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Newage PRM 301, Workshop Manual

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Newage PRM 301 Workshop Manual Download Page 38

Summary of Contents for PRM 301

Page 1: ...SHOP MANUAL NEWAGE NEWAGE TRANSMISSIONS LIMITED Barlow Road Coventry CV2 2LD Englan H 1 Telephone 0203 617141 Telex 31333 Registered in England Reg No 345283 Registered Office Barlow Road Coventry CV2...

Page 2: ...ust be quoted in order to ensure correct identification and supply of parts CLAIMS UNDER WARRANTY Claims for replacement of parts under warranty must always be submitted to the distributor who supplie...

Page 3: ...nd the components and materials used in its production thus ensuring that the correct components can be supplied as spare parts The lower line is the gearbox specification in the example given this tr...

Page 4: ...the flywheel housing 5 3 Checking the flywheel 5 4 Mounting the gearbox to the engine 5 5 Oil cooler 5 5 1 PRM3O1 standard gearbox 5 5 2 PRM3O1 with power take off 5 5 3 PRM3O1A with angle drive 5 6 A...

Page 5: ...drive end bearing 9 5 7 Piston rings and feeder 9 6 Replacing the input and layshaft assemblies r 9 7 Servicing output shaft assembly 9 7 1 Front bearing and output gear 9 7 2 Rear bearing and oil sea...

Page 6: ...mounting clockwise engin s Hydraulic and lubricating oil circuits Checking engine flywheel and flywheel housing Engine and gearbox cooling circuit Oil cooler connections PRM301 Oil cooler connections...

Page 7: ...cal distributor Input speed Up to 3000 rev min continuous 3600 rev min intermittent Input rotation Clockwise or anti clockwise see section 2 Output rotation Clockwise or anti clockwise as required see...

Page 8: ...f c 1 60 t t t t t t 1200 1400 11500 1100 2000 2200 2400 2800 2800 3000 FIE 1 MIN 1 1 09 1 459 1 AND 1 935 1 RATIOS 21 2 565 1 AND 2 904 1 RATIOS THESE RATINGS ARE FOR PLEASURE CRAFT OPERATING FOR LES...

Page 9: ...sure the torsional compatibility of the total propulsion system from engine through to propeller since disregarding this may result in gear chatter particularly at low speeds and in extreme cases comp...

Page 10: ...ng lever A magnetic drain plug is provided at the front of the gearcase this removed if required to allow suitable pipework to be connected hand operated drain pump can be to a Connections are provide...

Page 11: ...arings of adequate size for all Newage approved ratings 3 4 Valve block The valve block is located on the top of the gearcase and contains the main control valve integral with which is the high pressu...

Page 12: ...ts When the transmission is used with anti clockwise engines looking at the flywheel or with clockwise engines when an angle drive unit is fitted the oil pump is fitted in its standard position For cl...

Page 13: ...of the vessel Similarly when the control lever is moved to the astern position the clutch on the opposite shaft is engaged and drive applied to the reverse pinion This turns the output shaft gear in...

Page 14: ...BE HIGH PRESSURE LINE TO FORWARD CLUTCH ENGAGED HIGH PRESSURE LINE TO REVERSE CLUTCH DISENGAGED LUBRICATING CIRCUIT Fig 6 Hydraulic and Lubricating Oil Circuits Oil for lubrication purposes is also de...

Page 15: ...40 Fina or or or Fina 20W 50 Fina 20W 50 Fina 20W 50 G M O XHD l0W 30 G M O XHD l0W 30 G M O XHD 10W 30 Gulf or or or G M O XHD 10W G M O XHD 20W 20 G M O XHD 30 Mobil Super 15W 50 Mobil Super 15W 50...

Page 16: ...ion system from engine through to propeller since disregarding this may result in gear noise at low speed operation and in extreme cases damage or failure of components Newage Transmissions Ltd will p...

Page 17: ...ction window provided on the gearbox adaptor flange 2 Remove the gearbox and fully tighten the flexible input coupling bolts 3 Taking care to ensure correct alignment mount the adaptor flange to the f...

