Winget 500R Instruction manual

ISSUE 10 2016
WORKSHOP MANUAL
500R
WINGET LIMITED
PO BOX 41
EDGEFOLD INDUSTRIAL ESTATE
PLODER LANE
BOLTON
LANCS
BL4 0LR
Tel:-++ 44 (0) 1204 854650
Fax:- ++ 44 (0) 1204 854663
[e-mail]
part[email protected].uk
www.winget.co.uk

WORKSHOP MANUAL
500R
WINGET REVERSING DRUM CONCRETE MIXERS
ISSUE 10 2016
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 10 2016
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

WORKSHOP MANUAL
500R
WINGET REVERSING DRUM CONCRETE MIXERS
ISSUE 10 2016
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 two ‘L’ 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.

WORKSHOP MANUAL
500R
WINGET REVERSING DRUM CONCRETE MIXERS
ISSUE 10 2016
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.

WORKSHOP MANUAL
500R
WINGET REVERSING DRUM CONCRETE MIXERS
ISSUE 10 2016
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.

WORKSHOP MANUAL
500R
WINGET REVERSING DRUM CONCRETE MIXERS
ISSUE 10 2016
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.

WORKSHOP MANUAL
500R
WINGET REVERSING DRUM CONCRETE MIXERS
ISSUE 10 2016
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