Wyco Sure Speed WVD1 Betriebsanleitung

Flex Shaft Concrete Vibrator

Operator’s and Service Manual

Patent Pending

™

Safety Tested,

UL Listed

SPANISHPORTUGUESEFRENCHGERMANITALIAN ENGLISH

CONTENTS

GENERAL POWER TOOL

SAFETY WARNINGS ......................................................................................................3

Work Area ..........................................................................................................................................3

Electrical Safety ................................................................................................................................. 3

Personal Safety ..................................................................................................................................3

Power Tool Use and Care ................................................................................................................... 4

Service ................................................................................................................................................4

Safety Symbol Explanations .............................................................................................................4

INTRODUCTION ...........................................................................................................5

OPERATION ...................................................................................................................5

Connecting the Vibrator Casing ........................................................................................................5

Disconnecting the Vibrator Casing ...................................................................................................5

Before Starting the Motor .................................................................................................................5

Variable Speed Control Models Only ................................................................................................6

PREVENTIVE MAINTENANCE ......................................................................................7

Brush Removal ......................................................................................................................................7

Brush Replacement ............................................................................................................................7

Filter Replacement .............................................................................................................................7

ELECTRIC VIBRATOR HEAD SERVICE & MAINTENANCE ...........................................9

Flexible Shaft - Lubrication .............................................................................................................10

Extension Cords ...............................................................................................................................11

ELECTRIC VIBRATOR HEAD ASSEMBLY DRAWINGS & PARTS LISTS .....................12

Vibrator Head Model 750-D ............................................................................................................12

Vibrator Head Model 750-EH ..........................................................................................................12

Vibrator Head Models 750-FI, 750-GI, 750-LI, and 750-MI .............................................................13

Vibrator Head Model 750-SBI ..........................................................................................................13

RESTRICTIONS OF HAZARDOUS SUBSTANCES ROHS DIRECTIVE .....................14

WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT WEEE DIRECTIVE ............14

ABBREVIATED MANUFACTURER’S LIMITED WARRANTY ......................................15

MODEL NUMBER

SERIAL NUMBER

DATE PURCHASED

ENGLISH

Page 2 Form No. W160 02/10

SAVE ALL WARNINGS AND

INSTRUCTIONS FOR

FUTURE REFERENCE

GENERAL POWER TOOL

SAFETY WARNINGS

Work Area

1. Keep your work area clean and well lit.

Cluttered benches and dark areas invite

accidents.

2. Do not operate power tools in explosive

atmospheres, such as in the presence of

ammable liquids, gases or dust. Power tools

create sparks which may ignite the dust or fumes.

3. Keep children and bystanders away while

operating a power tool. Distractions can cause

you to lose control.

Electrical Safety

1. Power tool plugs must match the outlet.

Do not use any adapter plugs with earthed

(grounded) power tools. Unmodied plugs

and matching outlets will reduce risk of electric

shock.

2. Double insulated tools are equipped with a

polarized plug (one blade is wider than the

other). This plug will t in a polarized outlet

only one way. If the plug does not t fully in

the outlet, reverse the plug. If it still does not

t, contact a qualied electrician to install a

polarized outlet. Do not change the plug in

any way. Double insulation eliminates the need

for the three-wire grounded power cord and

grounded power supply system.

3. Avoid body contact with earthed or grounded

surfaces such as pipes, radiators, ranges

and refrigerators. There is an increased risk of

electric shock if your body is grounded.

4. Do not expose power tools to rain or wet

conditions. Water entering a power tool will

increase the risk of electric shock.

5. Do not abuse the cord. Never use the cord to

carry the tools or pull the plug from an outlet.

Keep cord away from heat, oil, sharp edges

or moving parts. Replace damaged cords

immediately. Damaged cords increase the risk of

electric shock.

6. When operating a power tool outside, use an

outdoor extension cord marked “W-A” or “W”.

These cords are rated for outdoor use and reduce

the risk of electric shock.

7. If operating a power tool in a damp location

is unavoidable, use a residual current device

(RCD) protected supply. Use of an RCD reduces

the risk of electric shock.

Personal Safety

1. Stay alert. Watch what you are doing and

use common sense when operating a power

tool. Do not use tool while tired or under the

inuence of drugs, alcohol or medication. A

moment of inattention while operating power

tools may result in serious personal injury.

2. Use personal protective equipment. Always

wear eye protection. Protective equipment

such as dust mask, non-skid safety shoes, hard

hat, or hearing protection used for appropriate

conditions will reduce personal injuries.

3. Prevent unintentional starting. Ensure the

switch is in the o-position before connecting

to power source and/or battery pack, picking

up or carrying the tool. Carrying power tools

with your nger on the switch or energizing

power tools that have the switch on invites

accidents.

4. Remove adjusting keys or switches before

turning the tool on. A wrench or a key that is

left attached to a rotating part of the tool may

result in personal injury.

READ ALL SAFETY WARNINGS AND INSTRUCTIONS

Failure to follow all warnings and instructions may result in

electric shock, re and/or serious personal injury.

WARNING

ENGLISH

Form No. W160 02/10 Page 3

5. Do not overreach. Keep proper footing and

balance at all times. Proper footing and balance

enable better control of the tool in unexpected

situations.

6. Use safety equipment. Always wear eye

protection. Dust mask, non-skid safety shoes,

hard hat or hearing protection must be used for

appropriate conditions.

