Control Cables - Westerbeke 65A-FOUR Operator's Manual

TRANSMISSION TROUBLESHOOTING (ZF MODELS)
CONTROL CABLES
The majority of transmission difficulties arise as a result of
improper clutch adjustments (manual transmissions) or
problems with control cables (hydraulic transmissions)
rather than from problems with the transmission itself.
A new cable and perhaps a new linkage mechanism may be
needed. While the cable is loose, shift the transmission in and
out of gear using the lever on the side of the transmission to
make sure there's no binding inside the case.
ZF clutches, in particular, are very sensitive to improper
cable adjustments.
If you experience operating problems with the transmission,
shut the engine down. First check the transmission-fluid
level, then have a helper move the cockpit shift lever through
the full range - from neutral to full forward, back to
neutral, into full reverse, and back to neutral - while you
observe the actuating lever on the transmission. If the remote
is stiff to operate, break the cable loose at the transmission
and try again. If it is still stiff, check the cable for kinks or
excessively tight bends, and check any linkage for binding.
If the transmission passes these tests, crank the engine and
have a helper put it in forward and reverse while you observe
the propeller shaft; if the shaft isn't turning, the transmission
needs professional attention. If it does turn but there's no
thrust, check to see you still have a propeller on the end of
the shaft or, if you have a folding or feathering propeller, that
it isn't stuck in the "no pitch" position.
Problem
Transmission gears cannot be shifted.
1.
Fails to move into gear.
2.
3.
Transmission shifts into gear,
1.
but fails to propel the boat.
2.
3.
Delay of gear engagement or engages
1.
only after an increase in speed.
2.
3.
Transmission noise becomes louder.
1.
2.
Chattering transmission noise,
1.
mainly at low engine speed.
Boat fails to attain specified max. speed.
1.
2.
Oil Leakage.
1.
2.
NOTE:
If
you suspect a major problem in your transmission,
immediately contact your WESTERBEKE dealer or an
authorized marine transmission facility.
Probable Cause Verification/Remedy
Actuating lever is loose.
1.
Tighten damping bolt on shifting lever.
Shifting cable is broken, bent or
2. Check the cable, reattach or replace.
unattached. Cable radius is too severe.
Actuating lever is binding against the 3. Detach the shift cable and operate the actuating lever by
hand. Clearance should be 0.02 in (0.5mm).
Output coupling is not turning.
1.
Transmission needs professional attention.
Propeller shaft is not turning. 2. The coupling bolts are sheared or the coupling is slipping
Output coupling is turning. on the propeller shaft. Tighten or replace set screws, keys,
pins and coupling bolts as necessary.
Output coupling and
3. Inspect the propeller. It may be missing or damaged.
propeller shaft are turning.
A folding propeller may be jammed. A variable pitch
propeller may be in "no pitch" position.
Actuating lever travel N to 8 not
1.
Adjust cover plate until the lever is exact mid-position.
equal to N to A. See ACTUATING LEVER TEXT AND DIAGRAM.
Actuating level travel in insufficient. 2. Check shift lever cable length. See ACTUATING LEVER
DIAGRAM.
Actuating lever is binding against cover plate. 3. Check clearance, adjust if necessary.
Damage starting on flexible coupling due
1.
Check alignment, inspect flexible coupling. If noise persists,
to wear or fatigue, possibly due to inspect the damper plate between the transmission and the
misalignment between engine and engine. Replace if necessary.
transmission.
Beginning damage of bearings in 2. Transmission needs professional attention.
transmission due to torsional vibrations,
running without fluid, overload, wrong
alignment of transmission, or excessive
engine output.
The engine or propeller generates torsional
1.
Mount a flexible coupling with another stiffness factor
vibrations in the drive unit which produces
between the engine and transmission; a coupling with
a "chattering" noise in the transmission. a higher stiffness factor might be sufficient.
2. Inspect the damper plate between the engine and the
transmission. Replace if necessary.
Operating temperature is high.
1.
Wrong type of fluid. Use Dextron Ill, check fluid level.
Operating without cooling. 2. Check cooler. Inspect coolant hoses and coolant flow.
Corrosion at radial sealing ring and shaft.
1.
Transmission needs professional attention.
Damaged sealing ring.
Misalignment of output flanges.
2. Check alignment. Must be within 0.003 in (0.08mm).
Engines & Generators
44