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PRM1750 - PRM marine

1. LIST OF ILLUSTRATIONS amp PARTS LISTS ILLUSTRATIONS SUBJECT Installation Drg Deep Case Installation Drg Shallow Case Internal Layout Deep Internal Layout Shallow Wiring Diagram for Neutral Safety Start Switch Hydraulic amp Lubricating Oil Circuits Checking Run Out of Flywheel amp Flywheel Housing Engine amp Gearbox Cooling Circuit Oil Cooler Connection To PRM1750 Gearbox Propeller Rotation on Twin Installations Operating Lever Positions on 1500 Twin 1500S Installations Operating Lever Positions on 1500D Twin Installations Piston Ring Fitting Procedure Taper Roller Bearing End Float Shimming Procedures Taper Roller Bearing End Float Shimming Procedures Taper Roller Bearing End Float Shimming Procedures PAGE NO SECTION DRAWING A WM93 1 WM B WM12 1 WM12 2 C WM5 D WM 1 E WMA G WM13 H WM6 1 WM6 2 J WM7 1 K WMB8 1 WMa8 2 WMB8 3 WMa8 4 WMB8 5 L WM9 1 WM9 2 WM9 3 WM9 4 WM9 5 M WM10 1 N WM10 2 p WM6 3 WM6 4 PARTS LIST SUBJECT PRM1750D Gearcase Assy Parts List PRM1750D Sectional View PRM1750D General Assy PRM1750S Gearcase Assy Parts List PRM1750S Sectional View PRM1750S General Assy PRM1750D Secondary Pinion Shaft Parts List PRM1750D Secondary Pinion Shaft Sub Assy Sectional View Lay shaft Sub Assy Parts List Lay shaft Sub Assy Sectional View Input Shaft Sub Assem
2. 7 16 SHIM TO PRODUCE SNNT NOMINAL 0 5 Na CLEARENCE AT SS E o e ER SSA UNS xS Nr Muy LL 5 lt TM 212 WE 27222 W SSE SE oss 722897 lt Am E ed E EC Cis s Mee SS D JN SHIM TO PRODUCE MIN lt gt SE ENDFLOAT OF 1 GEAR 20 NDTE CLEARENLE KN 0 5 NOMINAL T 19 0 AF QA COCOS C OC xm C ET OC F D COME OC ME J m 2 Eg Eg KW ES KEW PRM1500 PTO 209Nm SEE PARTS LIST kr DRD ND PRM15OIWMB 1 MTG LZ RETURN FROM COOLER m c rn n 4 as cc LLI 5 D Sg P m c LL usa Lig Lit 111 LLI ex LL LJ r uy t LL Hz zl S Dl LL v c Sr Jane OFF RETURN FROM COOLER CIRCUIT zi r ru LL N PTO OPERATING 3 LEVER TRAVEL 15990 ASSY PRMIS000 PTO 209NM SCHEMATIC PIPEWORK DRG NO PRMISDOWM8 2 MTG FEED TO COOLER e e 431002 01 0333 20 ddd EN BEE 44100 093 Ndflldd _ 43100 15
3. 1 0191718 1 0 015038 5 R81 7 M80 1 832 Thustbering j CP1307 1 833 _ 1448 1 ITEM NO lt IGO N ch a sch sch sch sch sch esch 90 JOINT GASKET OPTIONAL Lu 171 gt NN VEI 22 ML RECH A CO 22772221 EE 12 s JOINT GASKET COMPLETE VALVE BLULK ASSEMBLY ELECTRIC SWITCH SUB ASST ALTERNATIVE FITMENT DRONO PRMIBOQ WHMT 3 1509 VALVE BLOCK SUB ASSEMBL Y SEE PARTS LIST H 91 SECTION S TROLLING VALVE JOYSTICK CONTROLLER amp SWITCH DESCRIPTION 51 12 Volt joystick Assy S2 12Voltsolenoid 3 12Voltlamp 54 24 joystick Assy S5 24Voltsolenoid S6 X 24Voltlamp 51 52 o3 o4 55 56 92 66 12v LANP 17 PART OF OH OFF SWITCH LIMIT SWITCH MT Aa 24V LAMP NTEAA OF HT4B235 A EN HT 4875 PART OF MTB3825 5 TERM 4 PART OF YELLOW A GREEN BLUE TO TERM 3 CLOSE At Den 7 SIN FUSE CONTROL LENS CAF BLUE A 12v RAAT DF ATS 82354
4. 21 1 Ji2 j Jeitgasket 1 MTe32 1 __ J18 JjSteelball opiona 1077 2 J14 0201715 1 J5 Sping 1 3 _ 1 9 ____ 16 Switch optiona 1 CP1358 d ____ 17 Spriingwaher 1 01911005 1 ____ 18 ___ j 0081220 2 J19 Hexheadscrew 0480 1 J20 X Plug opina 1360 1 J22 ___ o 0041014 01 J23 X Presuepug JL M3 1 J24 Hexheadscrew 0040812 01 J235 Hexheadscrev 0040815 1 J26 X Hexheadscew 1 004008 3 J27 Bondedwasher 1 0191710 1 J28 Bondedwasher 1 01917080 5 J29 Bondedwasher 1 0191718 1 BO 105038 5 J331 M80 1 J32 Thrstbeaing CP1307 __ 1 lt J7 C 66 ES T LI m r ES cd mz JOINT GASKET 5 a h Pa M A WS 220110 AIRS SN hee Qo 222 i s BET I mL JOINT GASKET COMPLETE BLOCK ASSEMBLY ELECTRIC SWITCH SUB ASSY ALTERNATIVE FITMENT DRONO PRMTSUO WMT 1 1500 VALVE BLOCK SOFT SHIFT SUB ASSEMBL Y SEE PARTS LIST J 67 SECTION K 209NM PTO REFER TO D
5. EREEN JUSTICE ass a MR OF ATS 82954 Tt SWITCH PLATE JOTE TE ASA Y OF 2355 ATS 239 ME ELLE rev OR 249 De IE OF BC OM OFF 50 ELECTRICAL CIRLUIT DIAGRAM PRMISQ0DEEP amp PRMIS99S5HALLOW TROLLING VALVE SCHEMATICS IRAN TD CASE PRIPIR TIONAL REGULATING VALVE PROPORTIONAL SOLEMOIC CLUTCH FEED PRESSURE TB PROF VAL VE TE COOLER FROM TROLLING VALVE CIRCUIT DIAGRAM 17 BAA REG PRESSURE SCHEMATIC LAYOUT OF VALVE BLUCK DRG NO FRM1TS00WH11 1 81 4 HOLES 4 7 THAD Ty KY STICK SEAL CONMHELTIOHS OF SLICOM PAINT RED For A BLUE FOR z CABLES BE SECURED BGETHER LENG TIES amp CORE CABLE LONG kO 2 CORE CABLE 3H LONG LEAD AAC F IT 2504 SAND FLE END CONMEC TOR FE REF 483 350 AND THEN TO BATTERY ARE BARE PRMTBOODEEP amp SHALLOW TROLLING VALVE JOYSTICK CONTROLLER DETAILS PRM1500WM11 2 MTG v6 G6 4 HOLES 15 0 i TEMPLATE FOR MTO IO Y STICK CONTROLLER SCALE 1 21 2 00 Ge 3 00 5 1 HILE SB 20 THRE SWITCH PLATE MT 4 amp BBSH 15005 A PRM1500D TROLLING VALVE
6. BIYE K Ze sss B 144 ERD FLOAT E SN SN K 175 FI 2 MHKM OF Dinn A FE gt CHANFER np TN LD GRADOVE LH HELIX EN EM LAY SHAFT SUB ASSEMBL Y REFER PARTS LIST D DRG NO PRM1500WM1 MTG SECTION E INPUT SHAFT ASSEMBLY DESCRIPTION QTY Input shaft Pinion 29 teeth 2 45 1 Pinion 31 teeth 2 25 1 Pinion 34 teeth 1 94 1 Pinion 39 teeth 1 56 1 Piston Clutch Reaction plate Spacer Thrust washer Taper roller bearing Needle bearing Needle bearing Thrust washer ITEM NO lt E8 E10 E12 E13 FR rni rmi rmi mim 05 Po Spring ring MT8240 Et7 18136 8 _ Ef8 friction 81355 8 E24 Pinion 25 teeth 1 22 1 E33 Pinion 45 teeth 3 00 1 MT8128 1 E34 57 SECTION F OUTPUT SHAFT ASSEMBLY DEEP CASE DESCRIPTION PART NO Output shaft Assembly MT8161ASSY Output flange MT8176 Output coupling washer MT8165 Output seal housing MT8162 Shims MT8163 A E End plate MT8147 Taper roller bearing 0540701 Taper roller bearing 0540702 Nu lip seal 0740601 Oil seal 0401101 O ring 0431693 Locknut 075F701 Locknut 075F601 Socket cap screw 0081420L Pressure plug 0150416 0041210 8 Output gear 74 teeth 2 00 1 MT8226 ITEM NO
7. Mi 47 LIFTING EYE amp DIL FILLER HOLE Gs pe Le VALVE BLOCK S SEE DRG ND WM OIL PUMP SrA 0 DU 17 ROA Ga atl S TZ gow ZW SEE NO 1 IMPLIT amp IDLER SHAFT S A S SEE ORGS NO WMI X wiz YZ PEDAL en 5 2 CAS IR Ea IE bn SS oT SECONDARY PINION SHAFT 3 4 SEE ORG WMS NEUE SSG 5 lt Yu rr px qu 22 mm DUUM SASS Se 2 Hr Lt OUTPUT SHAFT 574 SEE ORG NU PRMTBOOWwM3 1 DEEP G A SHT 1 OF 2 SEE PARTS LIST 48 6v LIFTING EYE VALVE BLOCK SEE ORG Mo WHT 1549 G A PARTS TIST ee AF JOIP STICK EN OIL PUMP 574 EE DRG NO WIM 1 DIL HOSE 574 SEE ORG Who A DRO No PRMIS00wMa 2 SECTION B GEAR CASE ASSEMBLY SHALLOW CASE DESCRIPTION QTY Rear shallow gear case 1 Front shallow gear case 1 Adapter ring SAE3 to SAE1 1 Dowel 2 Hex head screw 20 Screwed plug O ring Gasket valve block Lifting eye Screws adapter ring 12 B11 Washers adapter ring Breather B13 Oil level plug B14 Oil drain plug
8. ROTATIOH ep rw J a LATE G PPE ATIPE SES Ea In amp HDLLS d ZETHBE LPT MAE Fig 2 Installation Drawing PRM1750S Shallowcase 14 2 INTRODUCTION Newage Transmissions Ltd PRM1750 marine transmissions are oil operated gearboxes of the counter shaft type with separate oil operated multi disc clutches which need no adjustment for both ahead and astern drive This design permits full power to be transmitted in astern as well as ahead and also allows right hand or left hand propeller rotation in ahead drive with identical ratios in ahead and astern The PRM1750 can be fitted to both left hand anti clockwise and right hand clockwise rotating engines see section 3 4 NOTE Throughout this manual engine gearbox and propeller rotations are described as seen when standing behind the boat i e facing towards the transmission and engine 3 CONSTRUCTION 3 1 Geartrain There are two types of geartrain a three shaft shallow design and a four shaft deep design All shafts run in taper roller bearings The engine must rotate A C W looking on flywheel The shallow type will therefore have output rotation opposite to input rotation with operating lever to rear of box i e with input shaft clutch engaged With a R H this gives forward motion The deep type will therefore h
9. Marine Transmissions PRM 1750 WORKSHOP MANUAL PRM1750 WORKSHOP MANUAL The following international symbols are used in this service manual WARNING THIS SYMBOL WARNS OF POSSIBLE PERSONAL INJURY A CAUTION THIS SYMBOL WARNS OF POSSIBLE DAMAGE TO TRANSMISSION Newage Transmissions operate a policy of product improvement and therefore reserve the right to change specifications without prior notification Whilst every effort is made to ensure complete accuracy of the information in this manual no liabilities for inaccuracies or the consequences thereof can be accepted by the manufacturer or the distributor dealer who supplied the manual PRM1750 WORKSHOP MANUAL ISSUE 2 2004 SECTION CONTENTS LISTING CONTENTS List of Illustrations Drawings Tools Parts Lists Foreword Warranty Information Pre Delivery Test Identification Plate Information General Data Specifications Basic Installation Data Introduction Construction Geartrain Oil Pump Valve Block Neutral Safety Switch Operating System Output Rotations Hydraulic System Lubrication Approved Oils Installation General Checking Flywheel Checking Flywheel Runout Mounting Gearbox to Engine Oil Cooler Fitting Oil Cooler to Standard Gearbox Fitting Oil Cooler to P T O Alignment to Propeller Shaft Installation Angle Twin Installation Remote Control Operating Systems Operation First Time Operation Drive Selection Trailing The Pr
10. H1 Gasket Mogo 1 Ht2 Spingwsher 1 0191105 5 H13 Hexheadbot 1 0041215 2 Hi4 Hexhadbit 1 0484 5 H15 j Hexhedbot o j 0429 1 Ht6 Hexheadbot o j 004211 2 Hi7 j Hexhedbot 004121 1 H18 Bondedwaher 02017200 1 H19 0840 1 H20 FlexiblehoseeAsy 18308 1 H21 JOilsmainer MT8 2 1 H22 Bondedwaher 0201760 1 x H23 Specaladaper MT8307 1 H24 0130 2 H25 MT808 1 lt CO 00 NID 5 GO 4 4 11111 1 401 N OT IN sch 63 v9 7 77 22 Jv E Z K JOINT GASKET OIL FROM SUMP COMPLETE OIL PUMP ASSEMBLY Ann PRMIBJODEEP PUMP SUB ASSEMBLY amp OL HOSE SEE PARTS LIST H DpRGNU PRM1500wM8 1 MTG G9 GEAR CASE CL L LL KE I HH YO mm PRHISOUDEEP DIL STRAINER amp HOSE SEE PARIS LIST H DRG NO PRM1500wM6 2 MTG SECTION J VALVE BLOCK ASSEMBLY SOFT SHIFT REFER TO DRG 7 1 ITEM NO DESCRIPTION Complete valve block Assy Valve block body End cover Thrust race Control valve Piston Spacer optional Operating lever Washer J10 Spring 1 Maag 1 O Ji1
