T-400 Portable Irrigation Machine Maintenance & Repair Manual

T-400 Portable Irrigation Machine Maintenance & Repair Manual

A. Inspection of external leakage 1. Deep - groove ball bearing and rotary shaft lip seal on turbine shaft 1.1 Leakage on relief well In case there is a recognisable leakage on the relief well or in the turbine housing, it must be looked for the reason of the malfunction in the rotary shaft lip seal. In the majority of cases as consequence of the leakage, the deep-groove ball bearing in the turbine housing and partial the deep-groove ball bearing in the gear wheel is damaged (please check leakage monthly). Relief Well 1.2 Radial tolerance on turbine shaft In case it appears a radial clearance on the turbine shaft (that can be determined on the turbine wheel if the turbine cover is screwed off) the cause is always a defect deep-groove ball bearing in the turbine housing (Examination twice a year).

2. Repair of turbine bearing and rotary shaft lip seal In case it appears such a problem on your Tracker, the repair has do be done in the accomplish manner. Dismantle bonnet (BTV784337), gearbox cover (BTV784342) and plastic wheel (ZK3794434, screw axle BTC584383 and hub cover ZK3794435) completely. Dismantle tripping arm (BTR684344) Tripping arm Screw off cover for turbine (BTV784310)

Adhere turbine wheel (BTV784312) with the left hand and remove screw for turbine shaft turbine shaft (BTC484330) M10 from turbine shaft. Screw for turbine shaft BTA484370 Turbine shaft BTC484330 Clamping sleeve ZD1593196 Turbine wheel BTV784312 Beat back clamping sleeve (ZD1593196) with punch drift 4mm (standard tool). Pull out turbine wheel (BTV784312) with turbine shaft (BTC484330). Pull out sliding bush short (BTC484389) with pliers. Take out gear and spacer ring off gear case.

Beat out shaft seal packing (ZK0994377) together with guide bush for turbine shaft (BTC584388). In case grooved ball bearing (ZK1994372) is still complete: drive out with help of pressure bolt No.1 (BTC584431) to gear case. In case deep grooved ball bearing (ZK1994372) is broken (individual parts): Ball bearing remover ZB1198227 Outer ring ZK1994372 Pressure bolt 1 BTC584431 Apply internal extractor Ø19-24 and strike through with help of pressure bolt No.1 (BTC584431) towards gear case. Check whether turbine housing is OK, otherwise it should be replaced by: 1 piece Turbine housing BTP684311 4 pieces O-ring ZK1816551 4 pieces Countersunk screw ZD0493195

Set up housing edgewise and inferior Press in new grooved ball bearing (ZK1994372) with pressure bolt no. 2 (BTC584432) Insert new guide bush for turbine shaft (BTC584388) with pressure bolt no. 1 (BTC584431) Insert new shaft seal packing (ZK0994377) with pressure bolt no. 3 (BTC584433) opening has to be visual outside

Lubricate rotary shaft lip seal with acid free grease. Check the assembled ball bearings on zero clearance and ease of movement in the gears and the cover turbine shaft, if necessary replace it by a new grooved ball bearing (ZK1994372). Grooved ball bearing ZK1994372 Grooved ball bearing ZK1994372

Insert and respect the right position of turbine shaft and turbine wheel with sliding bushing (BTC484389) Chamfer Bead than following pieces on turbine shaft: Spacer bushing 1 (BTC584317) Gear 2 (BTV784347) Spacer bushing 2 (BTC584318) Gear 2 (BTV784347) Spacer bushing 2 (BTC584318) Gear 1 (BTV784346) Spacer (BTC584372) Spacer BTC584372 Gear 1 BTV784346 Spacer bushing 2 BTC584318 Gear 2 BTV784347 Turbine shaft BTC484330 Spacer bushing 2 BTC584318 Gear 2 BTV784347 Spacer bushing 1 BTC584317 Sliding bush BTC484389 Turbine wheel BTV784312

Screw tightly cover for turbine shaft (BTC684371) with grooved ball bearing (ZK1994372) (3x ZD0293188) Cover turbine shaft BTC684371 Screw for turbine shaft BTA484370 Cylinder head screw ZD0293188 Turn turbine shaft and gear 1 in that way that the boreholes are congruent. Drive into clamping sleeve (ZD1593196) with punch drift 4mm, deeper than the dedendum. Clamping sleeve Apply blue Loctite on thread of turbine shaft

Unscrew screw for turbine shaft (BTA484370), adhere turbine wheel with the left hand and tighten screw with 9-10Nm. If the clamping torque is to small a leakage on the turbine shaft arise; thereby the deep groove ball bearing is destroyed. Before screwing on turbine cover, lubricate face surface of the turbine housing with acid free grease.

Tighten turbine cover Assembly trip lever, but it must has at least 2mm clearance. Axial clearance Assembly wheels, gear cover and cover to the unit.

Annotation Shim (BTK484374) is not necessary any longer (old type), if the new screw for turbine shaft (BTA484370) is used. For this repair following pieces are to be ordered: - 6 pieces deep grooved ball bearing ZK1994372-1 piece shaft seal packing ZK0994377-1 piece guide bush for turbine shaft BTC584388-1 piece clamping sleeves spare part ZD1593196-1 piece screw for turbine shaft BTA484370 (because clamping nut has changed dimension) Following special tools are needed: - Pressure bolt 1 BTC584431 - Pressure bolt 2 BTC584432 - Pressure bolt 3 BTC584433 - Ball bearing remover ZB1198227

B. Examination of cable and cable drum 1. Examination of cable Cable should be examined once a month, check if plated bands are broken. (Only on steel cable). Hoisting drum should be replaced in case of any broken plated bands. Damages of the cables can occur when the cable is coiled beside the drum. Frequent causes here for is an insufficient preload of the cable before putting into operation. 2. Replacement of cable drum Remove nuts from shearing screw BTC484336 and beat through shearing screw through the shaft. Pull down driver BTP584354 from the shaft. Cut cable therewith stop for Tracker BTC584357 can be deduct from the cable. Deduct cable drum from the arbor and replace it by a new cable drum BB0284412.

Lead in the cable into the cable guide, trip lever and limit stop. In the end make a bow with a cable robe clip. Cable guide Please note, that spring and Teflon disk (drum brake) between cable drum and locating bearing are assembled on the shaft. Assembly driver. It should be used a new shearing screw BTC484336. Adjust limit stop and put device again into operation. Necessary spare parts: 1 piece cable drum BTR684343 1 piece cable rope clip ZK2494382 1 piece shearing screw BTC484336 Remark: On the TrackerV2 only a knot instead of the cable rope clip is required.

C. Examination of ball valve (only for Tracker) 1. Examine ball valve for leakage After process of surface irrigation it is to examine, whether the ball valve is tight. Especially after the frost period, after this time it can occurs that the ball valve is burst. 2. Replace ball valve Dismantle retaining spring from anchorage Dismantle trip lever from the ball valve with help of socket head wrench SW5 Unscrew stuffing box from ball valve with help of open-ended spanner SW19. Heat area, where ball valve is screwed in, with a dryer up to approx. 150 C. Unscrew ball valve with gas pipe pliers. Clean thread in turbine housing. Take care that nozzle for turbine BTC584333 does not get lost. Dismantle stuffing box on new ball valve ZK2094381. Seal ball valve with red Loctite and let it harden 24 hours. Assembly stuffing box, trip lever and retaining spring. Ensure thread with blue Loctite. Examine function Attention: Danger of accident when initiate ball valve Necessary spare parts: 1 piece ball valve ZK2094381