. Tappo. Plug 064 80 0 0740. Rosetta. Washer 4 08 07 50008. Vite di guida. Guide bolt 5 08 047 500044. Molla. Spring 6 065 460 04 06695. Sfera. Ball 7 08 09 455764. Interruttore completo. Neutralsafety switch assy. 8 00.05.058 0557. Guarnizione OR. O-Ring 9 08 09 50000. Boccola. Bushing 0 060 50 005 50008. Anello elastico. Snap ring 08 08 50009. Boccola. Bushing 08 04 5000. Molla per lubrificazione. Spring 065 460 0 500097. Sfera. Ball 4 08 06 50007. Distanziale. Spacer 9

Repair Manualand Spare Parts List ZF 85 A FIG. 4 ZF 85 A versions 004-007 - 00-00 ELECTRIC SELECTOR VALVE ON/OFF V - 6 BAR ELECTRIC SELECTOR VALVE ON/OFF 4V - 6 BAR 0 6 4 5 7 0 8 9 0 F4078 94

Repair Manualand Spare Parts List ZF 85 A FIG. 4 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 99 06 Distributore elettrico ON/OFF Elecric selector valve ON/OFF V - 6 bar V - 6 bar [ 99 064 Distributore elettrico ON/OFF Elecric selector valve ON/OFF 4V - 6 bar 4V - 6 bar [[ 08 069 Elettrovalvola ON/OFF V Solenoid valve ON/OFF V Ma=0 Nm 08 06 Elettrovalvola ON/OFF 4V Solenoid valve ON/OFF 4V Ma=0 Nm 06 405 06 Tappo Dummy plug 4 066 0 05 Tappo M0x Screw plug M0x Ma= Nm 5 064 80 0 Rosetta Washer 6 066 09 007 Tappo Screw plug Ma=5 Nm 7 066 0 709 Vite T.E. M8x65 Cap screw M8x65 8 066 0 77 Vite T.E. M8x40 Cap screw M8x40 4 9 060 0 090 Rosetta elastica Spring washer 6 0 6 7 00 Assieme connettore Connector kit 08 00 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. 99 06. To transform the solenoid valve from V to 4V it will be enough to replace only the solenoid - available loosen P/N 99 06. 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 95

Repair Manualand Spare Parts List ZF 85 A FIG. 5 ZF 85 A versions 004-007 - 00-00 ELECTRIC SELECTOR VALVE ON/OFF V - 6 BAR WITH TROLLING VALVE ELECTRIC SELECTOR VALVE ON/OFF 4V - 6 BAR WITH TROLLING VALVE 0 0 6 4 5 0 7 8 9 0 F4078 96

Repair Manualand Spare Parts List ZF 85 A FIG. 5 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 99 065 Distributore elettrico ON/OFF Electric selector valve ON/OFF [ V, 6 bar con TV V, 6 bar with Trolling valve 99 066 Distributore elettrico ON/OFF Electric selector valve ON/OFF [ [ 4V, 6 bar con TV 4V, 6 bar with Trolling valve 08 069 Elettrovalvola ON/OFF Solenoid valve ON/OFF Ma=0 Nm V, 6 BAR V, 6 bar 08 06 Elettrovalvola ON/OFF Solenoid valve ON/OFF Ma=0 Nm 4V, 6 bar 4V, 6 bar 06 405 06 Tappo Dummy plug 4 066 0 05 Tappo a vite M0x Screw plug M0x Ma= Nm 5 064 80 0 Anello di tenuta Sealing ring 6 066 09 007 Tappo a vite Screw plug Ma=5 Nm 7 066 0 709 Vite TCEI M8x65 Cap screw M8x65 8 066 0 77 Vite TCEI M8x40 Cap screw M8x40 4 9 060 0 090 Rosetta elastica Spring washer 6 0 6 7 00 Assieme connettore Connector kit 08 07 Trolling valve Trolling device 08 096 Valvola proporzionale V Proportionalvalve V Ma=7 Nm 08 4 Valvola proporzionale 4V Proportionalvalve 4V Ma=7 Nm 08 00 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. 99 06. To transform the solenoid valve from V to 4V it will be enough to replace only the solenoid - available loosen P/N 99 06. 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 97