11. 6 A F Hex Allen Key Extended Get You Home Device Tightening Torques Nt Gearcase Bolts OTS Valveblocktouppergearcase 280 210 Operating lever to valve block 280 206 End cover to valve block 95 70 7 ___ ____ Pump body to gearcase 560 415 End cover to gearcase 7 50 415 Pump cover to pump body 280 210 Adaptor plate to gearbox 5980 725 P T O to rear gearcase 560 415 2 44 14 REPLACEMENT PARTS ORDERING When ordering replacement parts the following should be quoted a b C d Gearbox model and serial number Description s and part number s of the component s required Quantity required Orders and enquiries for replacement parts must be made through Newage distributor dealer network NOTE Enquiries relating to a technical or service nature can be made direct to NEWAQE TRANSMISSIONS LIMITED BARLOW ROAD COVENTRY CV2 2LD ENGLAND TEL 44 0 24 7661 7141 FAX 44 0 24 7661 1845 EMAIL mail newage prm co uk WEB www newage prm co uk 45 DRAWINGS amp PARTS LIST 46 SECTION GEARCASE ASSEMBLY DEEP CASE DESCRIPTION Rear deep gear case Front deep gear case SAE1 Front deep gear case SAE2 Adapter ring SAE1 to SAE3 Hex head screws Hex head bolts Screws Adapter ring Dowel Screwed plug A10 Lifting eye A11 Gasket valve block A13 Washer Adapter ring 12 ITEM NO lt ITEM NO ____ 4____
12. For this reason PRM gearboxes are capable of providing either hand of output rotation with any of the available gear ratios It is also preferable for the starboard right hand propeller to rotate clockwise and the port left hand anti clockwise rather than the other way about In the latter case when the propeller blades are at the lowest point of their rotational arc they tend to create a vacuum which affects the other propeller by reducing the flow of water to it Also when the boat is making a tight turn with one gearbox in ahead and the other in astern the thrust side of one propeller will be acting diametrically opposite to the other causing the boat to be deflected off line which delays completion of the manoeuvre SHALLOW BOX DEEP BOX ENGINE LH RH LH RH OP LEVER FWD OPLEVERREAR OPLEVERREAR OP LEVER FWD LAY CLUTCH INPUT CLUTCH INPUT CLUTCH LAY CLUTCH ENGAGED ENGAGED ENGAGED ENGAGED AHEAD MOTION VIEWED ON REAR WITH ACW ENGINE Fig 10 Propeller Rotation on Twin Installations When connecting remote control units for twin installations ensure that propellers counter rotate outward with ahead selected The gearbox operating levers will read to move in opposite directions to achieve this refer to 4 1 regarding output rotation of gearboxes Fig 11a Fig 11b SHALLOW BOX PORT SIDE SHALLOW BOX STARBOARD SIDE LEVER FORWARDS SUITS LEVER BACKWARDS LH PROPELLER AHEAD SUITS RH PROPELLER AHEAD 2
13. Manifold Freshwater Pump a i Internal Engine Passages 222 ee Fig 8 Engine and gearbox cooling circuit AN CAUTION Remove the Redcap plugs from the valve block and gearbox prior to the installation of the cooler Connect suitable hoses to the connections on the oil cooler and valve block which can then be incorporated into the engine cooling system as outlined at Fig 8 AN CAUTION Operating oil temperature should not exceed 90 C under any circumstances If the checks listed in the fault finding chart have been carried out without any fault being found and the gearbox consistently runs at a temperature higher than 80 C Newage strongly recommends that a larger capacity oil cooler be fitted 5 5 1 Fitting Oil Cooler to PRM1750 Standard Gearbox Remove Redcap seals from valve block and using fittings and hoses supplied plus extensions as necessary connect the valve block outlet to the oil cooler inlet and the valve block inlet to the oil cooler outlet Plumb the cooler into the engine water circuit Refer to Drg WM14 Fig 9 Oil Cooler Connections 5 5 2 Fitting Oil Cooler to P T O See Drgs WM 8 and 9 22 5 6 Alignment to Propeller Shaft CAUTION Alignment between the propeller shaft and the mating flange on the gearbox output shaft is extremely important since excessive vibration and stress may lead to premature failure if correct align
14. ONLY ITEM NO DESCRIPTION PART NO QTY Mounting bracket Flexible hose Flexible hose Flexible hose Swivel adapter M M adapter M M adapter M M adapter Proportional valve 12v solenoids optional 24v solenoids optional 1 lt ITEM NO M8 81 c8 VEND EW a EN ES ES ES E OLT 2440LT d ME 7 OPTIONAL Hh 211114 PRIPORTIHAL 5 BWE gt SNL NN So re Op EE 15005 VIEW WALVE BLOCK 2557 ED 150 05 TROLLING SEE PARTS LIST M SEE ORG WM 2 d Hs PRHTSQOWBMTU T SECTION N PRM1750 TROLLING VALVE DEEP CASE ONLY DESCRIPTION QTY Mounting bracket Flexible hose Flexible hose Flexible hose Swivel adapter M M adapter M M adapter M M adapter Proportional valve 12v solenoid optional 24v solenoid optional 1 ITEM NO lt ITEMNO 83 VALVE BLOCK ASSY SEE ORG MU wh 7 2 p A 1j 5 E 4 p d PRMIS000 TROLLING VALVE SEE PARTS LIST N opp no PRM1500WM10 2 MTG SECTION P OIL PUMP ASSEMBLY amp OIL HOSE STRAINER SHALLOW CASE ITEM NO DESCRIPTION QTY Complete oil pump Assy 1 Oil pump body Pump cover Drive spindle Drive spindle S A Pump plate Needle bearing Needle bearing Sealing plug PO Orig 1 0430682
15. and astern thrust is carried by the output shaft taper roller bearings which are of ample capacity for all factory approved ratings APPROXIMATE WEIGHT AND OIL CAPACITY GEARBOX TYPE APPROXIMATE DRY WEIGHT OIL CAPACITY PRM1750D deep Case 300 kg 663 Ib 8 0 litre 14 pint PRM1750S Shallow Case 260 kg 570 Ib 10 0 litre 17 6 pint Note Weight excluding drive coupling and cooler Note Oil capacity does not include amount to fill cooling circuit FLEXIBLE INPUT COUPLINGS FOR PRM1750 MANUFACTURER FLYWHEEL PART NO SIZE Centa Transmissions Ltd SAE 11 5in CF DS 40 011 61230 MT SAE 14in CF DS 40 014 61229 MT Torflex KT410 1KT4100031 MT8424 Vulkan Industries Ltd Vulkardan E3414 MT8425 SAE 11 5in Vulkardan E3411S4000 Series MT 8426 SAE 14in Vulkardan E3411S4000 Series MT R amp D Marine Ltd 1200lbf ft 1630Nm MT8328 SAE 14 in 1200Ibf ft 1680Nm MT8329 11 OTHER ACCESSORIES PART NO DESCRIPTION MT8330S A Oil Cooler PRM1750S engines to 340kW MT8331S A Oil Cooler PRM1750D engines to 393kW Clutched power take off for SAE B hydraulic pump 209NM max Clutched power take off for SAE C hydraulic pump 640NM max 0497 Shallow Case Adaptor Ring to SAE1 MT0415 Kit Deep Case Adaptor Ring to SAE3 Note When ordering it is necessary to specify the flywheel size The choice of coupling must be made by the engine manufacturer boat builder to ensur
16. circuit Start and run the engine for a short time so that the oil circulates through the cooling circuit Stop the engine and allow the oil to settle re check the level and top up as required CAUTION Using the gearbox with insufficient oil will lead to low pressure unsatisfactory operation overheating and eventual failure Equally over filling the gearbox may cause overheating and oil leaks it is the duty of the owner operator to make sure that the oil level is correct at all times 6 2 Drive Selection The PRM1750 has been designed and tested to ensure rapid shifts from ahead to astern or vice versa and can be operated at full horsepower ratings and speeds In these circumstances the transmission will respond rapidly CAUTION Full power reversals however do place abnormal even if short lived loads on the gearbox and operating life will be prolonged if full power reversals are reserved for emergency only Newage Transmissions Ltd recommends that when changing direction the engine speed be brought down to approximately 1000 rev min For this reason it is recommended that a proprietary single lever remote control operating system be fitted which links the engine throttle control to the gearbox operating lever 6 3 Trailing Free Wheeling The Propeller The bearings used in the Newage PRM1750 gearbox have been carefully selected to ensure that prolonged trailing free wheeling of the propeller will not have any detrimental effect on
17. magnetic ____815 Straghtadaper MM 6 1 6 X CP1418 T B1i7 Bondedwaher 0201714 1 4 N ITEMNO B3 B6 ___ B BH B3 B14 l 50 d d ALT SIZES VALVE BLOCK 5 SEE DRG NO WH ES amp OL FILLER HOLE L B 2 CLUTCH 5 45 SEE ORGS NO amp WM mp LIFTING EYE DM a S iJ ST N Cp Ta 5 4 x wv Gan 4 S m E FH cal LH capu SHAFT ASSEMBLY SEE ORG 13 FOR OUTPUT ER GN C ME ES mn A SIXKETI E a 205 ES PUMP 575 SEE ORO ND 146 1 SECTIONAL PRM1500 SHALLOW SEE PARTS LIST 51 LIFTING EYE amp OIL FILLER Si HOLE VALVE BLOCK SEE ORG WHT BREATHER PUMP 574 SEE PRG 46 1 OIL HOSE SEE Ww 2 1 GIL E AT SAKIT LEVEL Ba D 89 EH Om EN PLUG SEL TIONAL 1500 SHALLOW DA SEE PARTS LIST DRG Nn PRM1TSOQWM12 2 MTG SECTION C SECONDARY PINION SHAFT ASSEMBLY DEEP CASE DESCRIPTION Secondary pinion shaft End cover secondary shaft Breather Shims A R Taper roller bearin
18. relevant service classification without labouring 2 It is also important to ensure the torsional compatibility of the complete propulsion system from engine through to propeller since disregarding this may result in gear noise particularly at low speed operation In addition it may result in damage to the engine as well as to transmission components Newage Transmissions Limited will provide all possible information and assistance to help find solutions to potential torsional problems However it is the ultimate responsibility of the person assembling the drive and driven equipment to ensure that they are torsionally compatible Operating Pressure Minimum 2827kPa 410Ibf in maximum 3100 kPa 450Ibf in Two tapped holes 1 hole 1 8 in BSP on the top and 1 hole M18 on the side of the valve block are provided so that a pressure gauge can be fitted If required The gear selector is designed with modulated engagement for soft shift Oil Cooling The normal operating temperature of the oil should be in the 50 C 80 C range and should not be permitted to exceed 90 C An oil cooler is necessary to ensure that correct operating temperatures are maintained Two 12 in BSP connections are provided on the valve block to allow it to be fitted The size of the cooler will depend on a number of factors including the transmitted horsepower operating speed duty cycle inlet water temperature and ambient temperature Propeller Thrust Both ahead
