Foley Engines ZF 45 C - Walter Mode d'emploi

R E P A I R M A N U A L A N D S P A R E P A R T S L I S T

ZF 45 C version 10; 001

ZF 45 C - Walter version 002

ZF 45 C - Toyota version 11; 003

ZF 63 C version 07; 001

ZF 88 C version 001

Cod.

310.01.0056d

FOLEY ENGINES

1-800-233-6539

Repair Manual and Spare Parts List ZF 45C / 63C / 88C

TABLE OF CONTENTS

Introduction ........................................................... 2

SECTION I: GENERAL DATA .................................... 2

1. Transmission Set-up ....................................... 2

2. Consumable goods ......................................... 3

3. Measuring Tools .............................................. 3

4. Standard Tools and Fixture ............................. 3

SECTION II: SPECIAL TOOLS ................................. 4

SECTION III: DISASSEMBLY PREPARATION......... 5

Introduction ........................................................... 5

1. Preliminary operation ...................................... 5

2. Housing disassembly ...................................... 5

3. Input shaft ....................................................... 8

4. Forward clutch housing disassembly .............. 9

SECTION IV: ASSEMBLY .......................................... 12

Introduction ........................................................... 12

1. Input shaft ....................................................... 12

2. Housing assembly........................................... 15

3. Complementary operations............................. 18

4. Oil pump.......................................................... 21

SECTION V: PLAYADJUSTMENT ........................... 22

1. Reverse clutch clearance................................ 22

2. Forward clutch clearance................................ 23

3. Input shaft play................................................. 24

4. Output shaft bearing play................................. 25

SECTION VI: TIGHTENING TORQUES ................... 26

SECTION VII: FUNCTION TEST .............................. 26

1. Filling up with transmission fluid ..................... 26

2. Check fluid level.............................................. 26

3. Function test ................................................... 27

4. Shifting pressure ZF 45C / 63C / 88C............. 28

5. Lube oil delivery ZF 45C / 63C / 88C.............. 29

SECTION VIII: TROUBLESHOOTING...................... 30

SECTION IX: AUTOMATIC TRANSMISSION

FLUID.................................................. 33

SECTION X: SPARE PARTS LISTAND

EXPLOSION DRAWINGS.................... 35

Repair Manual and Spare Parts List ZF 45C / 63C / 88C

INTRODUCTION

Thismanualgivesspecificinstructionsfortheproperrepair

on ZF 45C / 63C / 88C model transmissions.

Please follow the procedures carefully to insure quality

service.

ZF HURTH MARINE recommends to read the manual

completely before starting with repairs, as some of the

procedures described are rather complex.

Along with standard tools, ZF HURTH MARINE

recommendstheuseofspecialtools,necessarytoperform

repairs correctly. The special tools are available trough

your local ZF HURTH MARINE dealer.

This manual is based on the technical information at the

timeof printing.The manualhas beenchecked carefullyin

order to avoid errors. However ZF HURTH MARINE is not

liable, for any misrepresentations, errors of description or

omissions.

Modificationsonfuturemanualsmaybeintroducedwithout

prior notice.

Thefollowinginternationalsymbolsareusedinthisservice

manual.

SECTION I: GENERAL DATA

1. TRANSMISSIONS SET-UP

The main components of the HSW Marine Transmissions

are:

Item 1two-piece aluminum die cast

1.1 oil filter

1.2 oil dipstick

1.3 pump

Item 2gears

2.1 input shaft with forward clutch

pack assembly

2.2 planet gear carrier assembly

Item 3control valve

1.2

2.2

2.1

WARNING:THISSYMBOLWARNSOFPOSSIBLE

PERSONAL INJURY.

CAUTION:Thissymbolwarnsofpossibledamage

to transmission.

1.3

1.1

Repair Manual and Spare Parts List ZF 45C / 63C / 88C

2. CONSUMABLE GOODS

For cleaning:

Cold cleaner such as benzine, trichloroethane or Loctite

fast cleaner No. 7063.

WARNING

Keepdetergentsawayfromyourskin,donotdrinkand

do not inhale their vapors! Always wear protective

gloves and safety glasses!

Note accident prevention rules!

For assembly:

•Loctite 245 for securing output flange on spline

•Loctite 574 on the outside diameter of the seals and on

mating surfaces

•Grease: Klüber STABURAGS NBU 30, for radial shaft

seals

•ATF Fluid - 1.75 Liters (1.85 US qts)

[see ATF fluid list chap. IX]

3. MEASURING TOOLS

Dial indicator gauge with arm-type support

Range 0 - 1" (0 - 25 mm) in 0.0005" (0.01 mm) increments

Caliper

Range0-6"(0-150mm)in0.0005"(0.01mm)increments

1/2" tool bar

working edge within 0.0002" per 12"

4. STANDARD TOOLS AND FIXTURE

Wrench

for hexagon bolts (8 mm, 13 mm, 14 mm, 17 mm, 19 mm,

22 mm)

Allen wrench

(5 mm, 6 mm, 8 mm)

Hexagon drive socket wrench

(13 mm, 17 mm, 19 mm)

Torque wrenches

Ranges:

-20 lb in -200 lb in (5 Nm - 65Nm)

-15 lb ft - 100 lb ft (30 Nm - 150 Nm)

Plastic hammer (1000 g) (24 oz)

sturdy screwdriver

- Pullers

blindholebushing (planetarygearassembly)range1/4" to

1 3/4" 4 lb slide hammer

output flange range 3 1/2" to 5 1/2" 5 ton; 3 - jaw

No. 2 Pry bars

1/2" stock

Snap ring pliers

sizes: 9" (shaft diameter 1 1/2" to 3 1/2")

10" (bore diameter 1 1/2" to 4")

Repair Manual and Spare Parts List ZF 45C / 63C / 88C

SECTION II: SPECIAL TOOLS

It is assumed that all standard tools, such as, torque

wrenches,open-endwrenches,AllenKeysandextractors,

are available.

