300R & 400R WORKSHOP MANUAL WINGET LIMITED PO BOX 41 EDGEFOLD INDUSTRIAL ESTATE PLODER LANE BOLTON LANCS BL4 0LS Tel:-++ 44 (0) 1204 854650 Fax:- ++ 44 (0) 1204 854663 service@winget.co.uk parts@winget.co.uk www.winget.co.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 CONTENTS Section 1 Introduction Section 2 Repair and Service Procedures Section 3 General Arrangement Dimensions Section 4 Service Schedules Lubrication Diagram Section 5 Hydraulic Circuit Diagrams Section 6 Wiring Diagrams Section 7 Noise Levels Section 8 Special Tools Section 9 Hydraulic Control Valve Service Manual (Where available) Section 10 Parts Listings Section 11 Batchweigher Maintenance Instructions
WORKSHOP MANUAL 300R & 400R SECTION 1 INTRODUCTION
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Introduction The following procedures should enable experienced service personnel to strip, repair and rebuild Winget 300R and 400R Reversing Drum Concrete Mixers in a safe and competent manner. The procedures are not intended to be used by personnel who are unfamiliar with the product nor mechanically inexperienced.
WORKSHOP MANUAL 300R & 400R SECTION 2 REPAIR & SERVICE PROCEDURES
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Lifting Points Lifting Points capable of supporting the weight of the Mixer are incorporated in both of the Water Tank Supports just below the height of the Drum Top Guard. The Lifting Points are highlighted with an ISO ‘Hook’ symbol adjacent to each Point. On Military/Nato mixers the Lifting Points are also painted white. The Hopper also incorporates Lifting Points to assist in removing the Hopper.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Anti-Bounce Bracket An Anti-Bounce Bracket is fitted between the L/H side of the Hopper Cradle and Mainframe whilst transporting the mixer to prevent the Hopper bouncing and causing damage to the Batchweigher Loadcell and other components. One end of the Hopper Anti-Bounce Bracket is bolted to the Hopper Cradle, the other end is retained by the Jack Leg retaining pin.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Wheels – Steel Steel wheels are retained to simple stub axles using a collar retained by a single cross bolt. To remove the wheel, jack up the machine, remove the bolt, remove the collar and lift the steel wheel clear. Reverse the procedure to refit coating the shaft, bore of he steel wheel and collar with copperslip.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 circlips and using a suitable drift, knock the shafts through the bearings and out of the rollers. Drift the bearings out of the rollers. Using a sharp instrument remove the seals from the new bearings and pack the bearings with clean good quality grease, replace the seals. Reassemble in reverse order taking care not to forget the ‘V’ seals.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Release the Engine/Fuel Tank Cover from the Right Hand Water Tank Support, if a UK step is fitted, separate the top step from the rest of the step assembly. Unbolt both Water Tank Supports and lift clear using suitable lifting equipment. Unbolt and lift off the Drum Top Guard. Attach suitable lifting gear to the Drum Assembly (The Drum weighs approximately ¾ tonne when clean) and lift out of the Mainframe.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Remove the Inspection Covers from each side of the Drum Housing. Block up the Drum taking the weight off the Roller Assemblies or support the weight of the Drum using suitable lifting equipment.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Idler Roller/Drum Drive Pinion L/H Whilst it is recommended that the Drum is removed to enable the Roller Assemblies to be replaced it is possible to remove the Rollers and Drum Drive Shaft with the Drum in situ provided care is taken. Remove the Water Tank or Flowmeter and the Drum Edge Rollers as described previously. Remove the Inspection Covers from each side of the Drum Housing.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Refit the Edge Rollers and Water Tank or Flowmeter as described previously. Run the mixer, check the operation of the Drum coating the Rollers/Gear with open gear lubricant. Stop the engine and replace the inspection covers. Drive Chain Adjustment The Drive Chain is located behind the cast cover on the front of the Mainframe. The cover contains an inspection aperture through which the Chain Tension can be checked.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Start the engine, running the drive train checking for unusual noises. Adjustable Bearing Bracket/Lower Drive Shaft Remove the Chain Cover, Drive Chain and Lower Sprocket as described above. Remove the L/H inspection cover, disconnect the Propshaft between the Gearbox and Lowe Drive Shaft.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Refit the Adjustable Bearing Bracket, proposhafts, Lower and Upper Sprockets not forgetting the bolts securing the Bearing Carrier Drive Chain and Chain Cover. Top up with oil, run, test the mixer and check for oil leaks.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Gearbox from the Mainframe, using suitable slings and lifting equipment lift the Gearbox clear of the Mainframe. Reassemble in reverse order ensuring the centreline of the Engine and Gearbox are in line by shimming as necessary to avoid straining the Couplings and Flanges. Engine Removal On Electrical Start Diesel and machines fitted with a Dragline and Alternator, isolate the Battery and disconnect the wiring.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Controls. Stop the engine and allow the oil in the Tank to settle for approximately two minutes before rechecking the level. Note: The Hydraulic Systems holds approximately 22 Litres (5 gallons) of oil. Located on the top of the tank is the Bleed Valve which allows oil discharged from the single Acting Hopper Ram (as the Ram lowers the Hopper) to bleed back into the tank.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Hopper Ram & Restrictor Lift the Hopper and support with the Safety Chain provided. Disconnect the ¼ bore hose leading from the Header Tank to the Ram cylinder and plug the hose to prevent oil loss. Remove the bolt retaining the Upper Pivot Pin through the Hopper Cradle and knock out the pin. Do not lose the Washers placed each side of the Ram Eye.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Hose Failure Valve Machines bearing the “CE” mark indicating compliance with the EC Machinery Safety Directive have a Hose Failure Valve fitted to the Ram Inlet/Outlet port in addition to the restrictor.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Attach the lifting equipment to the Hopper Cradle, raise the Cradle to allow removal of the upper Ram pivot pin, lower the Cradle. Remove both Link Arms and the Link Shaft which passes through the Cradle, lift the Hopper Cradle clear. Reassemble in reverse order. Pivot Shaft The Pivot Shaft is retained in the “A” frame by two grubscrews one each end of the Shaft.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 2) 3) 4) 5) 6) 7) Hopper resting on ground or build up of waste material below Hopper. Ensure at least 50mm (2”) clearance between the ground and Hopper. Build up of material around the Hopper Cradle Link Shaft. Worn Hopper Cradle Pivot Bearings. Loadcell Striker guide fouling Mainframe or failing to rotate freely. Worn Loadcell Striker Pin.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Reassemble in reverse order coating the Pivot Pin with copperslip, and ensuring the Guide rotates freely and does not foul either side of the Mainframe. Feed Apron Two or Three Compartment Feed Aprons are designed to assist the flow of materials into the Hopper in conjunction with a Dragline.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 2) 3) 4) 5) 6) 7) Dirty or loose electrical connections at the Plug and Socket, at the Solenoid Valve, at the Alternator or Battery. Bad Earth Connections. Worn or badly adjusted “V” Belt. Worn or dirty Alternator Brushes. Failure to turn on the Isolator Switch before starting the Engine or Motor. Flat Battery.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Remove the Terminal Block, Connect a D.C. Voltmeter to the Terminal Block and start the engine. Depress the Shovel mounted Button/witch and note the voltage reading it should not exceed 14.5 volts. If the Voltmeter indicates a negative reading or reads in the reverse direction interchange the Voltmeter leads.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Dragline Solenoid Valve The Dragline Solenoid Valve contains no user serviceable parts, and if checks of the electrical system indicate it is faulty it must be replaced. Oil leaks between the Valve and Control Block indicate the failure of the small ‘O’ rings which can be replaced following removal of the Solenoid Valve which is retained by four socket headed capscrews.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 If the Control Lever is operated to lower the Hopper, the weight of the Hopper displaces oil out of the Cylinder, pressure in the circuit is not sufficient to retain the Ball on its seat and oil returns to the tank via both the Bleed Valve and Control Valve.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Should for any reason the Motor jam or seize in operation the Relief Valve in the Distribution Block should “Blow off” dumping the oil down the return line via the tee piece back into the tank. Relief Valve Adjustment Main Relief Valve With the Engine or Electric Motor at rest and the Hopper fully lowered ensure no residual pressure remains in the hydraulic system by operating the hydraulic control lever a number of times.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 with length of hose but without the tee piece, this will form a ‘dead head’ within the circuit as the oil can go no further than the gauge. Operate the Dragline Isolator Switch (handstart and electric machines only).
