WINGET 500R Reversing Drum Concrete Mixers User Manual

WINGET 500R Reversing Drum Concrete Mixers

Product Information

Specifications

• Model: 500R
• Manufacturer: Winget Limited
• Address: PO Box 41, Edgefold Industrial Estate, Ploder Lane, Bolton, Lancs, BL4 0LR
• Contact: Tel: ++ 44 (0) 1204 854650,
• Email: service@winget.co.uk, parts@winget.co.uk
• Website: www.winget.co.uk
• Issue: 11, Year: 2021

Introduction

The Winget 500R Reversing Drum Concrete Mixer is designed for experienced service personnel to perform stripping, repair, and rebuilding procedures. It is important to note that these procedures should not be attempted by individuals unfamiliar with the product or lacking mechanical experience.

Health and safety regulations should always be followed during all working practices. The following reminders should be noted:

• Ensure all work tools are in good condition.
• Always wear safety spectacles when using hammers, chisels, air tools, or when cleaning hardened concrete or mortar off components.
• Be cautious with compressed air to avoid potential damage.
• Check lifting equipment for good condition and ensure the safe working load exceeds the weight of the components to be lifted.
• Avoid skin contamination by applying barrier creams, wearing suitable protective clothing, or cleaning the area with soap and water if contamination is unavoidable. Do not use thinners or solvents to clean the skin.
• Apply common sense to improve health and safety and reduce the risk of accidents.

Refer to the Parts Listings in Section 10 or the Parts & Operators Manual for guidance on the correct sequence for assembling components and subassemblies.

For the purposes of this manual, it is assumed that the machine is standing on firm level ground and is horizontal in both planes. Left-hand and right-hand views are taken when looking directly at the feed hopper.

Repair and Service Procedures

Section 2 of the workshop manual provides detailed repair and service procedures for the Winget 500R Reversing Drum Concrete Mixer. It includes step-by-step instructions on how to strip, repair, and rebuild the mixer.

General Arrangement Dimensions

Section 3 of the workshop manual contains general arrangement dimensions for the Winget 500R Reversing Drum Concrete Mixer. These dimensions provide information on the overall size and layout of the mixer.

Service Schedules Lubrication Diagram

Section 4 of the workshop manual includes service schedules and a lubrication diagram for the Winget 500R Reversing Drum Concrete Mixer. These schedules and diagram outline the recommended maintenance tasks and lubrication points for the mixer.

Hydraulic Circuit Diagrams

Section 5 of the workshop manual presents hydraulic circuit diagrams for the Winget 500R Reversing Drum Concrete Mixer. These diagrams illustrate the hydraulic system and its components.

Wiring Diagrams

Section 6 of the workshop manual provides wiring diagrams for the Winget 500R Reversing Drum Concrete Mixer. These diagrams show the electrical connections and components of the mixer.

Noise Levels

Section 7 of the workshop manual contains information on the noise levels of the Winget 500R Reversing Drum Concrete Mixer. This information helps users understand the noise produced by the mixer and take necessary precautions.

Special Tools

Section 8 of the workshop manual lists the special tools required for working on the Winget 500R Reversing Drum Concrete Mixer. These tools are specifically designed to assist with repair and maintenance tasks.

Hydraulic Control Valve Service Manual (Where available)

Section 9 of the workshop manual provides a service manual for the hydraulic control valve (where available) of the Winget 500R Reversing Drum Concrete Mixer. This manual offers detailed instructions for servicing the hydraulic control valve.

Parts Listings

Section 10 of the workshop manual features parts listings for the Winget 500R Reversing Drum Concrete Mixer. These listings help users identify and order the correct parts for their mixer.

Batchweigher Maintenance Instructions

Section 11 of the workshop manual includes maintenance instructions for the batch weigher system of the Winget 500R Reversing Drum Concrete Mixer. These instructions guide users on how to properly maintain and care for the batchweigher system.

Reversing Gearbox Manual

Section 12 of the workshop manual provides a manual for the reversing gearbox of the Winget 500R Reversing Drum Concrete Mixer. This manual offers detailed information on the operation and maintenance of the reversing gearbox.

Blank Sections

Sections 13-18 of the workshop manual are blank and do not contain any information.

IMPORTANT Engine Change

From mid-2004, the Lister Petter TS2 and TS3 engines were replaced by the Lister Petter TR2 and TR3 engines. The TR range of engines is completely interchangeable with the TS range, and consumable items such as filter elements are identical. However, there are some internal component differences. When ordering spares, it is important to specify whether it is a TS or TR engine.

Instructions and notes throughout this manual that refer to TS engines are also applicable to the TR engine.

Product Usage Instructions

Step 1: Preparation

1. Ensure the Winget 500R Reversing Drum Concrete Mixer is placed on firm level ground.
2. Ensure the machine is horizontal in both planes.
3. Inspect all work tools to ensure they are in good condition.

Step 2: Safety Precautions

1. Always wear safety spectacles when using hammers, chisels, air tools, or when cleaning hardened concrete or mortar off components.
2. Be cautious with compressed air to avoid potential damage.
3. Check lifting equipment for good condition and ensure the safe working load exceeds the weight of the components to be lifted.
4. Avoid skin contamination by applying barrier creams, wearing suitable protective clothing, or cleaning the area with soap and water if contamination is unavoidable. Do not use thinners or solvents to clean the skin.

Step 3: Repair and Service Procedures

Follow the detailed repair and service procedures outlined in Section 2 of the workshop manual. These procedures provide step-by-step instructions for stripping, repairing, and rebuilding the Winget 500R Reversing Drum Concrete Mixer.

Step 4: General Arrangement Dimensions

Refer to Section 3 of the workshop manual for general arrangement dimensions. These dimensions provide information on the overall size and layout of the mixer.

Step 5: Service Schedules and Lubrication Diagram

Consult Section 4 of the workshop manual for service schedules and a lubrication diagram. Follow the recommended maintenance tasks and lubrication points to ensure proper functioning of the mixer.

Step 6: Hydraulic Circuit Diagrams

Refer to Section 5 of the workshop manual for hydraulic circuit diagrams. Study these diagrams to understand the hydraulic system and its components.

Step 7: Wiring Diagrams

Consult Section 6 of the workshop manual for wiring diagrams. These diagrams illustrate the electrical connections and components of the mixer.

Step 8: Noise Levels

Refer to Section 7 of the workshop manual for information on noise levels. Take necessary precautions to protect yourself from excessive noise exposure.

Step 9: Special Tools

Review the list of special tools provided in Section 8 of the workshop manual. Ensure you have the necessary tools for performing repair and maintenance tasks on the mixer.

Step 10: Hydraulic Control Valve Service Manual (Where available)

If applicable, refer to Section 9 of the workshop manual for the hydraulic control valve service manual. Follow the instructions provided in this manual for servicing the hydraulic control valve.

Step 11: Parts Listings

Use the parts listings in Section 10 of the workshop manual to identify and order the correct parts for your Winget 500R Reversing Drum Concrete Mixer.

Step 12: Batchweigher Maintenance Instructions

Follow the maintenance instructions in Section 11 of the workshop manual for proper care and maintenance of the batchweigher system.

Step 13: Reversing Gearbox Manual

Refer to Section 12 of the workshop manual for detailed information on the operation and maintenance of the reversing gearbox.

Step 14: Additional Information

If you have any additional questions or require further assistance, refer to the FAQ section below or contact Winget Limited directly using the provided contact information.

FAQs

• Q: Can individuals without mechanical experience perform repair and rebuilding procedures on the Winget 500R Reversing Drum Concrete Mixer?
  • A: No, the procedures outlined in the workshop manual are intended for experienced service personnel only. Individuals without mechanical experience should not attempt these procedures.
• Q: What precautions should be taken when using air tools?
  • A: Always wear safety spectacles when using air tools to protect your eyes. Mis

500R
WORKSHOP MANUAL
WINGET LIMITED PO BOX 41
EDGEFOLD INDUSTRIAL ESTATE PLODER LANE BOLTON LANCS BL4 0LR
Tel:-++ 44 (0) 1204 854650 service@winget.co.uk parts@winget.co.uk www.winget.co.uk
ISSUE 11 2021

WORKSHOP MANUAL 500R
WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 11 2021

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

Section 12

Reversing Gearbox Manual

Section 13-18

Blank

IMPORTANT Engine Change

From mid 2004 the Lister Petter TS2 and TS3 engines were replaced by the Lister Petter TR2 and TR3 engines. The TR range of engines is completely interchangeable with the TS range and consumable items such as filter elements are identical. There are some internal component differences and when ordering spares it is important to state whether it is a TS or TR engine.

Instructions and notes found throughout this manual which refer to TS engines are also applicable to the TR engine

WORKSHOP MANUAL 500R
SECTION 1

INTRODUCTION

WORKSHOP MANUAL 500R
WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 11 2021

Introduction

The following procedures should enable experienced service personnel to strip, repair and rebuild Winget 500R 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.
It is assumed that personnel are aware of Health and Safety Regulations which should be applied to all working practices, but the following should act as a reminder.
Ensure all work tools are in good condition.
Always wear Safety Spectacles when using Soft or Hard Faced Hammers, Chisels or when using Air Tools. Wear Safety Spectacles when cleaning hardened concrete or mortar off components.
Do not misuse Air Lines and be aware of the damage Compressed Air can cause if misused.
Always make sure lifting equipment is in good condition and the Safe Working load exceeds the weight of the components to be lifted.
Oils, Fuels, Silicone Sealers and Open Gear Lubricants can cause skin diseases if allowed to contaminate the skin. Always apply barrier creams, wear suitable protective clothing, or when contamination is unavoidable clean the area with soap and water as soon as possible. Do not use thinners or other solvents to clean skin.
Health and Safety is a matter of common sense. If common sense is applied correctly Health and Safety can be improved and the risk of accidents reduced.
Refer to the Parts Listings in Section 10 or the Parts & Operators Manual for a guide to the correct sequence for assembling components and sub assemblies.
It is assumed for the purposes of this manual that the machine is standing on firm level ground and is horizontal in both planes.
Left hand and Right Hand views are taken when looking directly at the Feed Hopper.
Whilst every effort is made to ensure the contents of this manual are accurate Winget Limited accept no responsibility for errors or omissions and reserve the right to alter specification without prior notification in which case certain sections may then no longer apply.

WORKSHOP MANUAL 500R
SECTION 2

REPAIR & SERVICE PROCEDURES

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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. The L/H Point is used to secure the Hopper Safety Chain which is attached to the raised Hopper during maintenance work. The Hopper Lifting Points are not highlighted to avoid confusion with the main lifting points. On no account must the Hopper Lifting Points be used to support the weight of the mixer. Drawbars ­ Standard & Military/Nato The Drawbars are retained to the Front axle by twoL’ shaped retaining pins which are in turn secured by two lynch pins c/w chains which are inserted through the retaining pins once the drawbar is in position. To remove the drawbar first remove the lynch pins, withdraw the retaining pins and lift the drawbar clear, refit the retaining pins and prevent their loss by refitting the lynch pins. Reverse the procedure to refit the drawbar.
Military/Nato Towing Eye (Used with Military/Nato Drawbars)
Remove the split pin, castle nut and flat washer retaining the eye in the drawbar. Remove the eye. To refit reverse the above procedure, do not fully tighten the nut, allow the eye to rotate in the drawbar. New eyes will require drilling for the split pin when fitted in place.
Jack Legs
To remove a Jack Leg either jack up and support the machine or using suitable lifting equipment lift the machine. Pull out the retaining pin remove the leg. Refit in the reverse order.
Military/Nato machines have an additional security measure in the form of a lynch pin through the jack leg retaining pin to prevent the jack leg dropping unintentionally.
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.

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To remove the Hopper Anti-Bounce Bracket, start the engine and raise the Hopper very slightly to release its weight off the bolt and jack leg retaining pin (it is normal for the Hopper to settle slightly during transportation).
Remove the bolt, pull out the pin and lift the Anti-Bounce Bracket clear. Refit in the reverse order.
On no account must attempts be made to fully raise the Hopper whilst the Anti- Bounce Bracket is in place.
Pneumatic Wheels, Stub Axles, Hubs
The complete Wheel, Stub axle and Hub assemblies are retained to the axles by four bolts, two positioned vertically and two horizontally. To remove the assemblies, support the machine on the jack legs, remove the bolts and lift the assemblies clear. If fitted take care not to lose the tapered washers. Reverse the procedure to refit.
Wheels ­ Pneumatic
To change a wheel, first slacken the five nyloc nuts, jack up the machine supporting the weight on a jack leg. Remove the nuts and wheel. To refit, reverse the procedure.
Hubs
Remove the wheel as described previously. Knock off the dust cap. Remove the split pin and nut, pull off the hub assembly complete with bearings and oil seal. Knock out the bearings and oil seal clean the hub and shaft. Pack the new bearings with grease. Fit the new bearings and oil seal into the hub. Coat the shaft with copperslip, push the hub complete with bearings onto the shaft. Fit the flat washer and castle nut and tighten the nut. Back off until the wheel spins freely with no end float. Align the nut with the cross drillings in the shaft, fit the split pin. Refit the wheel as described previously.
Steel Wheels, Stub Axles and Hubs
To remove the complete assembly refer to Pneumatic Wheels, Stub axles and Hubs.
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.

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Front Axle and Pivot Bracket
To remove the axle or pivot bracket, support the front of the machine and fully raise the jack legs. Remove the drawbar, stub axles, hubs and wheel assemblies as described previously. Remove the split pins and washers retaining the tie bar between the axle and mainframe, support the axle and remove the tie bar, remove the split pins, and washers though the pivot pin, knock out the pin. Remove the supports and lift the axle clear of the pivot bracket. The pivot bracket may be held in place by either a split pin and washer or nut and bolt. Reassemble in the reverse order coating pins etc. with copperslip, replacing damaged split pins.
Water Tank Removal (Where fitted)
Turn off and disconnect the water supply. Remove the split pin and disconnect the operating rod. Unbolt and remove the outlet pipe. Unbolt the tank and using suitable lifting equipment lift the tank clear of the mainframe. Refit in the reverse order.
For an explanation of the Water Tank operation and repair instructions see pages 25- 29.
Flowmeter Removal (Where fitted)
The Flowmeter is mounted on a bracket on the L/H side of the mainframe and is connected to the inlet pipe at the drum charge mouth by a 1.5 bore rubber hose. The meter is a mechanical device featuring a reset facility and includes a water on/off valve and an inline strainer which is removable for cleaning. To Remove the Meter disconnect the rubber hose by either slackening one of the hose clamps or removing one of the threaded connectors, remove the two `U’ bolts securing the meter in place and lift the meter clear. Reverse the procedure to refit. Note:- the meter itself contains no user serviceable components.
Drum Edge Rollers
Where fitted remove the water tank as previously described. Support the front of the drum to prevent it falling forward suddenly when the Edge Roller assembly is removed.
Release the adjusting screw then unbolt and remove the edge roller assembly taking care not to lose the shim packers. Remove the setscrews holding the rollers into the housing and remove the rollers. Support the rollers in a soft jawed vice remove the 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 with a good quality grease, refit the seals.

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Reassemble in reverse order taking care not to forget the `V’ seals. When assembling the rollers back into the housing do not fully tighten the setscrews until the assembly has been refitted and final adjustment carried out.
Refit the assembly onto the drum housing. Adjust the height of the assembly using the shims so the rollers do not foul the drum circumference and the drum gear ring will not foul the assembly.
Adjust the rollers against the track ring so that a total 1.5mm clearance exists between the rollers and ring. Tighten the setscrews. Lock the adjusting screws with locking wire.
Note:
Incorrectly setting the rollers in relation to the track ring will result in premature bearing failure and/or excessive wear of the track ring and idler rollers.
As a final check that all adjustments are correct remove the support from below the drum, engage either forward or reverse drive and crank the engine rotating the drum checking visually that neither a foul condition nor tight rollers exist.
If removed refit the water tank assembly.
Drum Removal
It is necessary to remove the Drum for replacement of the Drum Gear Ring it is also strongly recommended that the Drum is removed if repair or replacement of the Idler Rollers is necessary.
Remove either the Water Tank or Flowmeter and Water Inlet Pipe and Drum Edge Rollers as described previously.
On machines fitted with a Dragline remove the Mast and Cable. Disconnect the Wire Rope from the Shovel and wind back onto the Winch Motor. Mark for identification purposes the hoses to the Winch Motor and disconnect both the hoses from the Motor. Fit blanking caps and plugs to both the hoses and Winch motor adaptors to prevent the ingress of foreign matter. Disconnect the Electrical Cable and using suitable lifting equipment support the Dragline Winch Motor Bracket, remove the retaining setscrews and nuts and lift the assembly clear. Where a Batchweigher is fitted unbolt the Gauge from the left hand Water Tank Support and stow in the Mainframe (Do not disconnect the small bore pipe).
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.

