Foley Engines ZF 45 C - Walter Instrucciones de funcionamiento
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
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
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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
1
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
2
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
3
1
1.1
3
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
4
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
5
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
6
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).
7
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
8
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).
Este manual sirve para los siguientes modelos
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