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 The Water Inlet Valve consists of a Body and Cover sandwiching a Brass and Rubber Diaphragm. The Cover is machined to carry the sprung Pilot Valve. Water enters the Valve Body through the Strainer filling the chamber acting on the rear rubber face of the Diaphragm, causing the Diaphragm to stretch and lift off its seat and allowing water to enter the Tank.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 4) 5) Water Flow failing to stop when Pilot Valve closed – ruptured Diaphragm, worn or perished Pilot Valve “O” ring, worn Pilot Valve, weak Pilot Valve spring or blocked orifice. To high a water pressure causing the Diaphragm to rupture or stretch Strainer Replacement Turn off the water supply. Remove the hexagonal plug from the strainer body, lift out the strainer, clean or renew.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Discharge Valve and Rubber Seat Turn off the water supply, drain and remove the Tank. Remove the Water Outlet Pipes from the base of the Tank retrieve the Rubber Seat. Slacken the locknut slightly and unscrew the Discharge Valve Rod from the Connector attached to the Operating Lever, remove the Discharge Valve and Rod through the opening in the Tank base. Knock out the Roll Pin securing the Discharge Valve to the Rod.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 5) Set the Pointer to the 5 gallon mark on the Graduated Scale and tighten the wing nut. Turn on the water supply and proceed to fill the Tank through the Inlet Valve. When the Float trips the Lever shutting off the flow of water into the Tank, turn of the water supply, open the Discharge Valve discharging the water into the collection tank.
WORKSHOP MANUAL 300R & 400R SECTION 3 GENERAL ARRANGEMENT DIMENSIONS
GENERAL ARRANGEMENT ON LATER MACHINES THE DRAGLINE WINCH IS RELOCATED TO THE CENTRE OF THE MAINFRAME IN FRONT OF THE WATER TANK AND THE DRAGLINE JIB IS NOT REQUIRED (ON OPPOSITE SIDE OF TANK) ON LATER MACHINES THE DRAGLINE WINCH IS RELOCATED TO THE CENTRE OF THE MAINFRAME IN FRONT OF THE WATER TANK AND THE DRAGLINE JIB IS NOT REQUIRED
DIMENSIONS ALL STATED DIMENSIONS ARE APPROXIMATE AND CANNOT BE GUARANTEED DUE TO OUR POLICY OF CONTINUOUS PRODUCT IMPROVEMENTS AND IMPROVEMENTS IN SPECIFICATION
WORKSHOP MANUAL 300R & 400R SECTION 4 SERVICE SCHEDULES LUBRICATION DIAGRAM
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Service Schedule The engine will require additional services or adjustments in addition to those listed below. (See the appropriate Engine Operators Handbook or Workshop Manual) Daily: (8) Hours Before Work Lubricate all grease points. Check fuel and lubricating oil levels. Check for oil and fuel leaks. Check/clean/replace air filter element, cup and baffle. After Work Top up fuel tank.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Hydraulic Oil Check level in main and header tanks. (with hopper down and engine stopped) Dynamo/Alternator Drive Check belt tension, adjust if necessary Controls and Pivots Battery Lubricate all levers, rods, pivots and pins with oil Check terminals, clean if necessary, top up Monthly: (100 Hours) The above and the following: Hydraulic Tank Check oil tank, filler and breather, clean if necessary.
WORKSHOP MANUAL 300R 400R WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 8 2012 Every 12 Months: (1200 Hours or earlier if conditions dictate) The above and the following: Hydraulics Ref: SHSC1216 Drain and clean out tank, suction strainer and filling filter, refill with clean hydraulic oil.
Note:- later mixers will not be fitted with all the Lubrication & Grease points shown as sealed for life roller bearings are used extensively where ever possible. Lubricate drum drive gears and drum track and roller contact surfaces using open gear lubricant on a regular basis, in some operating conditions the gears and track should be lubricated every 40 hours or weekly.
WORKSHOP MANUAL 300R & 400R SECTION 5 HYDRAULIC CIRCUIT DIAGRAMS
Hyd circuit.
Hyd. Circuit - RSeries Mixer (With dragline).
WORKSHOP MANUAL 300R & 400R SECTION 6 WIRING DIAGRAMS
YELLOW RED 5 LE C 5 4 2 1 4 2 3 14/0.30 14/0.30 65/0.30 35/0.30 35/0.30 TO AVOID BREAKING MOUNTING LUGS OFF THE REGULATOR CLEAN PAINT OFF THE FANSHROUD BOSSES AND ENSURE REGULATOR IS SEATED LEVEL ON BOTH BOSSES 5 35/0.30 65/0.30 6 4 START SWITCH RED (THICK) BROWN WHITE/RED RED (THIN) BLACK BLACK (BRIDGE WIRE) 3 14/0.
Hourmeter & lamp.
Hourmeter no lamp.
loom.
Alternator.
WORKSHOP MANUAL 300R & 400R SECTION 7 NOISE LEVELS
SECTION 7 NOISE LEVELS Noise Tests were carried out in accordance with EC Directive 79/113 on a 10 metre Hemisphere with the drum empty and rotating and in accordance with EC Directive 2000/14/EC again on a 10 metre hemisphere with the drum loaded and rotating. Operators Ear Tests were carried out at a distance 1 metre from the Drum and Hydraulic Control Levers at a height of 1 metre.
WORKSHOP MANUAL 300R & 400R SECTION 8 SPECIAL TOOLS
TOOL1.
TOOLS3.
TOOLS2.
TOOL.
WORKSHOP MANUAL 300R & 400R SECTION 9 HYDRAULIC CONTROL VALVE SERVICE MANUAL
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WORKSHOP MANUAL 300R & 400R SECTION 10 PARTS LISTINGS
The following Parts Illustrations do not contain a breakdown of assemblies such as Gearbox, Drum, Hydraulic Ram etc, only the complete items are shown.
400R MAINFRAME, TANK SUPPORTS AND COVERS FIT SPACING WASHERS V2004220 BETWEEN FUEL TANK SHROUD, ITEM 13 AND MAINFRAME TO AVOID DISTORTING SHROUD. RUN SILICONE SEALER ROUND REAR FACE OF PLATE, ITEM 20, PRIOR TO ASSEMBLY. RUN A BEAD OF SILICONE AROUND FLANGE FACE OF COVER, ITEM 19, ALLOW TO CURE FOR A SHORT TIME PRIOR TO ASSEMBLY. DO NOT FILL CHAIN CASE WITH OIL UNTIL SEALER HAS FULLY CURED.