Repair Manualand Spare Parts List ZF 85 A COMPOSIZIONE KIT - KIT COMPONENTS ZF 85 A versions 004-007 - 00-00 Fig. Pos. Part number Old P/N Descrizione Description Q.ty ± ± 9 5 8 6 7 99 09 064 0 505 064 0 846 064 9 04 08 00 064 04 405 0 04 064 09 6 064 04 688 064 06 04 0 008 8476 44860 40888 50 44708 500065 447 0554 4965 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 ± ± ± ± 5 4 99 00 99 09 0 0 0 0 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 ± ± 6 9 4 6 7 8 9 5 5 5 5 5 0 0 0 6 6 6 99 0 065 50 95 075 606 065 50 95 065 50 97 065 7 08 065 7 008 065 50 94 075 607 0 04 0 04 0 044 0 045 0 046 08 04 0 08 04 04 08 04 07 0 008 0 009 0 00 0 0 060 000 9 060 000 98 060 000 74 447754 848 4960 496 496 496 4964 4495 4496 4497 Kit cuscinetti. Cuscinetto a rullini conici. Cuscinetto a rullini. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini. Spessore 0, mm. Spessore 0,5 mm. Spessore 0,0 mm. Spessore 0,50 mm. Spessore,00 mm. Spessore 0,5 mm. Spessore 0,0 mm. Spessore 0,50 mm. Spessore 0,0 mm. Spessore 0,5 mm. Spessore 0,0 mm. Spessore 0,50 mm. Spessore 40x50x0,0. Spessore 40x50x0,5. Spessore 40x50x0,0 Bearing kit. Tapered roller bearing. Needle bearing. Tapered roller bearing. Tapered roller bearing. Tapered roller bearing. Tapered roller bearing. Tapered roller bearing. Needle bearing. Shim 0.0 mm. Shim 0.5 mm. Shim 0.0 mm. Shim 0.50 mm. Shim.00 mm. Shim 0.5 mm. Shim 0.0 mm. Shim 0.50 mm. Shim 0.0 mm. Shim 0.5 mm. Shim 0.0 mm. Shim 0.50 mm. Shim 40x50x0.0. Shim 40x50x0.5. Shim 40x50x0.0 98

Repair Manualand Spare Parts List Section 4 : Spare parts list ZF 80 A (ZF 85 A Derivate version) 4. SPARE PARTS LIST ZF 80A (ZF 85 A DERIVATE VERSION) Preface The spare parts list is only valid for the type and versions of transmission, as shown below. You will find the transmission type and version on your transmission name plate. If the type and version indicated differs from that printed in this Manual, the relative Spare Parts List should be ordered from ZF HURTH MARINE. The indicated dimensions and standards are as such not enough for ordering parts. When ordering parts, please state:. Transmission type. Transmission version. 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 08 (.57 R); 09 (.75 R); 040 (.96 R); 04 (.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 99

Repair Manualand Spare Parts List ZF 80 A (ZF 85 A Derivate version) FIG. ZF 80A versions 08-09 - 040-04 4 5 8 8 9 9 5 6 7 0 4 0 7 6 8 6 7 8 9 4 5 00

Repair Manualand Spare Parts List ZF 80 A (ZF 85 A Derivate version) FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 99 00 Assieme scatola Housing, assy. 0 00. Scatola. Housing 0 0. Tubo aspirazione con supporto. Suction pipe with support 066 0 4. Vite TCEI M6x6. Cap screw M6x6 0 008. Guarnizione. Gasket 066 0 04 447 Tappo M6x,5 Plug M6x.5 064 9 04 44860 Paraolio uscita Output shaft seal 4 0 00 500484 Coperchio filtro completo Filter cover, assy. 5. Coperchio filtro. Filter cover 6 064 04 688 447. Guarnizione OR. O-Ring 7 064 06 04 0554. Guarnizione OR. O-Ring 8 060 00 085 6700. Rosetta. Washer 9 066 0 475 00. Vite M8x0. Screw M8x0 0 0 007 4867 Filtro olio Oilfilter () old part number 0 008 4965 Guarnizione Gasket 99 0 4677 Filtro olio completo Oilfilter, assy 064 04 688 447. Guarnizione OR. O-Ring 4 064 06 04 0554. Guarnizione OR. O-Ring 5 0 07 4867. Filtro olio. Oilfilter () new part number 6 0 0 Tubo aspirazione con supporto Suction pipe with support 7 066 0 4 0879 Vite T.E. M6x6 Hex head screw M6x6 (fascetta tubo aspirazione) (suction pipe clamp) 8 06 5 50 587 Spina Locator pin 9 064 0 846 Paraolio entrata Input shaft seal 0 0 00 4469 Valvola di sfiato Breather valve 0 00 Coperchio Cover (housing) 0 00 50099 Asta livello olio + OR Oildipstick + OR 064 04 405 50. Guarnizione OR (Asta livello olio). O-Ring (Oildipstick) 4 060 0 09 447 Rosetta Washer 4 5 066 05 7 4475 Vite T.E. M0x5 Hex head screw M0x5 4 6 0 07 46969 Tappo scarico olio Oildrain plug 7 0 00 Targhetta di identificazione Name plate 8 060 00 085 6700 Rosetta Washer 9 066 0 475 00 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 99 0 0

