Winget 200TM Service manual

200TM
OPERATORSHANDBOOK
&
PARTS
Manual V601651 August 2018
(This publication also includes Manual MANS545)
WINGET LIMITED, P.O. Box 41, Edgefold Industrial Estate, Plodder Lane, Bolton, BL4 0LR, England
Tel: [phone]
www.winget.co.uk
MECHANICALLY-FED MIXER

CONTENTS
INTRODUCTION
Introduction to the Handbook II
Warranty III
Safe working 1.1
Lashing down and lifting points 1.6
INSTALLATION AND REMOVAL
Main components of mixer 2.1
Installing the mixer on site:
Lifting the mixer 2.2
Stabiliser 2.2/2.8
Hopper 2.3/2.6
Dragline 2.3/2.7
Feed apron and ramp 2.5/2.6
Water tank 2.5
Electrically driven mixers 2.5/2.6
Dismantling for transportation 2.6
OPERATION
Mixer drum positions 3.1
Hopper controls 3.1
Electric motor: Starting and stopping 3.2
TS/TR1 engine: Starting and stopping 3.3
Installation trials 3.6
Mixing 3.6
Batch weigher 3.8
End of work procedure 3.9
SERVICING
Service schedule 4.1
Servicing procedures:
TS/TR1 engine 4.2
Batteries 4.6
Hydraulic system 4.7
Bolt torques 4.8
General lubrication 4.9
Drum drive 4.10
Batch weigher 4.10
Dragline 4.10
Mixer drum assembly 4.11
Mixer drum drive overhaul 4.13
TS/TR1 electrical fault finding 4.14
Hour meter wiring 4.15
Dragline electrical system 4.16
Hydraulic circuits 4.18/4.21
SPECIFICATIONS
Lubricants 5.1
Noise level of mixers 5.1
Drum speed 5.1
Mixer drum sealant 5.1
Engine and motor outputs 5.1
Dimensions 5.2
PARTS
Illustrated parts listings
CALIFORNIAN HEALTH WARNING
INTRODUCTION
I

II INTRODUCTION
THE HANDBOOK MUST NOT BE REMOVED FROM THE MACHINE.
The Handbook must be kept clean and in good condition. Additional copies of the
Handbook can be obtained from your Distributor.
The contents of this Operator's Handbook are designed as a guide to the machine's
controls, operation, working capacities and maintenance. It is not a training manual.
Only trained operators should use this machine. Contact the C.I.T.B. or equivalent body fo
r
advice on training.
The Handbook
The operator must read all the Handbook and fully understand its contents
before attempting to operate the machine.
In this Handbook are WARNING notes. They are preceded by this symbol:
These notes are used to indicate the procedure being described in the
Handbook must be followed to avoid serious injury or death to yourself or to
others, or damage to the machine.
The warnings are also used to protect the machine from unsafe servicing
p
ractices.
Pay particular attention to the warnings given in the Handbook.
If you have any doubts about any aspect of the machine's capability or servicing
procedures, you must consult the manufacturer.
The contents of this Handbook, although correct at the time of publication
may be subject to alteration by the Manufacturers without notice.
Winget Limited operate a policy of continuous product development.
Therefore, some illustrations or text within this publication may differ from
your machine.
IMPORTANT Engine change
From June 2005 (mixer serial number 1110) the Lister-Petter TS1 engine was replaced
by the Lister-Petter TR1 engine. 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 TS1 or TR1 engine.
Starting and maintenance instructions found throughout this Handbook which refer to
TS engines are also applicable to the TR engine.