400R MAINFRAME TANK SUPPORTS + COVERS 1 2 3 4 5 6 7 8 9 9A 10 12 12A 12B 12C 13 14 16 19 20 21 22 23 23A 24 26 26A 27 28 28A 29 29A 30 31 32 32A 33 34 35 36 37 38 39 40 41 41A 42 42A 43 555272300 555130600 555264802 555264801 555145700 555145600 V2003183 555189900 555190400 555163500 555131500 221101000 192S01 10S02 66S02A 555193100 555193200 555193400 555263900 555257800 555114700 555168100 127S03 100S03 V2000772 28S03E 6S03B 87S03 10S03 17S05 16S07C 17S03 236S04 90S06H 41S07 10S04 6S05Z 87S05 10S04 11S04
400R MAINFRAME TANK SUPPORTS + COVERS 44 45 46 46A 47 48 49 50 51 52 192S01 10S01 233S03F 267S03 7S01 17S02 11S03B 17S04 66S01BB 41S03 NUT BINX WASHER FLAT SCREW COUNTER SUNK WASHER FLAT NUT WASHER SPRING SCREW SET WASHER SPRING SCREW SET WASHER SPRING 1 1 6 6 6 6 7 7 4 4
400R FRONT AXLE, TOWBARS, AXLE SPRAGS AND JACKS COAT PINS AND WELDED BOSSES WITH COPPERSLIP ON ASSEMBLY COAT THREADS ON SPRAG SCREWS ITEM 63 WITH COPPERSLIP ON ASSEMBLY ITEM 2B, NATO TOWING EYE SHOULD BE CROSS DRILLED ON ASSEMBLY TO ENABLE FITMENT OF SPLIT PIN ITEM 2E
400R FRONT AXLE TOWBARS AXLE SPRAGS & JACKS 2 2A 2B 2C 2D 2E 3 5 6 6A 8 9 10 10A 11 17 37 38 40 55A 56 56A 57 63 64 65 555101200 555283300 555283600 150S15 92S15 44S18N 555101400 555101900 513354800 902S02 555287300 44S17K 8S03E 61S03 44S17K 555255700 10S20 10S43 10S65 555285600 555267800 124108001 555190500 555256200 555255900 44S05H BAR TOW-STANDARD BAR TOW-NATO/MOD EYE TOWING-NATO/MOD WASHER FLAT NUT CASTLE PIN SPLIT PIN PIVOT AXLE PIVOT BRACKET PIN RETAINING LYNCH PIN & CHAIN AXLE FRONT-STANDARD/NATO
400R PNEUMATIC WHEELS, HUBS & STUB AXLES IF THE AXLE CHANNEL SECTION IS PRODUCED FROM PARALLEL RATHER THAN TAPERED SECTION, SUBSTITUTE THE TAPERED WASHERS ITEM 20 FOR FLAT WASHERS 267S07 WHEN THE WHEEL IS ATTACHED TO THE HUB ROCK THE WHEEL TO CHECK FOR EXCESS HUB BEARING PLAY IF BOLT ITEM 22 FOULS JACK LEG SUPPORT BRACKET INSERT FROM OPPOSITE SIDE
400R HUB STUB AXLE AND PNEUMATIC WHEELS 1 15 20 21 22 23 24 25 26 26A 555287600 475600019 105S05 8S05M 8S05K 267S07 17S06 7S05 555226500 555287300 HUB & STUB AXLE ASSEMBLY (FAD) WHEEL ASSEMBLY WASHER TAPERED BOLT UPPER BOLT LOWER WASHER FLAT WASHER SPRING NUT PLAIN MAINFRAME AXLE FRONT-STANDARD/MOD/NATO 4 4 8 8 8 16 16 16 1 1
400R STEEL WHEELS AND STUB AXLE IF THE AXLE CHANNEL SECTION IS PRODUCED FROM PARALLEL RATHER THAN TAPERED SECTION SUBSTITUTE THE TAPERED WASHERS ITEM 20 FOR FLAT WASHERS 267S07 IF BOLT ITEM 22 FOULS JACK LEG SUPPORT BRACKET INSERT FROM OPPOSITE SIDE COAT SHAFT WITH COPPERSLIP ON ASSEMBLY
400R HUB STUB AXLE AND STEEL WHEELS 2 7 10 11 12 13 15 15A 19 20 21 22 23 24 25 26 511146701 150S15 555277900 6S03M 41S05 9S03 131S01 176S01 555288500 105S05 8S05M 8S05K 267S07 17S06 7S05 WHEEL STEEL, FABRICATED WASHER FLAT COLLAR BOLT WASHER SPRING NUT NIPPLE GREASE CAP NIPPLE AXLE STUB WASHER TAPERED (SEE NOTE RE 267S07) BOLT BOLT WASHER FLAT WASHER SPRING NUT CHASSIS-FRONT AXLE 4 4 4 4 4 4 4 4 4 8 8 8 16 16 16 1
400R NOISE REDUCTION KIT REFER TO THE ENGINEERING DRAWING WHEN DRILLING THE MAINFRAME AND PANELS TO SECURE THE CLADDING KIT.
400R NOISE REDUCTION KIT 80 81 82 83 555286500 61S02 10S56 11S02C KIT NOISE REDUCTION NUT BINX WASHER SCREW SET 1 30 30 30
400R 'CE' GUARDING
400R 'CE' GUARDING 1 3 555290700 555290800 GUARD HORIZONTAL GUARD ANGLED 1 1 4 4 555290900 555291000 GUARD ELECTRIC MOTOR-GEARBOX COUPLING GUARD LISTER TS2-GEARBOX COUPLING 1 1 10 11 12 13 14 7S03 17S04 267S05 V2004220 11S03C NUT WASHER SPRING WASHER FLAT WASHER SPECIAL SCREW SET 12 12 12 12 12 555131500 COVER RETAINED BY:11S03C 267S05 17S04 7S03 SCREW SET WASHER FLAT WASHER SPRING NUT 2 2 2 2
400R HOPPER ANTI BOUNCE BRACKET ATTACH ANTI BOUNCE BRACKET BETWEEN THE LEFT HAND SIDE OF THE HOPPER CRADLE AND MAINFRAME TO PREVENT DAMAGE TO COMPONENTS WHEN TRANSPORTING THE MACHINE
400R ANTI BOUNCE BRACKET 1 4 5 6 555288600 66S06D 104S06 41S09 BRACKET ANTI BOUNCE SCREW SET NUT WASHER SPRING 1 1 1 1
400R HYDRAULIC TANK ASSEMBLY THE BALL ITEM 9 SHOULD BE CORRECTLY SEATED WITHIN THE BLEED VALVE BODY ON ASSEMBLY, PLACE THE BALL INTO THE BODY WITHOUT THE SPRING THEN DRIVE THE BALL DOWN ONTO ITS SEAT USING A SOFT FACED PUNCH OR DRIFT. REMOVE THE BALL AND DROP THE SPRING INTO PLACE, ASSEMBLE THE VALVE AS ILLUSTRATED. IF NO DRAGLINE IS FITTED THE 1/2 BSP THREADED PORT ON THE TANK COVER SHOULD BE BLANKED OFF USING A 120S03 CAP, THE HOPPER RAM RETURN HOSE FROM THE HEADER TANK TERMINATES AT THE1/4 BSP PORT.
400R HYDRAULIC TANK ASSEMBLY 1 2 3 4 5 6 7 8 8A 9 10 11 12 13 14 20 21 22 23 24 25 26 27 31 555257900 555284800 555255600 555264000 555267100 10565A01 220591000 127S02 100S02 101120000 100S03 100S04 122S03 119S08 417735000 11S04C 7S04 17S05 11S02A 17S03 332719000 7S02 17S03 101S07E TANK HYDRAULIC COVER BODY BLEED VALVE GASKET BLEED VALVE SPRING BLEED VALVE BREATHER FILLER STRAINER PLUG TANK DRAIN SEAL BONDED BALL STEEL SEAL BONDED SEAL BONDED FITTING ADAPTOR, MALE, STUD FITTING ADAPTOR, MALE, STUD GASKET
400R REVERSING GEARBOX AND FITTINGS TO SET BACKLASH BETWEEN HYDRAULIC PUMP AND GEARBOX BEVEL GEARS, ASSEMBLE LOCATING RING AND GEAR ON PUMP AND OFFER PUMP UPTO GEARBOX WITHOUT SHIMS, MEASURE GAP BETWEEN PUMP AND CASTING AND ADD 5-8 THOU (0.02-0.20MM) TO MEASUREMENT OBTAINED TO GIVE CORRECT GEAR BACKLASH. ADD SHIM PACK EQUIVALENT TO TOTAL MEASUREMENT.
