Installation manual

ManualsBrandsWesterbeke ManualsAutomotive108B

ZF

TRANSMISSIONS

(HSW

MODELS)

CHANGING

THE

TRANSMISSION

FLUID

DIPSTICK

FILTER

\

16MM

'

SCREW

Filter

Elen~ent

PN#

049737

The

ZF

transIllission

has

a

filter

element located"opposite the

dipstick. This

filter

mnst be replaced whenever the

fluid

is

changed

Remove the

filter

by loosening

the

screw on the cover using

a 6mm Allen

wrench.

Twist

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.

Removing

the

Fluid

Pnsh a snction

pump

hose

down

through the

pipe

hole (under

the

filter)

to

the bottom of

the

housing and suck out the

fluid.

Remove

the

oil

retum line

from

the

cooler

and

allow

the

oil

to

drain

into

a container, then reconnect the oil retum line.

Wipe.

down

the

transmission

and

properly dispose of

the

nsed

fluid.

Replacing

the

Fluid

Pour

in

new

Dextran

III

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

ttansmission.

Approximate

Quantities

HSW450A2 -

2.65

U.S.Quarts

(2.5

liters)

HSW630Al-

4.2

U.S.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 "T"

handle

in

place

of

a

screw

on their filter

assemblies.

After

running

the

englne,

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

h~le.

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 cettain 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:

[]

Drain water

from

the

transmission

oil

cooler and

replace

with a proper mixture of antifreeze coolant

NOTE:

This

operation

will normally occur when

the

engine

raw

water cooling system

is

properly

winterized.

o 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).

o Loosen attaching hardware

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

storedfor a

long

time

(twelve

months

or

more),

it

should

be

topped off

with

fluid

to

prevent internal

corrosion.

Reduce

the

fluid

level

before putting

the

engine back

into

service.

Engines & Generators

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