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Attach suitable lifting gear to the Drum Assembly (The Drum weighs approximately ¾ tonne when clean) and lift out of the Mainframe. It may be necessary to remove the Drum Mouth Extension to allow attachment of the lifting equipment.
Reassemble in reverse order, following the instructions for adjusting the Drum Edge Rollers.
Drum Gear
Remove the Drum as described previously. Stand the Drum Assembly on the charge mouth. Remove the Socket Headed Capscrews securing the Gear to the Drum. Using suitable lifting equipment lift the Gear clear of the Drum.
Drum Cone Extensions
The various mouth extensions either Standard Steel Cone, Steel Extension Cone or Rubber Extension Cone bolt to the Drum mouth. Removal is simply a matter of removing the ring of bolts and lifting off the mouth extensions.
Drum Blades
Drum Blades can be changed with the Drum in Situ. The Blades are bolted in place and if the Drum interior is clean replacement is fairly straightforward although two pairs of hands are necessary. Unbolt and discard the old Blades and bolt the new Blades in their place using new bolts.
Take care if using oxyacetylene cutting equipment to remove corroded bolts for the concrete can “explode” violently spitting pieces of concrete. Wear suitable safety goggles or spectacles. Do not breathe in the fumes generated by the cutting and burning process ensure the drum is adequately ventilated and wear suitable air fed breathing apparatus.
Idler Roller Non Drive R/H
Whilst it is recommended that the Drum is removed to enable the Rollers Assemblies to be replaced It is possible to remove the Rollers with the Drum in situ provided great care is taken.
Remove the Water Tank or Flowmeter and the Edge Rollers as described previously.
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.
Remove the Stop Bracket secured with two M10 bolts, unbolt the Rear Carrier Bracket, remove the nuts and washers from the bolts securing the Front Carrier Bracket but do

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not remove the bolts which are supporting the Front Bracket and preventing the complete assembly dropping into the Drum Housing.
Carefully manoeuvre the Roller Assembly through the access hole, the assembly is quite heavy and extra hands or suitable lifting equipment are recommended. Take care not to lose the Shim Pack below the rear carrier bracket.
Remove the bolt securing the Rear Carrier and the grubscrew securing the Front Carrier remove both from the shaft.
Remove the setscrews holding the Oil Seal Housing/Bearing Retainer to each side of the Roller, take care not to lose or mix up the shims.
Support the Roller and using a suitable soft faced hammer knock the shaft and Bearings out of the Roller, remove the Outer Bearing Cones from within the Seal housings/Bearing Retainers. Secure the shaft in a soft jawed vice and remove the Taper Roller Bearing Cages from the Shaft.
Fit the new Inner Bearing Cages to the shaft (tapering outwards) and the Outer Cones into the Seal Housings. Fit the Shaft and bearings into the Roller. Slip a 0.60 thou thick shim (usually cream in colour) onto the front Bearing Retainer and secure in place on the Front of the Roller. Turn the roller over, slip the remainder of the shim pack onto the rear Seal Housing/Bearing Retainer and secure to the Roller, adjust the shimming behind the rear Housing to give a bearing pre-load of between 0.000″ to 0.002″ thou. Check the shaft rotates freely within the bearings.
Charge the roller with grease until it can be seen to squeeze out through both bearings, carefully fit the new Oil Seals into both Bearing Retainers. Refit the Front and Rear Carrier Brackets. Using suitable lifting equipment, lift the Roller Assembly back into the Mainframe, loosely secure the front Carrier to the Mainframe with the four nuts, bolts and washers. Insert the Shim pack under the Rear Carrier and Shim the Roller and Shaft until it is horizontal.
Place a straight edge across the rear face of the Roller and ensure it is square with the opposite roller. Tighten the retaining bolts. Refit the stop bracket. Remove the Drum supports and lower the Drum back onto the rollers.
Refit the Edge Rollers and Water Tank or Flowmeter as described previously. Run the mixer, checking operation of the Drum. Coat the Rollers/Gear with open gear lubricant. Stop the engine. Replace the inspection covers.
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 great care is taken.

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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. Block up the Drum taking the weight off the Roller Assemblies or support the weight of the Drum using suitable lifting equipment.
Remove the Chain Cover, Drive Chain and Upper Sprocket as described on page 11. Remove the Stop Bracket secured by two M10 bolts, unbolt the Plummer Block and Bearing Assembly, remove the nuts securing the front Bearing Carrier/Housing but do not remove the bolts which are supporting this housing and preventing the complete assembly dropping into the Drum Housing.
Carefully manoeuvre the Roller Assembly through the access hole, the assembly is very heavy and it is recommended that either an additional pair of hands or suitable lifting equipment are used. Take care not to lose the shimpack.
Release the Grub Screw and remove the Plummer Block and Bearing off the rear of the Shaft. Remove the Front Bearing Carrier/Housing off the shaft and retrieve the spacer. Using a soft faced hammer knock the cast Drive Pinion off the shaft, remove the Parallel Key and V’ Seal. Following the procedure for the R/H Idler Roller, strip and rebuild the Roller Shaft and Bearing. Refit the Plummer Block and Bearing to the rear of the Shaft and lock the Grubscrew. Smear theV’ Seal with grease and fit both the `V’ Seal and Parallel Key to the shaft. Slide home the cast Drive Pinion and spacer. Clean all traces of silicone sealer from the front Bearing Housing/Carrier and Mainframe mating surfaces. Refit the Housing to the Shaft, note the grease nipple is located on the top face. Apply a bead of silicone to the housing face.
Lift the Roller Assembly back into the Mainframe loosely securing the front Carrier/Housing. Insert the Shim Pack below the Plummer Block and Bearing shim the Roller and Shaft until it is horizontal.
Place a straight edge across the rear face of the Roller and ensure it is square with the opposite roller. Tighten the retaining bolts. Refit the Stop Bracket.
Refit the Upper Drive Sprocket, Drive Chain and Chain Cover as described previously.
Remove the Drum supports and lower the Drum back onto the Rollers.
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.

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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. The Tension is correct when the chain deflects 8mm- 12mm mid way between the sprockets.
To adjust the chain, remove the Inspection cover on the L/H side of the Drum Housing. Slacken the three nuts on the lower Bearing Bracket, do not slacken the nuts too much to avoid oil leaks following chain adjustment. Using the adjusting screw above the Bearing Bracket increase or decrease tension on the chain as necessary. Lock up the nuts. Replace the Inspection Covers.
Drive Chain/Sprocket Replacement
Drain the oil from the Chain case. Remove the setscrews and lift the Cast Chain Cover from the Mainframe. The joint between the Chain Cover and Backplate/Mainframe is made with Silicone Sealer and the Cover may require gently prising from the Mainframe.
Slacken the Adjustable Bearing Bracket as previously described to release the Chain Tension. Disconnect the Chain split link and remove the Chain.
To remove the upper sprocket cut the locking wire, remove the special screws and retaining washer, pull off the sprocket. Take care not to lose the key. In some cases it may be necessary to use a suitable two legged puller.
To remove the Lower Sprocket remove the Circlip and Grubscrew. Pull off the sprocket taking care not to lose the key. In some cases it may be necessary to use a suitable two legged puller.
Reassemble in the reverse order.
Re-tension the Chain as previously described on page 10.
Ensure the joint faces on the Cover and Backplate are clean. Apply a generous bead of Silicone Sealer to the Cover, allow the sealer to cure for a few minutes then refit the Covers.
Top up the oil through the inspection aperture and refit the cover plate.
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 Lower Drive Shaft. Release the adjusting screw above the Bearing Bracket remove the

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nuts from the three studs securing the Bracket and carefully pull off the Bearing Bracket taking care not to damage the gasket. If damaged the gasket must be replaced.
The Bearing Bracket is sealed to the Mainframe using a thick gasket which is coated with silicone sealer on assembly. Clean all traces of jointing materials from the Mainframe and Bearing Bracket.
Remove the Binx’ nut securing the Drive Flange to the Drive Shaft, remove the Retaining Washer and Shim Pack and pull off the Flange, remove the Seal Protector from the shaft. Using a suitable Bearing tube and a soft faced hammer knock the Drive Shaft and Taper Roller Bearing out of the Bracket from the sprocket end. Remove the Outer Bearing Cones from within the Bracket and the remaining Inner Bearing Cage off the shaft. Reassemble the Bearing Bracket assembly fitting the new Outer Bearing Cones into the Bracket using a suitable bearing tube. Fit one of the Inner Bearing Cages to the Sprocket end of the Shaft with the taper inwards i.e away from the Sprocket. Pass the Shaft complete with the Bearing through the housing from the flanged end until the Cage is located into the Outer Cone. Support the Bracket and using a suitable bearing tube fit the second Inner Bearing Cage over the Shaft and down into the Cone. Fit the parallel key and Drive Flange, (but not the Seal or Seal Protector so as not to increase the drag on the Shaft and Bearings) install the Shim Pack, Washer and Binx nut and adjust the shimming to give a bearing pre-load of 0.000″ to 0.002″ thou. Check the Shaft turns freely within the Bearings. Slacken and remove the Binx nut, Washer, Shim Pack and Flange, fit the Seal Protector over the Flange smearing the lip with a little grease, coat the lip of the Oil Seal with grease and using a suitable tool install the Oil Seal into the Bracket. Note that item No3 on the illustration, theV’ Seal, is not required.
Refit the Flange, sized Shim Pack, Washer and Binx nut to the shaft. Ensure the mating surfaces of the Bracket and Mainframe are clean and apply Silicone Sealer to both surfaces, allow the Silicone to cure for a short time then apply the gasket to the Bracket and apply a bead of Silicone Sealer to the gasket. Take care when fitting the Bracket not to damage the gasket. Refit the Propshaft.
Following the procedures described previously fit the Lower Sprocket, Drive Chain and Chain Cover. Take care when adjusting the chain not to damage the gasket. Top up the Chain Case oil and refit the inspection cover.

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Drum and Gearbox Controls
Hand Lever
The Hand lever pivot is retained on the inside of the Drum Housing with a split pin and washer, removal of the Hand lever will allow replacement of the pivot bushes, (which should be reamed to size following replacement) and the Roller and Bush.
Slotted Operating Lever
The Slotted Lever is retained to its pivot via a circlip and flat washer. To renew either the Lever or its Bushing remove the Handlever as previously described, disconnect the Connecting Rod, remove the Circlip and Washer, pull off the Lever. If the Bushing is renewed it will require reaming to size.
Reassemble in reverse order.
Connecting Rod
Disconnect the Spherical Bearing at the end of the Connecting Rod from the Slotted Lever, remove the locknut and adjusting nut from the other end of the rod. Carefully pull the Rod through the Long Sliding Gland, Clevis Block, Spring, Sleeve and Short Sliding Gland. Remove the second adjusting nut and locknut. Remove the Spherical Bearing.
Reassemble in the reverse order.
Drum Clutch Adjustment
Set the Handlever in the Mix/Charge position and rotate the nut on the Connecting rod to allow 3mm of the Short Sliding gland to protrude beyond the end of the Clevis Assembly, lock up the locking nut.
Repeat this operation in the Discharge position and rotate the nut on the Connecting Rod to allow 3mm of the Long Sliding gland to protrude beyond the end of the Clevis Assembly, lock up the locking nut.
Gearbox Removal
Disconnect the Connecting Rod as previously described.
Disconnect and plug the pipework and fittings at the Hydraulic Pump. Split the Driveshaft between the Engine and Gearbox at the Nylon Splined Coupling. Unbolt the 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.

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Engine Removal
On Electrical Start Diesel and machines fitted with a Dragline and Alternator, isolate the Battery and disconnect the wiring. Split the Driveshaft between the Engine and Gearbox at the nylon splined sliding coupling. Unbolt the Engine from the Mainframe, disconnect the Air Cleaner pipework. Using suitable lifting equipment lift the Engine clear taking care not to lose the two engine packers. (Later `CE’ machines are fitted with guarding over the propshaft)
Reassemble in the reverse order ensuring the centreline of the Engine and Gearbox are in line by shimming as necessary to avoid straining the Couplings and Flanges.
Air Filter
The Air Filter is located on the Engine/Fuel Tank Shroud on the R/H side of the mixer.
During operation dust collected the body is ejected through the rubber valve in the side of the filters cylindrical body. The Element, which should be removed daily for cleaning and replaced at least once every 300 hours or three months is retained in the main body by a large wing nut, which when released allows removal of the element for cleaning.
Hydraulic Tank
The Hydraulic Tank contains a Suction Filter suspended below the Tank Lid. To access, clean any debris from the top of the tank, disconnect the Hydraulic Pipework from the Tank Lid, plug all hoses and blank off all fittings, remove the screws and carefully lift off the Lid to avoid damaging the lid seal. Unscrew and clean the filter.
Reassemble in reverse order ensuring the seal between the Lid and Tank Body is in good condition.
Oil Draining
The oil drain plug is located centrally in the base of the Hydraulic Tank and can be accessed from below the machine.
To drain the oil run the engine and circulate the oil through the system until warm. Stop the engine and remove the Tank Lid as described above. Place a collection tray below the Tank, remove the plug and allow the Tank to drain completely. Clean out the Tank and refit the drain plug. Refit the Lid. Top up the oil until the oil is level with the tip of the cone at the base of the oil filler neck. Run the engine, operate the Hopper and Dragline Controls. Stop the engine and allow the oil in the Tank to settle for approximately two minutes before rechecking the level. Recheck the oil level in the Header Tank.

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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.
If replacing the Bleed Valve body, ensure that the Ball in the Body forms a good seat by driving the Ball down on the seat using a soft faced punch.
The tank is retained in the Mainframe by three M10 setscrews, however it is not possible to remove the Tank unless the Gearbox is first removed.
Hydraulic Pump
The Hydraulic Pump is located on top of the Gearbox secured by four setscrews and is driven through the Gearbox Bevel Gears, via a Pump Mounted Bevel Pinion. If replacing a Bevel Pinion on the pump be aware that many pumps have more than one keyway cut into the tapered shaft, selecting the wrong keyway will result in premature shearing of the key.
Hydraulic pumps should be shimmed to give 5-8 Thou (0.02-0.20mm) gear backlash.
Place the Pump Assembly 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 the correct number of shims.
Hydraulic Control Valve
The Hydraulic Control Valve is mounted on the L/H side of the machine below the step being secured to its bracket by at least two bolts, nits and washers.
Lifting the control lever raises the Hopper whilst lowering the lever lowers the Hopper.
The Control Valve powers the Single Acting Hydraulic Ram and also provides oil for the Dragline Winch Motor via a High Pressure Carryover located in one of the control valves ports. The adjustable system relief valve is located in the Control Valve and apart from a spool seal kit no and handle kit no other user serviceable parts are available.
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. Allow the ram to drop forward, the upper eye bush is now visible and can be

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replaced if necessary. When replacing the upper bush with the ram in situ it is important that the ram is prevented from moving from side to side. When fitting a new bush ensure the lubrication hole in the bush is aligned with the grease nipple.
To remove the Ram Assembly, disconnect and plug the Hydraulic Hose and the Restrictor on the Ram port. Remove the bolt retaining the lower pivot pin through the Mainframe. Support the Ram with suitable lifting equipment and knock out the lower pin.
Lift the Ram Assembly clear drain out any oil and support in a suitable soft jawed vice. Clean the area around the end cap and attaching a suitable tool unscrew the end cap, carefully remove the rod and piston assembly and secure in a soft jawed vice.
Examine the cylinder bore carefully for signs of scoring or corrosion and the piston rod for signs of pitting or peeling, it is pointless attempting to reseal a ram which has a damaged bore or rod.
Remove the split pin securing the Piston Nut and remove the Nut, Piston Assembly and End Cap. Remove and discard the old seals, new seals should be soaked in clean hydraulic oil before fitment. Ensure all components are clean. Fit the new seals, rebuild the Ram in reverse order fitting a new split pin through the piston retaining nut.
The Restrictor screwed into the Ram Inlet/Outlet port restricts the flow of oil out of the Ram as the Ram is closed ensuring a more controlled descent.
The Restrictor contains a spring and Poppet valve and does not usually cause problems in service.
Note:
The Hydraulic Ram is single Acting and in operation when the Ram is closed the majority of the Hydraulic Oil is discharged from the full bore side of the Ram. To avoid condensation forming in the annulus (upper) side of the cylinder as the Ram is closed, oil is drawn into the annulus side from the Header Tank to fill the void with oil, this oil is expelled back into the Header Tank as the Piston raises extending the Ram and lifting the Hopper.
The Header Tank contains a sight glass and it is important that the oil level within the Tank is checked on a daily basis. The oil level is correct if it is just visible in the sight glass when the ram is fully closed.
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.