19. to confirm pinion end float and refit shafts into box A CAUTION If clutch gears or pinions are found to be worn or damaged it is strongly recommended that they are changed as a set Itis also false economy not to change all seals and piston rings during overhaul 10 7 Replacement of Piston Rings Fig 13 Piston ring fitting procedure 1 Remove piston ring using special extractor pliers or small screwdriver to ease the ring from its groove 2 Replacement is a delicate operation as the rings are fragile ring loading tool is not available use thin shim steel strip to carry the ring along the shaft and into its groove 9 Liberally lubricate the piston ring its mating part before assembly Refer fig 13 10 8 Servicing of Secondary amp Output Shafts Note these will require the use of oil injection equipment to remove them completely from the case 10 8 1 Removal of Secondary and Output Shafts from Deep Type Case 1 Referring to WM 4 and WM5 2 Remove plug F15 from front case and replace with M16 x 1 5 pitch screw 40mm or larger Screw in to support the end of the output shaft 3 Remove locknut F13 followed by spacer F3 seal F9 coupling F2 and bearing housing assy F4 use 2 off screws F16 to jack housing from case if necessary Keep bearings and shims safely together 4 Remove endcover C2 use 2 off screws C6 to jack housing from case if necessary 9 Referring to 10 4 and 10 5 split the gear case remove th
20. 095 ASSY dd 014 1444 014 PTO OPERATING LEVER TRAVEL OFF RETURN FROM CO ORG NO HB 3 MTO 15005 209 SCHEMATIC PIPE WORK 72 A Lit Lit D E uF e 5 n LL 11 L N n B LUE EE Y TH 81 X 5 BEI at eet EE 14 m K fo a P m PTO 655 Y SEE DRG ND wh 1 15000 209Nm PIPEWORK SEE PARTS LIST 4 E E Lit M El iel 5 5 a oi EE DRG WHB 1 DRG NO 5 MT 1 005 205Nm PIPEWORK SEE PARTS LIST ITEM NO QTY 1 L2 1 L3 1 L4 A R L10 L11 L12 L13 L14 L16 L17 L18 L19 S L20 L21 L22 L23 L24 L25 L26 L32 Breather 1500S only 008 0080 0 NIN rami L27 L30 L31 L33 L35 1 75 SS SMS LA TSHAFT VUE oS 5 2 2228 22228 m 8 PTO ASST 2 ES ES ES 19 AF 3 80 HEX KEY B HEX KEY PRM1500 PTO amp amp ONM MOUNTING DETAILS SEE PARTS LIST L AMET PEE PTO LUBE FEED SOLENOID VALVE 3 B BSP PORTS iil TH SC 841002 PRESS
21. 2 ___ 11 _ Gasket 1 M8609 1 0 P12 Spingwasherr 1 0911005 5 1 04125 2 ____ 14 Hexheadbolt 1 0040814 5 P15 Hexheadbodt 0041218 1 16 1 004211 2 17 Hexheadbot 1 0041210F 1 18 Bondedwashe 1 00720 1 Pi9 MMadaper o 0081420 1 P20 Flexible hose assembly 1 18308 1 P 21 LQ Olltriner 1 8212 1 22 Bondedwasher 1 0076 1 P 3 Special adapter MT8307 1 N U U U OO 85 98 2 XS 4 1 21 D N i 55 bM ka Sa FROM SUMP ISSN NSDS 2222226 N NE PI Z siz SS ANN at 222225 m D i w ES ES m E EN COMPLETE OIL ES EB JOINT GASKET PUMP ASSEMBLY PRMISO0SHALLOW PUMP SUB ASSEMBLY amp GIL HOSE SEE PARTS LIST pRGND PRM1500WM6 3 28 mp ee zi 2 GEAR CASE i pcs LL nu cx L PH PA J C PE KE ES PRMISVJOSHALLOW OIL STRAINER amp OIL HOSE SEE PARTS LIST F 6 4 SECTION Q VALVE BLOCK TROLLING REFER TO DRG WM7 2 DESCRIPTION Complete valve block Assy Valve block body End cover Thrust race Control valve Piston Spacer shim option
22. 4 Fig 12a Fig 12b DEEP BOX PORT SIDE DEEP BOX STARBOARD SIDE LEVER BACKWARDS SUITS LEVER FORWARDS SUITS LH PROPELLER AHEAD RH PROPELLER AHEAD 5 9 Remote Control Operating Systems The PRM1750 can be used with remote control operating systems which links the engine throttle to the gearbox operating lever e g Morse Controls single lever type The following points should be noted The gearbox operating lever is provided with a positive neutral position which greatly assists the setting up of the remove control unit A CAUTION Care should be taken to ensure that the cable moves the gearbox operating lever approximately 2mm short of its maximum forward or backward travel to prevent the lever being brought hard up against the end stop with every gear shift The control equipment should in all cases be connected in accordance with the manufacturer s recommendations 25 6 OPERATION 6 1 First Time Usage Deep type note dipstick should be fully screwed home or until oil flows from the level hole shallow type Repeat this process as necessary to confirm correct oil level with all circuits full CAUTION Before starting the engine fill the gearbox to the correct level with a suitable oil refer to recommended list section 4 4 page 17 Ensure the gearbox is in neutral the neutral safety switch should be wired into the starter circuit to avoid uncontrolled boat movement on start up See fig 5 page 15 for wiring
23. CUT OUT RECURRED VARIOUS MOUNTING DETAILS 4 HOLES 5 40 THRO OUTLINE MORSE FLANGE TEMPLATE FOR MTG OPTIONAL MORSE CONTROL DRONO 3
24. F2 F3 F4 F5 A JJ F10 F11 F12 F13 A R ITEMNO L pe D o WE CNN F5 FO LEM T EE NEN x 59 09 n e p mb a Tm G 22 m Sz 221 x 8 18 11457 04115 1 FRMTSUO DEER DUTPUT SHAFT SUB ASSEMBLE T REFER TO PARTS LIST PF DRG ND 1500 5 MTG TI DOM SECTION G OUTPUT SHAFT ASSEMBLY SHALLOW CASE DESCRIPTION Output shaft Output flange Output coupling washer Output seal housing Shims A R End plate Taper roller bearing Taper roller bearing Nu lip seal GIO Ollseah ___ __ 4 1 Gi 0431693 1 Gi2 Loknt FOV LI 03 FOOT 1 Gi4 Socketcapscev 00814200 8 Output gear 75 teeth 3 00 1 ITEM NO sch sch sch lt G2 G3 lt 00 61 s E E 74 PaA 1500 OUTPUT SHAFT SHALLOW REFER TO PARTS LIST Di C m m gt Lem EN EE EE lira Ai POSITION SLOT SECTION H OIL PUMP ASSEMBLY amp OIL HOSE STRAINER DEEP CASE ITEM NO DESCRIPTION Complete oil pump Assembly Oil pump body Pump cover Drive spindle Pump spindle S A Pump plate Needle bearing Needle bearing Sealing plug HO _ 0480682 2
25. FEEDER OIL PUMP HIGH PRESSURE LINE TO CLUTCH A ENGAGED HIGH PRESSURE LINE TO CLUTCH DISENGAGED DEE LIBRICATING CIRCUIT OIL INTAKE FROM SUMP Fig 6 Hydraulic and lubricating oil circuits 18 4 3 Lubrication Lubrication oil is delivered via the internal supply to the control block Irrespective of whether ahead or astern is engaged oil is diverted from the discharge side of the pressure relief valve to an external oil cooler After passing through the cooler the oil is directed through channels in the valve block and thence through the layshaft and drive shaft to lubricate the clutch assemblies 4 4 Approved Oils TEMP TYPE OF OIL 10W30 or 20W engine oil to API designation CD 0 to 30 10W30 15W40 engine oil to API designation CD C Above 30 C 10W30 40W engine oil to API designation CD NOTE Gearboxes are despatched from the factory without oil It is essential that only good quality engine oil supplied by a recognised and well known manufacturer be used in the PRM1750 Do not mix different brands types or grade of oil CAUTION Failure to comply with the above oil types may result in the forfeiture of warranty cover since no claims under warranty will be entertained if oil of the wrong specification is used 5 INSTALLATION 5 1 General The Newage PRM1750 marine gearbox is supplied with a choice of adaptor sizes to SAE1 SAE2 and SAE3 dimensions enabling it to
26. G2 and bearing housing assy G4 using 2 off screws G16 to jack housing from case if necessary Keep bearings and shims safely together Referring to 10 4 and 10 5 split the gear case remove the rear half Using oil injection equipment remove the output gear G18 to G23 as fitted Unscrew 8 cap screws G14 together with end plate G6 The shaft assy may now be removed from the gear case Inspect the gears bearings and seals and replace with new as necessary Commence re assembly by placing output shaft into front case half Adjust the M16 screw to support the shaft with its bearing G7 just below the endplate G6 mounting face Secure end plate into position and lock its screws up fully Fit gear using oil injection equipment Rebuild case and bearing housing S A noting that lock nuts used must have a minimum run up torque when moving along their threads as stated in chart 13 1 Tightening Torques Any nut that is too loose a fit should be replaced It is strongly recommended that oil seals G9 G10 and G11 are replaced with new items Check shimming with reference to 10 9 3 and 10 9 4 3 10 9 Shimming Procedure The allowable endfloat on all shafts between their taper roller bearings is 0 00 0 05 0 000 0 002 This can be checked with the use of depth micrometers or feeler gauges Refer to figs 14 15 and 16 10 9 1 Input amp Layshafts Micrometer Measure depth of bearing inside case ensurin
27. RG WM8 1 WM8 2 WM8 3 WM8 4 WM8 5 ITEM NO DESCRIPTION PART NO QTY 209NM PTO S A 1 Adapter housing 1 Sealing plug 2 Shims A R Splined adapter PTO body Selector valve End cap Cover K10 Joint gasket K11 K12 Piston K13 Clutch end cover K2 K5 OO ch c 1156 6 Ki5 Drveadaper MT500 1 Kt6 JOpertinglever 1500 1 K7 M9 1 Ki8 UnonSA S 5 1 Ki9 CP 1 K20 __ Clutchendplate MH 1 Clutchplate MIDI 5 2 jPi JJ S A41 J 3 Ko Sping 1157 3 K24 QGluchbody M50 1 K25 X Bondedwaherr 0201715 1 K26 lt Internalcirclip 7 055 1 K27 ___ External circlip f 0830300 1 Koa 10013 2 9 _ 7 6 K33 Socket cap screw 0081525 4 K34 O ring 004124 1 K35 Hex nut 0050801 1 8 Hexheadbolt 0010420 6 _ 9 Washer 6 _ ____ Stud 005 0050 6 45 0051205 6 68 SECTION K 209NM PTO REFER DRG WM8 1 WM8 2 WM8 3 WM8 4 WM8 5 DESCRIPTION QTY Flexible hose 2 Flexible hose Flexible hose Bonded washer Bonded washer Plug M M adapter Ball bearing Gasket Cooler PRM1750 Shallow type Cooler PRM1750 Deep type 69 02
28. URE FEED CONDITION ne FEED 10 COOLER CIRCUIT RETURN FROM COOLER CIRCUIT d em 3 FTO CONDITION f a 0 gt TO SUMP qr am EC RETURN LUBE OUT 15060 ASSY 15000 640NM SCHEMATIC PIPEWDRK SEE PARTS LIST L PRM4S00WM9 2 MTG 22 LUBE FEED FROM COOLER CIRCUIT COOLER gt Ln sl LQ a ac a RETURN FROM COOLER 43100 WOdd Mal 11001 5 5 01 0333 0334 391553 RETURN B 91 V 38111 014 umm il PRESSURE FEED CONDITIDN o ar s T NOLLICINQJ 440 014 i E 39155454 T m az 2 A I m DRONO 49 3 15005 BAUNM SCHEMATIC 78 EL 439r PRMTS OW M3 4 r EE RENI n ESN 1590990 PIPEWORK SEE PARTS LIST 1 E 1 3 E VE 18 19 08 Pd T 5 Em UE 3 Ce E 15095 PIPEWORK SEE PARTS LIST 1 Ip d lam DR 9 5 SECTION M PRM1750 TROLLING VALVE SHALLOW CASE
29. aft must be reshimmed See section 10 10 and refer to Drg WM2 Oil Strainer The gearbox oil strainer is attached to the end of the oil pump feed hose and is situated in the sump It 10 4 may be removed for inspection replacement as follows Refer to Drgs WM3 6 and 12 Loosen hose connecting at oil pump 38 0 A F disconnect hose at other end 38 0 A F and remove large brg 70 0 A F item P23 H23 together with its sealing washer and the oil strainer Wash the strainer in a suitable cleaning solvent or replace if damaged Dry thoroughly Refit with minimum strain applied to hose Removing the Transmission CAUTION Before commencing work see section 9 The following instructions must be complied with to avoid damage to the gearbox Ensure that the gearbox operating lever J8 is in the neutral position disconnect the operating cable or cables and the wiring for the neutral safety switch Drain the gearbox oil into a suitable container and disconnect the oil cooler pipes Unscrew and withdraw the bolts connecting the gearbox output flange from the flexible coupling or mating half coupling on the propeller shaft CAUTION Sling ropes around the gearbox securely to provide support while it is being WARNING removed from the engine Remove the bolts securing the adaptor flange to the flywheel housing Slacken the bolts that secure the flexible drive coupling to the flywheel Withdraw the gearbox if necessary rocking the u
