Merlo DBM 2000 XS, DBM 2000 EV, DBM 2500 EV and DBM 3500 EV Loader and Mixing Drum Removal Service Manual [PDF] ENG

This PDF service manual provides detailed workshop instructions for removing and reinstalling the principal loading and mixing assemblies fitted to selected Merlo DBM concrete mixers.

It is designed for qualified mechanics, service workshops and experienced technicians carrying out repairs that require access to the loader mechanism, loader lifting arms, mixing drum or drum-supporting chassis.

The procedures explain how to secure and prepare the machine, disconnect hydraulic pipes, remove retaining plates and pins, support heavy components with suitable lifting equipment and safely separate them from the machine.

The manual includes

• Safety and general workshop instructions;
• Required standard and special tools;
• Merlo special tool reference numbers;
• Estimated removal and reinstallation times;
• Loader and loader rotation cylinder removal;
• Loader reinstallation instructions;
• Mixing drum removal;
• Drum hydraulic pipe disconnection;
• Loader lifting-arm removal;
• Drum chassis removal;
• Reinstallation of the loader arms and drum chassis;
• Pin installation procedures;
• Hydraulic connection and component-support instructions;
• Metric tightening-torque specifications;
• Information about thread-locking products, sealants and assembly lubricants.

The manual is divided into sections covering the necessary tools, expected repair times and the dismantling and servicing of the relevant components.

Loader and rotation cylinder removal

The loader section explains how to:

• Lower and position the loader safely;
• Secure the machine against accidental movement;
• Remove the retaining devices and loader mounting pins;
• Separate the loader from the lifting arms;
• Disconnect the loader rotation cylinder pipes;
• Remove the loader rotation cylinders;
• Reinstall the components in the correct sequence.

The reinstallation procedure specifies the correct order for inserting the loader mounting pins and the use of Merlo special tool 057001.

Mixing drum removal

The drum-removal section includes instructions for:

• Disconnecting the drum motor drain and hydraulic lines;
• Temporarily joining the relevant hydraulic pipes;
• Supporting the drum with suitable lifting equipment;
• Removing the drum-to-chassis tie rods;
• Lifting and safely positioning the drum;
• Reinstalling the drum by reversing the removal procedure.

The manual warns that the disconnected hydraulic pipes must be joined correctly before starting the motor, otherwise serious system damage may occur.

It also explains how to balance and support the drum during lifting so that it cannot overturn after removal.

Loader lifting-arm removal

The loader-arm section explains how to:

• Disconnect the lifting-cylinder hydraulic pipes;
• Remove the cylinder retaining pins;
• Separate the cylinder rods from the lifting arms;
• Remove the arm supports;
• Lift and move the loader-arm assembly away from the machine;
• Reinstall the assembly using the specified special tool.

The lifting arms may be removed with or without first removing the loader, although suitable lifting equipment must be used to support the assembly.

Drum chassis removal

The drum-chassis procedure covers:

• Supporting the chassis with an appropriate lifting device;
• Removing the water-delivery pipe;
• Removing retaining plates and shared mounting pins;
• Separating the loader-arm and drum-chassis lifting cylinders;
• Removing the chassis supports;
• Lifting the drum chassis away from the machine;
• Reinstalling the chassis and inserting the mounting pins correctly.

The drum chassis can be removed either with or without the mixing drum installed.

Special care is required because some mounting pins support both the loader-arm lifting cylinder and the drum-chassis lifting cylinder.

Required tools

The manual lists the standard workshop tools required, including:

• Spanners;
• Hexagon drivers;
• Ratchet and sliding handles;
• Torque wrench;
• 100 mm and 200 mm extensions.

It also specifies Merlo special tool 057001, a cone used when installing mounting pins on the DBM concrete mixer.

Estimated repair times

The manual provides the following estimated workshop times:

• Loader removal: 20 minutes;
• Loader reinstallation: 30 minutes;
• Loader lifting-arm removal: 40 minutes;
• Loader lifting-arm reinstallation: 45 minutes;
• Drum removal: 40 minutes;
• Drum reinstallation: 50 minutes;
• Drum chassis removal: 40 minutes;
• Drum chassis reinstallation: 50 minutes.

These estimates do not include additional time required for removing related assemblies where specifically noted.

Product information

Manufacturer: Merlo
Applicable models: DBM 2000 XS, DBM 2000 EV, DBM 2500 EV and DBM 3500 EV
Manual type: Workshop Service Manual
Content covered: Loader, loader arms, mixing drum and drum chassis removal
Manual reference: DBM-PABO.01
Application: From SAV 741511 onwards
Language: English
Format: Digital PDF file
Number of pages: 33 pages

Important information before purchase

Please check your machine model and SAV number before purchasing.

This is a specialised dismantling and installation service manual. It does not provide complete repair information for the engine, transmission, electrical system or all hydraulic components.

The procedures involve heavy assemblies, hydraulic connections and lifting equipment. They are intended for qualified technicians with suitable workshop tools, hoists and knowledge of safe machinery repair procedures.