INTRODUCTION
III
Warranty terms & conditions
The Manufacturer assures you that if any part of the machine becomes defective due to
faulty manufacture or materials within 12 months from the date of purchase, the part will
be repaired or replaced under warranty free of charge by any authorised Winget
Distributor. Warranty repairs must be carried out by Winget Distributors.
This Warranty is given to the first owner and may be transferred to subsequent owners for
the balance of the Warranty period.
The Manufacturer’s liability only extends to the costs of repair or replacement of the faulty
parts and necessary labour charges involved in the repairs. The Company accepts no
liability for any consequential loss, damage or injury, resulting directly or indirectly from
any defect in the goods.
Items not covered by Warranty and considered to be the customer’s responsibility include
normal maintenance services; replacement of service items and consumables;
replacement required due to abuse, accident, misuse or improper operation; replacement
of wearable items e.g. pins, bushes, brake linings, clutch linings etc.
The Warranty will not apply where the equipment is modified, converted, or used for
purposes other than those for which it was designed, unless clearance for the
modifications etc. have been granted by the Manufacturer, in writing.
The Pre-Delivery Inspection and Warranty Registration Document must be completed
correctly and returned to the Manufacturer within 7 days of sale date. Failure to do so may
result in the claim being subsequently rejected.
Tyres and tubes are not covered by Warranty, but are covered by the tyre manufacturer’s
own warranty system which provides against defects in material or workmanship. Engines
are covered separately by the engine manufacturers, and engine warranty repairs must be
handled by the relevant engine manufacturers’ distributors.
No claim will be considered if other than genuine Winget Limited parts, which must be
obtained from Winget Limited via an
authorised Distributor, are used to effect a repair, or if
lubricants other than those recommended by Winget Limited are used.
The equipment must be serviced in accordance with the service schedules laid down by
Winget Limited. Evidence that these have been complied with may be required before
Warranty Claims are reimbursed.
The Manufacturer’s policy is one of continuous improvement. Winget Limited reserve the
right to change specifications without notice. No responsibility will be accepted for
discrepancies which may occur between specification of machines and the descriptions
contained in publications.

IV
INTRODUCTION

OPERATION
SAFE
WORKING 1.1
Safety is the responsibility of the persons working with this
machine. Think “safety” at all times.
Read and remember
the contents of this Handbook.
MACHINE MODIFICATION
Any modifications to the machine will affect its working parameters and safety
factors. Refer to the Manufacturers before fitting any non-standard equipment
or parts.
The manufacturers accept no responsibility for any modifications made after
the machine has left the factory, unless previously agreed by the
Manufacturers in writing. The Manufacturers will accept no liability for damage
to property, personnel or the machine if failure is brought about due to such
modifications, or fitment of spurious parts.
Only trained operators should use this machine.
Always be aware of local and national regulations governing the use of the
machine.
Always ensure that all guards are in position and correctly fitted.
Electrically driven mixers: Always ensure that the power supply has been
correctly connected by a qualified electrician.
Electrical cables must be of a suitably armoured type. Ensure that
they are protected from damage and not liable to be tripped over.
Do not connect to a household socket!
Use only with an RCD protected supply. Only connect via special
feeding point (e.g. power distribution panel on building site with fault-
current-breaker).
Only authorised persons should be allowed to operate the mixer, or be in the
immediate area.
Never add fuel or lubricant to the machine while it is running.
Keep the area around the machine clear of obstructions which could cause
persons to fall onto moving parts.
Keep the body and clothing clear of all moving and hot parts.
Always ensure that during operation the mixer is standing on stable and level
ground and that the wheels are chocked.
Keep the engine/motor housing lid closed when the engine or electric motor
are running.
In the case of mixers fitted with a loading hopper, do not allow any person to
walk, stand or lean under the hopper when raised. It is recommended that the
area around the hopper is guarded to prevent persons standing or walking
under the hopper when the machine is in operation.