30. al Operating lever Washer ITEM NO lt Q7 88 zi E Ir Ir E E E JOINT GASKET i hb Om UT 72272 CH AA 22277727 be BB Be qu 5 ELECTRIC SWITCH SUB ASSY ALTERNATIVE FITMENT DRG NO PRMI500WM7 2 MTG 1500 VALVE BLOCK TROLLING SUB ASSEMBLY SEE PARTS LIST 89 SECTION R VALVE BLOCK PTO REFER DRG WM7 3 DESCRIPTION Complete valve block Assy Valve block body End cover Thrust race Control valve Piston Spacer shim optional Operating lever Washer RIO _ Spring 4928 1 ____811 21 MIO 1 12 __ 1 M82 1 _ R13 Steelball oppgiona j CP107 2 R14 Bondedeal 01 0201715 1 815 Spring MT30 1 ____816 Switch optiona 138 1 ____817 Sp ngwaher 00191105 1 ____818 ___ 1 00812220 2 R19 Hexheadscrewv 1 0040800 1 R20 X Plug optional CP1360 1 8201 MMadater 1446 1 R22 Hexheadscrew 1 004100104 1 23 jPresuepug 1 R24 Hexheadscrewv 1 00408122 1 R25 Hexheadscrewv 1 00408105 1 R26 Hexheadscrewv 1 0040808 3 R27 X Bondedwasher 1 0191710 1 R28 Bondedwasher 1 019178 5 R29
31. alled vertically with the bowl facing downwards The 10 micron element must be replaced after initial 50 hours operation and with regard to the filter indicator reading thereafter The system must not be run with the indicator in the red 8 If used with a PTO then the clutch pressure feed for the PTO must be taken from either the 1 8 BSP tapping on the valve block or port P on the proportional valve Under no circumstances should the PTO connection be taken from Port C clutch feed line 9 The trolling valve system is failsafe and will return to full pressure in the event of electrical failure In the event of mechanical failure e g sticking valve the on off solenoid at the side of the proportional valve can be operated manually by depressing the button in the centre of the solenoid This will release the valve and return to full pressure 10 The trolling valve must not be operated above 1200rpm An inter lock switch is fitted to prevent this 11 Prior to retro fitting a trolling valve to an older gearbox drain gearbox and cooler circuit and clean oil strainer Refill to correct oil level and follow procedure 6 1 43 13 1 TOOL KIT amp APPLICATIONS 18mm A F Spanner gt Dipstick 70mm 2 75 A F Spanner gt Oil hose amp strainer 41mm Spanner gt Bung 38mm 1 57 A F Spanner 19mm A F Spanner gt Gearcase joint 17mm A F Spanner 13mm A F Spanner 10 A F Hex Allen Key 8 A F Hex Allen Key Extended
32. alve Valve Block Sub Assembly Parts List Trolling Valve Valve Block Sub Assembly Sectional View PTO Valve Block Sub Assembly Parts List PTO Valve Block Sub Assembly Sectional View Trolling Valve Joystick Controller amp Switch Parts List Trolling Valve Schematic Trolling Valve Joystick Controller Detail Trolling Valve Mounting Detail FOREWORD Provided it is correctly installed aligned and maintained the PRM1750 gearbox should have a long and trouble free life This workshop manual contains important instructions to ensure that this is so and it is of the utmost importance that these are carefully followed Newage Transmissions Ltd can accept no responsibility under warranty or otherwise for any loss or damage resulting from failure to observe these instructions To avoid prejudicing your rights under warranty do not undertake any repair or other work on the gearbox during the warranty period without first contacting Newage Transmissions Ltd or an authorised distributor for advice In the event of failure you should do this via the engine distributor who supplied the gearbox or his local dealer if this is not possible you should notify the local Newage distributor dealer or Newage Transmissions Ltd direct quoting the serial number CLAIMS UNDER WARRANTY Claims for replacement of parts under warranty must always be submitted with the gearbox serial number to the distributor who supplied the gearbox if this
33. ans of stopping the boat using engine power Great care is therefore required when manoeuvring or docking 27 ifs 7 1 ROUTINE MAINTENANCE Initial maintenance after 25 hours running WARNING Hot oil can cause burns Do not work on the gearbox with the engine running Drain all oil from the gearbox using the magnetic drain plug located at the rear of the box This requires a 1 A F spanner Clean any debris from magnet and re fit Refer to Drgs WM 3 2 and 12 2 The oil strainer should also be checked and replaced if necessary refer to Drg WM6 requiring spanners of 70 0 2 75 41 0 38 0 1 5 A F Refill using a recommended lubricant see 4 4 chart Page 17 as per instructions 6 1 7 2 1 2 7 3 4 7 4 Daily Checks Check the gearbox oil level Make visual inspection of the general condition of the transmission and check for oil leaks especially at the output shaft seal and at gasket sealing surfaces Annual Checks Check oil cooler connections Check propeller shaft alignment and correct if necessary Check remote control operating linkage is accurately adjusted to give correct travel on the gearbox operating lever Check that all fasteners are correctly tightened see torque chart page 42 Winter Storage Drain water from the transmission oil cooler to avoid freezing or the collection of harmful deposits 7 9 1 Other Maintenance Operations The gearbox oil should be changed at pe
34. arefully to prevent damage if they are to be re used however it is best to replace these items Carefully examine all cast iron piston rings for wear and corresponding wear damage in the bores Take care not to break these rings 9 2 Bearings If removing taper roller bearings for re use keep them in matched sets together with their shims and protect all bearings from contamination 9 3 Cleaning WARNING If using cleaning solvents these be toxic flammable a skin irritant or give off harmful fumes Avoid prolonged contact vapour inhalation or smoking Failure to take care can result in injury or death Rinse all metal parts in solvent to remove dirt grease and oil Be careful to remove solvent from items before re fitting 9 4 Inspection 9 4 1 Gearcase Inspect for cracks Check sealing surfaces for any scratches damage etc which will lead to oil leaks Check all threads for damage 9 4 2 Gears Inspect for any chipped broken or cracked gear teeth also for any excessive wear i e gear pitting 9 4 3 Bearings Inspect for any damage pitting or over heating 31 9 4 4 Clutch Plates Inspect all clutch plates for signs of overheating and or distortion Check friction surfaces for wear Replace if oil groves have worn away 9 4 5 Clutch Components Inspect clutch components for wear damage overheating or debris Check all oil feed holes are clear 9 4 6 Threaded Parts Inspect for stripped or damaged t
35. ave output rotation the same as input rotation with input shaft clutch engaged With a L H propeller this gives forward motion It is normal practise for the input clutch to be used for ahead motion on single propeller installations with the layshaft clutch engaging astern All input and lay shafts incorporate a hydraulically activated piston operating the clutch pack set into a clutch gear which also contains the emergency get you home device This will engage the drive pinion available in various ratios which is set on needle bearings and so transmit drive The output shaft runs on amply proportioned bearings so allowing propeller thrust to be absorbed in either direction 3 2 Oil Pump A cast iron gear type pump externally mounted at the rear of the gearcase and driven by the input shaft supplies oil at high pressure for actuating the clutch assemblies and at lower pressure for lubrication It should be noted that pressure may vary at different operating speeds It is also likely that on start up when the gearbox is cold significantly higher pressures may occur 3 3 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 pressure valve controlling the supply of oil to the clutch assemblies Oil that is surplus to clutch operation requirements is used for lubrication purposes The control valve is fitted with a spring loaded neutral detent which pr
36. be fitted to engines having flywheel housings of equivalent specification See installation drgs Page no 12 amp 13 Drive is transmitted from the engine to the gearbox via a flexible centre drive plate damper plate which bolts to the engine flywheel The gearbox input shaft is driven from the centre spline These drive plates have a degree of torsional flexibility the purpose being to reduce engine torsional or cyclic vibrations and prevent them being passed to the transmission The strongest engine vibrations are usually those caused by the firing cycle Diesel engines which have high compression ratios usually generate stronger vibration pulses than petrol gasoline engines and it is often the case that of two engines of roughly equivalent size the one having the greater number of cylinders will tend to run more smoothly than the one with fewer cylinders although this is by no means always the case In all marine installations correct alignment of the engine gearbox and propeller shaft is extremely important misalignment can cause noise vibration and premature failure and it is strongly recommended that all the procedures detailed in this manual are carefully followed AN CAUTION It is particularly important to ensure the torsional compatibility of the complete propulsion 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
37. ble end cover assy K9 by removing 4 screws K30 retaining gasket K10 From inside the PTO unscrew the central cap screw and remove the retaining bung these items can be discarded Determine the shims to produce running clearance at X of 0 5mm nominally Measure dimension B Protrusion of lay shaft from PTO adaptor housing K amp A minimum depth to clutch body housing Ks inside PTO Deduct B from A noting amount and whether the product is positive or negative If positive add the amount to 0 5mm to obtain shims required If negative deduct from 0 5mm to obtain shims required Shim sizes available are 0 1mm and 0 5mm e g of shim calculation A 14 30 A 14 55 B 14 55 14 30 0 25 Note negative product 0 25 Note positive product 0 50 0 50 0 25 0 25 25 shims 5 shims Therefore fit 2 off 0 1 shims Therefore fit 2 off 0 1 amp 1 off 0 5 shims giving theoretical clearance at X of 0 45 giving theoretical clearance at X of 0 45 Determine shims to give minimum endfloat of splined drive adaptor K5 Measure dimension C minimum depth to plug K1 inside PTO amp D minimum protrusion of splined drive adaptor K5 from PTO housing K2 40 10b Deduct D from C and divide by 2 0 Shims are available in 2 0mm only e g of shim calculation C 35 0 D 26 0 11 0 shim gap 2 0 divide 5 5 shims therefore fit 5 off shims 2 0 thick Stick O ring 134 to PTO
