Installation manual
CONTROL
CABLES
TRANSMISSION
TROUBLESHOOTING
OIL
COOLERS
The majority
of
transmission difficulties arise as a result
of
improper clutch adjustments (manual transmissions) or prob-
lems with control cables (hydraulic transmissions) rather than
from problems with the transmission itself.
HURTH 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-oil 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
exces-
sively tight bends, and check any linkage for binding. 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.
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 tum 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
Probable
Cause
Transmission
gears
cannot
be
shifted.
1.
Shifting
lever
is
loose.
2.
Shifting
cable
is
broken,
bent
or
unattached.
3.
Loss
of
transmission
fluid.
4.
Water
in
transmission
fluid.
Shifting
pressure
too
low.
1.
Improper
fluid.
2.
Filter
is
dirty
(if
applicable).
3.
Water
in
transmission
fluid.
4.
Transmission
fluid
too
low.
5.
Air
vent
is
clogged.
Transmission
noise
becomes
louder.
1.
Fluid
level
too
low,
so
that
pump
sucks
in
air.
The continued flow
of
raw water through the cooler will,
in
time, erode the inside
of
the cooler causing cross leaks to
occur. These internal cooler leaks will cause one
of
the fol-
lowing two problems:
1.
Transmission fluid will leak into the flow
of
raw water
and be discharged overboard through the engine exhaust.
A loss
of
transmission fluid will cause the transmission to
fail.
2. The raw water will leak into the transmission fluid caus-
ing
an
increase in transmission fluid. This contaminated
fluid will appear as strawberry cream.
The transmission
will eventually fail.
Either case requires an immediate response:
1. Install a new oil cooler.
2. Refill the transmission with
DEXTRON
III
ATF.
If
water has contaminated the fluid, the transmission fluid
needs to be cleaned out and replaced with fresh fluid. It will
take several fluid changes to get rid
of
the contamination.
Check your dipstick each time until it appears as pure trans-
mission fluid. Change the transmission filter and clean out
the fluid lines that connect to the cooler.
If
the transmission fails to shift properly, it will most likely
need the attention
of
a qualified transmission service facility.
A transmission cooler may last ten years or more but, in
some circumstances, depending on operating hours, tropical
waters, maintenance, etc. it might only last half that time.
WESTERBEKE recommends having a spare cooler aboard.
VerlflcatlonJRemedy
1.
TIghten
damping
bolt
on
shifting
lever.
2.
Check
the
cable,
reattach
or
replace.
3.
Check
for
leaks
at
transmission
seal
and
output
shaft.
Tighten
gear
case
bolts.
Check
all
oil
hoses
for
leaks.
Oil
cooler
leak
-
see
OIL
COOLER.
4.
Replace
oil
cooler
(see
OIL
COOLER).
High
water
in
engine
compartment,
remedy
cause.
Shifting
pressure
too
low,
see
item
2.
1.
Replace
with
DEXTRON
1/1
ATF.
2.
Replace
filter.
3.
Replace
oil
cooler
-
see
OIL
COOLER.
4.
Add
fluid.
5.
Remove
painVdirt
from
vent.
1.
Top
up
with
fluid
to
marking
on
dipstick.
2.
Damage
starting
on
flexible
coupling
due
2.
Replace
flexible
coupling.
Check
alignment
between
engine
to
wear
or
fatigue,
possibly
due
to
misalign-
and
transmission.
ment
between
engine.
and
transmission.
3.
Beginning
damage
of
bearings
in
trans-
3.
Transmission
needs
professional
attention.
mission
due
to
torsional
vibrations,
running
without
fluid,
overload,
wrong
alignment
of
transmiSSion,
or
excessive
engine
output.
(continued)
Engines & Generators
42