ENGINE
ELECTRICAL SYSTEMS
1.2 SAFE WORKING
Starting any diesel engine can be dangerous in the hands of inexperienced
people. Operators must be instructed in the correct procedures before
attempting to start any engine.
Always obtain advice before mixing oils; some oils are not compatible. If in
doubt, drain and refill.
The materials used in the manufacture and treatment of some filters and
elements may cause irritation or discomfort if they come into contact with the
eyes or mouth and they may give off toxic gases if they are burnt.
Engine lifting eyes must not be used to lift the complete machine.
Ether based cold start aids in aerosol cans must not be used under any
circumstances.
EXHAUST GASES CONTAIN CARBON MONOXIDE WHICH IS A
COLOURLESS, ODOURLESS AND POISONOUS GAS THAT CAN CAUSE
UNCONSCIOUSNESS AND DEATH.
Starting engines that are fitted with charge windings/alternators which have
been disconnected from the battery may cause irreparable damage.
The following points must be strictly observed when charge windings are
fitted otherwise serious damage can be done.
Never remove any electrical cable while the battery is connected in
the circuit.
Only disconnect the battery with the engine stopped and all switches
in the OFF position.
Always ensure that cables are fitted to their correct terminals. A short
circuit or reversal of polarity will ruin diodes and transistors.
Never connect a battery into the system without checking that the
voltage and polarity are correct.
Never flash any connection to check the current flow.
Never experiment with any adjustments or repairs to the system.
The battery and charge windings/alternators must be disconnected
before commencing any electric welding when a pole strap is directly
or indirectly connected to the engine.
BATTERIES CONTAIN SULPHURIC ACID WHICH CAN CAUSE SEVERE
BURNS AND PRODUCE EXPLOSIVE GASES. If the acid has been
splashed on the skin, eyes or clothes flush with copious amounts of fresh
water and seek immediate medical aid.

SERVICING & MAINTENANCE
Fuel tank filling point.
Attach lifting hooks to this eye.
Read Operators Handbook, or Operators
Handbook storage place.
The battery negative terminal is
connected to eath.
SAFE
WORKING 1.3
Never allow unqualified personnel to attempt to remove or replace any part
of the machine, or anyone to remove large or heavy components without
adequate lifting equipment.
Before maintenance work is begun, ensure that the engine is stopped, or
that the electric motor is switched off, and isolated from the mains.
Always conform to service schedules except when an emergency calls for
immediate action, or adverse conditions necessitate more frequent
servicing.
Always report any defect at once, before an accident or consequential
damage can occur.
On completion of maintenance, check that the machine functions correctly,
and that all guards are correctly fitted.
Disposal of waste oil.
Dispose of waste oil into waste oil storage tanks. If
storage tanks are not available, consult your Distributor or local authority for
addresses of local designated disposal points. It is illegal to dispose of
waste oil into drains or
water courses, or to bury it.
DECALS
Ensure that all warning decals fitted to the mixer are legible. If any should become
detached, they must be replaced immediately.
Descriptions of the pictorial decals are as follows:

Remove starting handle.
Beware of electrical hazards.
Engine stop.
Keep clear of chain drives.
These surfaces may be hot.
Keep hands clear of drum.
Battery isolator.
Wear ear protection.
Wear eye protection.
Conforms to EC standards.
1.4 SAFE WORKING

SAFE
WORKING 1.5

General
Care should be taken when lifting or
transporting the mixer to ensure that lifting
or retaining straps are in good condition
and the following procedures must be
followed when lifting or lashing down to
avoid causing unnecessary damage.
It is recommended that chains or webbing
slings are used to lift the mixer via the
lifting eyes on the mainframe (D) and
hopper (E), and that ratchet type webbing
straps are used to lash the mixer down.
Lifting the Mixer (Crane)
Using the tilting handwheel and locking
plunger, lock the drum so that the drums
open end is away from the hopper.
Raise the hopper (A) and insert the ram
safety prop (B).
To prevent the drawbar swinging freely as
the mixer clears the ground, lash it up to
the handwheel (C).
If the mixer is on site and the wheels are
immersed in dried concrete or mortar the
wheels must be freed before attempts are
made to lift the mixer.
Attach suitable lifting equipment to the
lifting eye (D) on the mainframe and the
lifting eye (E) on the hopper, and slowly
take the weight.
Do not 'snatch' the mixer otherwise
damage may be caused to the lifting eyes
or lifting equipment.
As the mixer clears the ground
the hopper safety prop (B) will
come free from its upper seat
and will swing down.
Be also aware that the mixer
will tend to swing as it leaves
the ground.
1.6 SAFE WORKING
LASHING DOWN & LIFTING POINTS