38. bly Parts List Input Shaft Sub Assembly Sectional View PRM1750D Output Shaft Sub Assembly Parts List PRM1750D Output Shaft Sub Assembly Sectional View PRM1750S Output Shaft Sub Assembly Parts List PRM1750S Output Shaft Sub Assembly Sectional View PRM1750D Oil Pump Hose Strainer Parts List PRM1750D Oil Pump amp Hose Sectional View PRM1750D Strainer amp Hose Sectional View Standard soft shif Valve Block Sub Assembly Parts List Standard soft shift Valve Block Sub Assembly Sectional View 209 NM PTO Parts List 209 NM PTO Sub Assembly Sectional View PRM1750D 209 NM PTO Pipework Schematic PRM1750S 209 NM PTO Pipework Schematic PRM1750D 209 NM PTO Pipework Sectional View PRM1750S 209 NM PTO Pipework Sectional View 640 NM PTO Parts List 640 NM PTO Sub Assembly Sectional View PRM1750D 640 NM PTO Pipework Schematic PRM1750S 640 NM PTO Pipework Schematic PRM1750D 640 NM PTO Pipework General Assembly PRM1750S 640 NM PTO Pipework General Assembly 17505 Trolling Valve Parts List PRM1750S Trolling Valve General Assembly PRM1750D Trolling Valve Parts List PRM1750D Trolling Valve General Assembly PRM1750S Oil pump Hose Strainer Parts List PRM17508 Oil Pump 4 Hose Sectional View PRM1750S Strainer amp Hose Sectional View PAGE NO 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 83 84 85 87 Trolling V
39. body using a light smear of clean grease Assemble PTO with shims K40 drive adaptor K5 cap screw K42 shims K43 and 4 off screws K33 to main gearcase Leaving screws K3 loose lock up cap screw K42 tight Check to conform endfloat of PTO Body K6 is approximately 0 5mm Tighten 4 screws K33 He assemble end cover assembly K9 being careful to align splined drive shaft K15 through clutch plate splines using original gasket K10 if serviceable and tighten 4 screws K30 Attach pipework per G A drgs WM8 Change valve block assembly to MT0503 as required for use with this PTO Refer to 10 1 41 11 4 3 Retro fitting of 680NM PTO Refer to WM 1 amp 9 1 Repeat as 11 4 2 2 Repeat as 11 4 2 3 Repeat as 11 4 2 4 Repeat as 11 4 2 5 Repeat as 11 4 2 6 Repeat as 11 4 2 7 Bolt adaptor ring L3 onto PTO adaptor housing L2 using 4 off screws L5 sealing joint with Hermatite or similar compound 8 Using 4 off screws L10 fit PTO assy L1 onto adaptor ring L again sealing joint with Hermatite 9 Remove blanking screws from case arm mounting holes where fitted 10 Bolt support arm assembly onto main gearcase and adjust to firmly support PTO body Ref G A WM9 Seal threads against oil leaks 11 Attach pipework as per G A 12 Change Valve Block Assembly to MT 0504 as required for use with this PTO Refer to 10 1 42 12 TROLLING VALVE A trolling valve assembly is availabl
40. clip D16 E16 followed by end plate D7 E7 clutch plates D17 E17 and D18 E18 thrust washer 09 9 springs D23 E23 and piston D6 E6 Note the clutch gear D37 E34 and bearing D10 E10 can only be removed with special oil injection equipment The clutch plates should be inspected for discolouring or distortion caused by overheating or lack of groove pattern caused by wear and replaced if at all doubtful All bearings and seals should likewise be inspected for damage or wear Commence re assembly by refitting piston into clutch gear locating over 2 pins D22 E22 Refit 12 springs and large thrust washer Place thrust wash E15 D15 over shaft with small chamfer downwards Position thrust bearing D11 E11 next followed by thrust washer D13 E13 with large chamfer away from bearing Fit 2 off snap rings D8 E8 into grooves Locate 7 off each type of clutch plate into clutch gear using plain steel D17 E17 first and alternating with friction plat D18 E18 followed by end plate D7 E7 Temporarily refit pinion on its bearings so as to line up clutch plate splines then remove Fit circlip D16 E16 into clutch gear groove Re assemble pinion with its bearings and spacers followed by thrust bearing D11 E11 and thrust washer D29 E29 35 11 Hold thrust washer firmly against shoulder on shaft check for pinion end float There should be a minimum of 0 1mm 12 Press on transfer roller bearing cone carefully so as not to trap thrust bearing 13 Re check
41. components Newage Transmissions Ltd will provide all possible information and assistance to help find solutions to potential torsional problems but it is the ultimate responsibility of the person assembling the drive and driven equipment to ensure that they are torsionally comptatible 19 5 2 Checking the Engine Flywheel Housing Attach a dia test indicator calibrated in units of 0 025mm 0 001in or smaller to the flywheel so that the measuring stylus of the indicator is perpendicular to the bore of the flywheel housing bore A on Fig 7 Rotate the flywheel and check the deviation on the indicator over one complete revolution this should not exceed 0 152mm 9 006in total indicator reading With the dial test indicator still attached to the flywheel re position the stylus so that it is perpendicular to the face of the flywheel housing face B on Fig 7 Rotate the flywheel and check the deviation over one complete revolution again this should not exceed 0 152mm 0 006in total indicator reading 5 9 Checking The Engine Flywheel Attach a dial test indicator calibrated to 0 025mm 0 001in or less to the engine flywheel housing so that the measuring stylus of the indicator is perpendicular to the bore of the register in the flywheel bore C on Fig 7 Rotate the flywheel through one complete revolution and note the deviation this should not exceed 0 125mm 0 005in total indicator reading With the dial test indicator still at
42. connect the control cable s from the lever J8 on the valve block Disconnect the oil cooler pipes and the wiring from the neutral switch 916 if fitted 3 Remove the 6 bolts J24 25 22 26 and together with washers J28 27 securing the valve block to the gearcase 4 To remove the control valve J5 and piston J6 simply remove the two cap screws J18 and withdraw the valve from the valve block J2 AN CAUTION Take care not to lose the detent ball and springs J13 J15 5 Inspect the seal J31 seal bore in J3 and bearing J32 and replace if worn damaged or defective Check that the valve spring J10 has retained its correct free length 62mm if not replace it 6 To assemble and refit the valve block simply reverse the above procedure It will be necessary to lightly grease the seal bore J3 and seal diameter of valve J5 to avoid damaging the seal J31 when re fitting 33 10 2 Oil Pump The oil pump can be removed with the gearbox in position on the engine refer to WM6 1 1 Remove the 6 bolts and washers H13 15 16 17 12 securing the oil pump to the maincase and withdraw the pump complete with gasket and shims Inspect the gasket H11 and replace if necessary If in good condition store carefully until required for refitting If the pump is damaged in any way the complete pump assembly H1 must be replaced A 10 3 CAUTION If a new pump assembly is fitted the clutch sh
43. d on the other shaft to give both drives ahead 2 To lock up the input shaft first remove the oil pump assy refer to Drg WM2 followed by its gasket and shims and then the bearing cup Using item E31 a long series 4 0 hexagon allen key align 1 2 holes amp screws 2 at a time and lock up all 4 screws item E30 2a Re assy ensuring shims are replaced and gasket is in usable condition 3 To lock up the layshaft first remove the encover Ref to WM1 or P T O assy Refer to WM8 or 9 and Sections 11 2 or 11 3 complete with gaskets 0 rings and shims as applicable Then remove bearing cup Using item D31 a long series 4 0 hexagon allen key align 1 2 holes amp screws 2 at a time and lock up all 4 screws item D30 3a Re assembly ensuring shims are replaced and all gaskets and all O rings are in usable condition CAUTION Ensure that sufficient oil remains in gearbox to avoid any further damage The engine can now be run but to minimise the possibility of any more damage being caused to the transmission it is recommended that engine speed is limited to 1 3 full throttle Disconnect the operating cable to the gearbox operating lever to prevent accidental selection of other clutch After emergency drive has been used the transmission must be checked over thoroughly before being used again WARNING When emergency drive ahead is engaged neither astern or neutral will be available therefore there will be no me
44. e as an option This electronically operated valve allows variable speed of the propeller down to zero whilst allowing a maximum engine speed of 120rpm valve uses the gearbox oil Valve block assembly MT0513 is required to replace MTO494 for use with trolling valve 12 1 Specifications a One 3m length of 6 core cable is supplied loose with one socket end connector and 2 Hirschman connectors on solenoid cables as part no MT4820 b The fuel rack switch is left with bare wires Customer is to connect wires and provide suitable mounting brackets The control lever is pre set and should not require any adjustment 12 2 Retro Fitting of Tolling Valve Refer to Drg WM10 1 Remove two screws from suitable positions on gear case joint see G A Discard these screws and using new screws N13 M13 fit mounting plate N1 M1 2 Change valve block assembly for 0513 as required with this trolling valve Refer to 10 1 3 Assemble proportional valve and solenoids on mounting plate using screws and nuts N14 M14 and N15 M15 4 Attach pipework and electrical connections as per G A o Mount joystick controller in suitable position and connect to solenoids Refer to drg WM1 1 6 The cooler circuit connections remain as on standard box 7 The oil filter can be re sited if necessary up to 0 5m from the gearbox For this case the customer must provide the required mounting bracket Note that the filter must be inst
