Installation manual
ZF
TRANSMISSIONS
(HSW
MODELS)
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
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
storro.
OUTPUT
\
COUPLlNG4
__
...
OIL
COOLER
~--,AIR
VENT
,
ASSEMBLY
The
oil
cooler,
mounted
above
the
transmission,
provides
continuous
cooling for
the
transmission
flui,d.
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
RAW
WATER
CONNECTION
TRANSMISSION
FLUID
ZF
COOLER
•
RAW
WATER
CONNECTION
.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
tum
it
to
tighten.
Durlng
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
tlie
shifting
lever
to
neutral
position (N). Start·the engine
and
let it
ron
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
tltis
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
canfree-wheel.
DAILY
OPERATION
o
Check
the
transmission
fluid.
o
Visuaily
check
the gear shift linkage
and
transmission,
q Start
the
engine
in
neutral,
allowing a
few
minutes
at
idle
to
warm
the
fluid.
o 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
(SO°C).
A connection for a
temperature
probe
is
provided.
At
maximum output of the
engine,
the
fluid
may
reach
220°F
(104°C).
A
CAUTIOtJ:
If
the
transmission
fluid
temperature
is
too
high,
stop
the
engine
immediately
and
check
the
transmission
fluid.
, . -.
NOTE:
Ensure
the
transmission
vent
is
operational.
Remove
seasonally
and
clean
with
carburetor
cleaner.
A
stuck
vent
will
cause
pressure
to
build
up
in
the
transmission
and
cause
fluid
to
be
forced
out
the
input
and/or shaft
seals.
1~/WESTEilBEKE'
I
Engines
&
Generators
42