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 fluid dipstick (figure 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 (fig
-
ure 14). Remove dipstick and check
fluid level: Fluid level has to be
between minimum and maximum
marks.
4) Check O-rings (figure 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 fluid cooler and all pipelines
are filled with fluid.
7) Switch off engine and check fluid
level within a short time. If neces-
sary, top fluid level off to the dipstick
mark. The fluid level on the dipstick
(figure 14) should be between the
min. and max. marks.The fluid 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 filter element (figure 16,
item 1) must be replaced whenever
the fluid 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 filter:
1) Turn the screw that fixes the oil filter
cover in an anticounter-clockwise
direction and remove the filter from
its housing (fig. 15 pos. 1). Use a 6
mm Allen wrench.
2) Pull filter element (figure 16, item
1) off.
3) Check O-rings (figure 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 (figure 22
item 1) and remove them together
with washers.
5) Pull cover (figure 22, item 2), seal,
filter element off.
6) Check seal for damage and filter for
wear. Replace if necessary.
6.1.4 DRAINING
TRANSMISSION FLUID
1)
ZF 45A, ZF 45-1, ZF 63A, ZF 63:
Push hose of suction pump (figure
17, item 1) through suction pipe
(figure 17, item 2) down to bottom of
the housing and remove the fluid.
2)
ZF 25 A
,
ZF 25, ZF 63 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 filling 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: ............. 4.2 US-qts (4 liters)
ZF 63:
.......... 4.0 US-qts (3.8 liters)
ZF 63 IV:.......... 4.6 US-qts (4,4 liters)
ZF 80 A/ZF 80-1A: .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 specification in the «List
of recommended oils» on page 61.
6.1.6 INSERT FLUID FILTER
INTO HOUSING
1) Place new filter element onto cover
(Fig. 20).
2) Lock the cover in its housing, fixing
it in place with the relative Allen
screw (fig. 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 filter element and seal onto
cover.
4) Lock filter cover in place by screw
-
ing in bolts (fig. 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 fill the cooler and
pipelines with transmission oil.