45. e rear half 6 Using oil injection equipment remove the output shaft gear F17 36 10 11 12 13 14 15 10 8 2 10 11 Unscrew 8 cap screws F14 together with end plate F6 The shaft assy may now be removed from the gear case The secondary shaft may now be lifted out This gear will also require oil injection equipment to remove it from its shaft Inspect the gears bearings and seals and replace with new as necessary Commence re assembly by placing output shaft into front case half Adjust the M16 screw to support the shaft with its bearing F7 just below the end plates F16 mounting face Secure end plate into position and lock its screws up fully Fit secondary shaft assembly into case half followed by output shaft gear which needs to be oil injected into position Rebuild case and end cover bearing housing S A s noting that locknuts used must have a minimum run up torque when moving along their threads as stated in chart 13 1 Tightening Torques Any nut that is too loose a fit should be replaced It is strongly recommended that oil seals G9 G10 and G11 are replaced with new items Check shimming with reference to 10 9 3 and 10 9 4 Removal of Output Shaft from Shallow Type Case Referring to WM13 Remove plug G15 from front case and replace with M16 1 5 pitch screw 40mm or longer Screw in to support the end of the output shaft Remove locknut G13 followed by spacer G3 seal G9 coupling
46. e vibratory torque levels within the driveline are kept to a minimum within the engine operating speed range This is particularly important as PRM1750 uses two stage gear reduction Gearcase Heavy duty cast iron for use in the marine environment constructed in two halves for ease of servicing ribbed internally for rigidity and strength A magnetic drain plug is provided at the rear face of the gearcase this can be removed if required to allow suitable pipework to be connected to a hand operated drain pump Connections are provided on the valve block for accessories and pressure gauge Input shaft 44 75 mm diameter with 12 24DP 20 teeth Propeller thrust Ahead and astern thrust is carried by output shaft bearings of ample capacity for all Newage approved ratings Installation angle The maximum fore and aft installation angle at rest is 17 Output flanges a Deep type box uses MT 8176 267 0 with 8 holes 26 2 on 222 26 PCD b Shallow type box uses MT 8175 185 0 with 6 holes 16 25 on 152 4 PCD 12 18 188 1 Q siepe antcm 1 yi 2 i E 2 2 Ezra 2 z AES EF i 625 sy V Bou mui rand dz E EIERE TOMOUNTG Fig 1 Installation Drawing PRM1750D Deepcase 13 E Bir TEE RATER PLE OPA NG LIS 717 GAME AR MPRT POTATO
47. ealing against leaks Once fitted the pump can be piped up as specified by the manufacturer After installation is complete the gearbox should be run with the pump off load to check PTO for correct hydraulic functioning 11 4 Retro Fitting of PTO s 11 4 1a Note that the standard gearbox without PTO uses a special soft Shift valve block assembly 494 which is not suitable for PTO applications The 209NM PTO requires valve block assy MT0503 and the 640NM requires valve block assy MT0504 11 4 1b If a trolling valve is also to be used with a PTO installation then the valve block assembly will be part no MT0513 Refer to 12 11 regarding special instructions 39 11 4 2 Retro Fitting of 209Nm PTO MTO199 Refer to Drgs WM1 amp 8 1 9a 9b 10 10a Remove end cover D14 and gasket D32 retain gasket if to be re used Discard end cover and its screws Remove screw D26 and discard Select shims E4 D25 to suit new PTO adapter housing K2 Refer to 10 8 for shimming procedures Fit 2 plugs K3 to housing K2 if necessary requires special gun Fit 39 piston ring K41 to layshaft Refer to 10 7 for piston ring replacement procedures Fit 6 studs K44 to gearcase using Loctite stud lock on threads Fit correct shims K4 and housing K2 with its gasket K56 D32 using 6 off nuts K45 From PTO assembly MT0199 remove the transit cover plate and 2 screws and disregard Dis assem
48. erate the PTO clutch Low pressure oil direct from the oil cooler provides lubrication for the internal PTO components 11 2 Specification Two sizes of PTO are available a 209Nm 155lbft 22KW 29 5HP per 1000rom b 640Nm 472lbft 67KW 90 per 1000rpm a The 209Nm PTO is to SAE J744C series B with splined output and 2 or 4 bolt flange mounting The clutch control is a mechanical lever See WM8 b The 640Nm PTO is to SAE J744C series C with splined output and 4 bolt flange mounting The clutch control is via electric 12V or 24V solenoid See Drg WM9 Pumps of larger capacity must not be used The PTO s are designed to drive hydraulic pumps of the gear valve or piston type conforming to SAE J744C specification only They must emphatically NOT be fitted with any adaptor drive to an outrigger pulley as the mounting will not support the inflicted side loads Advice cannot be given regarding the design of ancillary power circuits of which the PTO forms part It is expected that such circuits are in accordance with the recommendations of the manufacturers of the hydraulic equipment used and to be adequately safe guarded against overloading 11 3 Fitting of Hydraulic Pump The 209Nm PTO requires 2 or 4 bolts of M12 thread to attach the required pump The joint face will need sealing against leaks The 640Nm PTO requires 4 bolts of gt UNC thread to attach the required pump The joint face will need s
49. g 2 O ring Locknut Secondary pinion 61 teeth 1 56 1 Secondary pinion 66 teeth 1 94 1 Secondary pinion 69 teeth 2 23 1 Secondary pinion 71 teeth 2 45 1 r r r r r r pp MEE be Hex head screw 004032000 6 EC 21 nr mms 53 AS Yim a SECTION D LAY SHAFT ASSEMBLY DESCRIPTION QTY Lay shaft Pinion 29 teeth 2 45 1 Pinion 31 teeth 2 25 1 Pinion 34 teeth 1 94 1 Pinion 39 teeth 1 56 1 Piston Clutch reaction plate Spacer Thrust washer Taper roller bearing Needle bearings Needle bearings D13 Thrust washer D14 PTO manifold cover D17 Clutch plate plain 16 8 D18 Clutch plate friction 8135 5 8 0024 Hexheadsrewv 00412200 6 ITEM NO lt rs 7 D10 D12 ITEM NO D6 D8 D9 DO __013 __ 014 D33 Self locking nut 075F501 1 D34 Pinion 45 teeth 1 22 1 MT8124 1 D35 Pinion 25 teeth 3 00 1 MT8128 1 55 SENE ES W V X w Z i SSN Le 2 22 AIRY gt E Sy ped EOM cM 1 222 20 2 SCH Lem D ALA IR Z09NG Uhr Em HHHH eee De OY BEN 0 NUN E Su IE SEE NA
50. g bearing is correctly seated 2 Measure length of pump or cover PTO Housing location diameter with gasket removed 3 Deduct 2 from 1 and add 0 10 0 004 to allow for gasket to give shims required 10 9 2 Input amp Layshaft Feeler Gauge Method 1 Fit enough shims to make pump or cover or PTO housing stand proud of box with gasket removed 2 Tighten screws or nuts and rotate shaft until it starts to bin ensure the gap between case and component is even all round 3 Measure gap produced and deduct 0 10 0 004 to allow for gasket 4 Deduct this final figure from actual shims originally fitted 10 9 3 Secondary amp Output Shafts 1 Assemble with no shims in place and tighten screws whilst rotating shaft until it starts to bind Ensure gap between case and endcap or housing is even all round 2 Measure this gap with feelers and fit that amount of shims 10 9 4 Shims are available in thicknesses of 0 05 0 002 0 075 0 003 0 25 0 010 0 40 0 016 1 00 0 025 38 11 POWER TAKE OFF UNITS 111 The hydraulically operated PTO units available are of 2 sizes MT0199 rated at 209Nm and MT8279 rated 640Nm the former is mechanical lever operated and the latter solenoid valve operated They both take their drive from the layshaft replacing the standard cover fitment The PTO provides a clutched link between the gearbox and a hydraulic pump Oil pressure is taken from the valve block to op
51. he gearbox specification in the example given this translates as follows 1500 D First 4 digits Gearbox Model 1500 Fifth digit Out put shaft configuration Sixth amp Seventh digit ratio NOTE throughout this manual engine gearbox and propeller rotation are always described as seen looking forward from the propeller to the engine 1 GENERAL DATA 1 1 SPECIFICATIONS PRM1750 NOMINAL POWER RATINGS PRM1750 DEEP CASE MARINE GEARBOX PLEASURE LIGHT COMMERCIAL HEAVY MODEL RATIOS COMMERCIAL BHP KW BHP KW BHP KW 1500D31SAE1 1500D31SAE2 3 12 1 21 06 15 70 19 65 14 65 18 28 13 63 Maximum operating speeds intermittent 3000 rev min continuous 2500 rev min D Denotes Deep Case manufactured only with integral SAE1 or SAE2 adaptor housings If there is a need to convert from to SAE3 then additional adaptor ring is available as accessory NOMINAL POWER RATINGS PRM1750 SHALLOW CASE MARINE GEARBOX PLEASURE LIGHT COMMERCIAL HEAVY MODEL RATIOS COMMERCIAL BH KW BHP KW BHP KW 1500S12SAE3 1500S15SAE3 Maximum operating speeds intermittent 3000 rev min continuous 2500 rev min S Denotes Shallow Case manufactured only with integral SAE3 adaptor housings If there is a need to convert SAE3 to SAE1 then additional adaptor ring is available as accessory Note These powers are expressed in BHP and kW per 100 rev min engine speed and are measured at the engine fl
52. hreads 32 10 SERVICING AND REPAIR PROCEDURES CAUTION When re assembling the gearbox all threaded fasteners must be tightened to the torques listed in table page prevent premature failure It should be noted that each shaft has one gear assembled to it using oil injection If this equipment is not available the shaft gear sub assy can be supplied ready assembled if replacement parts are required Also note that the output shaft cannot be removed from the case half without specialised oil injection equipment Some servicing operations can be carried out with the gearbox still mounted to the engine provided of course that the engine compartment is sufficiently large to allow this examples are the replacement or repair of the valve block and the oil pump To repair or replace the input shaft layshaft or output shaft however you will need to remove the gearbox from the engine If the details outlined below are carefully followed no difficulty will be found in stripping and rebuilding the gearbox ltis most important that all components are perfectly clean and in good condition before re assembly CAUTION shafts are supported in taper roller bearings Each time a shaft is dismantled it will be necessary to check for correct shimming see section 10 10 10 1 Valve Block The complete valve block is easily removed for inspection and servicing with the gearbox still in the boat refer to WM7 1 1 Dis