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In service it is not unusual for violent operation of the Control Valve (In order to shake material free from the Hopper when the Ram is at the full extent of its stroke) to blow off the relief valve activating the Hose Failure Valve. Which then prevents closing of the Ram and lowering of the Hopper.
Should this occur, slowly lift the Hopper slightly by extending the Ram without blowing off the relief valve, then slowly close the Ram lowering the Hopper. Once the Hopper has lowered by approximately 300mm normal operation can be resumed.
If a new hose failure valve is to be fitted the valve should first be unscrewed from the body, and the gap between the valve baffles adjusted to 2mm by means of the small capscrew and nut. Following adjustment, the valve should be screwed fully home into the body and operation of the machine checked when it is fitted.
Hopper, Cradle, Link Arms and Pivot Shaft
Link Arms
The Hopper Cradle pivots on Needle Bearings contained within the “L” shaped Link Arms.
To remove the Arms lower the Hopper Cradle and block up the Hopper to prevent the assembly dropping when a Link Arm is removed.
Remove the Bearing Caps, each secured with three setscrews which pass through the Caps and Arms into the Bearing Housings. Remove the Nut and Flat Washer retaining the Link Arm to the Shaft, pull off the Arm, retrieve the Housings and “O” Rings from the Pivot Shafts.
Remove the Inner Bearing of the Shafts, using a suitable bearing tube and soft faced hammer remove the Outer Bearings from the Link Arm.
Reassemble in the reverse order greasing the Needle Bearings on Assembly.
Hopper Cradle and Hopper
Removal
Raise the Hopper slightly to allow access to the Hopper retaining bolts and nuts, attach suitable lifting equipment to the Hopper, remove the bolts and carefully lift the Hopper clear.
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.

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Pivot Shaft
The Pivot Shaft is retained in the “A” frame by two grubscrews one each end of the Shaft.
To remove the Shaft carry out the procedures describing removal of the Hopper, Link Arms and Cradle. Remove the Inner Bearings from the ends of the Shaft. Remove the grubscrews and using a soft faced hammer knock out the Shaft.
Reassemble in reverse order coating the Shaft with copperslip and ensuring the Shaft is central in the “A” frame before tightening the Grubscrews.
Batchweigher
The Batch Weigher Gauge is located on the L/H Water Tank Support and is mounted on rubbers to dampen vibrations. The Gauge is connected to the Loadcell which is located in the Mainframe below the Hopper Cradle via a hydraulic pipe.
The Loadcell and Gauge must be considered a sealed unit and on no account must the hydraulic pipe be removed.
Damage to the Gauge or Loadcell is most commonly caused by dropping a loaded Hopper onto the Loadcell, allowing an empty Hopper to free fall directly onto the Loadcell or filling the Hopper directly from a Site Dumper, Skid Steer Loader, Tipping Lorry or other similar equipment.
These cause high shock loadings which can loosen the Needle Pointer in the Gauge, damage the Loadcell seals, or cause the top half of the Loadcell to turn over at an angle.
Although the both Workshop Manual and the Operators Manual contains instructions for overhauling the unit, it is recommended that the Loadcell and Gauge Assembly are returned to Winget Limited whenever possible for repairs. Field service and repairs can often cause complications and accurate calibration of the Assembly cannot be guaranteed. Winget Limited can accept no responsibility should attempts be made to overhaul or repair the units.
Assuming the Loadcell and Gauge are in good condition the most common causes of inaccurate weighing are:-

1. Mixer not level 2) Hopper resting on ground or build up of waste material below Hopper. Ensure at
   least 50mm (2″) clearance between the ground and Hopper. 3) Build up of material around the Hopper Cradle Link Shaft. 4) Worn Hopper Cradle Pivot Bearings. 5) Loadcell Striker guide fouling Mainframe or failing to rotate freely.

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6) Worn Loadcell Striker Pin. 7) Failure to Re-Zero Batchweigher Gauge by means of the Zeroing knob on the
side of the Batchweigher Gauge.
Batchweigher Adjustment
Should the Batchweigher require adjustment the following procedure should be carried out.
With the Loadcell Striker resting on the Loadcell, check the top of the Link Arms are horizontal to within 2-3mm, and the Link Shaft is clear of the holes on the Cradle, if not, adjust the packing below the loadcell.
Check the Loadcell Striker is resting centrally on the Loadcell button, if not, slacken the setscrew below the Loadcell and adjust its position, or slacken the grubscrews securing the Hopper Cradle Pivot Shaft to the “A” frame and move the assembly over. Tighten the screws following adjustment.
Check the Loadcell Striker is at approximately 25 degrees to the Hopper Cradle, if not, adjust by altering the Loadcell Striker packing between the Striker and Hopper Cradle.
Place known weights in the Hopper to check the Gauge reading progressively throughout its range.
To increase the Gauge reading at low loads, increase the amount of packing below the Loadcell.
To increase the Gauge reading at high loads, increase the amount of packing behind the Striker.
Loadcell Striker Guide
The Loadcell Striker Guide is mounted in the Mainframe just behind the Loadcell, and rotates on Needle Roller Bearings.
To remove the Guide, raise and support the Hopper. From inside the Mainframe remove the grubscrew retaining the Guide Pivot Pin. Knock out the Pin and Lift the guide clear.
Prise out the Seals and using a suitable bearing tube and soft faced hammer remove the Needle Roller Bearings.
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.

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Feed Apron
Two or Three Compartment Feed Aprons are designed to assist the flow of materials into the Hopper in conjunction with a Dragline.
The Feed Aprons consist of L/H and R/H side panels, Base Panel, Centre Dividers (one or two depending on the option chosen) Support Bar, Rubber Flap, (to prevent materials falling between the Hopper and Apron) and Rubber Retainer.
To assemble the Feed apron, place the Base smooth side up in front of the Hopper, lay the Rubber Flap on the Base and secure with the Retainer and countersunk screws.
Using a suitable support raise the Base so that the Rubber is approximately 520 millimetres (1’8″) off the ground and the Base slopes back at an angle, bolt both Side panels in place. Remove the support so the weight of the Base is taken by the side Panels. Fit the Support Bar between the Side Panels and bolt the Centre Dividers in place.
Check that the Rubber Flap projects slightly out over the Hopper Mouth and that both are in line, stake the Feed Apron securely in place using the four picketing lugs, two on each Side Panel.
The Feed Apron can be extended backwards to separate aggregate by fitting boards into the ends of the Side Panels and Centre Dividers.
Dragline Electrical System
Two different electrical systems or method of power generation are utilised depending on the engine or electric motor fitted.
Hand Start Lister-Petter TS/TR & Electric Motor
When a Hand Start Engine or Electric Motor are fitted, the Gearbox drives via a “V” belt a 12 volt automotive type Alternator. This is in turn connected via 2 core cable to a Panel Mounted Isolator Switch and Warning Light. A Battery (acting as a storage device for the Alternators output) mounted on the R/H side of the mainframe, through a Two Pin Plug and Socket to the Shovel Mounted Operating Button/Switch and on to the Dragline Solenoid Valve.
The most common causes of electrical failure are:-

1. Break in the two core cable between the Shovel mounted Button/Switch and the Socket and Plug mounted below the Winch Motor. (If the Cable is shortened do not reduce the length to less than 19.8 metres, 65 feet).
2. Dirty or loose electrical connections at the Plug and Socket, at the Solenoid Valve, at the Alternator or Battery.
3. Bad Earth Connections.

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4) Worn or badly adjusted “V” Belt. 5) Worn or dirty Alternator Brushes. 6) Failure to turn on the Isolator Switch before starting the Engine or Motor. 7) Flat Battery.
Voltage/Setting Instructions
It is not possible to adjust the Voltage Setting but the voltage can best be measured at the Terminal Block on the Solenoid Valve.
Remove the Terminal Block, Connect a D.C. Voltmeter to the Terminal Block, operate the Isolator Switch and start the Engine or Motor. 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.
Electric Start Lister-Petter TS/TR
When an Electric Start Engine is fitted the Charging System built into the Engine provides the electrical power to operate the Dragline Solenoid Valve.
Power is taken from Terminal 2 on the Ignition Switch, through 2 core cable via a Plug and Socket through the Shovel Mounted Operating Button/Switch, back through the Plug and Socket down to the Dragline Solenoid Valve (See Wiring Diagram).
The most common causes of electrical failure are:-

1. Break in the two core cable between the Shovel Mounted Button/Switch and the Socket and Plug mounted below the Winch Motor (If the cable is shortened do not reduce the length to less than 19.8 metres, 65 feet).
2. Ignition Switch in the “Off” position. 3) Dirty or loose electrical connections at the Plug and Socket, the Solenoid Valve,
   Ignition Switch or Battery. 4) Flat Battery. 5) Charging System Failure (See Engine Workshop Manual). 6) Bad Earth Connections.
   Voltage Setting Instructions
   It is not possible to adjust the Voltage Setting but the voltage can best be measured at the Terminal Block on the Solenoid Valve.
   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

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should not exceed 14.5 volts. If the Voltmeter indicates a negative reading or reads in the reverse direction interchange the Voltmeter leads.
Dragline Winch Motor
The Dragline Winch Motor is mounted on a bracket which is supported across the Water Tank supports, the hydraulic motor itself contains no user serviceable parts and should be replaced in the event of failure. The motor and winch drum are protected by a removable cover which is retained by two setscrews and nuts.
Four replaceable Nylon or Steel Rollers are mounted directly in front of the Winch Motor and allow the Wire Rope to operate without damage. The Rollers are retained by long through bolts and self locking nuts which are removed to allow replacement of the rollers. NOTE:- The position of the rollers can be alternated to even up the wear on them and prolong their service life and later bushes are fitted with replaceable oilite bushes.
Operation of the Winch Motor is controlled by the Shovel Mounted Button/Switch via the Solenoid and Dragline Control Valves.
When correctly piped up the Winch Motor rotates in a Clockwise Direction to pull the Dragline Shovel in and freewheels in an Anti-clockwise Direction when the Dragline Shovel is being pulled out by the Operator.
If the hoses to the Winch Motor are disconnected they should be marked to aid identification and both the hose ends and fittings in the Motor plugged to prevent the ingress of dirt or foreign matter. The Dragline Winch Motor circuit is protected by a secondary `relief valve’ contained in the Dragline Control Block.
Refer to the Dragline Hydraulic System Description on Page 26 for further information.
Dragline Control Block
The Dragline Control Block is mounted onto and above the Solenoid Valve, and in conjunction with the Solenoid controls the hydraulic oil flow to the Winch Motor.
The Control Block contains no internal user serviceable components apart from a simple Relief Valve, the setting of which is altered by adding or removing Shim Washers to increase or decrease the Spring Setting which in turn increases or decreases the hydraulic pressure to the Dragline Motor.
Refer to the Hydraulic System Description for additional information.
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.

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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.
Refer to the Hydraulic System Description for additional information.
Hydraulic System Description
The Basic Hydraulic System is simple in design consisting of a gearbox mounted Hydraulic Pump, Main Hydraulic Tank onto which is mounted the Bleed Valve, the tank also contains the Suction Strainer. A Header Tank connected to the annulus side (full bore or upper) of the Hopper Ram with a drain hose to the main hydraulic tank. A Single Spool Control Valve and Single Acting Hydraulic Cylinder onto which the Flow Restrictor and Hose Failure Valve are also fitted. The Hose Failure Valves are only fitted to those machines intended for use within the European Community.
The Pump is driven by the gearbox drawing oil from the Tank through the Suction Strainer. The Pump delivers the oil to the Control Valve, if the Valve Control Lever is in the neutral position the oil is directed back to the tank through the tank return line. (When a Dragline is fitted the threaded adaptor on the tank is fitted with an additional Tee piece to allow for extra return lines)
When the Control Lever is raised to lift the Hopper, the Valve Spool directs the oil through the tank mounted Bleed Valve down to the Ram where it passes through the Hose Failure Valve (where fitted) and Flow Restrictor before operating the Cylinder.
The tank mounted Bleed Valve is designed to ensure that when the Hopper is fully lowered, no residual pressure remains in the circuit between the Cylinder and Control Valve which could affect the Batchweigher readings. The Bleed Valve contains a Ball and Spring and is ported to allow oil to flow back into the tank. Oil flowing under pressure from the Control Valve to the Cylinder enters the top of the Bleed Valve and acts on the Ball which is depressed against spring pressure closing off the Tank Port thus directing oil to the base of the Cylinder.
If the Control Lever is returned to neutral during the lift or lowering cycle, the pressure created in the circuit between the Cylinder and Control Valve by the weight of the Hopper acting on the Cylinder, is sufficient to hold the Ball on the seat within the Bleed valve, preventing the Hopper from dropping. (Should the Hopper continue to drop the Ball/Seat within the Bleed Valve possibly requires attention).
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.

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When the Hopper is fully lowered the residual pressure in the pipework between the Control Valve and Cylinder is dispersed through the Bleed Valve, allowing the Hopper’s weight to act fully onto the Batchweigher Loadcell.
The Header Tank connected to the annulus side of the Single Acting Ram is designed to ensure the cylinder is always full of oil preventing changes in climatic conditions causing the formation of damaging condensation. The oil level in the Tank can be checked on a daily basis when the Hopper is lowered via the sight glass built into the face of the Tank. The level is correct when it is just visible in the sight glass, should the tank be overfilled the excess oil will be returned to the Main Tank via the overflow/return pipe.
In service it is expected that over time oil under pressure will migrate from the full bore side of the cylinder into the annulus side, passing the piston seals as they wear. This migration will increase the level of oil in the Header Tank whilst at the same time lowering the oil level slightly in the Main Tank, once the oil in the Header Tank reaches a certain level the excess will return via the return/overflow pipe to the Main Tank.
Excessive topping up of the Header Tank may cause an increase in the oil level within the Main Tank, levels should be monitored on a regular basis and the levels reduced if necessary.
Dragline Hydraulic System
The Dragline Hydraulic System consists of a 12 Volt Solenoid Controlled Oil Distribution Block (otherwise known as the Dragline Control Block) containing an adjustable Relief Valve. A Hydraulic Motor is fitted to operate the Dragline Winch. The system is continuously supplied with oil whilst the engine is running via a High Pressure Carryover at the Main Control Valve.
When the 12 volt Solenoid is not energised, oil flow from the Main Control Valve is directed by the Distribution Block direct back to the hydraulic tank through the centre return line which terminates on the tank lid/cover. The supply and return hoses supplying oil to the Winch Motor from the Distribution Block are at the same time ported within the Block to form a closed loop enabling the Winch Motor to revolve freely with minimum resistance when the Dragline Shovel is manually pulled backwards by the operator.
When the 12 volt Solenoid is energised by operating the Shovel Button/Switch, the tank return is closed, the loop is opened and oil is directed to the Winch Motor which revolves reeling in the Dragline Shovel. Oil exiting the Winch Motor is returned to the Distribution Block where it is directed down the second return line through the tank mounted tee piece, back into the tank.
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.

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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. Check and top up the hydraulic oil level.
Disconnect the supply hose to the top of the Bleed Valve, attach a suitable tee piece to the Bleed Valve and reconnect the hose. Connect a Hydraulic Pressure Gauge to the tee piece. The gauge should preferably be a minimum of 75mm in diameter with a minimum scale reading of 3500 psi and should be attached to a length of two wire hydraulic hose C/W crimped adaptors which is long enough to reach to the operator’s station by the Control Valve.
Start the Engine or Motor and allow to run until the oil is warm. Operate the Control Valve raising the Hopper to its maximum height until the relief valve blows off’ note the maximum pressure recorded on the gauge, it should read 2400 psi (166 BAR) If the reading is higher or lower the Relief Valve requires adjusting. Lower the Hopper, stop the Engine or Motor and disperse any residual pressure as described above. If the Hose Failure Valve haslocked out’ the Ram follow the procedures described on page 17 to release. Slacken the Relief Valve locking nut (some valves may be protected by a removable cap) and identify whether the Valve is adjusted by means of a screwdriver or hexagon key.
Start the Engine or Motor and raise the Hopper again to momentarily blow off’ off the relief valve, noting the reading, release the Control Valve Lever to neutral and adjust the relief valve either clockwise or anti clockwise dependant on whether the pressure requires increasing or decreasing. Do not turn the valve more than ¼ turn each time an adjustment is made, after each adjustmentblow off’ the relief valve noting the pressure obtained until the correct pressure is recorded.
Lower the Hopper, stop the Engine or Motor, disperse any residual pressure and remove the gauge, hose and tee piece. Reconnect the supply hose directly to the Bleed Valve, clean up any oil spills and check the oil level within the tank. Top up if necessary.
Dragline Relief Valve
Check the Main System oil pressure as described above. Disperse any residual oil pressure. Identify and disconnect at the Dragline Control Block the feed hose from the Dragline Control Block upto the Winch Motor, plug the open end of the hose. Attach to the Dragline Control Block in place of the hose removed the hydraulic test gauge c/w 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.

