Installation manual

ManualsBrandsWesterbeke ManualsAutomotive108C SIX

ZF

TRANSMISSIONS

CHANGING

THE

TRANSMISSION

FLUID

16MM.(8")

SCREW

O-RINGS

ZF·45

FILTER

Filter

Element

The ZF

transmission

has

a

filter

element

located opposite the

dipstick.

This

filter

must be

replaced

whenever

the

fluid

is

changed.

Remove

the

filter

by

loosening

the

screw

on the cover

using

a 6mm

Allen

wrench.

1\vist

and

pull

out

the

filter

and

remove

the

element.

Place

the

new

filter

onto the cover

and

lock

it

into

place

by

turning

it

clockwise.

Check

the

O-rings

for

damage

and

replace

if

necessary.

Replacement

filters

can

be

obtained

from

your

local

WESTERBEKE

dealer or ZF

dealer.!>

Removing

the

Fluid

Push a suction

pump

hose

down

through

the pipe hole (under

the

filter)

to

the

bottom of

the

housing

and

suck

out

the

fluid.

Remove

the

oil

return line

from

the

cooler

and

allow

the

oil

to drain

into

a

container,

then

reconnect

the

oil

return

line.

Wipe

down

the

transmission

and

properly

dispose of the

used

fluid.

Replacing

the

Fluid

Pour

in

new

Dextron

1II

ATF

fluid

and

check

the

quantity

with

the

dipstick.

Transmission

fluid

quantities

will

vary

with

the

use

of

cool-

ers,length of

hoses

and'the

angle

of

the

transmission.

Approximate

Quantities

ZF

45

-

2.12

quarts

(2.0

Liters)

ZF

63

-

3.2

quarts

(3.0

Liters)

ZF

63V

-4.2

quarts

(4.0

Liters)

Reinsert

the

filter

assembly

into

the

housing.

Press

it

in

place

and

tighten

the

Allen

screw.

NOTE:

Some

ZF

transmissions

use

a "Tn

handle

in

place

of

a

screw

on

their filter

assemblies.

After

running

the

engine,

shut

down

and

recheck

the

fluid

level.

A

WARNING:

Never

pullout

the

dipstick

while

the

engine

is

running.

Hot

fluid

will

splash

from

the

dipstick

hole.

This

could

cause

severe

burns.

MAINTENANCE

Transmission

maintenance

is

minimal.

Keep

the

exterior

housing

clean,

check

the

fluid

level

as

part of

your

regular

routine,

and

change

the

fluid

every

300

operating

hours.

Periodically inspect

the

transmission

and

the

cooler

for

leaks

and

corrosion.

Make

certain

the

air vent is

clear

and

when

checking

the

fluid

level

look

for

signs of

water

contamination

(fluid

will

appear

as

strawberry

cream).

Lay-up/Winterize

Storage

requires

special

care.

Follow these

procedures:

D Drain

water

from

the

transmission oil cooler

and

replace

with

a proper

mixture

of antifreeze coolant

NOTE:

This

operation

wiU

nonnally

occur

when

the

engine

raw

water

cooling

system

is

properly

winterized.

Clean

up

the

transmission

and

touch

up

unpainted

areas

(use

heat

resistant

paint).

o Fill the

transmission

with

Dextron

III

ATF

fluid

to

prevent internal

corrosion

(extended

storage

only,

twelve

months

or

more).

Loosen attaching

hardwarf?

from

the

transmission

output

flange

and

propeller shaft

coupling

flange

before

removing

the

boat

from

the

water.

Separate

the

flanges

and

spray

with

lubricant.

o Inspect

the

gear shift

cable,

linkage,

and

attachments.

Look

for

corrosion of

the

end

fittings,

cracks

or

cuts

in

the

conduit,

and

bending

of

the

actuator

rods.

Lubricate

all

moving

parts.

NOTE:

If

the

transmission

is

to

be

stored

for a

long

time

(twelve

months

or

more),

it

slwuid

be

topped

offwith

fluid

to

prevent

internal

corrosion.

Reduce

thf'

fl1lii/

level

before

putting

the

engine

back

into

service.

Engines & Generators

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