53. is not possible application may be made to the nearest distributor who must however be advised of the supplier s name and address SERVICE PARTS The comprehensive illustrated parts list gives full information and ordering procedure PRE DELIVERY TEST Before it leaves the factory every gearbox is subjected to a final test and inspection which includes the following Flush clean Fill with oil to correct level Pressurise the case and check for oil leaks Check for noise levels Check for drag in neutral Check input spline dimensions Check bolt torques Check coupling concentricity Check for conformance to customer spec 10 Record time to working temperature 11 Record gearbox temperature Deg C 12 Record valve block force N to F Ibf 13 Record valve block force N to R Ibf 14 Record oil pressure 1800rpm Ib sq in in forward neutral and reverse pe eu Nc IDENTIFICATION PLATE Every PRM gearbox is fitted with an identification plate on the top half of the gearcase before it leaves the factory an example of such a plate is shown below NEWAGE PRM COVENTRY NEWAGE PRM COVENTRY 123456 1500 D3 1 MADE IN ENGLAND MADE IN ENGLAND Please complete the above box with serial number and specification of your own gearbox It should be noted that there are two lines of numbers The top line is the gearbox serial number and should always be quoted when ordering spare parts the lower line is t
54. ment is not achieved In the majority of boats whose hulls are rigid enough to prevent excessive flexing in heavy sea conditions which could cause the engine and transmission to shift relative to the propeller shaft it is generally considered preferable to couple the propeller shaft direct to the gearbox output flange by means of a rigid coupling The two main conditions when a flexible coupling should be used are a In boats whose hulls are not sufficiently rigid to prevent the flexing referred to above b In cases where the engine is mounted on flexible mounts In both instances the flexible coupling helps to isolate engine vibration or other movement from the propeller shaft thus enabling correct alignment with the propeller shaft and stern tube to be maintained Whether a solid or flexible coupling is used it is extremely important that the following points are carefully checked l The coupling should be a tight press fit on the shaft and the keyway accurately made to the correct size li The two halves of the coupling should be carefully aligned This should be done by bringing the two flanges close enough together so that a feeler gauge can be used to check the vertical and horizontal alignment lil Alignment should only be carried out with the boat afloat The maximum permissible misalignment being 0 05mm Since the propeller shaft line is normally fixed in the boat alignment is usually obtained by adjusting engine mount shi
55. ms on the mounts themselves NOTE Whenever possible the engine and gearbox should be installed whilst the hull is afloat otherwise there is a danger of the hull distorting because of insufficient support over its surface If the engine and transmission are fitted before the hull is in the water the installation should be very carefully re checked for alignment after launching In designing PRM1750 SAE standards were adhered to as far as possible However other manufacturers of similar sized transmissions have a different but common output coupling spigot which is not to SAE This spigot size has become the industry standard and most proprietary flexible output couplings are made to suit 5 7 Installation Angle The transmissions should normally be installed so that the maximum fore and aft angle relative to the water line does not exceed 17 C with the boat at rest Please consult Newage Transmissions Ltd if installation angles greater than this are required 23 5 8 Twin Installation The rotation of the propeller even in a single engine installation tends to have a slight turning effect on the handling of the boat but this can normally be corrected with very slight adjustments on the rudder In twin installations the turning effect on the handling of the boat will be much more pronounced if both propellers rotate in the same direction It is therefore desirable that handed i e counter rotating propellers be fitted
56. ng at the correct attitude to provide the output shaft offset and insert the gearbox input shaft into the centre of the coupling it may be necessary to rock the shaft slightly to ensure that the shaft enters Press the assembly fully into position align the mounting holes in the adaptor flange with those on the flywheel housing and tighten fully See torque chart page 34 Oil Cooler All Newage PRM1750 gearboxes must be fitted with an oil cooler to maintain correct working temperature 50 80 C To permit a suitable cooler to be fitted two 3 8in BSP connections are provided on the valve block NOTE These are blanked off with plastic Redcap plugs on delivery from the factory A CAUTION Failure to correctly install an oil cooler into the lubrication circuit can result in damage to the gearbox see figs 8 amp 9 for correct circuit After a gearbox failure it is extremely important to flush the cooler and hoses completely to remove any contamination Failure to do so could result in the new repaired gearbox failing prematurely The gearbox oil cooler is normally mounted on the gearbox adaptor flange or the bulkhead of the boat and then connected into the cooling system on the engine one method of arranging the engine and gearbox cooling circuit is shown at Fig 8 NOTE Cooling water must pass through gearbox cooler before engine cooler 21 Heat Exchanger and Header Tank Discharge s Down Exhaust Pipe
57. nit slightly in order to disengage the input shaft spline from the internal spline in the coupling and lift clear 34 10 5 10 Overhauling The Input amp Layshaft amp Clutch Assemblies Remove gearbox from boat as described in section 10 4 Referring to Drgs WM2 and 6 remove 6 bolts and washers securing the oil pump and withdraw pump with its shims and gasket Note Retain shims with pump Referring to Drgs WM1 8 and 9 3a If cover D14 is fitted undo 6 hexagon screws and remove cover with gasket and shims Retain as a set or 3b If 209Nm 199 is fitted undo 4 cap screws remove P T O End Cover Assy and unscrew but do not remove cap screw K41 in centre of unit Undo 4 cap screws holding P T O Body K6 onto P T O Housing K2 Remove P T O assy and shims K43 on end of cap screw K41 Housing K2 with its gasket and shims can now be removed by releasing 4 nuts K45 Retain parts as a set or If 640Nm MT8279 is fitted undo 4 cap screws 110 and remove P T O Remove P T O support bracket if required Release 4 nuts L8 and remove housing L2 with gasket and shims Retain as a set Case can now be split by removing screws retain 2 dowels The shaft assemblies can now be removed from box for inspection Clutch Assembly Overhaul Referring to Drgs WM1 and 2 using a pulley extractor located behind the pinion withdraw the pinion taper roller bearing and various bearings and spacers Remove cir
58. opeller Emergency Operation Routine Maintenance Initial Maintenance Daily Checks Annual Checks Winter Storage Outer Maintenance Operations Fault Finding Servicing amp Repairs Seals Bearings Cleaning Inspection Inspection Gearcase Inspection Gears SECTION 9 4 3 9 4 4 9 4 5 9 4 6 10 10 1 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 8 1 CONTENTS Inspection Bearings Inspection Clutch Plates Clutch Components Inspection Threaded Parts Servicing amp Repair Procedures Valve Block Oil Pump Oil Strainer Removing the Transmission Overhauling the Inout amp Lay Shaft Overhauling the Clutches Replacement of Piston Rings Servicing of Secondary amp Output Shafts Deep Case Shallow Case Shimming Procedures Shimming Input amp Lay Shafts Micrometer Method Shimming Input of Lay Shafts Feeler Gauge Method Shimming Secondary amp Output Shafts Feeler Gauge Method Shim Sizes Available Power Take Off Units P T O Descriptions P T O Specifications Fitting Hydraulic Pump Retro fitting of P T O s Suitable Valve Blocks for P T O Retro fitting of 209NM Retro fitting of 640NM P T O Trolling Valve Description Trolling Valve Specification Retro fitting of Trolling Valve Tool Kit amp Applications Tightening Torques Replacement Parts Ordering PAGE NO ILLUS NO Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig
59. ovides a positive neutral position ensuring correct selection of either ahead or astern drive The standard fit valve block is of soft shift design When using a P T O or trolling valve a special valve block is to be used instead 15 3 4 Neutral Safety Starter Switch A neutral safety start switch which prevents the engine from being started unless the gearbox is in neutral is fitted as standard This device is of obvious benefit since it will help prevent accident or damage caused by a boat moving ahead or astern on engine start up in a crowded marine or other area The switch is located on the valve block refer to Drg WM7 1 item J8 and should be wired into the starter circuit as shown in Fig 5 1 Start key switzh 2 Starter push switch 3 Neutral safety switch d motor Fig 5 Wiring diagram neutral safety switch 16 4 OPERATING SYSTEM 4 1 Output Rotations With the control lever at the mid point of travel or neutral position and the engine running the splined input shaft and the clutch gear rotate at engine speed The clutch gear is in constant mesh with the clutch gear on the layshaft which is therefore also driven at engine speed but in the opposite rotation Since neither clutch is engaged the drive pinions do not rotate When the control lever is moved to the ahead position the hydraulic system is actuated and oil is directed at high pressure to the clutch on the appropriate shaft