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Operate the Dragline Isolator Switch (handstart and electric machines only). Start the Engine or Motor, there should be no need to allow the oil to warm up as it should still be warm from the previous tests, momentarily depress the Switch /Button on the Dragline Shovel to `blow off’ the relief valve and note the reading on the gauge. Do not unduly hold down the Switch/Button, only depress long enough to obtain a reading then release otherwise a steep increase in oil temperatures will be experienced and damage may be caused to the hydraulic system.
The gauge should read a maximum of 1500psi (103BAR), to adjust stop the Engine or Motor and disperse any residual pressure. Identify the large hexagon on the side of the Dragline Control Block which is the head of the relief valve and carefully unscrew, withdraw the hexagon which incorporates the spring guide, the bonded seal, spring and poppet valve. Small flat washers are placed on to the spring guide to increase the tension on the spring thereby increasing the pressure, removing a washer will reduce the pressure. During initial manufacture one washer is placed on to the spring guide and this is usually sufficient but over time in service the spring may weaken and require additional washers adding. Add or subtract a washer as may be necessary, refit the relief valve assembly and repeat the procedures described above to recheck the pressure.
Failure to attain the required pressure may indicate a worn or sticking poppet valve or worn seat.
Water Tank Description
The Tank is designed to automatically shut off the flow of incoming water once the desired measured quantity (between 10-110 litres/2-25 Gallons) is achieved.
Mounted on the front of the Tank Body is a Graduated Scale and Carrier, passing through the Carrier is a Pointer and Pivot Pin. Once the Pointer is set to the required amount on the Scale the Pointer and Scale Carrier are locked together with a wing nut and coach bolt.
Both the Scale Carrier and Pointer Pivot Pin pass into the interior of the Tank where the Scale Carrier terminates in a Cam, the Pointer Pivot Pin carries the Float Arm and Plastic Float Assembly and terminates at the Operating Lever.
Moving the Pointer along the Graduated Scale effectively raises and lowers the height of the Float Assembly in the Tank.
Mounted on the outer L/H side of the Tank adjacent to the Scale Carrier is the Water Inlet containing the Water Strainer. Attached to the Water Inlet on the inner face of the Tank is the Water Inlet Valve assembly.
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.

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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.
There is a “pin hole” orifice in the centre of the Diaphragm which allows water to pass through into a second smaller chamber in the Valve Cover where the Pilot Valve is located.
The Pilot Valve is held off its seat, against spring pressure, by the Trip Lever allowing the water to bypass the Pilot Valve and bleed into the Tank via a drilling in the Cover, thereby preventing water pressure building up in the second chamber. The Trip Lever is operated by the Cam located on the end of the Scale Carrier.
Water entering the Tank through the Inlet Valve very quickly reaches the level of the Float set by the Pointer which is locked to the Scale Carrier and Cam. The rising water level lifts the float/Pointer/Scale Carrier and Cam assembly causing the Trip Lever to “trip”, allowing the Pilot Valve to close preventing incoming water bleeding out of the second chamber.
Incoming water is still passing through the orifice but because it can no longer escape past the Pilot Valve, water pressure in the smaller second chamber increases equalling the pressure in the first chamber allowing the stretched Diaphragm to return to its original position, closing off the incoming water.
A seal is maintained by the Diaphragm against the first chamber due to the differential areas in the two chambers, i.e. the second chamber now has a greater effective surface area than the first chamber.
Pulling down on the Operating Lever opens the Discharge Valve in the base of the Tank discharging water into the Drum.
Pushing up on the Operating Lever closes the discharge Valve, resets the Trip Lever and opens the Pilot Valve allowing water to enter the tank once again.
The most common symptoms of Water Tank failures and their causes are:-

1. Reduced water flow ­ blocked Water Strainer or insufficient head of water or lack of water pressure.
2. Water leaking from the discharge Pipe ­ Worn or perished Discharge Valve Rubber Seat or corroded Valve.
3. Float failing to lift ­ punctured Float. 4) 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. 5) To high a water pressure causing the Diaphragm to stretch or split

WORKSHOP MANUAL 500R
WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 11 2021
Strainer Replacement
Turn off the water supply. Remove the hexagonal plug from the strainer body, lift out the strainer, clean or renew. Refit in reverse order sealing the threads of the plug with P.T.F.E. tape and threadseal. Turn on the water supply and check for leaks.
Diaphragm Replacement
Turn off the water supply. Remove the split pins retaining the trip Lever pivot pin through the Inlet Valve Cover, remove the binx nuts securing the pin to the Operating Lever and Scale Carrier Support. Slide out the pivot pin retrieving the Trip Lever.
Remove the eight setscrews (seven short, one long) holding the Valve Cover to the body retrieving the fibre or nylon washers. Lift off the cover and remove the Diaphragm. Clean out the Body and Cover.
Fit the new diaphragm, inspecting for damage, note the Brass Face should face the Pilot Valve. Reassemble the Valve, replacing any damaged Fibre or Nylon sealing washers. Do not overtighten the setscrews retaining the cover or the Diaphragm will not operate correctly and the fibre washers may split.
On completion adjust the long setscrew opposite the Trip Lever so that when the Pilot Valve is closed the gap between the head of the setscrew and triplever is 1mm.
Pilot Valve and “O” Ring
Follow the previous instructions under Diaphragm Replacement and remove the Inlet Valve Cover.
The Pilot Valve is retained in the Cover by a split pin, flat washer and Spring. Remove the Pilot Valve and “O” Ring. Reassemble in reverse order following the instructions under Diaphragm Replacement.
Float
Turn off the water supply. Loosen the locknut slightly and unscrew the Float. Fit the new Float in the same position on the Float Arm to avoid upsetting the Tank Calibration.
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

WORKSHOP MANUAL
500R
WINGET REVERSING DRUM CONCRETE MIXERS
ISSUE 11 2021
opening in the Tank base. Knock out the Roll Pin securing the Discharge Valve to the Rod.
Reassemble in the reverse order screwing the Discharge Valve Rod back to its original position in the Connector to avoid upsetting the Tank Calibration. Renew the plastic sealing washers on the Water Outlet pipe if damaged.
Water Tank Adjustment and Calibration
Following major overhauls of the Water Tank it will be necessary to re- calibrate the Graduated Scale, Scale Carrier, Pointer and Float Assembly to ensure the Tank delivers the amount of water pre-set on the Graduated Scale.
A large set of platform scales with a minimum reading of around 200lbs and a water collection tank of around 25 gallons capacity will be required to calibrate the Tank and the following procedures should be carried out.

1. Connect a suitable water supply to the Water Inlet, it will be more convenient for the purposes of the test if a shut off tap is located adjacent to the Tank.
2. Check that the ends of the Graduated Scale align with the outer edge of the Scale Carrier, loosen the wing nut and make sure the Pointer and Float Arm move freely.
3. Checking the Discharge Valve is closed, turn on the water supply allowing water to enter the Tank through the Inlet Valve until the water is level with the top of the baffle within the Tank. The height of the baffle equates to a water level of eight gallons. Turn off the water supply. Allow the Pointer/Float to stabilise and check the reading on the Graduated Scale. Depending on the distance the Pointer is from the 8 gallon mark on the Scale, either move the Scale along the Scale Carrier to align with the Pointer, or shorten the Float Arm by screwing further through the Pointer Pivot Pin or slightly bend the Float Arm so the Pointer and Graduated Scale are correctly aligned on the 8 gallon mark. Open the Discharge Valve and drain the Tank. Close the Discharge Valve resetting the Tank.
4. Place the collection tank on the platform scales and position below the Water Discharge pipe. Zero the platform scales.
5. Set the Pointer to the 8 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.
   Check the weight registered by the platform scales, as a gallon of water weighs 10lbs the platform scales should read 80lbs.

WORKSHOP MANUAL 500R
WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 11 2021
If the reading is lower than 80lbs bend the Float Arm slightly, raising the Float, thereby allowing more water to enter the Tank before the Float trips the Inlet Valve. If higher than 80lbs bend the Float Arm to lower the float and re-test from “5”. 6) When the 8 gallon/80lbs test is successfully completed, set the Pointer to 16 gallons and re-test, a reading of 160lbs should be achieved on the platform scales. 7) Drain the Tank, refit to the mixer.

WORKSHOP MANUAL 500R
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 500R
SECTION 4

SERVICE SCHEDULES LUBRICATION DIAGRAM

WORKSHOP MANUAL 500R
WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 11 2021

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.

Clean out drum and hopper

Wash down the mixer

Drain the water tank or flow meter.

Weekly: (40 Hours) The above and the following:

Dragline Wire Rope

Check for wear or damage

Drive Chain

Check tension, adjust if necessary

Drive Chain Case

Check oil level, top up if necessary.

WORKSHOP MANUAL 500R
WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 11 2021

Hydraulic Oil
Dynamo/Alternator Drive Controls and Pivots Battery

Check level in main and header tanks. (with hopper down and engine stopped)
Check belt tension, adjust if necessary
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
Drum Drive

Check oil tank, filler and breather, clean if neccessary.
Inspect and lubricate the faces and teeth of the drum track ring, gear idler rollers and edge rollers using open gear lubricant.

Every 3 Months: (300 Hours)

The above and the following: Engine

Change air filter element

Change lubrication oil and filter

Change fuel filter

(Also see relevant Engine Handbook/Workshop Manual)

Every 6 Months: (600 Hours)

The above and the following: Gearbox

Drain and refill

Drive Chain Case

Drain and refill

WORKSHOP MANUAL 500R
WINGET REVERSING DRUM CONCRETE MIXERS ISSUE 11 2021

Every 12 Months: (1200 Hours or earlier if conditions dictate)

The above and the following: Hydraulics

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 500R
SECTION 5 HYDRAULIC CIRCUIT
DIAGRAMS

Hyd circuit.dwg 04/03/02 12:56:51 Scaled to fit

Hyd. Circuit – RSeries Mixer (With dragline).dwg 04/03/02 12:58:17 Scaled to fit

WORKSHOP MANUAL 500R
SECTION 6

WIRING DIAGRAMS

LISTER-PETTER `NISCA’ CHARGING SYSTEM

WIRING DIAGRAM

WIRING COLOUR CODES
1 STARTER MOTOR-REG’B’ 2 START SWITCH TER 1-STARTER MOTOR 3 START SWITCH TER 3 -STARTER SOLENOID 4 START SWITCH TER 4-REG `C’ 5 REG’LE’-WARNING LAMP 6 START SWITCH TER 4- LAMP

B+ C
LE
4
5

TO AVOID BREAKING MOUNTING LUGS OFF THE REGULATOR CLEAN PAINT OFF THE FANSHROUD BOSSES AND ENSURE REGULATOR IS SEATED LEVEL ON BOTH BOSSES

WARNING LIGHT

RED (THICK) BROWN WHITE/RED RED(THIN) BLACK BLACK (BRIDGE WIRE)
START SWITCH

YELLOW RED
YELLOW

3 35/0.30

1

35/0.30

2 65/0.30

6

5

14/0.30

4 2
3

2

65/0.30

4

14/0.30

3

5

14/0.30

35/0.30

21000/2B1500/2B2000/4B2000/4B2500/4B3000/4S2000E/4S2500E/200TM/300R/400R/500R/FFB COLLECTOR 1000

Hourmeter & lamp.dwg 04/03/02 12:50:36 Scaled to fit

Hourmeter no lamp.dwg 04/03/02 12:53:33 Scaled to fit

loom.dwg 04/03/02 12:59:24 Scaled to fit

Alternator.dwg 04/03/02 13:33:44 Scaled to fitWORKSHOP MANUAL 500R
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.

Lister Petter TS/TR3-01 Standard Build (79/113)

10 metre

111Lwa

Operators Ear

98Lpa

Lister Petter TS/TR3-01 Standard Build (2000/14/EC)

10 metre

115Lwa

Operators Ear

98Lpa

Lister Petter TS/TR3 Low Noise Build with cladding kit fitted to mainframe and engine (79/113)

10 metre

109Lwa

Operators Ear

97Lpa

415 Volt Electric Motor (79/113)

10 metre

109Lwa

WORKSHOP MANUAL 500R
SECTION 8

SPECIAL TOOLS

TOOL1.dwg 04/03/02 13:02:23 Scaled to fit

TOOLS3.dwg 04/03/02 13:06:20 Scaled to fit

TOOLS2.dwg 04/03/02 13:07:58 Scaled to fit

TOOL.dwg 04/03/02 13:01:18 Scaled to fit

TOOL.dwg 05/07/02 06:41:07 Scaled to fit

WORKSHOP MANUAL 500R
SECTION 9 HYDRAULIC CONTROL VALVE SERVICE MANUAL

PAGE INTENTIONALLY BLANK

WORKSHOP MANUAL 500R
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. For a breakdown of these items please refer to the
Operators and Parts Manual

50 0R 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 FLANGE FACE OF COVER ITEM 19, ALLOW TO CURE FOR A SHORT TIME BEFORE ASSEMBLY. DO NOT FILL CHAIN CASE WITH OIL UNTIL SILICONE HAS CURED

500R MAINFRAME TANK SUPPORTS + COVERS

1

555226500

2

555225400

3

555225300

5

555225900

5A

6S05M

5B

10S04

5C

41S07

5D

9S04

6

555225800

6A

6S05M

6B

10S04

6C

41S07

6D

9S04

7

V2003183

8

555189900

8A

28S03E

8B

10S03

8C

41S05

8D

9S03

9

555190400

9A

555163500

10

555131500

12

221101000

13

555193100

14

555193200

16

555193400

19

555112800

21

555114700

22

555168100

23

127S03

23A 100S03

24

V2000772

26

28S03E

26A 6S03B

27

87S03

28

10S03

28A 17S05

29

66S02BB

29A 41S04

31

90S06J

32

41S07

32A 10S04

33

6S05Z

34

87S05

35

10S04

36

11S04C

37

28S05G

38

9S04

MAIN FRAME

1

GUARD DRUM

1

PLATE COVER

2

SUPPORT, WATER TANK, L/H FOR STEP

1

BOLT

3

WASHER FLAT

3

WASHER SPRING

3

NUT

3

SUPPORT, WATER TANK, R/H FOR ENGINE HOUSING

1

BOLT

3

WASHER FLAT

5

WASHER SPRING

3

NUT

3

SAFETY WALK, SELF ADHESIVE, CUT TO SHAPE

1

GUARD/FENCE UK/EUROPE/NORTH AMERICA/AUSTRALIA

1

SCREW SET

3

WASHER FLAT

3

WASHER SPRING

3

NUT

3

STEP UK/EUROPE/NORTH AMERICA/AUSTRALIA

1

STEP-REST OF THE WORLD

1

COVER – CONTROL SIDE

1

SPRING CATCH

2

SHROUD FUEL TANK

1

COVER FUEL TANK

1

LATCH

1

COVER CHAIN CASE

1

COVER CHAIN INSPECT

1

GASKET COVER

1

PLUG BLANK 3/8 BSP

1

SEAL BONDED 3/8 (NOT ILLUSTRATED)

1

SEALER SILICONE

1

BOLT

9

BOLT (WATER TANK OPERATING ROD BRACKET)

2

NUT BINX

11

WASHER FLAT

11

WASHER SPRING

4

SCREW SET

8

WASHER SPRING

8

SCREW SKT CAP

8

WASHER SPRING

8

WASHER FLAT

8

SCREW SET (WATER TANK)