Repair Manualand Spare Parts List ZF 80 A (ZF 85 A Derivate version) FIG. ZF 80A versions 08-09 - 040-04 4 7 8 5 0 6 9 5 5 6 4 6 7 4 8 9 8 0 6 0 4 9 6 8 8 5 9 7 7 9 7 4 0 5 0

Repair Manualand Spare Parts List ZF 80 A (ZF 85 A Derivate version) FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 04 007 4958 Flangia Flange 064 0 505 8476 Guarnizione OR O-Ring 04 06 8784 Rondella Washer 4 066 06 085 08 Vite T.E. M6x45 Hex head screw M6x45 5 0 04 44708 Anello di tenuta Piston ring 6 065 50 95 Cuscinetto a rulli conici Tapered roller bearing 7 0 008 Rasamento Butting ring 8 0 06 Ingranaggio Z=44 Reverse gear Z=44 9 075 606 Cuscinetto a rullini Needle bearing 0 06 50 06 47956 Chiavetta Key 99 09 Albero di ingresso completo Input shaft, assy. 060 5 065. Anello elastico. Snap ring 0 07. Disco finale. End disc 4 0 0. Disco frizione esterno. Outer clutch disc 0 5 0 0. Disco frizione interno. Inner clutch disc 8 6 0 009. Anello di ritegno. Retainer ring 7 0 00. Ralla. Thrust washer 8 0 08. Molla a tazza. Cup spring 6 9 064 40 78 500066. Anello interno. Inner clutch piston ring 0 0 06. Pistone. Clutch piston 065 460 006 06690. Sfera. Ball 064 40 8. Anello esterno. Outer clutch piston ring 99 08. Albero di ingresso+. Input shaft and cilindro frizione clutch housing 4 065 50 95 Cuscinetto a rulli conici Tapered roller bearing 5 0 04 4960 Spessore 0, mm Shim 0. mm 0 04 496 Spessore 0,5 mm Shim 0.5 mm 0 044 496 Spessore 0, mm Shim 0. mm 0 045 496 Spessore 0,5 mm Shim 0.5 mm 0 046 4964 Spessore,0 mm Shim.0 mm 6 065 50 97 447754 Cuscinetto a rulli conici Tapered roller bearing 7 065 7 08 Cuscinetto a rulli conici Tapered roller bearing 8 065 7 008 848 Cuscinetto a rulli conici Tapered roller bearing 9 065 50 94 Cuscinetto a rulli conici Tapered roller bearing 0 08 04 0 4495 Spessore 0,5 mm Shim 0.5 mm 08 04 04 4496 Spessore 0,0 mm Shim 0.0 mm 08 04 05 Spessore 0,5 mm Shim 0.5 mm 08 04 06 Spessore 0,0 mm Shim 0.0 mm 08 04 07 4497 Spessore 0,50 mm Shim 0.50 mm 0 0 Distanziale Spacer 075 607 Cuscinetto a rullini Needle bearing 0 008 Spessore 0,0 mm Shim 0.0 mm 0 009 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 4 060 50 0 Anello di sicurezza Retaining ring 5 060 00 00 Disco appoggio Support shim 6 060 000 9 Spessore 40x50x0,0 Shim 40x50x0.0 060 000 98 Spessore 40x50x0,5 Shim 40x50x0.5 060 000 74 Spessore 40x50x0,0 Shim 40x50x0.0 Vers. 08 (Rapporto I=,57) Vers. 08 (Ratio I=.57) 7 0 05 Ingranaggio Z=0 Forward gear Z=0 8 99 0 Albero intermedio Z4=44, Z5=0 Intermediate shaft Z4=44, Z5=0 ] 9 99 009 Albero di uscita Z=47 Output shaft Z=47 ] Vers. 09 (Rapporto I=,75) Vers. 09 (Ratio I=.75) 7 0 009 Ingranaggio Z=8 Forward gear Z=8 8 99 Albero intermedio Z4=44, Z5=8 Intermediate shaft Z4=44, Z5=8 ] 9 99 00 Albero di uscita Z=49 Output shaft Z=49 ] Vers. 040 (Rapporto I=,96) Vers. 040 (Ratio I=.96) 7 0 00 Ingranaggio Z=6 Forward gear Z=6 8 99 Albero intermedio Z4=44, Z5=6 Intermediate shaft Z4=44, Z5=6 ] 9 99 0 Albero di uscita Z=5 Output shaft Z=5 ] Vers. 04 (Rapporto I=,5) Vers. 04 (Ratio I=.5) 7 0 00 Ingranaggio Z= Forward gear Z= 8 99 Albero intermedio Z4=44, Z5= Intermediate shaft Z4=44, Z5= ] 9 99 0 Albero di uscita Z=55 Output shaft Z=55 ] ] Cuscinetti a rulli conici giaá assemblati - Tapered roller bearings already assembled 0

