Foley Engines ZF 45 C Repair Manual
  1. Manuals
  2. Brands
  3. Foley Engines Manuals
  4. Engine
  5. ZF 45 C - Walter
  6. Repair manual

Foley Engines ZF 45 C Repair Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

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
FOLEY ENGINES
1-800-233-6539
ZF 45 C
ZF 45 C - Walter
ZF 45 C - Toyota
ZF 63 C
ZF 88 C
310.01.0056d
Cod.
version 10; 001
version 002
version 11; 003
version 07; 001
version 001

Advertisement

Table of Contents
loading

Summary of Contents for Foley Engines ZF 45 C

  • Page 1 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 FOLEY ENGINES 1-800-233-6539 ZF 45 C version 10; 001 ZF 45 C - Walter version 002 ZF 45 C - Toyota version 11; 003 ZF 63 C version 07;...

  • Page 3: Table Of Contents

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C TABLE OF CONTENTS SECTION V: PLAY ADJUSTMENT ......22 1. Reverse clutch clearance ........ 22 Introduction ............2. Forward clutch clearance ........ 23 3. Input shaft play ..........24 SECTION I: GENERAL DATA ........

  • Page 4: Introduction

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C INTRODUCTION SECTION I: GENERAL DATA This manual gives specific instructions for the proper repair 1. TRANSMISSIONS SET-UP on ZF 45C / 63C / 88C model transmissions. Please follow the procedures carefully to insure quality The main components of the HSW Marine Transmissions service.

  • Page 5: Consumable Goods

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C 2. CONSUMABLE GOODS 4. STANDARD TOOLS AND FIXTURE For cleaning: Wrench Cold cleaner such as benzine, trichloroethane or Loctite for hexagon bolts (8 mm, 13 mm, 14 mm, 17 mm, 19 mm, fast cleaner No.

  • Page 6: Section Ii: Special Tools

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C SECTION II: SPECIAL TOOLS Mandrel Input shaft ball bearing (Id. No. 500498) It is assumed that all standard tools, such as, torque P/N 978.45.0027.0 wrenches, open-end wrenches, Allen Keys and extractors, are available.

  • Page 7: Section Iii: Disassembly Preparation

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C SECTION III: DISASSEMBLY 2. HOUSING DISASSEMBLY PREPARATION 2.1 Position the marine gearbox on the housing support (P.N. 500500). INTRODUCTION Clean the transmission thoroughly on the outside before disassembly. The repair area should be clean and well lighted.
  • Page 8 Repair Manual and Spare Parts List ZF 45C / 63C / 88C 2.4 Using pliers remove the key (28) from shaft. 2.7 Remove the cover (35). NOTE: Take note of the position of the key. 2.5 Screw off bolts (7), (8) and washers (10). 2.8 Remove reverse clutch first outer disc (63).
  • Page 9 Repair Manual and Spare Parts List ZF 45C / 63C / 88C 2.10 Remove inner disc (62), outer disc (63), inner disc 2.13 Turn the housing upside down. Using the tool (62), the last outer disc (63) and if present shims P.N.500446 loosen nut (72);...

  • Page 10: Input Shaft

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C 2.16 Don't disassemble the output shaft. 3.3 With pliers remove the circlip (44). If it's necessary to replace it, ask for complete gear carrier assembly (38). NOTE: Take note of the position of the circlip (44). 3.4 Support the ring gear allowing room for the input shaft with gears to come out bottom side.

  • Page 11: Forward Clutch Housing Disassembly

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C 4. FORWARD CLUTCH HOUSING 4.4 Remove forward clutch inner (60), outer (61) shims (73) (74) and end disc (59). DISASSEMBLY 4.1 Remove circlip (48). WARNING 4.5 Remove circlip (55), cup springs (54). WARNING 4.2 With a screwdriver remove the circlip (50).
  • Page 12 Repair Manual and Spare Parts List ZF 45C / 63C / 88C 4.8 Remove O-Rings (52), (53) from the piston (51). 4.11 Remove O-Rings (57) from piston (56). NOTE: Replace O-Rings (33, 57) if disassembled. 4.12 Remove the stop screw (17) and position screw (18), the two washers (13), the spring (20) and the ball (21).
  • Page 13 Repair Manual and Spare Parts List ZF 45C / 63C / 88C 4.17 Remove baffle (29). With a screwdriver take out an end of the baffle from the groove on the housing. By gripping and rolling up the baffle take it out from the housing.

