Workshop manual Pentruder 8-20 HF Saw head ( )

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1 Index: Removing the arm...2 Removing the Slip clutch...5 Removing the gearbox assembly...7 Removing the arm feed gear...13 To remove the feed and travel motors...18 Dismantle the gearbox...26 Assembly...35 Fitting index mechanism...46 Fitting gearbox to chassis...51 Dismantle the arm...62 Assembly of the arm...73 Fitting the arm...89 Fitting travel and feed motors...93 Fitting the arm feed gear Fitting slip clutch

2 Removing the arm 1. Remove the alloy plug to drain out oil from the arm. 2. Remove the eight M8 screws, O rings and washers from the arm 2

3 3. Lift off the arm. 3

4 4. Remove the packing ring and the O ring. 4

5 Removing the Slip clutch 1. Using the special tool, remove the slip clutch cover. 5

6 2. Using the special slide hammer draw out the slip clutch. 6

7 Removing the gearbox assembly 7

8 1. Remove the 3 locking tab screws. 8

9 2. Remove the locking tab; this may be a little tight on dowels. 9

10 3. Using the special C spanner undo the locking ring (counter clockwise) 10

11 4. When the locking ring is free enough you can use two 12mm pins to rotate the locking ring out of the chassis. 11

12 5. Lift out the gearbox assembly. 12

13 6. More oil will come out from the arm feed motor cavity. Removing the arm feed gear 13

14 1. Remove the two M8 screws. 2. Using a slide hammer draw off the cover. 14

15 3. Lift out the pin and gear, take care as the individual needle rollers can drop out. 15

16 16

17 4. Using special tool unscrew the cover on other side of chassis 5. Remove the arm feed gear. 17

18 To remove the feed and travel motors 1. Remove the 4 screws from the connector plug 18

19 19

20 2. Disconnect the cables and remove the connector plug. 3. Unscrew the two blade guard cones. 20

21 4. Unscrew the two M6 screws from each of the motor covers. 5. Unscrew the M8 screws from the two towers. 21

22 6. Carefully lift up motor cover and towers, feed through the cables. 22

23 7. Gently tap off the towers from the steel tube to feed the cable through. 23

24 8. Lift off the travel motor cover. 9. Remove the locking screws from the motors. (two in each) 24

25 25

26 10. To remove the travel motor rotate the travel gear and lift out the motor, the feed motor can just be lifted out. Dismantle the gearbox 26

27 1. Remove the M4 grub screw with a 2mm Allen key from the index knob. 2. Remove the four Torqx screws (T15) 27

28 3. Pull out index gear 28

29 4. With the aid of a screwdriver move the selector rod to the neutral position. (Output shaft should rotate freely) 5. Using a pair of levers withdraw output shaft, the steel balls may fall out of the shaft. 29

30 6. Lift out the two loose gears (3 rd and 4 th ) 30

31 31

32 7. Turn over the gearbox housing, support on some suitable blocks and press out the input shaft, take care not to drop the shaft and final two loose gears on the floor. 8. Input shaft with 1 st and 2 nd gear. 32

33 9. If the bearings are to be replaced evenly warm up the housing and they should fall out otherwise some even pressure from behind. 33

34 10. If the ring gear is to be replaced remove the 12 screws and evenly push off the gear, warm up a new gear to about 200 deg C and fit to housing, line up and fit the 12 screws quickly. 11. After cooling check that the gear and housing are parallel with each other, maximum run out is 0.03mm, check that the screws are tight. 34

35 Assembly 1. Fit bearing race and thrust washer (not sided) 35

36 2. 1 st gear, fitted in this direction to the gearbox housing. 36

37 3. Put 1 st and 2 nd gear into the housing. (2 nd gear orientation not important) 37

38 38

39 4. Place in the input shaft and lift up 1 st and 2 nd gear so they mesh to the input shaft. 5. While holding the gears in mesh press in the input shaft until seated. 39

40 6. Third gear orientation not important (left), 4 th gear to be fitted in this direction. 40

41 7. All gears in place ready to fit the output shaft. 41

42 8. Apply some grease to the holes on the output shaft 9. Fit the selector shaft into the output shaft, it should be placed in a neutral position so that the steel balls will sit in the shaft. 42

43 10. Steel balls fitted (12) all flush with the shaft. 11. Place the shaft assembly into the gears. 43

44 12. Press in the shaft until seated. 44

45 13. Check that the shafts rotate freely. 45

46 Fitting index mechanism 14. Engage 4 th gear, selector shaft should be flush with the end of the output shaft, shafts may have to be rotated to engage gear. 46

47 15. Arrange the index shaft so that the index mark and the indent on the shaft are in this position. 47

48 16. Fit the index assembly into the gearbox housing in this position. 48

49 17. Fit the 4 screws 18. Fit the gear knob in the position shown, take care that the screw locates with indent. 49