400R REVERSING GEARBOX AND FITTINGS 1 2 3 4 5 6 7 8 9 555268100 555107400 CONSISTS OF 1 X 555107401 1 X 555107402 2 X 555107403 6S05F 10S04 87S05 192S07 555106100 555107000 GEARBOX REVERSING SHIM PACKER SET 1 1 BOLT WASHER FLAT NUT BINX NUT BINX SHIM SET - SUPPLIED WITH GEARBOX GEAR PINION SUPPLIED WITH GEARBOX WASHER CENTRE SUPPLIED WITH GEARBOX 4 4 4 2 1 1 1
400R HOPPER RAM, RESTRICTOR & HOSE FAILURE VALVE THE CENTRE BAFFLE ASSEMBLY OF THE HOSE FAILURE VALVE ITEM 30 PART NO V2004171 SHOULD BE UNSCREWED FROM THE BODY BEFORE INSTALLATION AND THE GAP BETWEEN THE BAFFLES ADJUSTED TO 2.0MM, THE BAFFLE ASSEMBLY SHOULD THEN BE SCREWED FULLY HOME INTO THE BODY.
400R HOPPER RAM, RESTRICTOR & HOSE FAILURE VALVE 1 2 3 4 5 20 21 22 23 24 30 31 32 272150000 555167900 555108500 6S03G 87S03 119S08 100S04 555247000 555247100 424210500 V2004171 122S03 100S03 RAM, HOPPER WASHER PIN BOLT NUT, "BINX", SELF LOCKING FITTING, ADAPTOR, MALE/MALE SEAL BONDED POPPET FITTING, ADAPTOR, RESTRICTOR SPRING COMPRESSION VALVE HOSE FAILURE ADAPTOR MALE/MALE SEAL BONDED 1 2 2 2 2 1 2 1 1 1 1 1 2
400R LISTER TR2 ENGINE AND COUPLING SET ENGINE RPM TO 1800 UK ENGINES MUST BE FILLED WITH 10W/30 ENGINE OIL. CENTRES OF ENGINE AND GEARBOX OUTPUT/INPUT SHAFTS MUST BE ALIGNED TO AVOID STRAINING SHAFT AND LAYRUB COUPLINGS.
400R ENGINE & COUPLING LISTER TR2 1 1A 1B 1C 2 20350A03 20350A06 20350A07 20350A08 555280400 ENGINE LISTER TR2 HANDSTART (EXPORT VERSION) ENGINE LISTER TR2 ELECTRIC START (EXPORT VERSION) ENGINE LISTER TR2 HAND START (UK/EEC VERSION) ENGINE LISTER TR2 ELECTRIC START (UK/EEC VERSION) SHAFT CONNECTING 1 1 1 1 1 5 5A 7 11 12 13 14 15 16 17 555258100 90S04H 130972000 6S05K 10S04 87S05 304712863 555280300 555280500 195S03C2 ADAPTOR DRIVESHAFT SCREW SOCKET CAP (NOT ILLUSTRATED) COUPLING LAYRUB BOLT ENGINE W
400R LISTER TR2 ENGINE AND COUPLING APRIL 2010 ON SET ENGINE RPM TO 1800 8 9 UK ENGINES MUST BE FILLED WITH 10W/30 ENGINE OIL.
400R ENGINE & COUPLING LISTER TR2 APRIL 2010 ON 1 1A 1B 1C 20350A03 20350A06 20350A07 20350A08 ENGINE LISTER TR2 HANDSTART (EXPORT VERSION) ENGINE LISTER TR2 ELECTRIC START (EXPORT VERSION) ENGINE LISTER TR2 HAND START (UK/EEC VERSION) ENGINE LISTER TR2 ELECTRIC START (UK/EEC VERSION) 1 1 1 1 1 LONG EXTENSION SHAFT FITTED TO ENGINE 4 5 6 7 8 9 11 12 13 15 555248601 555280900 147320001 304712863 90S04L 188S04E1 6S05K 10S04 87S05 555280300 COUPLING-GEARBOX COUPLING-ENGINE SLEEVE COUPLING-NYLON KEY PARAL
400R EXHAUST SILENCER SETSCREW ITEM 7 PICKS UP ON MAINFRAME
400R EXHAUST SILENCER 1 2 555288900 10293A03 SILENCER ACOUSTIC EXHAUST GASKET 1 1 4 5 6 7 8 9 10 11 12 13 14 17S05 11S04C 555289000 11S04F 267S06 17S05 7S04 11S04C 267S06 17S05 7S04 WASHER SPRING M10 SCREW SET M10 BRACKET SILENCER SUPPORT SCREW SET M10 WASHER FLAT M10 WASHER SPRING M10 NUT M10 SCREW SET M10 WASHER FLAT M10 WASHER SPRING M10 NUT M10 2 2 1 1 2 1 1 1 2 1 1
400R AIR CLEANER AND PIPEWORK- FILTREL
400R AIR FILTER AND PIPEWORK-FILTREL 1 V2004797 AIR FILTER ASSEMBLY, FILTREL 1 10 11 12 13 14 15 16 11S03B 17S04 267S05 555188700 555280000 V600187 97S13 SCREW SET WASHER SPRING WASHER FLAT HOSE ELBOW RUBBER INLET TUBE INLET STEEL HOSE ELBOW 90' RUBBER CLIP HOSE 4 4 4 1 1 1 4
400R AIR CLEANER AND PIPEWORK- VIRGIO
400R AIR FILTER AND PIPEWORK-VIRGIO 12 V2005807 AIR FILTER ASSEMBLY C/W BAND, VIRGIO 1 12A 12B 12C 13 14 15 16 11S03D 267S05 61S03 555188700 555280000 V600187 97S13 SCREW SET, M8 X 30, WASHER FLAT NUT BINX HOSE ELBOW RUBBER INLET TUBE INLET STEEL HOSE ELBOW 90' RUBBER CLIP HOSE 2 4 2 1 1 1 4
400R TR2 ENGINE STOP CABLE
400R TR2 ENGINE STOP CABLE 1 3 4 5 6 7 8 9 10 460239 460242 67S04 87S03 11029A01 11030A01 V600192 V600193 V600194 CABLE STOP SCREW CLAMP, OUTER CABLE WASHER SHAKEPROOF NUT BINX BRACKET RETAINING LEVER PIVOT SCREW SET R CLIP FITTING SWIVEL, INNER CABLE RETAINING 1 1 1 1 1 1 1 1 1 PARTS NOT ILLUSTRATED 11 12 13 14 15 16 17 18 19 555292300 11S02A 267S04 61S02 143200900 16S05B 267S02 17S10 7S09 BRACKET, CABLE STOP SCREW SET WASHER FLAT NUT BINX CLIP NYLON SCREW SET WASHER FLAT WASHER SPRING NUT 1 2 4 2 1
400R 11KW MOTOR AND DRIVE SHAFT 415 VOLT
400R 11KW MOTOR AND DRIVE SHAFT 415 VOLT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 202424000 555145400 10S04 28S05G 6S05E 87S05 555142600 555145500 555258100 90S04H 195S03C2 304712863 130972000 8S05H 267S07 61S05 MOTOR ELECTRIC 11 KW MOUNTING MOTOR WASHER FLAT SETSCREW SETSCREW NUT BINX SHAFT CONNECTING FLANGE DRIVE ADAPTOR DRIVE SCREW CAP SCREW GRUB KEY COUPLING LAYRUB BOLT WASHER FLAT NUT BINX ITEMS 14-15-16 ARE SUPPLIED WITH LAYRUB COUPLING ITEM 13.