Lifting the Mixer
(Forklift/Telehandler)
Using the tilting handwheel and locking
plunger, lock the drum so that the drums
open end (G) is away from the hopper
Lower the hopper. (If not already down)
Remove stabiliser legs (J) (If fitted)
To prevent the drawbar swinging freely as
the mixer clears the ground, lash it up to
the handwheel (H).
If the wheels are immersed in dried
concrete or mortar, free them before
attempting to lift the mixer.
Spread the fork tines (K) as wide as
possible for them to pass under the
mainframe.Ensure the forks do not foul
the bottom hoses of the
hopper lifting ram
Position the carriage as close as possible
to the mixer
Slowly tilt the carriage back slightly to
prevent the mixer rocking forward, then
raise the mixer just clear of the ground.
Do not raise the mixer unnecessarily high.
Keep the height to the minimum required
to clear any obstructions without unduly
obstructing your forward vision.
When travelling keep your speed to the
minimum and when loading vehicles do
not raise the mixer to the height of the bed
until the mixer is close to the vehicle.
Similarly when unloading vehicles lower
the mixer just clear of the ground as soon
as it clears the side of the vehicle.
SAFE
WORKING 1.7

Lashing down
Unless the mixer is pulled up against a
headboard or some form of substantial
wheel chocks, it is recommended that two
ratchet type webbing straps are used to
retain the mixer, one pulling to the rear
and one pulling to the front.
Position the mixer on the vehicle bed and
chock the rear wheels to prevent it rolling
until lashed down.
Lower the hopper. (If not already down)
Turn the front axle so that the drawbar (N)
is below the mixer, or alternatively remove
it, so as not to form an obstruction on the
vehicle bed.
Fit the stabiliser legs (O).
Pass one of the webbing straps around
the front of the mainframe at point (P) and
secure the strap down to retaining hooks
on the vehicle bed in front of the mixer.
Pass the second strap around the rear of
the mainframe at point (M) and secure the
strap down to retaining hooks on the
vehicle bed to the rear of the mixer.
Tighten the straps by means of the
ratchets until the mixer is securely held.
1.8 SAFE WORKING

MAIN COMPONENTS OF MIXER
INSTALLATION AND
REMOVAL 2.1
1Stabiliser
2Hopper
3Hopper safety prop
4Hopper control lever
5Hopper loading ramp
6Dragline cable
7Cable support
8Dragline pulleys
9Jib tie bars
10 Jib legs
11 Pulleys for electric cable
12 Rubber flap
13 Staking lugs
14 Feed apron
15 Electric cable
16 Micro switch
17 Dragline shovel
18 Water tank
19 Weigher gauge

INSTALLING THE MIXER ON SITE
Lifting the mixer
Two lifting eyes are provided for using
hooks when unloading or loading the
mixer for transportation.
When viewing the mixer from the hopper
side, one lifting eye is situated on the left
hand side of the hopper cradle, and the
second eye is at the top of the trunnion
pedestal next to the engine housing. The
eyes are clearly marked with decals.
Installing stabiliser
The mixer must be sited on firm level
ground.
Fit the stabiliser (1) to the mainframe (20)
using the two locking pins (21). Secure
these with lynch pins.
Locate the top (angled) ends of the struts
(22) onto the pins (23) of mainframe, and
fit the bottom ends onto the pins (24) of
the stabliser. Fit the four locking pins and
secure with lynch pins.
As the mixer is standing on level ground, it
will be seen that there is a distance of
approximately 25mm between the
stabiliser feet and the ground (X). This
space must be packed with timber equal
to the area of the feet.
Chock all four roadwheels (25) to prevent
the mixer from moving.
Remove the the tow bar (26) and stow it
safely.
Ensure that the tyre
pressures are corrrect. (See
specifications section for
correct pressure.)
2.2 INSTALLATION AND REMOVAL