50 50

51 Fitting gearbox to chassis 1. Apply oil to the ring gear face

52 3. Fit one of the white nylon rings 4. Apply more oil 52

53 5. Fit O ring and apply some grease to chassis 53

54 6. Supporting the two shafts lower the gearbox assembly into the chassis, take care that the nylon ring stays in place, push down firmly to seat. 7. Liberally apply oil to the other nylon ring and fit. 54

55 8. Apply oil to the bearing strip 55

56 9. Grease and fit the O rings to the bearing support ring, fit the bearing strip. 56

57 10. Apply oil to the threads 11. Carefully locate in the chassis 12. Using two 12mm pins screw in the bearing ring, take care that the O rings stay in place and are not damaged. 57

58 13. Using the special tool tighten down until it has bottomed out then back off almost 1 hole, check that the gearbox rotates in the chassis. 58

59 14. Apply a bead of Loctite 518 between ring and chassis, wipe away excess. 59

60 60

61 15. Fit the locking plate 61

62 Dismantle the arm 62

63 1. Remove the blade guard support ring by removing one of the rollers. 63

64 2. Remove the eight screws from the seal carrier. 64

65 3. Carefully tap the seal carrier free from the arm. 65

66 4. Lift out the water seal 66

67 5. Using the special tool draw off the inner sleeve 67

68 6. Support the arm on suitable blocks, using a spacer press out the spindle unit. 68

69 7. Remove the four screws from the bearing spigot. 69

70 8. Press out spigot 70

71 9. Remove the four screws from the intermediate gear spigot 71

72 10. Fit two longer screws and carefully tap the spigot free. 72

73 11. Remove the intermediate gear and spacer Assembly of the arm 73

74 12. Gently heat up the arm to remove and install the bearings, make sure bearings are fitted before fitting intermediate gear. 13. Apply grease to thrust washer to help it stay in place 74

75 75

76 14. Carefully place the intermediate gear into position without dislodging the washer 15. Apply some grease to aid fitment of the spigot 76

77 16. Fit two M6 pins to the spigot so it will be pressed into the correct position. 77

78 17. Press in until seated taking care not to damage O rings. 18. Remove the guiding pins. 78

79 19. Fit the four screws with Dowty washers, fit dowels and O rings. 20. Fit two M4 guide pins and grease to help fitting of spindle spigot. 79

80 21. Evenly warm up the arm around spindle area. 80

81 22. Fit the O ring 23. Fit the spigot shaft in direction shown. 81

82 24. Press in spigot 25. Tighten screws. 82

83 26. Lubricate seal and fit in direction shown. 83

84 27. Lubricate spigot 84

85 28. Place the spindle unit in position 29. Press the unit into the arm until seated. 85

86 86

87 30. Fit O ring and seal, lubricate liberally with waterproof grease. 31. Fit seal housing and tighten screws. 87

88 32. Fit the blade guard support ring 88

89 Fitting the arm 89

90 1. Grease and fit O ring 2. Grease the nylon packing ring, recessed side to go over O ring. 90

91 91

92 3. Line up arm over the chassis, make sure that dowels and O rings stay seated. 4. Fit O rings and washers to screws. 92

93 5. Fit the eight screws and tighten down. Fitting travel and feed motors 1. Fit O ring and lubricate motor, note position of fixing holes, fill the motor cavity with 60ml oil. 93

94 2. Hold motor in correct position and lower into chassis 3. Turn the travel gear to mesh with the motor, push the motor fully down. 94

95 4. Fit the locking screws, (2 in each motor) 95

96 5. Fit the extension cables to the travel motor, fit the O ring to the motor cover and feed through the cables. 96

97 6. Fit the O rings to the towers and feed through cables 97

98 7. Fit the steel tube 8. Feed cables through other tower and feed motor cover. 98

99 9. Loosely screw in the tower screws 99

100 10. Gently tap each of the towers to seat the steel tube, take care not to damage the O rings 11. Check that the O rings are still in position on the motor covers 100

101 12. Fit the two screws to the motor covers (one short and one long) have the cables so they are protruding through the motor cover 13. Tighten down the towers. 101

102 14. Connect the cables to the connector 102

103 15. Position the connector with the location tab at the top, fit screws. 16. Use a spacer 8-10mm to fit cones 103

104 104

105 Fitting the arm feed gear 1. Fit the 15 needle rollers, axle pin and the thrust washers to the gear with grease. 105

106 2. Fit the gear into the chassis, you may have to move the arm to mesh the gears. 3. Tilt the chassis and pour in the oil ( approx 100ml) 106

107 4. Remove the locking screw to let the air out while filling. 107

108 5. Tap on cover 6. Tighten screws. Fitting slip clutch 108

109 1. Place the slip clutch on the input shaft 2. Tap down the slip clutch until seated 109

110 3. Fill with 30ml oil 110

111 4. Fit and lubricate O ring and seal, grease threads. 5. Fit over slip cluch 111

112 6. Tighten with special tool 112

113 7. Fill the arm with 500ml oil 8. Fit the plug and washer. 113

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