Repair Manualand Spare Parts List ZF 80 A (ZF 85 A Derivate version) FIG. ZF 80A versions 08-09 - 040-04 MECHANICAL SELECTOR VALVE 5 6 4 9 8 0 6 7 4 5 7 8 6 9 6 5 4 6 0 04

Repair Manualand Spare Parts List ZF 80 A (ZF 85 A Derivate version) FIG. Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 08 00 Valvola di comando Mechanicalselector alta velocitaá 6 bar valve 6 bar I. Valvola di comando. Controlvalve 08 00 40888. Guarnizione. Gasket 4 08 05 4596. Leva. Lever 5 066 0 77 4477. Vite T.E.. Hex head screw 7 6 060 0 090 447. Rosetta. Washer 8 7 067 006 57 455785. Dado. Nut 8 064 09 6 500065. Guarnizione. Gasket 9 08 04 50006. Vite di fermo. Stop screw 0 066 09 007 455756. Tappo. Plug 06 405 06 50007. Tappo. Plug 066 0 05 0465. Tappo. Plug 064 80 0 0740. Rosetta. Washer 4 08 07 50008. Vite di guida. Guide bolt 5 08 047 500044. Molla. Spring 6 065 460 04 06695. Sfera. Ball 7 08 09 455764. Interruttore completo. Neutralsafety switch assy. 8 00.05.058 0557. Guarnizione OR. O-Ring 9 08 09 50000. Boccola. Bushing 0 060 50 005 50008. Anello elastico. Snap ring 08 08 50009. Boccola. Bushing 08 04 5000. Molla per lubrificazione. Spring 065 460 0 500097. Sfera. Ball 4 08 06 50007. Distanziale. Spacer 05

Repair Manualand Spare Parts List ZF 80 A (ZF 85 A Derivate version) FIG. 4 ZF 80A versions 08-09 - 040-04 ELECTRIC SELECTOR VALVE ON/OFF V - 6 BAR ELECTRIC SELECTOR VALVE ON/OFF 4V - 6 BAR 0 6 4 5 7 0 8 9 0 F4078 06

Repair Manualand Spare Parts List ZF 80 A (ZF 85 A Derivate version) FIG. 4 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 99 06 Distributore elettrico ON/OFF Elecric selector valve ON/OFF V - 6 bar V - 6 bar [ 99 064 Distributore elettrico ON/OFF Elecric selector valve ON/OFF 4V - 6 bar 4V - 6 bar [[ 08 069 Elettrovalvola ON/OFF V Solenoid valve ON/OFF V Ma=0 Nm 08 06 Elettrovalvola ON/OFF 4V Solenoid valve ON/OFF 4V Ma=0 Nm 06 405 06 Tappo Dummy plug 4 066 0 05 Tappo M0x Screw plug M0x Ma= Nm 5 064 80 0 Rosetta Washer 6 066 09 007 Tappo Screw plug Ma=5 Nm 7 066 0 709 Vite T.E. M8x65 Cap screw M8x65 8 066 0 77 Vite T.E. M8x40 Cap screw M8x40 4 9 060 0 090 Rosetta elastica Spring washer 6 0 6 7 00 Assieme connettore Connector kit 08 00 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. 99 06. To transform the solenoid valve from V to 4V it will be enough to replace only the solenoid - available loosen P/N 99 06. 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 07

