Installation manual
ZF
TRANSMISSIONS
SHIPMENT
For safety reasons, the transmission
is
not filled
with
transmission
fluid
during shipment and the selector lever
is
temporarily attached
to
the actuating shaft.
Before leaving the
WESTERBEKE
plant, each transmission
undergoes
a test
run,
with Dextron
/II
ATF transmission
fluid.
The residual
fluid
remaining in the transmission after
draining
acts
as
a preservative and provides protection
against corrosion for at least one year
if
properly stored.
~~t....::..J.1-
FILTER
ASSEMBLY
OUTPUT
COUPLING:
---'0"-
ZF-63
OIL
COOLER
The oil
cooler,
mounted above the transmission, provides
continuous cooling for the transmission
fluid.
Raw water
passes through the tubes
of
the cooler and discharges
overboard. The transmission
fluid
is
cooled
as
it
flows
around
the
tubes
and back into the transmission.
WESTERBEKE
RECOMMENDS
HAVING
A
SPARE
COOLER
ABOARD
'.A?JJ·J-;---TRANSMISSION
•
RAW
WATER
CONNECTION
FLUID
CONNECTIONS
RAW
WATER
CONNECTION
TRANSMISSION
FLUID
ZF
COOLER
Fill
the
transmission with
Dextron
III
ATF.
The
fluid
level
should
be
up
to
the mark
on
the dipstick. After checking the
level, press the dipstick into the case and
~
it
to
tighten.
During the
first
25
operating hours, inspect the bell housing,
output shaft
and
transmission cooler for leakage. The
fluid
should be changed after the first
25
hours
and every
300
hours
thereafter.
NEUTRAL
SWITCH
These transmissions are equipped with a neutral safety
switch.
This
is
to
prevent the engine from starting
in
gear.
Unless the transmission selector lever
is
perfectly aligned in
neutral, the engine starter will not activate.
INITIAL
OPERATION
Set the shifting lever
to
neutral position (N). Start the engine
and
let it
run
long enough in idle
to
fill the cooler
and
hoses
with
transmission
fluid.
Shift into
gear,
forward
and
reverse;
shifting
should
be smooth
and
positive. Direct changes
from
forward
to reverse are permissible since the multiple
disc
clutch permits changing at high rpm including sudden
reversing at high speeds
in
the
event of
danger.
After initial operation,
make
a
visuaI
inspection of the output
coupling,
oil
cooler and
hoses,
and
the cable
connections
to
the
transmission.
LOCKING
THE
PROPELLER
Locking of the propellyr shaft by an additional brake
is
not
required:
use the gear shift lever position opposite
your
direction
of
travel for this purpose. Never put the gear shift in
the
position corresponding to the direction of
travel
of the
boat.
WHEN
UNDER
SAIL
OR
BEING
TOWED
Rotation
of
the propeller without a
load,
such
as
when
the
boat
is
being sailed, being towed or anchored
in
a
river,
as
well
as
operation of the engine with the propeller stopped
(for charging the battery),
will
have no detrimental effects
on
the transmission.
NOTE:
When
the
boat
is
being
sailed
(engine
stopped),
the
gear shift
must
be
in
the
neutral
position.
The
propeller
is
at
idle
and
can
free-wheel.
DAILY
OPERATION
o Check
the
transmission
fluid.
Visually
check the gear shift linkage
and
transmission.
Start
the
engine in neutral, allowing a
few
minutes
at idle
to
warm
the
fluid.
D Shift into
gear.
NOTE:
Too
Iowan
idle
speed will produce a
chattering
noise
from
the
transmission
gear
and damper
plate.
In
such
cases
the
idle
speed
should
be
increased.
Operating
Temperature
The operating temperature of the transmission
should
not
exceed 176°F (80°C). A connection for a temperature probe
is provided. At maximum output
of
the engine,
the
fluid
may
reach 220°F
(104
0c).
A
CAUTION:
If
the
transmission
fluid
temperature
is
too
high,
stop
the
engine
immediately
and
check
the
transmission
fluid.
Engines & Generators
51