8

NUT BINX

8

WASHER FLAT

8

SCREW SET

4

SCREW SET

2

NUT

2

500R MAINFRAME TANK SUPPORTS + COVERS

39

10S04

WASHER FLAT

2

40

41S07

WASHER SPRING

2

41

28S03E

SCREW SET

3

41A 10S03

WASHER FLAT

3

42

9S03

NUT

3

42A 41S05

WASHER SPRING

3

43

66S01CC

SCREW SET

1

44

192S01

NUT BINX

1

45

10S01

WASHER FLAT

1

46

233S03F

SCREW COUNTER SUNK

6

46A 267S03

WASHER FLAT

6

47

7S01

NUT

6

48

17S02

WASHER SPRING

1

49

6S02J

BOLT

6

50

41S04

WASHER SPRING

6

51

66S01BB

SCREW SET

4

52

41S03

WASHER SPRING

4

500R 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

500R FRONT AXLE TOWBARS AXLE SPRAGS & JACKS

2

555101200

BAR TOW STANDARD

1

2A

555283300

BAR TOW NATO/MOD

1

2B

555283600

EYE TOWING NATO/MOD

1

2C

150S15

WASHER FLAT

1

2D

92S15

NUT CASTLE

1

2E

44S18N

PIN SPLIT

1

3

555101400

PIN PIVOT AXLE

1

5

555101900

PIVOT BRACKET

1

6

513354800

PIN RETAINING

2

6A

902S02

LYNCH PIN & CHAIN

2

8

555287300

AXLE FRONT STANDARD/NATO

1

9

44S17K

PIN SPLIT

2

10

8S03E

BOLT

1

10A 61S03

NUT BINX

1

11

44S17K

PIN SPLIT

2

17

555255700

TIE BAR AXLE

1

37

10S20

WASHER FLAT

2

38

10S43

WASHER FLAT

1

40

10S65

WASHER FLAT

2

55A 555285600

JACK HYDRAULIC

1

56

555267800

PIN LOCKING

4

56A 124108001

BUCKLE

4

57

555190500

SUPPORT FOOT

4

63

555256200

SCREW AXLE SPRAG

2

64

555255900

PIN AXLE SPRAG

2

65

44S05H

PIN SPLIT

4

5 0 0 R PN EU M AT I C WH EELS, H U BS & ST U B AX LES

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

WHEN THE WHEEL IS ATTACHED TO THE HUB ROCK THE WHEEL TO CHECK FOR EXCESS HUB BEARING PLAY

500R HUB STUB AXLE AND PNEUMATIC WHEELS

1

555287600

HUB & STUB AXLE ASSY (FAD)

4

15

475600019

WHEEL ASSEMBLY

4

20

105S05

WASHER TAPERED

8

21

8S05M

BOLT UPPER

8

22

8S05K

BOLT LOWER

8

23

267S07

WASHER FLAT

16

24

17S06

WASHER SPRING

16

25

7S05

NUT PLAIN

16

26

555226500

MAINFRAME

1

26A 555287300

AXLE FRONT/STANDARD/MOD/NATO

1

500R 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

500R HUB STUB AXLE AND STEEL WHEELS

2

511146701

WHEEL STEEL, FABRICATED

4

7

150S15

WASHER FLAT

4

10

555277900

COLLAR

4

11

6S03M

BOLT

4

12

41S05

WASHER SPRING

4

13

9S03

NUT

4

15

131S01

NIPPLE GREASE

4

15A 176S01

CAP NIPPLE

4

19

555288500

AXLE STUB

4

20

105S05

WASHER TAPERED (SEE NOTE RE 267S07)

8

21

8S05M

BOLT

8

22

8S05K

BOLT

8

23

267S07

WASHER FLAT

16

24

17S06

WASHER SPRING

16

25

7S05

NUT

16

26

CHASSIS-FRONT AXLE

1

500R NOISE REDUCTION KIT
REFER TO THE ENGINEERING DRAWING WHEN DRILLING THE MAINFRAME AND PANELS TO SECURE THE CLADDING KIT.

500R NOISE REDUCTION KIT

80

555286500

KIT NOISE REDUCTION

1

81

61S02

NUT BINX

30

82

10S56

WASHER

30

83

11S02C

SCREW SET

30

500R ‘CE’ GUARDING

500R ‘CE’ GUARDING

2

555291100

GUARD HORIZONTAL

1

3

555290800

GUARD ANGLED

1

5

555290900

GUARD ELECTRIC MOTOR-GEARBOX COUPLING

1

5

555291000

GUARD LISTER TS3-GEARBOX COUPLING

1

10

7S03

NUT

12

11

17S04

WASHER SPRING

12

12

267S05

WASHER FLAT

12

13

V2004220

WASHER SPECIAL

12

14

11S03C

SCREW SET

12

555131500 COVER RETAINED BY:-

11S03C

SCREW SET

2

267S05

WASHER FLAT

2

17S04

WASHER SPRING

2

7S03

NUT

2

500R 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

500R ANTI BOUNCE BRACKET

1

555288600

BRACKET ANTI BOUNCE

1

4

66S06D

SCREW SET

1

5

104S06

NUT

1

6

41S09

WASHER SPRING

15 0 0 R H Y DRAU LI C TAN K ASSEM BLY
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 T H READED PORT ON T HE TANK COVER SHOULD BE BLANKED OFF USING A 120S03 CAP, THE HOPPER RAM RETURN HOSE T ERMI N AT ES AT T H E1 /4 BSP PORT.

500R HYDRAULIC TANK ASSEMBLY

1

555257900

TANK HYDRAULIC

1

2

555284800

COVER

1

3

555255600

BODY BLEED VALVE

1

4

555264000

GASKET BLEED VALVE

1

5

555267100

SPRING BLEED VALVE

1

6

10565A01

BREATHER FILLER

1

7

220591000

STRAINER

1

8

127S02

PLUG TANK DRAIN

1

8A

100S02

SEAL BONDED

1

9

101120000

BALL STEEL

1

10

100S03

SEAL BONDED

1

11

100S04

SEAL BONDED

1

12

122S03

FITTING ADAPTOR, MALE, STUD

1

13

119S08

FITTING ADAPTOR, MALE, STUD

1

14

417735000

GASKET TANK COVER

1

20

11S04C

SCREW SET

3

21

7S04

NUT

3

22

17S05

WASHER FLAT

3

23

11S02A

SCREW SET

8

24

17S03

WASHER SPRING

6

25

332719000

NUT CAPTIVE

6

26

7S02

NUT

2

27

17S03

WASHER SPRING

2

31

101S07E

RIVET

6

5 0 0 R REV ERSI N G GEARBOX AN D FI TT I N GS

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 PU M P AN D CAST I NG AN D ADD 5 -8 TH OU (0 .0 2 -0 .2 0 M M ) T O M EASU REM EN T OBT AI NED TO GIVE CORRECT GEAR BACKLASH. ADD SHIM PACK EQUIVALENT TO TOTAL MEASUREMENT.

FI LL WI T H 2 0 W/3 0 OI L

IF DRAGLINE IS TO BE FITTED LOOP V BELT OVER PULLEY WHEN FITTING GEARBOX
CENTRE LINE OF ENGINE AND GEARBOX SHOULD BE ADJUSTED USING SHIM PACK ITEM 2, PLAIN NUTS ON DRIVE COUPLINGS SHOULD BE CHANGED TO BINX NUTS.

500R REVERSING GEARBOX AND FITTINGS

1

555268100

GEARBOX REVERSING

1

2

555107400

SHIM PACKER SET

1

CONSISTS OF

1 X 555107401

1 X 555107402

2 X 555107403

3

6S05F

BOLT

4

4

10S04

WASHER FLAT

4

5

87S05

NUT BINX

4

6

192S07

NUT BINX

2

7

SHIM SET – SUPPLIED WITH GEARBOX

1

8

555106100

GEAR PINION SUPPLIED WITH GEARBOX

1

9

555107000

WASHER CENTRE SUPPLIED WITH GEARBOX

1

5 0 0 R H OPPER RAM , REST RI CTOR & H OSE FAI LU RE VALV E
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. IT IS IMPORTANT THAT THE VALVE IS FITTED ONTO THE RAM THE CORRECT WAY ROUND OTHERWISE THE VALVE WILL FAIL TO FUNCTION CORRECTLY
THE REST RI CTOR I S FI T T ED T O ALL CE’ MARK ED AN D N ONCE’ M ARKED M ACHI N ES, THE HOSE FAILURE VALVE IS FITTED ONLY TO `CE’ MARKED MACHI NES I NTENDED FOR SALE AND USE WITHIN THE EUROPEAN COMMUNITY.

500R HOPPER RAM, RESTRICTOR & HOSE FAILURE VALVE

1

272150000

RAM HOPPER

1

2

555167900

WASHER

2

3

555108500

PIN

2

4

6S03G

BOLT

2

5

87S03

NUT, “BINX”, SELF-LOCKING

2

20

119S08

FITTING, ADAPTOR, MALE/MALE

1

21

100S04

SEAL, BONDED

2

22

555247000

POPPET

1

23

555247100

FITTING, ADAPTOR, RESTRICTOR

1

24

424210500

SPRING COMPRESSION

1

30

V2004171

VALVE HOSE FAILURE

1

31

122S03

ADAPTOR MALE/MALE

1

32

100S03

SEAL BONDED

2

500R LISTER TR3 ENGINE AND COUPLING

SET ENGINE RPM TO 1800
8
UK ENGINES MUST BE FILLED WI TH 1 0 W/3 0 EN GI N E OI L.

9 7

4

5

6

CENTRES OF ENGINE AND GEARBOX OUTPUT/ INPUT SHAFTS MUST BE ALIGNED TO AVOID STRAINING COUPLING AND SLEEVE

500R LISTER TR3 ENGINE AND COUPLING

1

20351A02

1A

V2003680

1B

20351A03

1C

20351A04

ENGINE LISTER TR3 HANDSTART (EXPORT VERSION)

1

ENGINE LISTER TR3 ELECTRIC START (EXPORT VERSION)

1

ENGINE LISTER TR3 HANDSTART (UK/EEC VERSION)

1

ENGINE LISTER TR3 ELECTRIC START (UK/EEC VERSION

1

4

555248601

COUPLING-GEARBOX

1

5

555280900

COUPLING-ENGINE

1

6

147320001

SLEEVE COUPLING-NYLON

1

7

304712863

KEY PARALLEL

1

8

90S04L

SCREW SOCKET CAP

4

9

188S04E1

SCREW GRUB

1

11

6S05K

BOLT ENGINE

4

12

10S04

WASHER FLAT

4

13

87S05

NUT BINX “SELF LOCKING”

4

15

555281200

SHIM PACKER ENGINE

4

5 0 0 R LI ST ER T R3 EN GI N E & COU PLI N G, K T R/BOWEX M 6 5

SET ENGINE RPM TO 1800
8
UK ENGINES MUST BE FILLED WI T H 1 0 W/3 0 EN GI N E OI L.

9 7

4

5

6

CENTRES OF ENGINE AND GEARBOX OUTPUT/ INPUT SHAFTS MUST BE ALIGNED TO AVOID STRAINING COUPLING AND SLEEVE

500R LISTER TR3 ENGINE & COUPLING, KTR/BOWEX M65

FROM SERIAL NUMBER 0640 ONWARDS

1

20351A02

1A

V2003680

1B

20351A03

1C

20351A04

ENGINE LISTER TR3 HANDSTART (EXPORT VERSION)

1

ENGINE LISTER TR3 ELECTRIC START (EXPORT VERSION)

1

ENGINE LISTER TR3 HANDSTART (UK/EEC VERSION)

1

ENGINE LISTER TR3 ELECTRIC START (UK/EEC VERSION

1

4

V603759#

COUPLING-GEARBOX , KTR/BOWEX

1

5

V203760#

COUPLING-ENGINE, KTR/BOWEX

1

6

V603761#

SLEEVE COUPLING-NYLON, KTR/BOWEX

1

7

304712863

KEY PARALLEL

1

8

90S04L

SCREW SOCKET CAP

4

9

57S06G1#

SCREW GRUB, KTR/BOWEX

1

11

6S05K

BOLT ENGINE

4

12

10S04

WASHER FLAT

4

13

87S05

NUT BINX “SELF LOCKING”

4

15

555281200

SHIM PACKER ENGINE

4

PARTS MARKED “#” SUPPLIED AS PART OF ASSEMBLY NUMBER:-

555292200

COUPLING ASSEMBLY, KTR/BOWEX M65

1

500R EXHAUST SILENCER
SETSCREW ITEM 7 PICKS UP ON MAINFRAME

500R EXHAUST SILENCER

1

555288900

SILENCER ACOUSTIC EXHAUST

1

2

10293A03

GASKET

1

4

17S05

WASHER SPRING M10

2

5

11S04C

SCREW SET M10

2

6

555289000

BRACKET SILENCER SUPPORT

1

7

11S04F

SCREW SET M10

1

8

267S06

WASHER FLAT M10

2

9

17S05

WASHER SPRING M10

1

10

7S04

NUT M10

1

11

11S04C

SCREW SET M10

1

12

267S06

WASHER FLAT M10

2

13

17S05

WASHER SPRING M10

1

14

7S04

NUT M10

1

5 0 0 R AI R CLEANER AND PI PEWORK- FI LT REL

500R AIR FILTER AND PIPEWORK-FILTREL

1

V2004797

AIR FILTER ASSEMBLY, FILTREL

1

10

11S03B

SCREW SET

4

11

17S04

WASHER SPRING

4

12

267S05

WASHER FLAT

4

13

555188700

HOSE ELBOW RUBBER INLET

1

14

555280000

TUBE INLET STEEL

1

15

V600187

HOSE ELBOW 90′ RUBBER

1

16

97S13

CLIP HOSE

4500R AIR CLEANER AND PIPEWORK- VIRGIO

500R AIR FILTER AND PIPEWORK-VIRGIO

12

V2005807

AIR FILTER ASSEMBLY C/W BAND, VIRGIO

1

12A 11S03D

SCREW SET, M8 X 30

2

12B 267S05

WASHER FLAT

4

12C 61S03

NUT BINX

2

13

555188700

HOSE ELBOW RUBBER INLET

1

14

555280000

TUBE INLET STEEL

1

15

V600187

HOSE ELBOW 90′ RUBBER

1

16

97S13

CLIP HOSE

4

5 0 0 R 1 5 K W MOTOR AND DRI VE SHAFT 4 1 5 VOLT

500R 15KW MOTOR MOUNT AND DRIVE SHAFT

1

202426000

MOTOR ELECTRIC 15 KW

1

2

555145400

MOUNTING MOTOR

1

3

10S04

WASHER FLAT

8

4

28S05G

SETSCREW

4

5

6S05E

SETSCREW

4

6

87S05

NUT BINX

8

7

555142600

SHAFT CONNECTING

1

8

555145500

FLANGE DRIVE

1

9

555258100

ADAPTOR DRIVE

1

10

90S04H

SCREW CAP

4

11

195S03C2

SCREW GRUB

1

12

304712863

KEY

1

13

130972000

COUPLING LAYRUB

2

14

8S05H

BOLT

8

15

267S07

WASHER FLAT

8

16

61S05

NUT BINX

8

ITEMS 14-15-16 ARE SUPPLIED WITH LAYRUB COUPLING ITEM 13.

500R 15KW 415V MOTOR AND DRIVE SHAFT LATER TYPE

500R 15KW 415V MOTOR MOUNT DRIVE SHAFT LATER TYPE

1

202426000

MOTOR ELECTRIC 15 KW

1

2

555145400

MOUNTING MOTOR

1

3

10S04

WASHER FLAT

8

4

28S05G

SETSCREW

4

5

6S05E

SETSCREW

4

6

87S05

NUT BINX

8

7

304712863

KEY

1

8

188S04E1

SCREW GRUB

1

9

555291700

COUPLING MOTOR

1

10

147320001

COUPLING SLEEVE NYLON

1

11

90S04L

SCREW SOCKET HEAD CAP

4

12

555248601

COUPLING GEARBOX

15 0 0 R START ER AN D STOP SWI TCH 4 1 5 VOLT

500R STARTER AND STOP SWITCH

1

208304103

2

208304105

3

555144200

4

6S03B

4A

CSE182

5

41S05

6

9S03

7

11S02A

8

17S03

9

7S02

10

208870000

11

103S02D

12

41S03

13

104S01

14

131770010

14A 144700200

14B 144700100

15

11S02C

16

17S03

17

7S02

18

V2004640

19

131736000

20

030788102

21

030788103

22

133275050

23

131575020

24

131271000

25

133272000

26

131272000

27

131592025

SWITCH STARTER-SCHNEIDER RELAY-OVERLOAD 28A-31A BRACKET STARTER BOLT SPACER (USED TO MOVE BRACKET AWAY FROM MOTOR) WASHER SPRING NUT SCREW SET WASHER SPRING NUT SWITCH STOP C/W KEYS SCREW SKT CAP WASHER SPRING NUT CONDUIT (1.5 MTR LONG) WIRE EARTH GREEN/YELLOW WIRE RED SCREW SET WASHER SPRING NUT P ‘CLIP’ NORMA 22MM CONDUIT 1 MT LONG WIRE RED WIRE EARTH GREEN/YELLOW NUT LOCK THIN M25 REDUCER COUPLING KOPEX NUT LOCK THIN M20 COUPLING KOPEX CONVERTER PG 29 TO M25 (IF REQUIRED)

1 1 1 4 4 4 4 4 4 4 1 2 2 2 1 2MT 4MT 2 2 2 2 1 6MT 1MT 3 1 2 2 2 1

500R DRUM DRIVE AND IDLER ROLLER

SH I M T O GI V E BEARI N G PRELOAD OF 0 .0 0 0 ”-

0 .0 0 2 ”, ALL SH I M S WI T H T H E EX CEPT I ON OF

0 .0 6 0 ” T O BE FI T T ED AT

THIS END

ON E 0 .0 6 0 ” T H I CK SH I M T O BE FI T T ED AT T H I S

END

APPLY LOCTITE OR THREADLOCK TO THE THREADS OF BOLTS ITEMS 57 & 57A

ADJUST THE SHIMS ITEM 23 SO THAT BEARINGS ITEM 31 ON LOWER SH AFT ARE PRELOADED BY 0 .0 0 ”-0 .0 0 2 ”

ADJUST DRIVE CHAIN ITEM 32 BEFORE LOCKING UP NUTS ITEM 52. CHAIN SHOULD DEFLECT 12MM IN TOTAL MIDWAY BETWEEN SPROCKETS. COAT GASKET, BEARING BRACKET AND MAINFRAME WITH SILICONE SEALER AND ALLOW TO CURE SLIGHTLY PRIOR TO ASSEMBLY.