400R 11KW 415V MOTOR AND DRIVE SHAFT LATER TYPE
400R 11KW 415V MOTOR MOUNT DRIVE SHAFT LATER TYPE 1 2 3 4 5 6 7 8 9 10 11 12 202424000 555145400 10S04 28S05G 6S05E 87S05 304712863 188S04E1 555291700 147320001 90S04L 555248601 MOTOR ELECTRIC 11 KW MOUNTING MOTOR WASHER FLAT SETSCREW SETSCREW NUT BINX KEY SCREW GRUB COUPLING MOTOR COUPLING SLEEVE NYLON SCREW SOCKET HEAD CAP COUPLING GEARBOX 1 1 8 4 4 8 1 1 1 1 4 1
400R STARTER AND STOP SWITCH 415 VOLT
400R STARTER AND STOP SWITCH 1 2 3 4 4A 5 6 7 8 9 10 11 12 13 14 14A 14B 15 16 17 18 19 20 21 22 23 24 25 26 27 208304103 208304104 555144200 6S03B CSE182 41S05 9S03 11S02A 17S03 7S02 20887000 103S02D 41S03 104S01 131770010 1444700200 144700100 11S02C 17S03 7S02 V2004640 131736000 030788102 030788103 133275050 131575020 131271000 56S07 131272000 131592025 SWITCH STARTER RELAY OVERLOAD 14A-21A BRACKET STARTER BOLT SPACER (USED TO MOVE BRACKET AWAY FROM MOTOR) WASHER SPRING NUT SCREW SET WASHER SPRING NUT S
PRIOR TO FITTING BEARINGS ITEM 18 REMOVE SEALS AND PACK BEARINGS WITH A GOOD QUALITY GREASE, WHEN REFITTING THE SEALS ENSURE THEY ARE CORRECTLY SEATED. THE IDLER ROLLER SHOULD BE SET HORIZONTAL IN THE MAINFRAME AND PARALLEL TO THE OPPOSITE ROLLER, CHECK WITH SPIRIT LEVELS AND STRAIGHT EDGES.
400R DRUM DRIVE SHAFT UPPER 2 3 4 5 6 6A 7 7A 7B 8 9 10 10A 10B 10C 11 12 13 14 15 16 16A 16B 16C 18 19 24 25 26 27 28 29 30 37 37A 38 38A 555113300 555113200 555113400 555113100 66S02A 41S04 6S05E 41S07 9S04 555113500 351931000 6S05H 10S04 41S07 9S04 555114600 555114400 555114300 555113600 555114900 555272400 11S04E 17S05 267S06 88S41D 111452000 417773000 417774000 417732440 304213200 305108160 134911062 134911064 555115000 477356000 333601010 176S01 PINION DRUM DRIVE CHAINWHEEL IDLER ROLLER CARRIER BEAR
THE ROLLER LOAD BEARING SURFACE SHOULD BE COATED WITH OPEN GEAR LUBRICANT BEFORE THE MACHINE IS SHIPPED TO THE CUSTOMER THE IDLER ROLLER SHOULD BE SET HORIZONTAL IN THE MAIN FRAME AND PARALLEL TO THE OPPOSITE ROLLER, CHECK WITH SPIRIT LEVELS AND STRAIGHT EDGES. PRIOR TO FITTING BEARINGS ITEM 7 REMOVE SEALS PACK WITH A GOOD QUALITY GREASE AND REFIT SEALS ENSURING THEY ARE SEATED CORRECTLY.
400R DRUM IDLER ROLLER 1 2 3 4 5 6 7 8 11 12 13 14 15 16 17 18 19 20 21 22 23 24 555113000 555113400 555113500 555113700 555263700 555114900 88S41D 417732440 188S06D1 555272400 11S04E 6S05E 9S04 41S07 66S02A 41S04 6S05M 6S05E 10S04 17S05 267S06 87S05 CARRIER IDLER SHAFT ROLLER IDLER COVER SHAFT IDLER BRACKET SUPPORT SHIM PACKER SET BEARING-DOUBLE SEALED SEAL OIL SCREW GRUB STOP BRACKET SCREW SET BOLT NUT WASHER SPRING SCREW SET WASHER SPRING BOLT BOLT WASHER FLAT WASHER SPRING WASHER FLAT NUT BINX 1 1 2
THE MATING SURFACES OF THE JOINT ITEM 8, REAR OF BEARING HOUSING ITEM 7 AND THE MAINFRAME SHOULD BE COATED WITH SILICONE SEALER, ALLOWING SILICONE TO CURE SLIGHTLY BEFORE ASSEMBLY, ENSURE THE OIL DRAIN HOLE IN THE BEARING HOUSING IS NOT OBSTRUCTED WITH SEALER.
400R DRIVE SHAFT - LOWER AND PROPSHAFT 1 2 3 4 5 6 7 8 9 10 20 21 23 30 31 32 33 34 35 36 37 38 39 555257700 V601338 7S05 17S06 267S07 61S05 555112900 555284900 555114100 555114000 113149000 417302000 417772000 95S05 142330000 463935240 28S05N 188S03C2 304106230 412818400 11S03B 17S04 176S01 SHAFT DRIVE FLANGED STUD NUT WASHER SPRING WASHER FLAT NUT BINX BRACKET BEARING ADJUSTABLE GASKET SPROCKET - DIESEL SPROCKET - ELECTRIC BEARING NEEDLE ROLLER SEAL OIL SEAL 'V' RING NUT CIRCLIP EXTERNAL WASHER THRUST S
400R DRUM AND GEARBOX CONTROLS
400R DRUM AND GEARBOX CONTROLS 1 3 3 4 4 5 6 7 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 28 29 30 31 32 555110100 555292100 555292100 307126000 307126000 555110400 555110500 555110600 555110800 555110900 555111000 555111100 555111200 555111300 555111400 112800200 383251000 132412010 6S05E 87S05 44S02E 10S18 44S05D 10S04 9S06 95S07 44S03F 95S05 10S18 LEVER SLOTTED LEVER HAND 5/8" UNC THREAD LEVER HAND M12 THREAD KNOB 5/8" UNC THREAD KNOB M12 THREAD LEVER OPERATING BLOCK CLEVIS PIN PIN CLEVIS PIN PIVOT
400R DRUM , DRUM MOUTH & EXTENSION CONES
400R DRUM ASSEMBLY DRUM MOUTH + EXTEN CONES 1 6 7 9 11 12 13 21 21A 21B 22 22A 22B 25 26 27 555280700 555126000 555127800 555127700 515143000 515142900 555112700 104S05 104S05 10S04 41S07 41S07 41S07 200S05G 206S05C 90S06R DRUM ASSEMBLY INC BLADES AND TRACK RING CONE DRUM MOUTH STND CONE DRUM MOUTH-USE WITH RUBBER EXTENSION CONE DRUM MOUTH-STEEL EXTENSION STRAP RETAINING (SET OF FOUR) CONE EXTENSION RUBBER GEAR RING CAST NUT NUT, (RUBBER RETAINING) WASHER FLAT, RUBBER RETAINING, (NOT ILLUSTRATED) WASHER S
400R DRUM EDGE ROLLERS PRIOR TO FITTING BEARINGS EASE THE SEALS OUT OF ONE SIDE AND PACK WITH A GOOD QUALITY GREASE, ENSURE SEALS ARE SEATED CORRECTLY WHEN REFITTING., ADJUST THE EDGE ROLLERS SO THAT 1.5MM CLEARANCE EXITS BETWEEN THE ROLLERS AND DRUM TRACK RING, SETTING THE ROLLERS TO TIGHT WILL LEAD TO PREMATURE FAILURE OF THE BEARINGS. THE SET SCREWS SECURING THE ROLLER ASSEMBLIES TO THE CARRIER SHOULD BE LOCKED TOGETHER USING THE WIRE TIES FOLLOWING ADJUSTMENT.
400R DRUM EDGE ROLLERS 1 2 5 6 7 8 10 11 12 13 14 15 16 17 20 21 555111700 555283700 555111800 555112000 555112100 555112200 88S05D 142321000 417771000 555167500 477356000 28S05K 28S05U 95S05 6S05E 41S07 ROLLER EDGE SHAFT EDGE ROLLER CARRIER EDGE ROLLER PLATE LOCKING SHIM PACKER SHORT SHIM PACKER LONG BEARING CIRCLIP SEAL 'V' RING SCREW SET SPECIAL WIRE LOCKING (NOT ILLUSTRATED) SCREW SET ADJUSTING SCREW SET ADJUSTING NUT LOCKING BOLT WASHER SPRING 2 2 1 2 12 6 2 2 2 4 2 1 1 2 4 4
400R CRADLE LINK ARMS & BATCHWEIGHER GUIDE COAT ALL PINS AND BUSHES WITH COPPERSLIP ON ASSEMBLY. CHARGE ALL GREASE POINTS .
