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ZF TRANSMISSIONS
SHIPMENT
Por 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 III 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.
SELECTION
LEVER
OUTPUT
COUPLING,
OIL COOLER
DIPSTICK
~~~~'!.fJ-
FILTER
ASSEMBLY
ZF-63
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
'Mi7J---
TRANSMISSION
RAW WATER
CONNECTION
FLUID CONNECTIONS
ZF COOLER
TRANSMISSION FLUID
Pill the transmission with De),:tron 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 tum 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 visual inspection of the output
coupling, oil cooler and hoses, and the cable connections to
the transmission.
LOCKING THE PROPELLER
Locking of the propeller 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: VVhen 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
D
Check the transmission fluid.
D
Visually check the gear shift linkage and transmission.
D
Start the engine in neutral, allowing a few minutes at idle
to warm the fluid.
D
Shift into gear.
NOTE: Too low an 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°P (80°C). A connection for a temperature probe
is provided. At maximum output of the engine, the fluid may
reach 220
0
P (104°C).
A
CAUTION:
If the transmission fluid temperature is
too high, stop the engine immediately and check the
transmission fluid.
Engines & Generators
36
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Troubleshooting