Repair Manualand Spare Parts List ZF 80 A (ZF 85 A Derivate version) FIG. 5 ZF 80A versions 08-09 - 040-04 ELECTRIC SELECTOR VALVE ON/OFF V - 6 BAR WITH TROLLING VALVE ELECTRIC SELECTOR VALVE ON/OFF 4V - 6 BAR WITH TROLLING VALVE 0 0 6 4 5 0 7 8 9 0 F4078 08

Repair Manualand Spare Parts List ZF 80 A (ZF 85 A Derivate version) FIG. 5 Pos. Part number Old P/N Descrizione Description Q.taÁ Q.ty Note 99 065 Distributore elettrico ON/OFF Electric selector valve ON/OFF [ V, 6 bar con TV V, 6 bar with Trolling valve 99 066 Distributore elettrico ON/OFF Electric selector valve ON/OFF [ [ 4V, 6 bar con TV 4V, 6 bar with Trolling valve 08 069 Elettrovalvola ON/OFF Solenoid valve ON/OFF Ma=0 Nm V, 6 BAR V, 6 bar 08 06 Elettrovalvola ON/OFF Solenoid valve ON/OFF Ma=0 Nm 4V, 6 bar 4V, 6 bar 06 405 06 Tappo Dummy plug 4 066 0 05 Tappo a vite M0x Screw plug M0x Ma= Nm 5 064 80 0 Anello di tenuta Sealing ring 6 066 09 007 Tappo a vite Screw plug Ma=5 Nm 7 066 0 709 Vite TCEI M8x65 Cap screw M8x65 8 066 0 77 Vite TCEI M8x40 Cap screw M8x40 4 9 060 0 090 Rosetta elastica Spring washer 6 0 6 7 00 Assieme connettore Connector kit 08 07 Trolling valve Trolling device 08 096 Valvola proporzionale V Proportionalvalve V Ma=7 Nm 08 4 Valvola proporzionale 4V Proportionalvalve 4V Ma=7 Nm 08 00 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. 99 06. To transform the solenoid valve from V to 4V it will be enough to replace only the solenoid - available loosen P/N 99 06. 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 09

Repair Manualand Spare Parts List ZF 80 A (ZF 85 A Derivate version) COMPOSIZIONE KIT - KIT COMPONENTS ZF 80A versions 08-09 - 040-04 Fig. Pos. Part number Old P/N Descrizione Description Q.ty ± ± 9 5 8 6 7 99 09 064 0 505 064 0 846 064 9 04 08 00 064 04 405 0 04 064 09 6 064 04 688 064 06 04 0 008 8476 44860 40888 50 44708 500065 447 0554 4965 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 ± ± ± ± 5 4 99 00 99 09 0 0 0 0 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 ± ± 6 9 4 6 7 8 9 5 5 5 5 5 0 0 0 6 6 6 99 0 065 50 95 075 606 065 50 95 065 50 97 065 7 08 065 7 008 065 50 94 075 607 0 04 0 04 0 044 0 045 0 046 08 04 0 08 04 04 08 04 07 0 008 0 009 0 00 0 0 060 000 9 060 000 98 060 000 74 447754 848 4960 496 496 496 4964 4495 4496 4497 Kit cuscinetti. Cuscinetto a rullini conici. Cuscinetto a rullini. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini conici. Cuscinetto a rullini. Spessore 0, mm. Spessore 0,5 mm. Spessore 0,0 mm. Spessore 0,50 mm. Spessore,00 mm. Spessore 0,5 mm. Spessore 0,0 mm. Spessore 0,50 mm. Spessore 0,0 mm. Spessore 0,5 mm. Spessore 0,0 mm. Spessore 0,50 mm. Spessore 40x50x0,0. Spessore 40x50x0,5. Spessore 40x50x0,0 Bearing kit. Tapered roller bearing. Needle bearing. Tapered roller bearing. Tapered roller bearing. Tapered roller bearing. Tapered roller bearing. Tapered roller bearing. Needle bearing. Shim 0.0 mm. Shim 0.5 mm. Shim 0.0 mm. Shim 0.50 mm. Shim.00 mm. Shim 0.5 mm. Shim 0.0 mm. Shim 0.50 mm. Shim 0.0 mm. Shim 0.5 mm. Shim 0.0 mm. Shim 0.50 mm. Shim 40x50x0.0. Shim 40x50x0.5. Shim 40x50x0.0 0