All fixtures for pressing in and out should be used in

conjunctionwithahydraulicormanualpress.Identnumbers

are also stock reference numbers.

Mandrel

Oil pump seal, (Id. No. 500493)

P/N 978.45.0022.0

Mandrel

Bushing, (Id. No. 500494)

P/N 978.45.0023.0

Mandrel

Control valve oil seal, (Id. No. 500495)

P/N 978.45.0024.0

Mandrel

Input shaft rollers bearing, (Id. No. 500496)

P/N 978.45.0025.0

Mandrel

Forward clutch circlip, (Id. No. 500497)

P/N 978.45.0026.0

Mandrel

Input shaft ball bearing (Id. No. 500498)

P/N 978.45.0027.0

Mandrel

Output shaft ball bearing, (Id. No. 500499)

P/N 978.45.0028.0

Plate

Housing support, (Id. No. 500500)

P/N 978.45.0029.0

Plug

Forward clutch, (Id. No. 500501)

P/N 978.45.0030.0

Wrench

Output flange, (Id. No. 500446)

P/N 978.40.0002.0

Antirotation bracket

Output flange, (Id. No. 500502)

P/N 978.45.0031.0

Clamp ring

Input shaft play, (Id. No. 618582)

P/N 219.354.3

Repair Manual and Spare Parts List ZF 45C / 63C / 88C

2. HOUSING DISASSEMBLY

2.1 Position the marine gearbox on the housing support

(P.N. 500500).

2.2 Screw off bolts (6) and washers (10). Remove the

pumpcoverassembly(34).Inspectsealingring(1)and

O-Ring(33);inspectforwearandreplaceifnecessary.

2.3 Removetherotorpumpfromtheshaft.Ifitneedstobe

replaced, the complete cover assembly (34) has to be

replaced.

NOTE:Pumpgearshould beinstalledthesamesidedown

as removed.

SECTION III: DISASSEMBLY

PREPARATION

INTRODUCTION

Clean the transmission thoroughly on the outside before

disassembly.

The repair area should be clean and well lighted.

ZF HURTH MARINE recommends using a stand (P.N.

500500) for aiding in assembly and disassembly.

1. PRELIMINARY OPERATION

1.1 Remove the breather valve (22) and oil dipstick (26).

Clean the breather with suitable cleaner, allow to dry

and coat with oil.

1.2 Screw off bolts (6) and washers (10), remove the filter

cover(5),seal(4)andfilterelement(3).Inspectsealfor

wearandreplaceifnecessary.Cleanthefilterelement

with suitable cleaner.

WARNING

Position a container to pick up the oil flow.

Repair Manual and Spare Parts List ZF 45C / 63C / 88C

2.7 Remove the cover (35).

2.8 Remove reverse clutch first outer disc (63).

2.9 Remove springs (58).

2.4 Using pliers remove the key (28) from shaft.

NOTE: Take note of the position of the key.

2.5 Screw off bolts (7), (8) and washers (10).

2.6 Bytappingwithasofthammerseparatethecover(35)

from the housing (36).

Repair Manual and Spare Parts List ZF 45C / 63C / 88C

2.13 Turn the housing upside down. Using the tool

P.N.500446 loosen nut (72); stop the output flange

(66) from turning using tool P.N.500502. Discard O-

Ring (71) and replace with a new one.

2.14 Remove flange using appropriate puller.

WARNING

[see type page 3].

2.15 With a soft hammer disassemble the output shaft.

Driving it out from the housing.

2.10 Remove inner disc (62), outer disc (63), inner disc

(62), the last outer disc (63) and if present shims

(64),(65).

2.11 Pull out the shaft and forward clutch assembly.

2.12 Removethrust washer(45)which isremainedon the

planetgearcarrierassemblyand(withstandardpuller)

bushing (46).

Repair Manual and Spare Parts List ZF 45C / 63C / 88C

3.3 With pliers remove the circlip (44).

NOTE: Take note of the position of the circlip (44).

3.4 Supportthe ringgear allowingroomfor theinput shaft

with gears to come out bottom side.

NOTE: Pressing on splined end of shaft disassemble it

from the clutch housing.

This operation will damage the bearing.

Use a press with:

distance: 200 mm (8 inches)

min. force: 2000 kg (4400 lbs)

3.5 Remove piston rings (40) from the input shaft (37).

3. INPUT SHAFT

3.1 Remove piston rings (39) from the input shaft (37).

3.2 Remove spacer (42b), needle bearing (42a), other

spacer (42b) and shims (75-76).

2.16 Don't disassemble the output shaft.

If it's necessary to replace it, ask for complete gear

carrier assembly (38).

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