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ZF 63 A Repair Manual & Parts List

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Repair Manual
and
ZF 63 A
ZF 63
ZF 80 A
ZF 80-1 A
ZF 80 A NEW VERSION
ZF 80-1 A NEW VERSION
ZF 85 A
NOVEMBER 2005
310.01.0054h
cod.

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Summary of Contents for ZF 63 A

  • Page 1 Repair Manual Spare Parts List ZF 63 A ZF 63 ZF 80 A ZF 80-1 A ZF 80 A NEW VERSION ZF 80-1 A NEW VERSION ZF 85 A NOVEMBER 2005 310.01.0054h cod.
  • Page 8 1.2 CLEANERS AND SEALANTS WARNING Keep detergents away from your skin, do not drink and do not inhale their vapors! Always wear protec- tive gloves and safety glasses! Note accident prevention rules! 1.3. MEASURING TOOLS 1.4. STANDARD TOOLS AND FIXTURE WRENCH MICROMETER ALLEN WRENCH...
  • Page 9 LEVER CLAMPING SCREW INPUT SHAFT DIAL INDICATOR LEGS KIT (composed of three legs) P/N 978.25.0006.0 (477776) ADAPTER FOR BASIC UNIT 454422 BASIC UNIT...
  • Page 15 NEW VERSION OLD VERSION...
  • Page 16 The inner race and the gear on the control block side can be removed by using the split ring and a standard hydraulic press (fig. 7-2b). Input shaft - Control block side ZF 85 A Remove the retaining ring (item 1, Fig. 7-2c) using a plier.
  • Page 20 4.1.2 Install needle bearings and gear ZF 63 A (Ratio= 2.7 only) ZF 63 A (no Ratio= 2.7) ZF 80 A - ZF 80-1 A - ZF 85 A ZF 63 Input spline side Install needle bearing (item 1, fig. 1-2) onto shaft.
  • Page 21 Repair Manual and Spare Parts List Section 4 4.1.6 Assemble piston rings Mount piston ring seals (item 1, Fig. 1-6) onto input shaft. IMPORTANT Make sure the interlocking position of the piston rings are staggered on the shaft. FIG. 1 - 6 4.2 INTERMEDIATE SHAFT 120 ˚...
  • Page 22 OLD VERSION NEW VERSION ZF80 A - ZF80-1 A OLD VERSION NEW VERSION ZF63A - ZF63 ZF85 A...
  • Page 24 0.2 mm (0.0079 in.) thickness from the shims packages which were removed during disassembly. Adjustment values Pretension (mm) FIG. 5 - 1 Shaft Input Intermediate Output ZF 80 A - ZF 80-1 A 0.02-0.12 0.00-0.12 0.00-0.12 ZF 85 A 0.02-0.12 0.00-0.12 0.1-0.15 ZF 63 A - ZF 63 0.02-0.12...
  • Page 26 ADAPTER FOR BASIC UNIT 454422 BASIC UNIT...
  • Page 28 O-RING Housing Housing...
  • Page 29 MIN. 1000 1500 2000 2500 3000 3500 4000 4500 5000 DRIVING SPEED (rpm) = ZF 63 A - ZF 63 - ZF 80 A = ZF 80-1 A - ZF 85 A 7.91 7.39 6.86 6.33 5.80 5.28 4.75 4.22 3.69...
  • Page 41 Repair Manual and Spare Parts List ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A 11. SPARE PARTS LIST ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A Preface The spare parts list is only valid for the type and ver- When ordering parts, please state: sions of transmission, as shown below.
  • Page 42 ZF 63 A...
  • Page 43 Q.ta Á Pos. Part number Old P/N Descrizione Description Note Q.ty Up to serial number 10730G From serial number 10731G Ratio I=2.52 uprated version & ratio I= 2.52 (also PCM) Supplied only included in the oil filter kit p/n 3312 199 031...
  • Page 44 ZF 63...
  • Page 45 Q.ta Á Pos. Part number Old P/N Descrizione Description Note Q.ty Up to serial number 18672F From serial number 18673F Supplied only included in the oil filter kit p/n 3312 199 031...
  • Page 46 Repair Manual and Spare Parts List ZF 80 A - ZF 80-1 A FIG. 1 ZF 80 A - ZF 80-1 A...
  • Page 47 Q.ta Á Pos. Part number Old P/N Descrizione Description Note Q.ty This housing is not suitable with cover p/n 3313 301 012. But only with the new cover p/n 3313 301 010 This cover is not suitable with housing p/n 3313 301 013. But only with the new housing p/n 3313 301 009 Suitable only to new housing p/n 3313 301 009 Supplied only included in the oil filter kit p/n 3312 199 031...
