PRM NEWAGE PRM 125, Workshop Manual

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PRM 125
9.7.3 Idler Shaft
Slide on bearing cone (28) so that it abuts fully against the idler shaft (2) shoulder as shown on the drawing. Fit the
internal spring ring (27) into the groove of the idler gear (24) bore and press the two bearing cups (28) (back to back)
into the idler gear (24) bore upto the internal spring ring (27). Assemble the idler gear (24) onto the bearing cone (28),
slide the second bearing onto the idler shaft (2) taking care to support it under the sholder not to the threaded end as
this could be damaged. Fit t
he ‘O’ ring (49) and locknut (33) and tighten to recommended torque (see torque chart 10.2)
9.7.4 Selector housing assembly
* Before proceeding with this assembly see shimming procedure 9.7.6.
Press in oil seal (6) flush to the face of selector housing (5).Using tool number PR29418 insert into seal to expand it
whilst assembling selector body (7) into the selector housing (5). This will displace the tool and allow the control body
(7) to slide through the seal (6)
. Fit the ‘O’ ring (12) to selector housing (5) and smear grease onto the ‘O’ ring (12),
insert spring (8) and selector shoe (9) into selector housing (5).
9.7.5 Shimming
Both the input and output shaft bearings must be shimmed 0-0.05mm pre-load.
This is achieved as follows:
1. Measure shaft over the bearing cups.
Dimension A
2. Measure gearcase bore depth to joint face. Dimension C
3. Measure front cover bore depth to joint face. Dimension B
4. Add cover and case bore depths to give “bore face lengths”.
Dimension Y
5. Subtract bore face lengths from shaft lengths over
bearings to achieve shim requirement.
Dimension Y-A
6. Fit shims as required to within zero to 0.05mm pre-load.
Place the shims into the appropriate bore of the front cover (29) so that they are located under the bearing cups (25). Fit
the remaining bearing cups (25) into the gearcase (1) bores. Locate both input and idler shaft assemlies into bearings.
Fit the two dowels (44) and apply silicon sealant to the joint face. Assemle the front cover (29) ensuring dowels (44) are
correctly located and fit 10 bolts (36) tightening to the recommended torque. (see torque chart 10.2)
Fit locknut (33) to the idler shaft (2), tighten to the recommended torque (see torque chart 10.2).
Move the cone clutch (21) to the neutral position and locate the selector shoe (9) into the groove of the cone clutch (21),
ensuring the identification pip of the selector shoe (9) is uppermost.
Fit the two cap bolts (42) and tighten to the recommended torque (see torque chart 10.2). Secure gear selector lever
(13) to the selector body (7) using bolt (14), washer (16) and nut (15). Fit oil seal (6) to gearcase bore and oil seal (34)
to the front cover (29). Assemble the output coupling (32) to the output shaft (19).
Apply a countiniues bead of silicone sealant to the flat face of the locknut (30) and hydraulic sealant to threads of the
shaft (19). Fit the locknut (30).
CAUTION:
Remember to tighten locknut to the recommended torque and stake the nut into slot.
When using sealants and locking compounds all surfaces should first be cleaned by degreasing.