60. p replace 29 gt Excessively high oil temperature Oil level needs constant topping up Escape of pressure from gearbox when checking oil level etc oil leaks Difficult to move single lever control No neutral Power too high Defective oil cooler or cooler too small Oil level too high low Incorrect oil type Defective oil pressure relief valve Slipping clutches Oil leaks Excessive internal pressure Control lever on valve block too stiff Faulty installation Control system not moving gear lever correctly Seized or dragging clutch Incorrect engine rating for gearbox Damaged or blocked oil cooler incorrectly specified cooler size Damaged or collapsed relief valve spring Worn clutches low oil pressure Defective oil seals 0 rings or gaskets Defective oil cooler amp hoses Defective breather causing leaks past oil seals Defective valve or detent spring Remote control operating cable badly installed or kinked Incorrect control cable set up Clutch badly worn or seized causing permanent engagement of a direction Re assess engine power Replace oil cooler or re specify cooler size Fill to correct oil level on dipstick Fill with correct oil type Remove amp examine valve spring Replace if necessary Replace defective clutch see remedy for low oil pressure Clean the outside of the gearbox particularly around output shaft and
61. riods that correspond to the intervals at which engine oil changes are carried out The gearbox oil should also be changed if it has been contaminated by water or if the gearbox has suffered major mechanical damage 28 FAULT FINDING The following fault finding chart is designed to help diagnose some of the problems that might be encountered It assumes that the installation and operating instructions in this manual have been followed and we advise that these are checked before proceeding to fault finding REFER TO SYMPTOM CAUSE REMEDY DRG NO No drive ahead or astern Intermittent or complete loss of drive Propeller speed does not increase with engine speed ahead or astern Propeller speed does not increase with engine speed in one direction only Excessive noise from gearbox at low speeds Excessive noise throughout operating range Excessive vibration throughout operating range No oil pressure Oil leaks lack of oil Low oil pressure to both clutches Low oil pressure to one clutch Engine idle speed too low Torsional vibration Defective input coupling Propeller shaft misalignment Propeller out of balance Engine gearbox misalignment Damaged oil pump Broken layshaft Broken input drive plate Broken Input shaft Broken output shaft Damaged oil seals or gaskets low oil level Damaged or worn oil pump Remote control cable not allowing correct gearlever movement Pre
62. ssure relief valve defective Piston rings or 0 ring worn Damaged clutch plates Blocked feed in valve Faulty adjustment hydraulic Torsional incompatibility of driveline components Input coupling worn or damaged Hull flexing or fault installation Propeller damaged or badly machined Defective bearing Remove oil pump amp replace complete Replace layshaft S A Replace input drive plate Replace input shaft S A Replace output shaft S A WM1 WM2 WM13 WM6 WM7 WM1 WM2 WM7 Check leakage area and replace relevant gasket or seal Re fill to correct level on dipstick Replace oil pump complete Remove cable and operate lever by hand adjust cable if necessary Remove valve replace spring block and Remove appropriate clutch shaft replace worn piston rings 0 rings Remove amp examine appropriate clutch amp replace if necessary Remove examine valve block and Increase idling speed If not cured by increasing engine idling speed refer to engine supplier Remove examine amp replace input coupling if necessary Check the alignment of the propeller shaft coupling If necessary rectify by adjusting shims under the engine mounts or engine mounts themselves Check pitch weight diameter amp balance of propeller Hemove transmission amp check flywheel face is flat or flexible coupling is correctly aligned see section 5 3 Isolate defective bearing am
63. tached to the flywheel housing reposition the stylus so that it is perpendicular to the face of the flywheel register D on Fig 7 Rotate the flywheel through one complete revolution and note the deviation this should not exceed 0 125mm 0 005in total indicator reading Flywheel Housing Fig 7 Checking the flywheel and flywheel housing 20 5 5 Mounting the Gearbox to the Engine CAUTION Failure to carry out the following mounting instructions correctly can cause vibration that could result in component or gearbox failure Taking care to ensure correct alignment bolt the adaptor flange to the front of the gearbox the maximum misalignment allowable between the adaptor and the gearbox is 0 002in 0 05mm Using an alignment mandrel if available mount and bolt the flexible input coupling to the flywheel via the holes provided If the flywheel and couplings are to SAE standard the outside diameter of the coupling should be a close fit in the flywheel register If no mandrel is available tighten the mounting bolts just sufficiently to prevent free movement assemble the gearbox to the coupling and rotate the engine two or three revolutions by hand to align the plate Tighten up two or three opposite bolts using the inspection window provided in the gearbox adaptor flange Remove the gearbox and fully tighten the flexible input coupling bolts Offer up the gearbox and adaptor to the input coupling and engine flywheel housi
64. the clutch engages and engine drive is directed to the forward drive pinion The pinion turns the gear on the output shaft and the propeller shaft and propeller are rotated in the direction corresponding to ahead movement 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 the opposite direction and the propeller shaft and propeller rotate in the direction corresponding to astern movement of vessel GEARBOX OUTPUT ROTATION Operating Lever Backwards Operating Lever Forwards NOTE i Rotations are as seen looking from the propeller forward to the gearbox ii Engine must be ACW looking on flywheel 4 2 Hydraulic System Oil is pumped from the gearbox sump through the internal supply pipe to the control block This incorporates a high pressure valve which ensures that the correct operating pressure is maintained When the operating lever is moved oil is delivered under pressure to a feeder on either the input shaft or the layshaft and thence to a piston which actuates the appropriate clutch for either ahead or astern drive Excess oil is then used for lubricating the gearbox also the angle drive and PTO if fitted 17 KOK et E E E EE E gt OL COOLER LEM NM M K we K K CONTROL VALVE CLUTCH MB g
65. the transmission This allows the propeller to turn freely with the engine shut down and makes the Newage PRM1750 particularly suited for use in motor sailers or multi engine installations where the boat may be operated with one or more engines shut down It is not therefore necessary to provide any propeller shaft locking device to protect the transmission Where propellers are allowed to free wheel they can be a useful source of free auxiliary power if a flat pulley is fitted to the propeller shaft a small generator can be belt driven for charging batteries AN CAUTION Care must be taken not to apply excessive side load which would cause vibration and misalignment 26 6 4 Emergency Operation Included as standard in every Newage PRM1750 gearbox is a Get You Home device allowing the gearbox to be mechanically locked in ahead drive in the unlikely event of hydraulic clutch failure WARNING To operate first switch off the engine select neutral on the operating lever and disconnect the operating cable then The method of operation is as follows 1 Decide which shaft requires locking up On single installation ahead will require the input shaft clutch locking providing that shallow type boxes are fitted with an RH propeller and deep type boxes are fitted with a LH propeller as per normal practise Twin installations will obviously require the port side box locked on one shaft and the starboard box locke
66. valve block inspect for leaks Check for traces of water in the gearbox oil or oil in the cooling water system Replace cooler or hoses as necessary Contact distributor or factory for advice Contact distributor or factory for advice Check the installation and eliminate all tight bends in the cable Check cable installation Check clutch and replace as necessary WM7 WM1 WMe2 WM 3 12 WM7 WARNING Before carrying out any service work always ensure that the engine is switched off and disconnect the operating cable from the gearbox CAUTION The above operations should be carried out by suitably qualified personnel and strictly in accordance with the procedures detailed in the workshop manual 30 9 SERVICING AND REPAIRS GENERAL WARNING Do carry out any servicing or repair work without first switching off the engine and disconnecting the control cable Before removal of the gearbox for repair or overhaul carefully study the following procedures Use proper hand tools slings or hoists for the job WORK SAFELY Keep all work areas tools and gearbox clean Wipe up any spilled oil or fluids to prevent accidents Wear correct safety equipment i e safety glasses and safety shoes to guard against personal injury Remember HOT OIL CAN CAUSE BURNS WORK SAFELY USE COMMON SENSE Drawings showing all internal components are contained in the parts lists See page 5 9 1 Seals Remove oil seals c
67. ywheel Ratings have been established to ensure the long trouble free lift of the gearbox and should not therefore be exceeded SERVICE CLASSIFICATION DEFINITIONS Pleasure limited to planning hull pleasure craft with a maximum of 500 hours operating time per year of which not more than 5 should be at full engine throttle with the balance of usage at 90 or less of full throttle The use of PRM marine gearboxes according to this classification in any commercial boat or in sport fishing charter boats or long range pleasure cruisers is not approved Light commercial planning or semi displacement craft used in pleasure or commercial application may qualify for light commercial rating if annual usage is less than 1500 hours and full throttle operation is limited with most operating time at partial throttle Heavy commercial all displacement and semi displacement craft used for commercial applications should be classified as heavy commercial duty In this type of vessel such as trawlers purse seiners lobster and crab boats tugs ferries offshore supply boats etc the gearbox is expected to work at full governed engine speed The power setting of the engine must be known and must be within the permitted heavy commercial rating of the gearbox 10 IMPORTANT NOTE 1 It is essential that the engine transmission model reduction ratio and propeller size are correctly matched so that the engine can attain its rated speed appropriate to the

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