Page 18: ...r take off Oil returned from the cooler to the valve block is first passed through the power take off unit to provide lubrication and the method of connecting the cooling system is as follows a remove...

Page 19: ...ment to the propeller shaft and the stern tube to be maintained Whether a solid or flexible coupling is used it is extremely important that the following points are carefully checked i the coupling sh...

Page 20: ...ventional in line or drop centre transmissions This has the effect of reducing the overall height required for installing the engine and will also help to prolong engine life 5 8 Twin installation The...

Page 21: ...ive Twin Installations 5 9 Remote control operating systems All PRM gearboxes can be used with remote control operating systems and indeed the use of the single lever type of remote control which link...

Page 22: ...to ensure rapid shifts from ahead to astern or vice versa can be operated at full horsepower ratings and speeds and the transmission will respond rapidly in these circumstances Full power reversals h...

Page 23: ...sure that there is sufficient oil in the gearbox to avoid further damage and refit the top cover 6 Check that the dipstick does not foul the head of the screw now fitted in the clutch end plate if nec...

Page 24: ...on the gearbox operating lever 7 4 Winter storage Drain water from the transmission oil cooler to avoid freezing or the collection of harmful deposits 7 5 Other maintenance operations 1 The gearbox o...

Page 25: ...box noise Excessive noise Propeller shaft Check the alignment of the from gearbox misalignment propeller shaft coupling see section 5 7 if necessary rectify by adjusting the shims under the engine mou...

Page 26: ...be necessary to recalculate the number of shims required to correctly load the bearings each time a shaft is stripped for inspection component repair or replacement Shimming procedure is described in...

Page 27: ...ble coupling or mating half coupling on the propeller shaft 4 Sling ropes around the gearbox to provide support while it is being removed from the engine S Unscrew and withdraw the bolts securing the...

Page 28: ...note keep the pump shims with the pump assembly 3 Remove the 3 bolts securing the shaft end cover and remove note keep shims and O rings with end cover 4 Remove 5 bolts and 1 nut retaining the valve b...

Page 29: ...gear 5 Fit the clutch end plate item D11 into the clutch gear and replace pull off springs over the assembly bolts Then starting with one of the driven clutch plates item D9 build up the replacement...

Page 30: ...r or damage may necessitate replacement of the piston rings and feeder in the following manner 1 Remove the non drive end bearing as described and remove the feeder and spacer 2 Remove the piston ring...

Page 31: ...he gearcase top half is lowered onto them The O rings on the connectors should be examined for damage or wear and renewed if necessary 4 Shim and refit the input shaft end cover replacing the O ring i...

Page 32: ...eal housing F15 and renew 2 If the rear housing F13 is damaged it can be removed from the shaft using a soft hammer or a hand press Note Whenever the output shaft is stripped it is always advisable to...

Page 33: ...tening the four securing bolts until the shaft starts to bind Note care must be taken to ensure that the oil pump or end cover is tightened squarely on to the gearbox face this can be checked by feele...

Page 34: ...il pipe assembly H23 as shown on the installation drawing between the T piece on the P T O housing and the connector on the valve block 8 Fit hydraulic pump to P T O unit 10 2 To repair an existing P...

Page 35: ...n the valve block 8 Bolt the adaptor to the front face of the angle drive Tighten bolts to 98 0Nm 10 0Kgfm 72 3lbf ft 9 Fit flew aitlOtielc te maift geaFfl8U afta fill wits oil Note When an angle driv...

Page 36: ...o spacer or place a weight of approximately 5 Kg on top of the spacer and turn shaft to seat the bearings c Measure step between gearcase face and lower face of the housing with a depth micrometer or...

Page 37: ...ock loctite 9 5 7 0 97 Pump body to gearcase 56 0 41 3 5 7 End cover to gearcase 98 0 72 3 10 0 Pump cover to pump body 28 0 20 6 2 8 Coupling to output shaft 340 0 250 34 58 Top cover to upper gearca...

Page 38: ...o that assembly are supplied For example if the clutch input shaft assembly is ordered the shaft itself and every item called up and shown on the corresponding illustration will be supplied with the e...