400R HOPPER CRADLE LINK ARMS & BATCHWEIGHER GUIDE 6 7 8 9 10 11 12 13 13A 14 15 15A 16 17 18 19 19A 20 30A 30B 30C 43 44 45 46 47 48 49 555108900 555109000 555255100 555255300 555255000 555255400 195S04E2 113179200 113179201 555255200 333506000 176S01 113149000 422702000 49S40 131S01 176S01 11S05E 512118301 512118302 512118303 17S06 195S04D3 9S11 10S31 8S03E 17S04 555269600 GUIDE-LOADCELL STRIKER PIN GUIDE SHAFT LINK HOUSING BEARING ARM LINK CAP BEARING SCREW GRUB BEARING NEEDLE BEARING NEEDLE INNER SHAFT
400R HYDRAULIC CONTROL VALVE (MHS-DINOIL) THE HYDRAULIC PRESSURE SHOULD BE ADJUSTED :- 2000 PSI (138 BAR) 400R 2400 PSI (166 BAS) 500R PORT 4- FEED FROM HYDRAULIC PUMP PORT 5-RETURN TO HYDRAULIC TANK PORT 6- SUPPLY TO HOPPER RAM PORT 8- (H.P.C.O.) TO DRAGLINE CONTROL BLOCK PORT 8 SHOULD BE FITTED WITH PLUG ITEM 9 WHEN NO DRAGLINE IS FITTED.
400R HYDRAULIC CONTROL VALVE MHS 1 2 3 4 5 6 7 8 9 20 21 22 23 V2004605 100S03 127S03 122S03 119S08 122S03 V2004607 122S03 127S03 8S03H 267S05 17S04 7S03 VALVE CONTROL SEAL BONDED PLUG BLANKING ADAPTOR M/M FROM PUMP ADAPTOR M/M TO TANK ADAPTOR M/M TO RAM SCREW SOCKET HEAD H.P.C.
400R HYDRAULIC TANK,HOPPER RAM & PIPEWORK TO HEADER TANK
400R HYDRAULIC TANK, HOPPER RAM & PIPEWORK 1 2 3 4 6 7 10 11 20 20 21 22 23 25 26 27 27 28 28 29 35 36 50 52 555257900 272150000 555204300 555231000 555258300 555189500 97S09 73S03B 365825000 10539A02 66S01C 41S03 10S01 100S06 119S15 100S04 100S06 119S08 119S10 110S07G 120S03 154S03 V2004605 32S01C TANK HYDRAULIC RAM HOSE, BLEED VALVE TO RAM HOSE, CONTROL VALVE TO BLEED VALVE HOSE, TANK TO PUMP HOSE, PUMP TO CONTROL VALVE CLIP HOSE HOSE, CONTROL VALVE TO TANK TEE PUMP- DIESEL DRIVEN PUMP- ELECTRIC MOTOR D
400R HYDRAULIC HEADER TANK TOP UP THE OIL LEVEL IN THE HEADER TANK WITH THE HOPPER RAISED AND THE RAM FULLY EXTENDED. LOWER THE HOPPER AND FILL THE TANK TO BRNG THE LEVEL UP TO THE MIDWAY POINT ON THE SIGHT GLASS. THE LEVEL WILL RISE AS THE HOPPER IS RAISED AND DROP AS THE HOPPER IS LOWERED. THE LEVEL SHOULD ONLY BE CHECKED WITH THE HOPPER LOWERED.
400R HEADER TANK 1 2 3 4 5 6 7 8 9 10 11 555288700 511100900 100S06 32S01C 11S03C 267S05 17S04 7S03 V2005114 V2003100 V2005122 TANK HEADER CAP FILLER/BREATHER SEAL BONDED HOSE SCREW SET M8 WASHER FLAT M8 WASHER FLAT M8 NUT M8 SIGHT GLASS DECAL HYDRAULIC OIL DECAL HYDRAULIC OIL LEVEL 1 1 1 2 4 8 4 4 1 1 1 15 16 272150000 555257900 RAM HYDRAULIC TANK HYDRAULIC 1 1
400R HOPPER CRADLE AND BATCHWEIGHER COAT ALL PINS AND THE BORES OF BUSHES AND WELDED BOSSES WITH COPPERSLIP ON ASSEMBLY. FOLLOW INSTRUCTIONS IN TEXT AT BEGINNING OF THIS MANUAL WHEN SETTING UP BATCHWEIGHER STRIKER PIN.
400R BATCHWEIGHER GAUGE AND HOPPER CRADLE 1 2 3 3A 3B 5 23 24 25 26 27 28 29 31 33 34 38 42 43 44 44A 45 46 47 47A 48A 48B 49 50 51 52 53 54 55 55A 56 57 58 555269600 555109300 555109202 555109203 555109204 555109100 555242414 555192700 555192800 555192900 555124900 555125000 555125100 013203000 143200300 555109600 195S03C2 6S05E 41S07 28S03D 10S03 9S03 41S05 6S05C 87S05 6S05C 87S05 6S03L 9S03 41S05 261S02M 206S05C 192S05 16S05B 267S02 7S09 17S10 V2003111 HOPPER CRADLE (ALL BUILDS) PIN STRIKER SUPPORT SHI
400R HOPPER AND SAFETY CHAIN
400R HOPPER AND SAFETY CHAIN 1 2 3 4 5 6 7 8 555265404 208S06J 104S06 203S06 555269800 11S05D 267S07 61S05 HOPPER SCREW COUNTERSUNK SOCKET NUT NUT LOCKING THIN HOPPER SAFETY CHAIN SCREW SET WASHER FLAT NUT BINX ITEMS 5, 6,7 & 8 ARE NOT ILLUSTRATED 1 8 8 8 1 1 1 1
400R WATER TANK CONTROLS COAT THE THREADS ON ITEM 2 WITH COPPER SLIP ON ASSEMBLY
400R WATER TANK CONTROLS 1 2 3 4 6 7 8 9 10 11 555265100 555255500 555255700 44S03C 267S06 56S04 6S03B 10S03 87S03 OPERATING LEVER SEE WATER TANK COUPLING END ROD OPERATING BRACKET PIN SPLIT WASHER FLAT NUT THIN BOLT WASHER FLAT NUT BINX 1 1 1 1 1 1 2 2 2
BRASS FACE OF DIAPHRAGM TOWARDS PILOT VALVE ITEM 18 CHECK THAT THE VALVE BODY IS FREE FROM SWARF BEFORE ASSEMBLY 400R WATER TANK INLET VALVE
400R WATER INLET VALVE 5 7 16 17 18 19 20 21 22 23 25 26 27 30 32 38 39 40 48 49 49A 50 51 52 53 61 555263000 555262900 555263500 555263600 555262700 51311400 513115200 513122000 555198300 555198400 555198800 241708000 130354000 49S39 44S02B 44S03C 10S02 61S03 11S02C 293S02 267S04 7S02 11S02F 11S03C 17S04 267S07 PIN PIVOT LEVER TRIP COVER VALVE BODY VALVE VALVE PILOT WASHER PILOT VALVE SPRING PILOT VALVE DIAPHRAGM BODY STRAINER ELEMENT STRAINER GASKET PLUG CONNECTOR HOSE SEAL 'O' RING PIN SPLIT PIN SPLIT
400R WATER TANK ASSEMBLY CHECK SCALE CARRIER ITEM 11 WILL NOT FOUL FACE OF TANK BODY, BEND SLIGHTLY IF CARRIER FOULS.
