PRM NEWAGE PRM90, Руководство по ремонту

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17 - PRM 90
9.6.2 Gearcase assembly
Remove the external locknut (20) securing idler shaft (4) into gearcase. Remove the ten bolts (51) securing both
gearcases (1, 5) and using a soft mallet lightly tap on the end of the input shaft (6) to separate the two gearcase (1, 5)
halves from sealant and dowels (18). Remove the front cover (5). Withdraw the idler shaft (4) the output shaft assembly
and the input shaft assembly .
9.6.3 Input Shaft
Removal of the bearings may damage them, therefore it is good practice to replace these items if removed. (see 9.4.3)
9.6.4 Output Shaft
Carefully remove “staked” portion of locking device so as to avoid damaging the thread and remove locknut (22) from
output shaft (10). Using a bearing puller remove the bearing (2) on the output end of the output shaft (10).
Remove the following: thrust washer (11) , gear (14) , needle bearing (13), inner ring (12) (carefully checking for wear),
thrust washer (11) , cone clutch (15). Using puller remove the bearing (2) on the input end of the shaft, thrust washer
(11), output reverse gear (16), needle bearing (13), inner ring (12) (again carefully checking for wear), and thrust washer
(11). Save shims for rebuild.
Note: Removal of ball bearings may result in damage, therefore replacement will be necessary.
9.6.5 Idler Shaft
Remove locknut (20) and supporting gear (9) on soft material i.e. wood or similar to prevent damage to gear (9), using a
soft mallet tap the shaft (4) through the gear (9) and remove the bearing (8).
Check condition of ‘O’ ring (17) on the idler
shaft (4).
9.6.6 Selector
By hand remove selector shoe (29) and the selector spring (28). Remove the lever (33). Pass the selector control body
(27) through the housing (25)
and remove ‘O’ ring (32) and oil seal (26) if replacing them.
9.6.7 Front Cover
If it is required to replace the front cover (5) then it will be necessary to remove the oil seal (23). If the bearings (3, 2) are
to be re-used then care must be taken not to damage them on removal. It is recommended to fit a new oil seal (23).
Note: When re-fitting oil seal (23) set in 1.5mm from face as shown on page 18.
9.6.8 Gearcase
If it is required to replace the gearcase (1) then again if the bearings (2, 3) are to be re-used care must be taken in their
removal. Remove output seal (24), dipstick (42), drain plug and oil filling plug (39), oil level plug (50), bonded washers
(41, 52) and the two dowels (18) .
9.7 Re-assembly of Gearbox
(Note: coat all bearings with clean gearbox oil prior to fitting).
9.7.1 Input Shaft
Press the two bearings (3) onto the input shaft (6) taking care to position correctly as illustrated. Make sure the waved
washer (49) is correctly positioned into case before fitting the input shaft (6).
9.7.2 Output Shaft (see 9.7.5 for shimming procedure)
All of the following components are fitted in order over the output spline end of the shaft (10).
Thrust washer (11), inner ring (12), needle bearing (13), output forward gear (14) with cone towards the scroll, thrust
washer (11) and the bearing (2) (Press on).
Fit the following components from the opposite end of the shaft (10) .
The cone clutch (15), thrust washer (11), inner ring (12), needle bearing (13), output reverse gear (16), thrust washer
(11) press on bearing (2) re-shim if components have been changed (see 9.7.5) fit locknut (48).
CAUTION:
Remember to tighten Locknuts to recommended torque.
(SEE TORQUE CHART 10.2)