Installing the hopper
If the hopper (2) has been removed to
assist with transportation, it will be
necessary to refit it as follows;
Ensure that the cradle (27) is in the
lowered position. if it is not, it can be
lowered by raising it slightly, then swinging
down the safety prop (3).
The hopper weighs
approximately 100 kgs.
Using suitable lifting equipment, raise the
hopper up to the cradle, aligning the eight
fixing holes.
Insert coach bolts through the holes from
the inside of the hopper. Fit nuts to the
bottom four bolts (Y) and tighten securely.
Fit nuts to the four top bolts (Z) leaving
them finger tight.
Raise the hopper/cradle assembly and
install the safety prop (3). Tighten the top
four bolts securely.
Detach and remove the lifting equipment.
Installing the dragline jib
(optional equipment)
Assemble the jib legs (30) to the top
beam (31) using the bolts provided.
Loosely attach the jib tie bars (9/9A) with
the longer bar (M) at the mixer tilt wheel
end.
Place the jib (10) in position against the
mainframe. Align the mounting holes at
the base of the jib with the corresponding
holes in the mainframe (34).
Using the nuts and bolts provided, fasten
the jib to the mainframe leaving the nuts
finger tight.
Support the top end of the jib on a trestle
(W) approximately 1200mm high.
INSTALLATION AND
REMOVAL 2.3

Pull out the dragline cable (6) from the
winch (35).
Remove the cable cleat and thimble (6A)
and thread the cable around pulley (8)
and between pulleys (8A) on the jib.
Replace the cleat and thimble, and
connect the cable to the shovel ring (36).
Slot the cable mast (7) into its sleeve (37)
on the jib leg.
Unwind the electric cable (15) from the
shovel (17). Connect the plug (17A) to the
socket situated beneath the engine
housing.
Loop the cable (15) around the crossbar
(38) at the bottom end of the cable mast,
and over the cleat (39) at the top, leaving
sufficient slack to allow the jib to pivot
upwards.
Two pulleys are assembled onto the
cable, the first one (40) is hung from the
cleat (39), while the second pulley (41)
hangs free between the first pulley and
the cleat.
Tension is added to the cable by a weight
(42) added to the free hanging pulley.
The jib assembly weighs
approximately 125 kgs.
Securely fasten suitable lifting equipment
to each end of the top beam (N).
Raise the jib assembly until the jib tie bars
(9) can be bolted in position in the holes
provided adjacent to the tilt wheel and in
the back of the engine housing.
Tighten bolts (34), to secure the jib legs to
the mainframe.
Connect the winch hydraulic motor (35) to
the two hoses running from the solenoid
valve.
Note: Ensure that the hoses are fitted to
the correct motor ports. Connect
together the hose and port marked
with the same colour.
Strap the hoses to the jib leg.
2.4 INSTALLATION AND REMOVAL

Installing the feed apron
(optional equipment)
It is recommended that when a dragline is
fitted, a feed apron and ramp (14) are also
installed in front of the loading hopper (2)
so that materials may easily be tipped into
it. This is particularly important when a
batch weigher is fitted, as it prevents the
build up of aggregate under the hopper,
which will cause faulty batch weights to be
given.
Assemble the feed apron and ramp. Place
it squarely in front of the mixer so that the
hopper does not foul it when being raised
and lowered.
The horizontal rubber flap (43) prevents
material from failing between the hopper
(14) and ramp.
Stake the apron securely into position,
using the four lugs (44), two on each side.
Extend the centre partition of the ramp by
adding boards (45). This will help to
separate the aggregates.
Installing water supply to tank
Connect the water tank stopcock (18) to a
mains supply of clean water.
Installing electrically driven
mixers
(optional equipment)
Electrically driven mixers must be
connected to the mains supply by a
qualified electrician.
INSTALLATION AND
REMOVAL 2.5

DISMANTLING THE MIXER FOR
TRANSPORTATION
Transportation
When transporting the mixer on a vehicle,
the dragline jib must be dismantled. It may
also be necessary to remove the hopper
from its cradle.
If the hopper is fitted during
transportation, the stabiliser
(1) and struts (22) must be
fitted.
If the mixer is to be towed, the dragline jib
must be dismantled, and the hopper and
stabiliser removed.
Disconnecting electrically driven
mixers
Electrically driven mixers must only be
disconnected from the mains supply by a
qualified electrician.
Dismantling the feed apron
Remove and stow the feed apron. Clear
the area in front of the mixer to aid the
dismantling of the hopper and dragline.
Dismantling the hopper
Use suitable lifting
equipment, securely fastened
to the hopper to take its
weight during dismantling.
The hopper weighs
approximately 100 kgs.
2.6 INSTALLATION AND REMOVAL