400R WATER TANK ASSEMBLY 1 1A 2 3 4 6 8 9 10 11 12 13 14 15 24 28 29 31 33 34 35 36 37 38 39 39A 40 41 42 43 44 45 46 47 47A 54 55 56 57 58 59 60 555260700 555261500 555263300 555263200 555263100 555262800 555262100 555262300 555261900 555262400 555262500 555262600 555261600 555263400 425434000 220302000 353830426 555119300 555119200 11S02C 17S03 267S06 44S03C 10S02 267S07 61S03 177S04 17S04 172S03A 104S02 56S04 11S03D V601330 267S05 70S04D 267S03 11S05F 7S05 17S06 267S04 236S04 TANK BODY VALVE WATER INLE
400R FLOWMETER
400R FLOWMETER 1 2 3 4 5 6 7 555176400 409255000 100S10 122S09 450151100 128S14 129S07G NOZZLE HOSE FITTING STRAIGHT FILTER STRAINER SEAL BONDED ADAPTOR MALE/MALE VALVE BALL FITTING FEMALE, FEMALE 90' ADAPTOR NOZZLE 90' ELBOW 1 1 6 2 1 1 1 10 11 12 13 202325000 153S09 267S05 17S04 GAUGE FLOWMETER CLAMP U BOLT WASHER FLAT M8 WASHER SPRING M8 1 2 4 4 15 16 17 18 19 555176800 6S03B 10S03 41S05 87S03 BRACKET FLOWMETER SCREW SET 3/8 WASHER FLAT 3/8 WASHER SPRING 3/8 NUT BINX 3/8 1 2 4 2 2 20 21 22 23
400R WINCH MOTOR & DRAGLINE CONTROL BLOCK SEAL ALL HYDRAULIC FITTING AND ADAPTORS WITH LIQUID HYDRAULIC THREAD SEAL CLEAN THE DRAGLINE CONTROL BLOCK ITEM 25 BEFORE USE ENSURING ANY SWARF LEFT FROM THE MACHINING PROCESS IS REMOVED. THE TEE ADAPTOR ITEM 16 ON TOP OF THE HYDRAULIC TANK IS ONLY USED WITH THE DRAGLINE OPTION.
400R DRAGLINE HYDRAULIC PIPEWORK AND VALVES 1 8 9 10 13 14 15 16 18 19 20 21 22 25 26 27 28 29 30 33 34 35 35A 36 36A 50 555257900 555268700 63S02F 73S03C 100S03 122S03 119S08 154S03 V2003253 35S03AK 267117000 391111000 126S09 555287500 555138200 555138300 555556100 100S04 10S02 11S03A 17S04 V2004676 V601234 68S02E 17S02 V2004605 TANK HYDRAULIC HOSE,CONTROL VALVE TO SOLENOID VALVE HOSE, SOLENOID VALVE TO WINCH MOTOR HOSE RETURN, SOLENOID TO TANK TEE SEAL BONDED ADAPTOR, MALE-MALE EQUAL ADAPTOR, MALE-MALE
400R DRAGLINE WINCH AND MOUNTING BRACKET DISCARD CLAMP FROM BULLDOG CLIP ITEM 7 COAT BOLTS ITEM 31 WITH COPPERSLIP ON ASSEMBLY, PACK BUSHES ITEM 52 AND ROLLERS ITEM 30 WITH COPPERSLIP OR GREASE ON ASSEMBLY
400R DRAGLINE BRACKET & WINCHMOTOR 1 2 3 5 6 7 8 9 10 11 12 15 16 17 18 19 25 26 27 28 29 30 31 32 35 36 37 40 41 42 43 50 51 52 267117000 7S05 17S06 11S05K 513330100 132204000 555266300 41S09 6S06H 477502000 555287800 7S04 17S05 267S06 11S04C 555287700 11S05D 267S07 17S06 7S05 555287900 8S05U 61S05 205304600 86S07 82S07F 555253800 11S01A 17S02 7S01 144734000 144734000 V2005386 MOTOR HYDRAULIC 'WHITE' NUT WASHER SPRING SCREW SET PULLY-DRUM CLIP BULLDOG WASHER SPECIAL NOT USED WASHER SPRING SCREW SET ROPE
400R DRAGLINE ALTERNATOR AND FIXINGS SECURE ALTERNATOR FAN AND PULLEY BEFORE INSTALLING ALTERNATOR, ADJUST DRIVE BELT TENSION SO THAT BELT DEFLECTS NO MORE THAN 12MM MIDWAY BETWEEN PULLIES. ADJUSTER ITEM 21 IS ATTACHED TO THE REVERSING GEARBOX.
400R DRAGLINE ALTERNATOR & FITTINGS 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 40 V2004793 513347400 11S03C 267S05 61S03 66S03A 10S03 41S05 555288300 8S03C 61S03 267S05 11S04C 7S04 17S05 267S06 397227000 ALTERNATOR ADJUSTER SCREW SET WASHER FLAT NUT BINX SCREW SET WASHER FLAT WASHER SPRING BRACKET ALTERNATOR BOLT NUT BINX WASHER FLAT SCREW SET NUT WASHER SPRING WASHER FLAT VEE BELT 1 1 1 2 1 1 1 1 1 2 2 2 2 2 2 4 1
400R DRAGLINE ALTERNATOR WIRING & PANEL REFER TO WIRING DIAGRAM WHEN INSTALLING LOOM AND CONNECTING TERMINALS USE NYLON CABLE TIES TO SECURE LOOM NEATLY AND PREVENT CHAFING ON HANDSTART DIESEL ENGINED MACHINES SECURE PANEL ITEM 15 TO MAINFRAME USING EXISTING SETSCREWS WHICH SECURE FUEL TANK SHROUD TO MAINFRAME COAT SETSCREWS SECURING BATTERY LEADS TO TERMINALS WITH GREASE TO PREVENT CORROSION
400R DRAGLINE ALTERNATOR WIRING & PANEL 1 2 3 4 5 10 11 12 15 16 17 18 19 20 25 26 27 28 29 30 31 32 109S10 11S02B 267S04 17S03 7S02 555288400 V2003253 V2003111 555288100 V2004794 11S02B 267S04 61S02 V2000326 V2004793 V2004795 V2004796 16S05B 143200900 17S10 267S02 7S09 BATTERY SCREW SET WASHER FLAT WASHER SPRING NUT LOOM WIRING CABLE TIE NYLON CABLE TIE NYLON PANEL SWITCH BATTERY ISOLATOR SCREW SET WASHER FLAT NUT BINX LIGHT WARNING ALTERNATOR DECAL ISOLATOR SWITCH DECAL ALTERNATOR SCREW SLOTTED RD HEAD
400R DRAGLINE BATTERY TRAY & GUARD EARLY MACHINES REQUIRE THE MAINFRAME DRILLING TO THE LEFT HAND SIDE OF THE ENGINE BED SO THAT THE BATTERY TRAY CAN BE ATTACHED. THE MAINFRAME OF LATER MACHINES IS PREDRILLED DURING MANUFACTURE. ALTERNATIVELY THE TRAY CAN BE WELDED IN POSITION.