  • Page 49 Q.ta Á Pos. Part number Old P/N Descrizione Description Note Q.ty Ratio I=2.52 uprated version & ratio I= 2.52 (also PCM)
  • Page 50 Repair Manual and Spare Parts List ZF 63 A FIG. 2 Q.ta Á Pos. Part number Old P/N Descrizione Description Note Q.ty Vers. 21,001,015 (Rapporto I=1,22) Vers. 21,001,015 (Ratio I=1.22) 31 3312 302 005 500860 Ingranaggio Z1=37 Forward gear Z1=37...
  • Page 53 Tapered roller bearings already assembled...
  • Page 55 From serial number 43448L (ZF 80 A) and 43463L (ZF 80-1 A)
  • Page 56 Tapered roller bearings already assembled...
  • Page 61 Q.ta Á Pos. Part number Old P/N Descrizione Description Note Q.ty - to be instelled with 12 V power supply - to be instelled with 24 V power supply - to be instelled with 24 V power supply - 26 bar - to be instelled with 12 V power supply - 26 bar...
  • Page 64 F1420176 F1420175...
  • Page 65 To be installed with 12 V power supply...
  • Page 66 F1420178...
  • Page 67 To be installed with 12 V power supply To be installed with 24 V power supply To transform the solenoid valve from 12V to 24V will be en- ough to replace only the solenoid - available loosen P/N 3312 199 062. F1420179 The valve is not available loosen and it is a common com- ponent both for 12V and 24V solenoid valve.
  • Page 68 F1420178...
  • Page 69 To be installed with 12 V power supply To be installed with 24 V power supply...
  • Page 70 ZF 63 A - ZF 63 KIT COMPONENTS ZF 63 A BEARINGS KIT, RATIO I = 2.52 (uprated version), Ratio I=2.7...
  • Page 71 ZF 80 A - ZF 80-1 A KIT COMPONENTS...
  • Page 73 (1.20 R) (1.41 R) (1.57 R) (1.96 R) (2.50 R) (2.85 R) (1.21 R) (1.41 R) (1.57 R) (1.96 R) (2.50 R) (2.85 R)
  • Page 75 Supplied only included in the oil filter kit p/n 3312 199 031...
  • Page 78 Tapered roller bearings already assembled...
  • Page 82 F1420176 F1420175...
  • Page 83 To be installed with 12 V power supply...
  • Page 84 F1420178...
  • Page 85 To be installed with 12 V power supply To be installed with 24 V power supply To transform the solenoid valve from 12V to 24V will be en- ough to replace only the solenoid - available loosen P/N 3312 199 062. F1420179 The valve is not available loosen and it is a common com- ponent both for 12V and 24V solenoid valve.
  • Page 86 F1420178...
  • Page 87 To be installed with 12 V power supply To be installed with 24 V power supply...
  • Page 88 KIT COMPONENTS...
  • Page 89 (1.57 R) (1.75 R) (1.96 R) (2.50 R) Tipo della trasmissione Transmission type Posizione della leva "B" Rapporto della trasmissione Shifting position "B" Transmission ratio Posizione della leva "A" Versione della trasmissione Shifting position "A" Transmission version Numero di serie Serial number Ogni anno è...
  • Page 90 ZF 85 A versions 004 - 007 - 003 - 002...
  • Page 91 Q.ta Á Pos. Part number Old P/N Descrizione Description Note Q.ty Supplied only included in the oil filter kit p/n 3312 199 031...
  • Page 93 Tapered roller bearings already assembled...
  • Page 96 F1420178...
  • Page 97 To be installed with 12 V power supply To be installed with 24 V power supply To transform the solenoid valve from 12V to 24V will be en- ough to replace only the solenoid - available loosen P/N 3312 199 062. F1420179 The valve is not available loosen and it is a common com- ponent both for 12V and 24V solenoid valve.
  • Page 98 F1420178...
  • Page 99 To be installed with 12 V power supply To be installed with 24 V power supply...
  • Page 100 KIT COMPONENTS...

This manual is also suitable for:

6380 a80 a new version8580-1 a new version80-1 a

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