  • Page 14: Section Iv: Assembly

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C 4.20 Support housing (36) flat on a press, press out bearing 1. INPUT SHAFT (67), then remove shims (68) (69). 1.1 Install O-Rings (52) (53) on the piston (51). Insert the NOTE: This operation will damage the bearing.
  • Page 15 Repair Manual and Spare Parts List ZF 45C / 63C / 88C 1.3 Position the circlip (55). 1.6 Insert end disc (finished side up) (59), shims (73 - 74) and alternatively outer clutch disc (61) and inner clutch disc (60). NOTE: To set correct play see item 2 page 23.
  • Page 16 Repair Manual and Spare Parts List ZF 45C / 63C / 88C 1.9 Press the forward clutch housing (47) on the input shaft 1.12 Install the circlip (50). (37). WARNING Be sure that snap ring has been properly seated (check circlip opening to be not close to slots in clutch housing).

  • Page 17: Housing Assembly

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C 1.15 With toll P.N. 500499 and a suitable support press ball 2.2 Insert the baffle (29) as shown in the picture. The fold bearing (67). of the baffle must correspond with the groove on the Add shims (68, 69) max bearing play: housing opposite to the breather position on the second 0,1 mm (0.0039 in)
  • Page 18 Repair Manual and Spare Parts List ZF 45C / 63C / 88C 2.5 Install O-Ring (57) into the piston (56). 2.8 Assemble the cover (5). Wet O-Ring with ATF oil and using a plastic hammer, Tights bolts (6) with washer (10). Tightening torque: 18 install the assembled piston (56) into cover (35).
  • Page 19 Repair Manual and Spare Parts List ZF 45C / 63C / 88C 2.11 Install bushing (16) in the way that its bigger diameter 2.14 Install plug (14) and washer (19). is up. NOTE: Tighten to 25 Nm (18.5 lb ft.) torque. 2.12 Install the ball (21).

  • Page 20: Complementary Operations

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C Neutral Safety Switch Function check 3.3 Install the thrust washer (45). Connect neutral safety switch with a lamp in series to a battery. The neutral safety switch operates when the lamp is lighted.
  • Page 21 Repair Manual and Spare Parts List ZF 45C / 63C / 88C 3.5 Install reverse clutch pack. 3.8 Install springs (58). Insert shims (64, 65). Install the first outer disc (63). NOTE: To set correct play see item 3 pag. 24. 3.9 Install the final outer disc (63).
  • Page 22 Repair Manual and Spare Parts List ZF 45C / 63C / 88C 3.11 Assemble the cover down over the input shaft. 3.14 Wet O-ring (71) with grease. NOTE: Be sure of the correct position of the outer disc (63) when pressing the cover against the housing. 3.15 Tighten the output shaft ring nut (72).

  • Page 23: Oil Pump

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C 4. OIL PUMP 4.4 Wet O-Ring (33) with ATF fluid and install it into the pump cover. 4.1 Install onto shaft (37) key (28) driving inner pump gear. NOTE: Check carefully correct position of key (28).

  • Page 24: Section V: Play Adjustment

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C 4.7 Install cover. Fig. V2 NOTE: Tighten the screws to 18 Nm. (13.3 lb ft.) torque in a criss cross pattern. 1) Install reverse clutch pack into housing: WARNING 3x external clutch discs p/n 3311 301 006 plus 2x The necessary time for a complete polymerization is 5...

  • Page 25: Forward Clutch Clearance

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C 3) Take measurement "B" (See fig. no. V2). 1) Install end disc p/n 3311 302 034 in ring gear p/n 3311 302 026. 2) Install snap ring p/n 0630 513 066 in ring gear. For example: "B"...

  • Page 26: Input Shaft Play

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C 4) Take measurement "A" in different points and make the average. For example: "E" = 22.55 mm For example: "A" = 48.53 mm 8) Select proper tickness shims to set the gap "F". 5) Remove snap ring p/n 0630 513 066 and measure its Shims available: tickness "B".

  • Page 27: Output Shaft Bearing Play

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C Take measurement "M" between cover (35) mating surface 4. OUTPUT SHAFT BEARING PLAY and the surface shown on figure V5. Select proper thickness shims (75) (76) to set the gap "I". This measurement has to be taken only is housing (36) is replaced.

  • Page 28: Section Vi: Tightening Torques

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C SECTION VI: TIGHTENING TORQUES Part Size Torque in Nm Torque in lb ft. Housing bolts 18 Nm 13 lb ft. Oil pump bolts 18 Nm 13 lb ft. Plate oil filter 18 Nm 13 lb ft.

  • Page 29: Function Test

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C • Temperature gauge 0-120°C (0-250°F), connecting 3. FUNCTION TEST thread 3/8"-18NPSF. • Flow meter 0-35 liters/min When the transmission has been completely assembled (0-10 gals/min). and filled up with transmission fluid, it would be convenient to make a function test.

  • Page 30: Shifting Pressure Zf 45C / 63C / 88C

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C 4. SHIFTING PRESSURE ZF 45C / 63C / 88C ZF 45C Max 20 bar (290 p.s.i.) at 70 °C (160 F°) and 4000 rpm. Min 14 bar (203 p.s.i.). max.