Page 39: ...a I A Z Wfb a A 2 1 A2 A20 I...

Page 40: ...t case halves 0041019 1 A5 Washer 0201706 11 A6 Top cover MT1203 1 A7 Gasket top cover MT343 1 A8 Screw 0040804 8 A9 Screw MT1283 2 Al0 Washer CP1223 10 All Dipstick MT472 1 Al2 End cover MT1267 1 Al3...

Page 41: ...a 0...

Page 42: ...CP1223 6 B3 Pump cover MT321 1 B4 Pump gear driver MT379 l Only supplied as part of B5 Pump gear driven MT379 1 MT0115 B6 Pump spindle MT4544 1 B7 Pump spindle MT378 1 B8 Pump plate MT372 1 B9 Dowel...

Page 43: ......

Page 44: ...1 ClO Thrust bearing CP1307 1 Cll Control valve MT4656 1 Cl2 Detent ball CP1077 l Cl3 Detent spring MT305 1 Cl4 Relief valve MT980 1 Cl5 Valve spring MT1194 1 Cl6 Valve block MT4739 1 Cl7 Gasket MT10...

Page 45: ......

Page 46: ...inion 1 1 MT1415 1 43 teeth D6 Snap ring 0320390 2 Drive Pinion S A 1 459 1 MT0196 l 5 1 Supplied complete only D4 Bush MT1266 1 D5 Pinion 1 5 1 MT1261 1 37 teeth D6 Snap ring 0320390 2 Drive Pinion S...

Page 47: ......

Page 48: ...ew Bolt Oil seal End cover 0 ring 0 ring Connector Shim 002 Shim 010 Shim 031 Nut PRM301 Part No MT1282 MT725 MT982 MT1067 MT983 MT939 0270350 MT1289 0421503 MT1264 003504 MT1286 MT1321 066M050 CP1191...

Page 49: ......

Page 50: ...266 1 ES Pinion 1 1 MT1415 1 43 teeth E6 Snap ring 0320390 2 Drive Pinion S A 1 459 1 MT0196 l 5 1 Supplied complete only E4 Bush MT1266 1 ES Pinion 1 5 1 MT1261 1 37 teeth E6 Snap ring 0320390 2 Driv...

Page 51: ...01 0...

Page 52: ...3 El5 Piston O ring 0421503 1 El6 Piston MT1264 1 El7 Piston 0 ring 003504 1 El8 Clutch gear MT1287 1 El9 Layshaft Ml260 1 E20 Ball 066M050 1 J1 E21 Ball 066M050 1 E22 Piston ring MT292 3 E23 Feeder...

Page 53: ...t...

Page 54: ...7 1 F9 Output gear 1 09 1 MT1324 1 47 teeth F9 Output gear 1 459 1 MT1064 1 54 teeth F9 Output gear 1 935 1 MT1254 1 60 teeth F9 Output gear 2 565 1 MT1419 1 59 teeth F9 Output gear 2 904 1 MT1316 1 6...

Page 55: ..._...

Page 56: ...aring Input gear Shim O ring End cover Oil seal Adaptor Oil pipe Tee piece Washer Metering union T o L _ _ i Washer Screw PRM301 Qty Remarks Part No MT0210 MT0189 l MT1273 l Not supplied separately MT...

Page 57: ...01 a H5 H4 H16...

Page 58: ...1302 1 H9 Screw 0041008 1 HlO Spring washer 0191107 3 Hll Bolt 0041216 1 Hl2 Ball bearing 40M43 1 Hl3 Adaptor flange MT1299 1 Hl4 Gasket MT1307 1 4 bolt Hl4 Gasket MT5012 1 2 bolt Hl5 Circlip 0250620...

Page 59: ...nversion Kit 1 459 1 01 MT1282 Clutch end cover 1 MT0196 l 5 Pin ion S A 2 X MT1209 rab washer 3 MT0251 O ring kit 1 MT725 Clutch plate driven 8 MT1064 Output gear 1 MT983 Clutch end plate 1 MT0255 Co...

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