400R DRAGLINE BATTERY TRAY 1 2 3 4 5 6 7 8 8A 8B 8C 10 11 12 15 16 17 18 19 30080A03 30080A0303 11S04E 11S04C 267S06 61S04 555290500 11S03C 267S05 17S04 7S03 10742A05 177S03 267S04 555288200 8S02F 267S04 61S02 V2004235 TRAY BATTERY BAR COVER SCREW SET SCREW SET WASHER FLAT NUT BINX GUARD BATTERY SCREW SET WASHER FLAT SPRING WASHER NUT COVER BATTERY NUT WING WASHER FLAT CLAMP BATTERY BOLT WASHER FLAT NUT BINX DECAL NEGATIVE EARTH 1 1 1 3 4 4 1 2 4 2 2 1 2 2 2 2 4 2 1
400R DRAGLINE CABLE MAST AND PULLIES
400R DRAGLINE MAST CABLE AND PULLIES 1 2 3 4 5 11 12 13 14 15 16 20 21 555121500 515134400 8S05L 17S06 7S05 555208100 555208400 44S03C 555208300 555204800 144734000 555287700 205304600 MAST LOWER MAST UPPER BOLT WASHER SPRING NUT PULLEY BLOCK PULLEY PIN SPLIT PIN PULLEY WEIGHT CABLE ELECTRIC 2 CORE BRACKET DRAGLINE WINCH PLUG & SOCKET 1 1 1 1 1 2 2 2 2 1 1 1 1
400R DRAGLINE SHOVEL ASSEMBLY
400R DRAGLINE SHOVEL 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 22A 23 24 25 26 27 555210400 555209100 135905000- (15 LINKS) 144734000 143200300 205304600 369200000 555214800 208561000 208143000 250166010 264705000 443105010 412606000 132204000 11S05D 59S04 267S07 16S05B 7S09 267S02 17S10 8S01H 7S01 17S02 44S17K 17S03 SHOVEL BODY SHOVEL HANDLE CHAIN & RING ASSY CABLE 2 CORE CLIP CABLE PLUG TUBE 300MM/12" LONG CLAMP SWITCH SWITCH SLEEVE PVC 55 MM LONG GLAND CABLE GRIP HANDLE THIMBLE ROPE WIRE SH
400R 2 AND 3 COMPARTMENT FEED APRON
400R 2 AND 3 COMPARTMENT FEED APRONS 1 2 3 4 5 6 7 8 9 10 11 12 13 555196302 555196301 555196303 555196307 555196315 208S03H 104S03 41S05 394413001 555196308 28S05E 9S04 41S07 14 15 16 17 555104800 28S05E 9S04 41S07 PLATE SIDE LH PLATE BOTTOM PLATE SIDE RH PARTITION CENTRE (2 COMPARTMENT) STRAP RUBBER RETAINER SCREW COUNTERSUNK SOCKET HEAD NUT WASHER SPRING RUBBER FLAP CENTRE SUPPORT SCREW SET NUT WASHER SPRING 30 NUTS WASHERS AND SETSCREWS REQUIRED WITH 2 COMPARTMENT FEED APRON PARTITION CENTRE (3 COMP
400R ELECTRIC START BATTERY, LEADS, TRAY & SWITCH WELD BATTERY TRAY TO SIDE OF MAINFRAME ADJACENT TO THE ENGINE BED, MAKING SURE THAT THE BATTERY LEADS WILL REACH BETWEEN THE BATTERY AND STARTER MOTOR. THE INSTRUMENT PANEL IS SECURED TO THE UNDERSIDE OF THE FUEL TANK SHROUD WHICH IS DRILLED TO ACOMODATE THE PANEL, USING THE PANEL AS A PATTERN FOLLOW THE WIRING DIAGRAMS WHEN WIRING UP THE SWITCH, LIGHT, CHARGE WINDINGS AND REGULATOR.
400R ELECTRIC START BATTERY AND LEADS 1 2 3 5 6 7 8 9 10 11 15 16 17 18 18A 20 21 22 23 24 25 26 27 109S08 10989A06 10990402 30080A03 11S04D 59S03 40SA17 9S01 267S04 10559A01 10742A05 267S04 177S03 V2004235 V2004204 20313A05 28S03D 41S05 9S03 366-07228 V2003561 ITEM 24-25 30231A11 V2003377 BATTERY CABLE BATTERY POSITIVE CABLE BATTERY NEGATIVE CARRIER BATTERY SCREW SET NUT LOCK ROD TIE NUT WASHER FLAT CLAMP BATTERY COVER BATTERY WASHER FLAT NUT WING DECAL 'NEGATIVE EARTH' INSULATOR POSITIVE NOT ILLUSTRATED
400R DECALS AND LOGO'S 1 2 3 4 10 11 12 13 5 14 6 15 7 16 8 17 9
400R DECALS AND LOGO'S 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 V2003037 504600900 504694600 V2003039 V2003126 555153700 555153500 555184900 V2004137 V2003038 V2003101 V2003100 515175000 V2003665 V2003598 10166A02 V2004259 V2004227 V2004229 V2004235 V2004282 V2004281 V2004288 V2004289 V2004302 V2004307 V2004223 V2004796 V2004744 V2004795 V2005122 V2005312 V2005319 V2005315 PLATE SERIAL NUMBER DECAL 'ENGINE HOUSING' DECAL 'SAFETY WARNING' DECAL 'WINGET' D
400R DECALS AND LOGO'S 28 18 19 29 20 30 21 22 31 23 24 32 25 26 33 27 34
WORKSHOP MANUAL 300R & 400R SECTION 11 BATCHWEIGHER MAINTENANCE INSTRUCTIONS
MAINTENANCE INSTRUCTIONS HYDRAULIC WEIGHING UNITS WWW.WINGET.CO.
INTRODUCTION This manual covers the Batchweigher Loadcell and Guage installed into 200TM Mechanically Fed Mixers and 300R, 400R and 500R Reversing Drum Mixers. Winget Limited do not recommend that attempts are made in the field to rectify faulty loadcells and gauges as the special tools and equipment required are unlikely to be available. It is recommended that faulty units are returned to Winget Limited for repair or overhaul.
WORKSHOP MANUAL 300R & 400R SECTION 12 REVERSING GEARBOX MANUAL
SERVICE MANUAL REVERSING GEARBOX FROM 1990 WWW.WINGET.CO.
INTRODUCTION This manual covers the Reversing Gearbox installed into 300R, 400R and 500R Reversing Drum Mixers. The following pages should enable a competent fitter/mechanic to fault find, repair or overhaul Reversing Gearboxes. The contents of this manual although correct at the time of publication, may be subject to alteration by the manufacturers without notice and Winget Limited can accept no responsibility for any errors or omissions contained within the following pages.
WORKSHOP MANUAL 300R 400R 500R Winget Reversing Gearbox From 1990 Asbestos Warning The clutch linings within the gearbox may contain asbestos and suitable precautions should be taken to avoid inhaling the dust which should not be blown out with an airline. Dispose of old linings, dust, wipers etc safely. Removal of Gearbox Place the gearbox into neutral and removing the circlip, drift out the pivot pin and pull the operating fork and linkage clear of the gearbox plunger guide.
WORKSHOP MANUAL 300R 400R 500R Winget Reversing Gearbox From 1990 Locate the operating pin in the centre of the cone clutches, remove the split pins and carefully drift out the pin, pull the operating plunger and shaft assembly out of the main shaft. Remove the rubber “O” ring off the operating plunger and remove the internal circlip securing the operating shaft and bearing into the plunger.
WORKSHOP MANUAL 300R 400R 500R Winget Reversing Gearbox From 1990 Slide the cone clutch assembly (21) over the main shaft (2) aligning the drilled hole through the cone clutches with the slot machined in the mainshaft. Loosely fit the outer cone of the bearing (15), lubricate the operating shaft (4) and insert into the centre of the mainshaft (2) align the hole in the operating shaft with the slot and holes in the mainshaft and cone clutch and fit the operating pin (22) retaining with the split pins (23).
WORKSHOP MANUAL 300R 400R 500R Winget Reversing Gearbox From 1990 When the preload reading is correct remove the flange (41) key (39) and housing (36). Using a suitable tool fit the oil seal (38) and lubricate the seal lips with a little grease. Coat the mating surfaces of the shim pack (Y) housing (36) and gearbox casing with a suitable silicone sealer and refit the housing securing with the four 3/8 x 1" UNC cap headed screws (37).
WORKSHOP MANUAL 300R 400R 500R Winget Reversing Gearbox From 1990 If not the shimpack thickness at points “X” and “Y” should be adjusted by moving the excess shims from either “X” to “Y” or “Y” to “X”. EXAMPLE Backlash measured on bevel gear “A” item 20 is:0.13mm Backlash measured on bevel gear “B” item 10 is:0.18mm Difference between the two = 0.05mm Divide by two, 0.025mm, remove 0.025mm from shim pack “Y” and add to “X”. Backlash now equal at both “A” and “B” = 0.175mm.
WORKSHOP MANUAL 300R 400R 500R Winget Reversing Gearbox From 1990 The pump should be shimmed to give 5-8 thou (0.02-0.20mm) gear backlash. Place the hydraulic pump onto the gearbox without any shims and measure the gap between the pump body and gearbox casting. Add 5-8 thou (0.02-0.20mm) to the measurement obtained and select a shim pack of the correct thickness.
Reversing Gearbox.
WORKSHOP MANUAL 300R & 400R SECTION 13-18 BLANK
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