500R DRUM DRIVE AND IDLER ROLLER

1

555223800

DRIVE SHAFT LOWER

1

2

555107200

WASHER RETAINING

1

4

555113300

DRIVE PINION DRUM

1

5

555223300

CHAINWHEEL

1

6

555223700

IDLER ROLLER

1

7

555113100

CARRIER BEARING

1

8

555223400

BRACKET BEARING ADJUST

1

9

555223600

CARRIER BEARING

1

9A

555225100

SHIM PACK ROLLER BRG

1

10

555223500

CARRIER BEARING

1

11

555224200

DRIVE SPROCKET DIESEL

1

11A 555229100

DRIVE SPROCKET ELECTRIC

1

13

555224000

SHAFT DRIVE UPPER

1

14

555114300

SPACER LONG

1

14A 555224100

SPACER SHORT

1

16

555114400

PLATE END

1

17

555114900

SHIM PACKER SET

1

18

555224900

SHIM PACKER THICK

1

19

285S07G

SCREW SET SPECIAL

2

19A 477356000

WIRE LOCKING (NOT ILLUSTRATED)

1

20

555284900

GASKET

1

21

555228600

BRACKET STOP

1

23

555225000

SHIM PACKER SET

1

25

V600186

BEARING TAPER ROLLER

2

26

111452000

BEARING

1

27

351931000

BEARING PLUMMER BLOCK

1

28

417774000

SEAL OIL

1

29

417732440

SEAL OIL

1

30

417773000

SEAL ‘V’ RING

1

31

119325000

BEARING TAPER ROLLER

2

32

134108046

CHAIN DIESEL

1

32A 134108047

CHAIN ELECTRIC

1

34

304213200

KEY PARALLEL

1

35

304714950

KEY PARALLEL

1

36

304712845

KEY PARALLEL

1

37

304106140

KEY PARALLEL

1

38

142326000

CIRCLIP

1

39

412818600

PROPSHAFT

1

41

555257600

FLANGE DRIVE

1

44

333601010

NIPPLE GREASE 135

1

44A 176S01

COVER NIPPLE GREASE

1

47

555224300

COVER SEAL PROTECT

1

50

61S06

NUT BINX

1

51

6S05G

BOLT

4

52

9S04

NUT

9

53

41S07

WASHER SPRING

9

53A 10S04

WASHER FLAT

3

54

411350816

STUD

3

500R DRUM DRIVE AND IDLER ROLLER

55

28S05N

56

95S05

57

8S03C

57A 8S03B

57B 17S04

58

57S06D2

59

17S05

59A 8S04G

59B 8S04J

61

11S03H

62

56S03

63

6S05M

64

11S03B

65

17S04

66

10S04

67

131S01

68

176S01

SCREW SET NUT LOCK THIN

BOLT BOLT WASHER SPRING SCREW GRUB WASHER SPRING BOLT BOLT, ALTERNATIVE USE WITH PACKING PIECE SCREW SET NUT LOCK THIN BOLT SCREW SET WASHER SPRING WASHER FLAT NIPPLE GREASE (FITTED IN IDLER ROLLER) COVER NIPPLE GREASE 1- ROLLER 1- PLUMMER BLOCK 3- PROPSHAFT

1 1
4/6 4/6 8/12 1 2 2 2 1 1 2 12 12 4 1 5

SHIM TO GIVE BEARING PRELOAD OF 0 .0 0 0 “-0 .0 0 2 “. ALL SH I M S WI T H T H E EXCEPTION OF ONE 0.060″ TO BE FITTED AT THIS END

ONE 0.060″ THICK SHIM TO BE FITTED AT THIS END

500R DRUM IDLER ROLLER AND SHAFT

APPLY LOCKTITE OR THREADLOCK TO THREADS OF BOLTS ITEMS 13 & 13A
IDLER ROLLER SHOULD BE SET HORIZONTAL IN THE MAINFRAME AND PARALLEL TO THE OPPOSITE IDLER ROLLER. CHECK WITH SPIRIT LEVELS AND STRAIGHT EDGES.

500R DRUM IDLER ROLLER AND SHAFT

1

555223600

2

555113000

3

555225100

4

555114900

5

555224900

6

555228600

7

555223900

8

555113800

9

V600186

10

417732440

11

131S01

11A 176S01

12

555223700

13

8S03C

13A 8S03C

14

17S04

15

6S05F

16

9S04

17

41S07

18

8S04G

18A 8S04J

19

56S03

20

17S05

21

11S03H

22

6S05M

22A 87S05

23

6S05K

23A 10S04

24

188S06D1

BEARING CARRIER CARRIER IDLER SHAFT SHIM PACK-BEARING SHIM PACKER SET PACKING PIECE BRACKET STOP SHAFT IDLER BRACKET SUPPORT BEARING TAPER ROLLER SEAL OIL NIPPLE GREASE COVER NIPPLE GREASE IDLER ROLLER BOLT BOLT WASHER SPRING BOLT NUT WASHER SPRING BOLT BOLT, ALTERNATIVE USE WITH PACKING PIECE NUT LOCK THIN WASHER SPRING SCREW SET BOLT NUT BINX BOLT WASHER FLAT SCREW GRUB

2 1 1 1 1 1 1 1 2 2 2 2 1 4/6 4/6 8/12 4 6 6 2 2 1 2 1 1 1 2 2 1

5 0 0 R DRU M AN D GEARBOX CON T ROLS

500R DRUM AND GEARBOX CONTROLS

1

555110100

LEVER SLOTTED

1

3

555110300

LEVER HAND 1/2″ UNC THREAD

1

3

555292100

LEVER HAND M12 THREAD

1

4

307126000

KNOB 1/2″ UNC THREAD

1

4

307120000

KNOB M12 THREAD

1

5

555110400

LEVER OPERATING

1

6

555110500

BLOCK CLEVIS PIN

1

7

555110600

PIN CLEVIS

1

9

555110800

PIN PIVOT

1

10

555110900

SLEEVE

1

11

555516700

GLAND SLIDING SHORT

1

12

555516600

GLAND SLIDING LONG

1

13

555111200

ROD CONNECTING

1

14

555111300

ROLLER

1

15

555111400

SPRING COMPRESSION

1

16

112800200

BUSH

3

17

383251000

ROD END BEARING

1

18

132412010

CIRCLIP

3

19

10S04

WASHER FLAT

1

20

6S05E

BOLT

1

21

87S05

NUT BINX

1

22

44S02E

PIN SPLIT

1

23

10S18

WASHER FLAT

1

24

44S05D

PIN SPLIT

1

25

10S04

WASHER FLAT

1

28

9S06

NUT

2

29

95S07

NUT LOCKING THIN

2

30

44S03F

PIN SPLIT

2

31

95S05

NUT LOCKING

1

32

10S18

WASHER FLAT

1

TO SET DRUM CLUTCH:- SET CONTROL LEVER IN CHARGE POSITION AND ADJUST NUT ITEM 28 SO THAT 3mm (1/8″) OF LONG SLIDING GLAND ITEM 12 PROTRUDES BEYOND THE END OF CLEVIS ITEM 6. REPEAT WITH LEVER IN DISCHARGE POSITION BUT ADJUST NUTS TO ALLOW 3mm (1/8”) OF SHORT SLIDING GLAND TO PROTRUDE BEYOND CLEVIS. LOCK NUTS ON COMPLETION.

500R DRUM , DRUM MOUTH & EXTENSION CONES

500R DRUM ASSY DRUM MOUTH + EXTENSION CONES

1

555280800

6

555126000

7

555127800

9

555127700

11

515143000

12

515142900

13

555112700

21

104S05

21A 104S05

21B 10S04

22

41S07

22A 41S07

22B 41S07

25

200S05G

26

206S05C

27

90S06R

DRUM ASSEMBLY INC BLADES AND TRACK RING

1

CONE DRUM MOUTH STND

1

CONE DRUM MOUTH-USE WITH RUBBER EXTENSION

1

CONE DRUM MOUTH-STEEL EXTENSION

1

STRAP RETAINING (SET OF FOUR)

1

CONE EXTENSION RUBBER

1

GEAR RING CAST

1

NUT

6

NUT, (RUBBER RETAINING)

14

WASHER FLAT, RUBBER RETAINING, (NOT ILLUSTRATED)

14

WASHER SPRING

6

WASHER SPRING (RUBBER RETAINING)

14

WASHER SPRING (GEAR RING)

8

SCREW SLOTTED ROUND HEAD

6

SCREW SLOTTED COUNTERSUNK

14

SCREW SOCKET CAP

8

500R DRUM EDGE ROLLERS

PRIOR TO FITTING THE BEARINGS ITEM 10 REMOVE THE SEALS AND PACK THE BEARINGS WITH A GOOD QUALITY GREASE, ENURE THE SEALS ARE CORRECTLY SEATED WHEN REFITTED.
ADJUST THE ROLLERS SO THAT 1.5MM CLEARANCE EXITS BETWEEN THE ROLLERS AND DRUM TRACK RING, SETTINGTHE ROLLERS TO TIGHT WILL LEAD TO PREMATURE FAILURE OF THE BEARINGS. THE SETSCREWS SECURING THE ROLLER ASSEMBLIES TO THE CARRIER SHOULD BE LOCKED TOGETHER USING THE WIRE TIES FOLLOWING ADJUSTMENT.

500R DRUM EDGE ROLLERS

1

555224600

ROLLER DRUM EDGE

2

2

555283800

SHAFT DRUM EDGE

2

3

555224700

SPACER BEARING

2

5

555112000

PLATE LOCKING

2

6

555111800

CARRIER ASSEMBLY

1

If ordering a replacement carrier for a machine prior to serial no 0660, order

replacement metric set screws and nuts, items 15, 16 & 17

7

555112100

SHIM PACKER SHORT

12

8

555112200

SHIM PACKER LONG

6

10

88S05D

BEARING

4

11

142321000

CIRCLIP

2

12

417771000

SEAL ‘V’ RING

2

13

555167500

SCREW SET SPECIAL

4

14

477356000

WIRE LOCKING (NOT ILLUSTRATED)

2

15

28S05K

15

11S05H

SCREW SET ADJUSTING, UNF, UP TO S/NO 0659

1

SCREW SET ADJUSTING, METRIC, M12, FROM S/NO 0660

1

16

28S05U

16

11S05T

SCREW SET ADJUSTING, UNF, UP TO S/NO 0659

1

SCREW SET ADJUSTING, METRIC, M12, FROM S/ NO 0660

1

17

95S05

NUT LOCKING, UNF, UP TO S/NO 0659

2

17

7S05

NUT LOCKING, METRIC, M12, FROM S/NO 0660

2

20

6S05E

BOLT

4

21

41S07

WASHER SPRING

4

5 0 0 R CRADLE LI N K ARM S & BATCH WEI GH ER GU I DE
COAT ALL PINS AND BUSHES WITH COPPERSLIP ON ASSEMBLY. CHARGE ALL GREASE POINTS .

500R HOPPER CRADLE LINK ARMS & BATCHWEIGHER GUIDE

6

555108900

GUIDE-LOADCELL STRIKER

1

7

555109000

PIN GUIDE

1

8

555255100

SHAFT LINK

1

9

555255300

HOUSING BEARING

4

10

555255000

ARM LINK

1A

11

555255400

CAP BEARING

4

12

195S04E2

SCREW GRUB

2

13

113179200

BEARING NEEDLE

4

13A 113179201

BEARING NEEDLE INNER

4

14

555255200

SHAFT PIVOT

1

15

333506000

NIPPLE GREASE

1

15A 176S01

COVER NIPPLE GREASE

1

16

113149000

BEARING NEEDLE

2

17

422702000

SEAL GREASE

2

18

49S40

SEAL ‘O’ RING

4

19

131S01

NIPPLE GREASE

4

19A 176S01

COVER NIPPLE GREASE

4

20

11S05E

SCREW SET

1

30A 512118301

SHIM PACKER

3

30B 512118302

SHIM PACKER

3

30C 512118303

SHIM PACKER

3

43

17S06

WASHER SPRING

1

44

195S04D3

SCREW GRUB

1

45

9S11

NUT

2

46

10S31

WASHER FLAT

2

47

8S03E

BOLT

12

48

17S04

WASHER SPRING

12

49

555269600

HOPPER CRADLE (ALL BUILDS)

1

5 0 0 R H Y DRAU LI C CON T ROL VALV E (M H S-DI N OI L)
THE HYDRAULIC PRESSURE SHOULD BE ADJ U ST ED :- 2 0 0 0 PSI (1 3 8 BAR) 4 0 0 R
2400 PSI (166 BAS) 500R
PORT 4- FEED FROM HYDRAULIC PUMP PORT 5 -RETU RN T O H Y DRAULI C T AN K 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. WHEN A DRAGLINE IS FITTED THE PLUG ITEM 7 SHOULD BE SCREWED FULLY HOME INTO PORT 8 FOLLOWED BY THE ADAPTOR ITEM 8

500R HYDRAULIC CONTROL VALVE MHS

500R

1

V2004605

VALVE CONTROL

1

2

100S03

SEAL BONDED

6

3

127S03

PLUG BLANKING

2

4

122S03

ADAPTOR M/M FROM PUMP

1

5

119S08

ADAPTOR M/M TO TANK

1

6

122S03

ADAPTOR M/M TO RAM

1

V2004607

SCREW SOCKET HEAD H.P.C.0 FIT INSIDE VALVE WHEN

1

7

DRAGLINE FITTED

8

122S03

ADAPTOR M/M WHEN DRAGLINE FITTED

1

9

127S03

PLUG BLANKING WHEN NO DRAGLINE FITTED

1

20

8S03H

BOLT

2

21

267S05

WASHER FLAT

2

22

17S04

WASHER SPRING

2

23

7S03

NUT

2

500R HYDRAULIC TANK,HOPPER RAM & PIPEWORK

500R HYDRAULIC TANK, HOPPER RAM & PIPEWORK

1

555257900

TANK HYDRAULIC

1

2

272150000

RAM

1

3

555204300

HOSE BLEED VALVE TO RAM

1

4

555231000

HOSE CONTROL VALVE TO BLEED VALVE

1

6

555258300

HOSE TANK TO PUMP

1

7

555189500

HOSE PUMP TO CONTROL VALVE

1

10

97S09

CLIP HOSE

2

11

73S03B

HOSE CONTROL VALVE TO TANK TEE

1

20

365825000

PUMP- DIESEL DRIVEN

1

20

10539A02

PUMP- ELECTRIC MOTOR DRIVEN

1

21

66S01C

BOLT

4

22

41S03

WASHER SPRING

4

23

10S01

WASHER FLAT

4

25

100S06

SEAL BONDED

1

26

119S15

ADAPTOR MALE

1

27

100S04

SEAL BONDED- DIESEL DRIVEN

1

27

100S06

SEAL BONDED- ELECTRIC MOTOR DRIVEN

1

28

119S08

ADAPTOR MALE-DIESEL DRIVEN

1

28

119S10

ADAPTOR MALE- ELECTRIC MOTOR DRIVEN

1

29

110S07G

FITTING NOZZLE

1

35

120S03

CAP -NOT USED WHEN DRAGLINE IS FITTED

1

36

154S03

FITTING TEE-USED ONLY WHEN DRAGLINE IS FITTED

1

50

V2004605

CONTROL VALVE

52

32S01C

HOSE RAM RETURN TO TANK

1

500R 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 BRING THE LEVEL UP TO THE MIDPOINT ON THE SIGHT GLASS. THE LEVEL WILL RISE AS THE HOPPER IS RAISED AND DROP AS THE HOPPER IS LOWERED. THE OIL LEVEL SHOULD ONLY BE CHECKED WITH THE HOPPER LOWERED.