  • Page 31: Lube Oil Delivery Zf 45C / 63C / 88C

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C ZF 88C Max 24 bar (348 p.s.i.) at 70 °C (160 F°) and 4000 rpm. Min 19 bar (275.5 p.s.i.). max. 88C min. 88C 1000 2000 3000 4000 5000 Driving Speed [rpm] 5.

  • Page 32: Section Viii: Troubleshooting

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C SECTION VIII: TROUBLESHOOTING If any interventions are necessary on the transmission, please refer to the Repair Manual. Warranty claims will be forfeited if work on the transmission In case of trouble, check first whether all items of the is performed by un-authorized persons during the warranty present mounting and operating instructions have been period.
  • Page 33 Repair Manual and Spare Parts List ZF 45C / 63C / 88C Syptom Possibly cause Remedy 6. Shifting pressure 6.1 Fluid filter clogged Clean or replace fine filter too low 6.2 Fluid level in transmission Top-up with fluid; in case too low.
  • Page 34 Repair Manual and Spare Parts List ZF 45C / 63C / 88C Syptom Possibly cause Remedy 11. Fluid leakage at 11.1 Excessive fluid in Pump excessive fluid out breather transmission with commercial hand pump 12. Fluid leakage at 12.1 Bolts are not tight Tighten bolts with prescribe joints torque.

  • Page 35: Section Ix: Automatic Transmission Fluid

    Repair Manual and Spare Parts List ZF 45C / 63C / 88C SECTION IX: AUTOMATIC TRANSMISSION FLUID MANUFACTURER PRODUCT MANUFACTURER PRODUCT ADDINOL MINERALÖL • ADDINOL ATF D IID ENGEN PETROLEUM, • ENGEN ATF 22D GMBH, KRUMPA/D • ADDINOL ATF D III CAPE TOWN/ZA •...
  • Page 36 Repair Manual and Spare Parts List ZF 45C / 63C / 88C MANUFACTURER PRODUCT MANUFACTURER PRODUCT STL TECNOL, • TECNOL TECMATIC D2 NIS-RAFINERIJA NAFTE • GALAX MATIC DAC ESCALQUENS/F BEOGRAD/YU SUN OIL COMPANY, • SUNAMATIC 149 OEST G. MIN.ÖLWERK, • ATF T 4011 AARTSELAAR/B •...

  • Page 37: Section X: Spare Parts List And Explosion Drawings

    ZF HURTH MARINE. Name plate The name plate is mounted to the transmission ZF HURTH MARINE Transmission Type. Tipo di invertitore. ARCO ITALY ZF 45 C MODEL Transmission ratio propeller rotation same to a engine rotation. 1.00 1.03 RATIO I...
  • Page 38 Q.ty Note Paraolio entrata Input shaft seal 3312 301 030 413883 Paraolio entrata ZF 45 C Toyota Input shaft seal ZF 45 C Toyota 0634 311 025 501151 Paraolio uscita Output shaft seal 0634 319 136 500064 Paraolio uscita ZF 45 C Toyota...
  • Page 39 Retaining ring 0630 513 066 455788 Pistone ZF 45 C / ZF 63 C Clutch piston forward ZF 45 C / ZF 63 C 3311 302 031 500275 Pistone ZF 88 C Clutch piston forward ZF 88 C 3313 302 040...
  • Page 40 3311 304 020 Retaining ring 0630 513 039 Retaining ring 0630 513 066 REVERSE CLUTCH KIT P/N 3311 199 034 ZF 45 C (no version 11 Toyota), ZF 63 C, ZF 88 C O-Ring 0634 304 400 O-Ring 0634 304 128 °...
  • Page 41 0635 302 019 Thrust washer 0635 290 002 Retaining ring 0630 531 227 REBUILT KIT P/N 3311 199 001 Thrust washer 3311 304 019 ZF 45 C Toyota Bushing 3311 304 020 ° Pos. Description Part. N Q.ty Retaining ring...
  • Page 42 Repair Manual and Spare Parts List ZF 45C / 63C / 88C FORWARD CLUTCH KIT P/N 3311 199 003 ZF 45C TOYOTA ° Pos. Description Part. N Q.ty Input shaft seal 0634 311 025 O-Ring 001.105.0374 O-Ring 0634 306 300 Piston ring 0634 402 175 Piston ring...
  • Page 43 Repair Manual and Spare Parts List ZF 45C / 63C / 88C...
  • Page 44 FOLEY ENGINES 1-800-233-6539 ZF-HURTH MARINE...

This manual is also suitable for:

Zf 45 c - toyotaZf 63 cZf 88 c

Table of Contents