ZF 63, Operating Instructions Manual

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12
Operating Manual ZF/ZFE 25 A - ZF/ZFE 85 IV
ver (figure 12) must be held in the
neutral position (N) to prevent the
boat from moving.
Avoid to run the hydraulic gearbox
in neutral at high engine speed for
a long time.
6.1 Maintenance
6.1.1 FLUID LEVEL CHECK
WARNING
Do not work on the transmission
when being towed, or anchoring in
a river because the propeller may
rotate.
Transmission fluid level may be
checked in cold or hot condition.
NOTE : Always check the oil level be-
fore operating the reverser. Proceed
as described below.
1) Loosen
fl
uid dipstick (
fi
gure 13, item
1) by turning the grip counterclock-
wise.
2) Wipe dipstick with a clean and
dustfree cloth.
3) Insert dipstick do not screw in (
fi
g-
ure 14). Remove dipstick and check
fl
uid level: Fluid level has to be
between minimum and maximum
marks.
4) Check O-rings (
fi
gure 14, item 1)
for damage, replace if necessary.
5) Insert the dipstick and lock it by
turning the grip clockwise.
CAUTION
According to the type and arrange-
ment of the cooler and pipelines
a certain amount of oil will collect
after stopping the engine and will
flow back into the transmission after
a longer rest period. This may cause
the oil level in the transmission
to exceed the max. mark. Do not
remove off the surplus oil but pro-
ceed according to steps 6 and 7.
6) Let engine run at idle speed with
shifting lever in neutral position
until
fl
uid cooler and all pipelines
are
fi
lled with
fl
uid.
7) Switch off engine and check
fl
uid
level within a short time. If neces-
sary, top
fl
uid level off to the dipstick
mark. The
fl
uid level on the dipstick
(
fi
gure 14) should be between the
min. and max. marks.The
fl
uid level
must be checked again after a short
driving period.
6.1.2 FLUID CHANGE
CAUTION
The first change must be performed
after 25 hours of operation. All sub-
sequent fluid changes to be made
after every 300 hours of operation
or once in a year (according to the
term which is reached earlier).
Note: The
fi
lter element (
fi
gure 16,
item 1) must be replaced whenever
the
fl
uid is changed.
CAUTION
The old lubricant and oil filter
must be treated in the same way
as special waste that pollutes the
environment: they must therefore
be disposed of according to their
differentiated structure.
6.1.3 REMOVE FLUID FILTER
Proceed as described below to replace
the
fi
lter:
1) Turn the screw that
fi
xes the oil
fi
lter
cover in an anticounter-clockwise
direction and remove the
fi
lter from
its housing (
fi
g. 15 pos. 1). Use a 6
mm Allen wrench.
2) Pull
fi
lter element (
fi
gure 16, item
1) off.
3) Check O-rings (
fi
gure 16, item 2
and 3) for damage, replace if nec-
essary.
Only ZF 25 A - ZF 25 old version
(Fig. 22)
4) Unscrew two M8x25 bolts (
fi
gure 22
item 1) and remove them together
with washers.
5) Pull cover (
fi
gure 22, item 2), seal,
fi
lter element off.
6) Check seal for damage and
fi
lter for
wear. Replace if necessary.
6.1.4 DRAINING
TRANSMISSION FLUID
1) ZF 45A, ZF 45-1, ZF 63A, ZF 63,
ZF 68 A, ZF 68: Push hose of
suction pump (figure 17, item 1)
through suction pipe
(
fi
gure 17, item 2) down to bottom of
the housing and remove the
fl
uid.
2) ZF 25 A, ZF 25, ZF 63 IV, ZF 68 IV
ZF 80 A, ZF 80-1A, ZF 80 IV, ZF
80-1IV, ZF 85 A, ZF 85 IV:
Remove the plug (Fig. 18, item 1)
and let the oil flow from the proper
hole.
NOTE: Maximum outside diameter of
suction hose is 5/8 inch (16 mm).
6.1.5 FILLING UP WITH
TRANSMISSION FLUID
Fill with ATF oil for automatic gearboxes
according to the indicated quantities.
Add the quantity considered necessary
for
fi
lling the heat exchanger and rela-
tive connection pipes (Fig. 19).
ZF 25 A: ........1.91 US-qts (1,8 liters)
ZF 25: ........2.12 US-qts (2,0 liters)
ZF 45 A: ........2.65 US-qts (2,5 liters)
ZF 45-1: ..........3.2 US-qts (3,0 liters)
ZF 63 A/ZF 68A:. 4.2 US-qts (4 liters)
ZF 63/ZF68:..... 4.0 US-qts (3.8 liters)
ZF 63 IV: ..........4.6 US-qts (4,4 liters)
ZF 80 A/ZF 80-1A:
ZF 68 IV:..........4.6 US-qts (4,4 liters)
.5.8 US-qts (5.5 lt)
ZF 80IV/ZF 80-1IV: ...7.4 US-qts (7.0 lt)
ZF 85 A: ................5.8 US-qts (5.5 lt)
ZF 85 IV: ................7.4 US-qts (7.0 lt)
Only use oil for automatic gearboxes,
as given in the speci
fi
cation in the «List
of recommended oils» on page 61.
6.1.6 INSERT FLUID FILTER
INTO HOUSING
1) Place new
fi
lter element onto cover
(Fig. 20).
2) Lock the cover in its housing,
fi
xing
it in place with the relative Allen
screw (
fi
g. 21) and using a min. 5
Nm (4 ft/lbs) max 8 Nm (6 ft/lbs)
driving torque. Check the oil level
after a brief period of service.
Only ZF 25 A - ZF 25 old version
(Fig. 22)
3) Place
fi
lter element and seal onto
cover.
4) Lock
fi
lter cover in place by screw-
ing in bolts (
fi
g. 22 item 1), driving
torque 18 Nm (14 ft/lb);
6.1.7 TRIAL RUN
1) Carry out a trial run after the oil
change.
2) Set shifting lever to neutral position
(N). Start engine and let it run idle
for a short time to
fi
ll the cooler and
pipelines with transmission oil.
IT, EN, DE, FR, ES, NO, PT, NL, FI, EL, HR 3315.758.001 - 2018-04