500R HEADER TANK

1

555288700

TANK HEADER

1

2

511100900

CAP FILLER/BREATHER

1

3

100S06

SEAL BONDED

1

4

32S01C

HOSE

2

5

11S03C

SCREW SET M8

4

6

267S05

WASHER FLAT M8

8

7

17S04

WASHER FLAT M8

4

8

7S03

NUT M8

4

9

V2005114

SIGHT GLASS

1

10

V2003100

DECAL HYDRAULIC OIL

1

11

V2005122

DECAL HYDRAULIC OIL LEVEL

1

15

272150000

RAM HYDRAULIC

1

16

555257900

TANK HYDRAULIC

1

5 0 0 R H OPPER CRADLE AN D BATCH WEI GH ER
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.
STOP BLOCKS ITEMS 34,53,54 ONLY FITTED TO BASIC MACHINES WITHOUT BATCHWEIGHERS

500R BATCHWEIGHER GAUGE AND HOPPER CRADLE

1

555269600

HOPPER CRADLE (ALL BUILDS)

1

2

555109300

PIN STRIKER SUPPORT

1

3

555109202

SHIM PACKER

1

3A

555109203

SHIM PACKER

1

3B

555109204

SHIM PACKER

1

5

555109100

STRIKER LOADCELL

1

23

555242418

LOADCELL & GAUGE

1

24

555192700

PLATE MOUNTING

1

25

555192800

BRACKET LOWER

1

26

555192900

BRACKET UPPER

1

27

555124900

PLATE MOUNT UPPER

1

28

555125000

COVER DIAL

1

29

555125100

SPACER

2

31

013203000

MOUNTING FLEXIBLE C/W NUTS

4

33

143200300

CLIP HOSE

1

34

555109600

STOP BLOCK CRADLE (WITHOUT BATCHWEIGHER)

2

38

195S03C2

SCREW GRUB

2

42

6S05E

SCREW SET

1

43

41S07

WASHER SPRING

1

44

28S03D

SCREW SET

2

44A 10S03

WASHER FLAT (NOT ILLUSTRATED)

2

45

9S03

NUT

2

46

41S05

WASHER SPRING

2

47

6S05C

SCREW SET

1

47A 87S05

NUT BINX

1

48A 6S05C

SCREW SET

1

48B 87S05

NUT BINX

1

49

6S03L

BOLT

1

50

9S03

NUT

1

51

41S05

WASHER SPRING

1

52

261S02M

THUMBSCREW

4

53

206S05C

SCREW COUNTERSUNK

4

54

192S05

NUT SELF LOCKING

4

55

16S05B

SCREW SLT RD HEAD

2

55A 267S02

WASHER FLAT (NOT ILLUSTRATED)

2

56

7S09

NUT

2

57

17S10

WASHER SPRING

2

58

V2003111

CABLE TIE NYLON (NOT ILLUSTRATED)

2

500R BATCHWEIGHER GAUGE AND HOPPER CRADLE

1

555269600

2

555109300

3

555109202

3A

555109203

3B

555109204

5

555109100

23

555242418

24

555192700

25

555192800

25A 6S05M

25B 9S04

25C 41S07

26

555192900

27

555124900

28

555125000

29

555125100

31

013203000

33

V2005209

34

555109600

38

195S03C2

42

6S05E

43

41S07

44

28S03D

44A 10S03

45

9S03

46

41S05

47

6S05C

47A 87S05

48A 6S05C

48B 87S05

49

6S03L

50

9S03

51

41S05

52

261S02M

53

206S05C

54

192S05

55

16S05B

55A 267S02

56

7S09

57

17S10

58

V2003111

HOPPER CRADLE (ALL BUILDS)

1

PIN STRIKER SUPPORT

1

SHIM PACKER

1

SHIM PACKER

1

SHIM PACKER

1

STRIKER PIN, LOADCELL

1

LOADCELL & GAUGE ASSEMBLY

1

PLATE MOUNTING

1

BRACKET LOWER

1

BOLT, LOWER BRACKET RETAINING, NOT ILLUSTRATED

2

NUT

2

WASHER SPRING

2

BRACKET UPPER

1

PLATE MOUNT, INTERMEDIATE, UPPER

1

COVER DIAL PROTECTION

1

SPACER, MOUNTING PLATE SWIVEL

2

MOUNTING RUBBER FLEXIBLE C/W NUTS

4

CLIP HOSE (1/2″ DIA CAPILLARY HOSE)

2

STOP BLOCK HOPPER CRADLE (WITHOUT BATCHWEIGHER) 2

SCREW GRUB

2

SCREW SET

1

WASHER SPRING

1

SCREW SET

2

WASHER FLAT (NOT ILLUSTRATED)

2

NUT

2

WASHER SPRING

2

SCREW SET, MOUNTING PLATE SWIVEL, UPPER

1

NUT BINX

1

SCREW SET, MOUNTING PLATE SWIVEL, LOWER

1

NUT BINX

1

BOLT, UPPER BRACKET RETAINING

1

NUT

1

WASHER SPRING

1

THUMBSCREW, DIAL COVER

4

SCREW COUNTERSUNK, STOP BLOCKS

4

NUT SELF LOCKING

4

SCREW SLOTTED RD HEAD

2

WASHER FLAT (NOT ILLUSTRATED)

2

NUT

2

WASHER SPRING

2

CABLE TIE NYLON (NOT ILLUSTRATED)

3

500R HOPPER AND SAFETY CHAIN

500R HOPPER AND SAFETY CHAIN

1

555265405

HOPPER

1

2

208S06J

SCREW COUNTER SUNK SKT

8

3

104S06

NUT

8

4

203S06

NUT LOCKING THIN

8

5

555269800

HOPPER SAFETY CHAIN

1

6

11S05D

SCREW SET

1

7

267S07

WASHER FLAT

1

8

61S05

NUT BINX

1

ITEMS 5, 6, 7, AND 8 NOT ILLUSTRATED

5 0 0 R WAT ER TAN K CON T ROLS
COAT THE THREADS ON ITEM 2 WITH COPPER SLIP ON ASSEMBLY

500R WATER TANK CONTROLS

1

OPERATING LEVER SEE WATER TANK

2

555265100

COUPLING END

1

3

555255500

ROD OPERATING

1

4

555255700

BRACKET

1

6

44S03C

PIN SPLIT

1

7

267S06

WASHER FLAT

1

8

56S04

NUT THIN

1

9

6S03B

BOLT

2

10

10S03

WASHER FLAT

2

11

87S03

NUT BINX

2

5 0 0 R WAT ER TAN K I N LET VALV E

CHECK THAT THE VALVE BODY IS FREE FROM SWARF BEFORE ASSEMBLY
BRASS FACE OF DIAPHRAGM TOWARDS PILOT VALVE ITEM 18

500R WATER INLET VALVE

5

555263000

PIN PIVOT

1

7

555262900

LEVER TRIP

1

16

555263500

COVER VALVE

1

17

555263600

BODY VALVE

1

18

555262700

VALVE PILOT

1

19

513114600

WASHER PILOT VALVE

1

20

513115200

SPRING PILOT VALVE

1

21

513122000

DIAPHRAGM

1

22

555198300

BODY STRAINER

1

23

555198400

ELEMENT STRAINER

1

25

555198800

GASKET

2

26

241708000

PLUG

1

27

130354000

CONNECTOR HOSE

1

30

49S39

SEAL ‘O’ RING

1

32

44S02B

PIN SPLIT

1

38

44S03C

PIN SPLIT

4

39

267S05

WASHER FLAT

2

40

61S03

NUT BINX

2

48

11S02C

SCREW SET

7

49

293S02

WASHER FIBRE

8

49A 267S04

WASHER FLAT

8

50

7S02

NUT

1

51

11S02F

SCREW SET

1

52

11S03C

SCREW SET

2

53

17S04

WASHER SPRING

2

61

267S07

WASHER FLAT

A/R

500R WATER TANK ASSEMBLY
CHECK SCALE CARRIER ITEM 11 WILL NOT FOUL FACE OF TANK BODY, BEND SLIGHTLY IF CARRIER FOULS.

500R WATER TANK ASSEMBLY

1

555286000

TANK BODY

1

1A

VALVE WATER INLET

1

2

555286100

LID TANK

1

3

555263300

LEVER OPERATING

1

4

555263200

LINK OUTER

1

6

555263100

ROD SPACER

1

8

555262800

CONNECTOR VALVE ROD

1

9

555262100

INDICATOR

1

10

555262300

ARM FLOAT

1

11

555261900

CARRIER SCALE

1

12

555262400

VALVE DISCHARGE

1

13

555262500

ROD DISCHARGE VALVE

1

14

555262600

SEAT VALVE RUBBER

1

15

555261600

TANK OUTLET

1

24

555286200

SCALE GRADUATED

1

28

425434000

SPRING TENSION

1

29

220302000

FLOAT PLASTIC

1

31

353830426

PIN

1

33

555119300

PIPE WATER DISCHARGE

1

34

555119200

GASKET

1

35

11S02C

SCREW SET

1

36

17S03

WASHER SPRING

1

37

267S06

WASHER FLAT

1

38

44S03C

PIN SPLIT

1

39

267S05

WASHER FLAT

3

39A

267S07

WASHER FLAT

1

40

61S03

NUT BINX

4

41

177S04

NUT WING

1

42

17S04

WASHER SPRING

1

43

172S03A

BOLT ROUND HEAD CUP SQUARE

1

44

104S02

NUT

2

45

56S04

NUT

1

46

11S03D

SCREW SET

4

47

V601330

WASHER NYLON

4

47A

267S05

WASHER FLAT

4

54

70S04D

SCREW SLT RD HD

2

55

267S03

WASHER FLAT

2

56

11S05F

SCREW SET

2

57

7S05

NUT

2

58

17S06

WASHER SPRING

2

59

267S04

WASHER FLAT

1

60

236S04

NUT BLIND

1

500R FLOWMETER

500R FLOWMETER

1

555176400

NOZZLE HOSE FITTING STRAIGHT

1

2

409255000

FILTER STRAINER

1

3

100S10

SEAL BONDED

6

4

122S09

ADAPTOR MALE/MALE

2

5

450151100

VALVE BALL

1

6

128S14

FITTING FEMALE, FEMALE 90′

1

7

129S07G

ADAPTOR NOZZLE 90′ ELBOW

1

10

202325000

GAUGE FLOWMETER

1

11

153S09

CLAMP U BOLT

2

12

267S05

WASHER FLAT M8

4

13

17S04

WASHER SPRING M8

4

15

555176800

BRACKET FLOWMETER

1

16

6S03B

SCREW SET 3/8

2

17

10S03

WASHER FLAT 3/8

4

18

41S05

WASHER SPRING 3/8

2

19

87S03

NUT BINX 3/8

2

20

555174500

SUPPORT

1

21

6S03L

BOLT 3/8

2

22

10S03

WASHER FLAT 3/8

4

23

41S05

WASHER SPRING 3/8

2

24

9S03

NUT 3/8

2

25

37S04CB

HOSE 1.5″ BORE

1

26

97S10

CLIP HOSE

3

27

V2003253

STRAP NYLON

1

30

555288800

PIPE WATER INLET

1

31

11S04C

SCREW SET M10

2

32

267S06

WASHER FLAT M10

4

33

17S05

WASHER SPRING M10

2

34

7S04

NUT M10

2

500R 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.
THE CONTROL BLOCK RELIEF VALVE ITEMS 2 6 -3 0 , SH OU LD BE ASSEM BLED WI T H ON E 10S02 WASHER, ITEM 29 AS SHOWN, THE HYDRAULIC PRESSURE SHOULD THEN BE CHECKED BY CONNECTING A PRESSURE GAUGE ON T O T H E R/H FI T TI N G I T EM 1 4 I N PLACE OF THE HOSE ITEM 9. WITH THE ENGINE OR MOTOR RUNNING AND THE DRAGLINE SHOVEL CONNECTED, THE SWITCH ON THE SHOVEL SHOULD BE OPERATED MOMENTARILY AND THE PRESSURE AT WHICH THE RELI EF V ALV E `BLOWS OFF’ N OT ED. T HE PRESSURE IS CORRECT IF THE GAUGE READS BETWEEN 1 0 0 0 -1 5 0 0 PSI , (6 9 -1 0 3 BAR). ADD OR SUBJECT WASHERS ITEM 29 TO ADJUST.

500R DRAGLINE HYDRAULIC PIPEWORK AND VALVES

1

555257900

TANK HYDRAULIC

1

8

555268700

HOSE,CONTROL VALVE TO SOLENOID VALVE

1

9

63S02F

HOSE, SOLENOID VALVE TO WINCH MOTOR

2

10

73S03C

HOSE RETURN, SOLENOID TO TANK TEE

1

13

100S03

SEAL BONDED

5

14

122S03

ADAPTOR, MALE-MALE EQUAL

3

15

119S08

ADAPTOR, MALE-MALE UNEQUAL

2

16

154S03

FITTING TEE TANK FITTING

1

18

V2003253

TIE CABLE NYLON

2

19

35S03AK

HOSE RETURN, CONTROL BLOCK TO TANK

1

20

267117000

MOTOR HYDRAULIC (WHITE)

1

21

391111000

O’ RING

2

22

126S09

ADAPTOR MALE MALE UNEQUAL

2

25

555287500

BLOCK, DRAGLINE CONTROL

1

26

555138200

GUIDE RELIEF VALVE

1

27

555138300

VALVE RELIEF

1

28

555556100

SPRING

1

29

100S04

SEAL BONDED

1

30

10S02

WASHER FLAT

A/R

33

11S03A

SCREW SET

4

34

17S04

WASHER SPRING

4

35

V2004676

VALVE SOLENOID

1

35A V601234

PLUG-HIRSCHMANN

1

36

68S02E

SCREW SOCKET CAP HEAD 5MM DIAMETER

4

36A 17S02

WASHER SPRING

4

50

V2004605

VALVE CONTROL MHS-DINOIL

1

500R 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

500R DRAGLINE BRACKET & WINCHMOTOR

1

267117000

MOTOR HYDRAULIC ‘WHITE’

1

2

7S05

NUT

4

3

17S06

WASHER SPRING

4

5

11S05K

SCREW SET

4

6

513330100

PULLY-DRUM

1

7

132204000

CLIP BULLDOG

1

8

555266300

WASHER SPECIAL

1

9

NOT USED

1

10

41S09

WASHER SPRING

1

11

6S06H

SCREW SET

1

12

477502000

ROPE WIRE

1

15

555287800

COVER WINCH DRUM

1

16

7S04

NUT

2

17

17S05

WASHER SPRING

2

18

267S06

WASHER FLAT

4

19

11S04C

SCREW SET

2

25

555287700

BRACKET WINCH

1

26

11S05D

SCREW SET

4

27

267S07

WASHER FLAT

8

28

17S06

WASHER SPRING

4

29

7S05

NUT

4

30

555287900

ROLLER – WIRE ROPE

4

31

8S05U

BOLT – ROLLER

4

32

61S05

NUT BINX

4

35

205304600

PLUG AND SOCKET

1

36

86S07

NUT NYLOC

1

37

82S07F

SCREW ROUND HEAD

1

40

555253800

CLAMP – SOCKET

1

41

11S01A

SCREW SET

2

42

17S02

WASHER SPRING

2

43

7S01

NUT

2

50

144734000

CABLE – TO SOLENOID

1

51

144734000

CABLE – TO SHOVEL

1

52

V2005386

BUSH-WINCH ROLLERS

8

5 0 0 R DRAGLI N E ALT ERNATOR AN D FI X I N GS
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.

500R DRAGLINE ALTERNATOR & FITTINGS

20

V2004793

ALTERNATOR

1

21

513347400

ADJUSTER

1

22

11S03C

SCREW SET

1

23

267S05

WASHER FLAT

2

24

61S03

NUT BINX

1

25

66S03A

SCREW SET

1

26

10S03

WASHER FLAT

1

27

41S05

WASHER SPRING

1

28

555288300

BRACKET ALTERNATOR

1

29

8S03C

BOLT

2

30

61S03

NUT BINX

2

31

267S05

WASHER FLAT

2

32

11S04C

SCREW SET

2

33

7S04

NUT

2

34

17S05

WASHER SPRING

2

35

267S06

WASHER FLAT

4

40

397227000

VEE BELT

1

5 0 0 R DRAGLI N E ALT ERNATOR WI RI N G & PAN EL
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

500R DRAGLINE ALTERNATOR WIRING & PANEL

1

109S10

BATTERY

1

2

11S02B

SCREW SET

2

3

267S04

WASHER FLAT

4

4

17S03

WASHER SPRING

2

5

7S02

NUT

2

10

555288400

LOOM WIRING

1

11

V2003253

CABLE TIE NYLON

6

12

V2003111

CABLE TIE NYLON

6

15

555288100

PANEL

1

16

V2004794

SWITCH BATTERY ISOLATOR

1

17

11S02B

SCREW SET

2

18

267S04

WASHER FLAT

2

19

61S02

NUT BINX

2

20

V2000326

LIGHT WARNING

1

25

V2004793

ALTERNATOR

1

26

V2004795

DECAL ISOLATOR SWITCH

1

27

V2004796

DECAL ALTERNATOR

1

28

16S05B

SCREW SLOTTED RD HEAD (NOT ILLUSTRATED)

11

29

143200900

CLIP P NYLON (NOT ILLUSTRATED)

11

30

17S10

WASHER SPRING (NOT ILLUSTRATED)

11

31

267S02

WASHER FLAT (NOT ILLUSTRATED)

11

32

7S09

NUT (NOT ILLUSTRATED)

11

5 0 0 R DRAGLI N E BAT T ERY T RAY & 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.

500R DRAGLINE BATTERY TRAY

1

30080A03

TRAY BATTERY

1

2

30080A0303 BAR COVER

1

3

11S04E

SCREW SET

1

4

11S04C

SCREW SET

3

5

267S06

WASHER FLAT

4

6

61S04

NUT BINX

4

7

555290500

GUARD BATTERY

1

8

11S03C

SCREW SET

2

8A

267S05

WASHER FLAT

4

8B

17S04

SPRING WASHER

2

8C

7S03

NUT

2

10

10742A05

COVER BATTERY

1

11

177S03

NUT WING

2

12

267S04

WASHER FLAT

2

15

555288200

CLAMP BATTERY

2

16

8S02F

BOLT

2

17

267S04

WASHER FLAT

4

18

61S02

NUT BINX

2

19

V2004235

DECAL NEGATIVE EARTH

1

500R DRAGLINE CABLE MAST AND PULLIES

500R DRAGLINE MAST CABLE AND PULLIES

1

555121500

MAST LOWER

1

2

515134400

MAST UPPER

1

3

8S05L

BOLT

1

4

17S06

WASHER SPRING

1

5

7S05

NUT

1

11

555208100

PULLEY

2

12

555208400

BLOCK PULLEY

2

13

44S03C

PIN SPLIT

2

14

555208300

PIN PULLEY

2

15

555204800

WEIGHT

1

16

144734000

CABLE ELECTRIC 2 CORE

1

20

555287700

BRACKET DRAGLINE WINCH

1

21

205304600

PLUG & SOCKET

1

5 0 0 R DRAGLI N E SH OV EL ASSEM BLY

500R DRAGLINE SHOVEL

1

555210400

SHOVEL BODY

1

2

555209100

SHOVEL HANDLE

1

3

135905000

CHAIN & RING ASSY

1

4

144734000

CABLE 2 CORE

1

5

143200300

CLIP CABLE

1

6

205304600

PLUG

1

7

369200000

TUBE 300MM/12″ LONG

1

8

555214800

CLAMP SWITCH

1

9

208561000

SWITCH

1

10

208143000

SLEEVE PVC 55 MM LONG

1

11

250166010

GLAND CABLE

1

13

264705000

GRIP HANDLE

2

14

443105010

THIMBLE ROPE WIRE

1

15

412606000

SHACKLE D + PIN

1

16

132204000

CLIP BULLDOG

2

17

11S05D

SCREW SET

2

18

59S04

NUT NYLOC

2

19

267S07

WASHER FLAT

2

20

16S05B

SCREW SLOTTED PAN HEAD

1

21

7S09

NUT

1

22

267S02

WASHER FLAT

2

22A 17S10

WASHER SPRING (NOT ILLUSTRATED)

1

23

8S01H

BOLT SWITCH

2

24

7S01

NUT

2

25

17S02

WASHER SPRING

2

26

44S17K

PIN SPLIT

2

27

17S03

WASHER SPRING (NOT ILLUSTRATED)

2

500R 2 AND 3 COMPARTMENT FEED APRONS

1

555196302

PLATE SIDE LEFT HAND

1

2

555196301

PLATE BOTTOM

1

3

555196303

PLATE SIDE RIGHT HAND

1

4

555196307

PARTITION CENTRE (2 COMPARTMENT)

1

5

555196315

STRAP RUBBER RETAINER

1

6

208S03H

SCREW COUNTERSUNK SOCKET HEAD

10

7

104S03

NUT

10

8

41S05

WASHER SPRING

10

9

394413001

RUBBER FLAP

1

10

555196308

CENTRE SUPPORT

1

11

28S05E

SCREW SET

30

12

9S04

NUT

30

13

41S07

WASHER SPRING

30

30 NUTS WASHERS AND SETSCREWS REQUIRED WITH 2

COMPARTMENT FEED APRON

14

555104800

PARTITION CENTRE (3 COMPARTMENT)

1PR

15

28S05E

SCREW SET

32

16

9S04

NUT

32

17

41S07

WASHER SPRING

32

32 NUTS WASHERS AND SETSCREWS REQUIRED WITH 3

COMPARTMENT FEED APRON

5 0 0 R ELECT RI C START BAT T ERY, LEADS, T RAY & SWI TCH

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.

500R ELECTRIC START BATTERY AND LEADS

1

109S08

BATTERY

1

2

10989A06

CABLE BATTERY POSITIVE

1

3

10990402

CABLE BATTERY NEGATIVE

1

5

30080A03

CARRIER BATTERY

1

6

11S04D

SCREW SET

2

7

59S03

NUT LOCK

2

8

40SA17

ROD TIE

2

9

9S01

NUT

6

10

267S04

WASHER FLAT

6

11

10559A01

CLAMP BATTERY

1

15

10742A05

COVER BATTERY

1

16

267S04

WASHER FLAT

2

17

177S03

NUT WING

2

18

V2004235

DECAL ‘NEGATIVE EARTH’

1

18A V2004204

INSULATOR POSITIVE NOT ILLUSTRATED

1

20

20313A05

PANEL INSTRUMENT

1

21

28S03D

SCREW SET

2

22

41S05

WASHER SPRING

2

23

9S03

NUT

2

24

570-35450

LIGHT WARNING

1

25

V2004189

SWITCH START

1

ITEM 24-25

SUPPLIED WITH ENGINE

26

30231A11

LOOM WIRING

1

27

V2003377

CLIP LOOM

1

500R DECALS AND LOGO’S

1

10

11 2

12 3

13 4

5

14

6 15
16 7

8

17

9

500R DECALS AND LOGO’S

1

V2003037

PLATE SERIAL NUMBER

1

2

504600900

DECAL ‘ENGINE HOUSING’

2

3

504694600

DECAL ‘SAFETY WARNING’

2

4

V2003127

DECAL ‘500R’

2

5

V2003039

DECAL ‘WINGET’

3

6

555153700

DECAL ‘DRUM CONTROLS’

1

7

555153500

DECAL ‘WATER TANK’

1

8

555184900

DECAL ‘DANGER HOPPER’

2

9

V2004137

DECAL ‘EAR PROTECTION’

1

10

V2003038

VINYL STRIPES 2 COLOUR

4

11

V2003101

DECAL ‘DIESEL FUEL’

1

12

V2003100

DECAL ‘HYDRAULIC OIL’

2

13

515175000

PLATE LOADCELL

1

14

V2003665

DECAL ‘SLING POINT’

2

15

V2003598

DECAL ‘BRITISH MADE’

1

16

10166A02

DECAL ‘TYRE PRESSURE’

4

17

V2004259

DECAL ‘HOPPER CONTROLS’

1

18

V2004227

DECAL ‘BATTERY ISOLATOR’

1

19

V2004229

DECAL ‘OPERATORS HANDBOOK’

1

20

V2004235

DECAL ‘NEGATIVE EARTH’

1

21

V2004282

DECAL ‘HOT SURFACE’

1

22

V2004281

DECAL ‘ENTRAPMENT’

1

23

V2004288

DECAL ‘STARTING HANDLE’

1

24

V2004289

DECAL ‘HANDS CLEAR’

2

25

V2004302

DECAL ‘ENGINE STOP’

1

26

V2004307

DECAL ‘ELECTRICAL HAZARD’

3

27

V2004223

DECAL ‘CE MARK’

1

28

V2004796

DECAL ALTERNATOR

1

29

V2004744

DECAL ‘EYE PROTECTION’

2

30

V2004795

DECAL ‘ISOLATOR SWITCH’

1

31

V2005122

DECAL ‘CHECK HYDRAULIC OIL’

1

32

V2005312

DECAL ‘NOISE 98 LPA’

2

33

V2005319

DECAL ‘NOISE 115 LWA’

2

34

V2005315

DECAL ‘WATER PRESSURE’

1

35

513371100

DECAL ‘EMERGENCY STOP’

1

36

V2006402

DECAL ‘UKCA MARK’

1

37

V2006403

DECAL ‘UKNI MARK’

1

500R DECALS AND LOGO’S

18

28

19
29 20

21

30

22
31 23

24 32
25

26 33
27 34

500R DECALS AND LOGO’S
35 36 37

WORKSHOP MANUAL 500R
SECTION 11 BATCHWEIGHER MAINTENANCE INSTRUCTIONS

MAINTENANCE INSTRUCTIONS
HYDRAULIC WEIGHING UNITS
WWW.WINGET.CO.UK

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. However in recognition of the fact that this advice is not always practicable Winget Limited have released this manual subject to the disclaimer below: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. Nor can we accept any liability whatsoever arising from the use of this manual howsoever caused. Winget Limited operate a ploicy of continuous product development, therefore some illustrations or text within this publication may differ from your machine.

WORKSHOP MANUAL 500R
SECTION 12 REVERSING GEARBOX
MANUAL

SERVICE MANUAL
REVERSING GEARBOX
FROM 1990
WWW.WINGET.CO.UK

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. Nor can we accept any liability whatsoever arising from the use of this manual howsoever caused. Winget Limited operate a ploicy of continuous product development, therefore some illustrations or text within this publication may differ from your machine.

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.
Disconnect the hydraulic hoses to the pump, plug the ports and hoses unbolt and remove the hydraulic pump taking care not to lose the shim pack.
Remove the ring of setscrews securing the propshaft to the gearbox output flange and lower the propshaft clear of the gearbox.
Unbolt the gearbox mounting bolts, disconnect the drive coupling between the engine/electric motor and using suitable lifting equipment lift the gearbox clear of the mainframe and support on a suitable worksurface.
Clean down the outer casing and place a suitable container below the drain plug. Remove the drain plug and allow the oil to drain. Refit the drain plug. Dispose of the oil safely and in accordance with local regulations covering the disposal of waste oil.
Disassembly of Gearbox
Remove the two 3/8 UNC self locking nuts and retaining washers, remove both the input and output flanges, it may be necessary to tap the flanges off the shafts using a soft faced mallet or suitable two or four leg puller taking care not to damage the flanges.
Remove the twelve 3/8 UNC headed screws securing the input pinion cartridge, output oil seal housing and plunger guide, note the four capscrews securing the pinion cartridge are shorter than those securing the oil seal housing and plunger guide.
Remove the cartridge, oil seal housing and plunger guide taking care not to lose or mix the shim packs. Remove both parallel keys from the pinion and output shaft and the loose pin located in the operating plunger.
Support the pinion cartridge in a soft faced vice and using a soft faced mallet tap the pinion out of the housing and remove the bearings, spacer and oil seal.
Remove the 3/8 UNC cap headed screws securing the two halves of the gearbox casing together and carefully prise the halves apart and lift the top half clear, note the two halves are dowelled together and care should be taken not to damage the mating surfaces when prising the casing apart.

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. Secure the end of the operating shaft into a soft jawed vice, using a soft faced mallet tap the operating plunger off the shaft and bearing.
The bearing is a loose fit on the operating shaft and is retained by a countersunk plate and countersunk capheaded screw. Remove the screw, plate and bearing.
Using suitable lifting equipment lift the mainshaft, bevel gears and cone clutches out of the case. Remove the bearings, shims, bevel gears and cone clutches off the shaft, layout, clean and inspect all components for wear or damage.
Inspect the friction linings for wear (4.8mm when new), note production linings are bonded to the clutch faces, replacements are either pre drilled for fixing by rivets, or plain, undrilled, requiring bonding using loctite 9497 or similar. Pre drilled linings can also be bonded as an alternative to rivetting. Do not attempt to drill plain linings.
Clutch Lining Replacement
Clean all traces of the old clutch linings off the clutch cones (taking suitable precautions to avoid breathing in the dust which may contain asbestos fibres).
Should the replacement linings be pre drilled use the following procedure if using rivets to secure and the clutch cones are not themsleves pre-drilled:- Slip the new friction linings onto the cones gently tapping fully home. Using the linings as a template drill the cones and insert the rivets. Using a suitable drift support the head of each rivet in turn and using a small ball pein hammer gently peen over the shank of the rivet on the inner face of the cone assembly. Repeat the operation until all the rivets are secure. If using loctite follow the manufacturers instructions for correct application.
Re-assembly of Gearbox
Locate the bearing (3) onto the operating shaft (4) coat the threads of the countersunk screw (6) with loctite and retain the bearing using the screw and retaining plate (7). Note the bearing should be free to move on the shaft once the screw and plate are inplace.
Using a soft faced mallet tap the shaft and bearing assembly into the plunger (8) and retain with the circlip (5). Fit the rubber “O” ring (9) onto the plunger.
Locate the four circlips (11) into the bevel gears (10, 20) and insert the four outer cones of the taper roller bearings (13, 14, 16, 17) into the bevel gears as illustrated.
Slip the 0.5mm thick shim (19) over the main shaft (2) followed by the inner race of the taper roller bearing (17). Insert the mainshaft (2) into the bevel gear (20) and tap home the inner race of the taper roller bearings (15, 16) as illustrated.

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).
Slip both the 1.00mm thick shim (18) and the 0.5mm thick shim (24) over the opposite end of the main shaft followed by the inner race of the taper roller bearing (14) locate the second bevel gear (10) over the mainshaft and fit the taper roller bearings (12, 13) as illustrated.
Carefully lift the assembly and locate into the lower half of the gearbox casing.
If removed refit the two dowel pins (27, 28) and coat the mating surfaces of the two halves of the gearbox case with a silicone sealer and secure the two halves together. Note do not tighten capscrews (25, 26, 29, 30, 31, 32) until assembly of the box is completed.
Lubricate and insert the pin (33) into the plunger (8). Select a 0.35mm thick shim pack (x) and fit over the plunger guide (34) coating the mating surfaces with a suitable silicone sealer. Install the plunger guide ensuring the machined slots in both the guide (34) and plunger (8) are aligned. Fit and tighten the four 3/8 x 1″ UNC cap headed screws (35).
Select a 0.50mm thick shim pack (Y) and fit over the oil seal housing (36), install the housing and tighten two of the four 3/8 x 1″ UNC capheaded screws (37).
Fit the feather key (39) and slide on the flange (41), rotate the shaft a few complete revolutions in either direction to seat the bearings then check the bearing pre-load.
The pre-load is best checked by winding a length of string tightly round the flange (41), attaching a spring balance and measuring the load required to turn the flange.
The preload is correct when a reading of around 1Kg is obtained.
If the preload is too low, remove the flange (41) and housing (36). Tap the shaft end with a soft faced mallet to release the loadings on the shaft and add additional 0.05, 0.125 or 0.25mm thick shims. Refit the housing and flange rotate the shaft then re-check the preload.
If the preload is too high, carry out the above procedure but reduce the shim pack thickness and re-check the preload.
If necessary repeat the operations above until the preload obtained is correct.

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). Fit the feather key (39) and carefully refit the

References

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