Power Tool Use and Care

1. Do not force the power tool. Use the correct

power tool for your application. The correct

tool will do the job better and safer at the rate for

which it is designed.

2. Do not use the power tool if switch does

not turn it on or o. Any tool that cannot be

controlled with the switch is dangerous and must

be repaired.

3. Disconnect the plug from the power source

before making any adjustments, changing

accessories or storing the tool. Such preventive

safety measures reduce the risk of starting the

tool accidentally.

4. Store idle power tools out of reach of children

and do not allow persons unfamiliar with the

power tool or these instructions to operate

the power tool. Power tools are dangerous in

the hands of untrained users.

5. Maintain power tools. Check for misalignment

or binding of moving parts, breakage of parts,

and any other condition that may aect the

power tools operation. If damaged, have

tool serviced before using. Many accidents are

caused by poorly maintained tools.

6. Keep cutting tools sharp and clean. Properly

maintained tools, with sharp cutting edges, are

less likely to bind and are easier to control.

7. Use the power tool, accessories and tool bits,

etc. in accordance with these instructions,

taking into account the working conditions

and the work to be performed. Use of the

power tool for operations dierent from those

intended could result in a hazardous situation.

Service

1. Have your power tool serviced by a

qualied repair person using only identical

replacement parts. This will ensure that the

safety of the power tool is maintained.

Safety Symbol Explanations

Volts

Amperes

Hertz

Alternating Current

Class II Tool

IP Symbol

Ground Terminal (Protective Earthing)

OFF

Refer to Instruction Manual

Variability in Steps

IPX4

FIGURE 1.0  SAFETY SYMBOLS

ENGLISH

Page 4 Form No. W160 02/10

INTRODUCTION

The Sure Speed vibrator motor is used to power

concrete ex shaft vibrators which provide vibra-

tion to consolidate freshly poured concrete. The

vibration is created by an eccentric (o center)

weight within the vibrator head. As the weight

spins it forces the head housing to move within the

fresh concrete. The continuous head movement

agitates the concrete mixture resulting in signi-

cantly reduced voids.

The Sure Speed motor can be used with any valid

Wyco vibrator head and shaft combination. Table

1.0 is provided to show the commonly used head

and shaft combinations. Shafts are available in

lengths of 2, 5, 7, 10, 14, and 20 feet.

Do not use non-approved parts. The use of non-

approved parts may cause a hazardous condition

for the operator.

Vibrator Head Vibrator Shaft

Size (in) Model No Length CK Series

⁄ 750-D 2-20 ft 8900

1 750-EH

1⁄ 750-FI

2-20 ft 9500

1¾ 750-GI

2 750-LI

2¼ 750-MI

2½ 750-SBI

TABLE 1.0 − HEAD AND SHAFT COMBINATIONS

OPERATION

Connecting the Vibrator Casing

NOTE: The casing must be tted with a quick disconnect

end. See Vibrator Head Service and Maintenance later in this

manual.

1. Align the end of the core with the driver inside

the quick disconnect tting on the motor.

2. Pull on the quick disconnect ring to withdraw

the locking pin from the quick disconnect

tting. The pin is spring loaded so tension will

have to be maintained while the casing is being

inserted.

3. Insert the casing being sure to line up the shaft

and driver so the shaft slides into the driver.

4. While holding the casing rmly into the quick

disconnect, release the quick disconnect ring

and then rotate the casing until you hear the

spring loaded pin engage the locking hole on

the quick disconnect tting.

Disconnecting the Vibrator Casing

1. Pull the quick disconnect ring to withdraw the

locking pin from the casing’s quick disconnect

tting.

2. Pull the casing straight out of the motor’s quick

disconnect tting.

Before Starting the Motor

Do not use damaged equipment.

Inspect the vibrator for damage prior

to using this equipment. Read, under-

stand and follow all safety and mainte-

nance instructions in this manual. Carefully check

that the power cord has no cuts or exposed wires

and that the vibrator housing is intact.

Do not start the motor without a shaft con-

nected. The exposed shaft connection presents a

safety hazard as it rotates at high speed. Clothing or

skin may become entangled in the shaft connection

causing injury.

Ensure that the motor, shaft and head are con-

nected securely as described in the maintenance

instructions.

Ensure that the power plug is connected to the

appropriate power source.

Ensure that the motor is not immersed in concrete

and that any cord connections are not in water or

fresh concrete.

Turn vibrator on by moving the rocker switch to

the “I” (on) position. (See Figure 3.0 for switch

location.)

NOTE: The motor has been designed with a soft start and will

slowly ramp up to speed over a 1 second period.

DANGER

ENGLISH

Form No. W160 02/10 Page 5

NOTE: Refer to Figure 3.0 for switch and button locations.

When the power switch is turned on, the motor

will always start at 10,500 VPM. From the time

the power is applied there is a 20 second window

in which to choose one of the alternate motor

speeds.

Holding the speed control button for 1 second

will change the motor speed to 8,000 VPM. Releas-

ing the speed control button and then pressing it

again for 1 second will increase the motor speed to

12,000 VPM.

Releasing and then pressing the speed control

button a third time for 1 second will return the

motor to 10,500 VPM. To reset the 20 second speed

change period, the power switch must be turned

o and then on again.

Insert the vibrator head into the concrete to be

consolidated.

Do not run the vibrator head outside of fresh con-

crete for an extended period of time. The vibrator

depends on moving concrete to cool the bearings.

Avoid sharp bends in the ex shaft during opera-

tion. Sharp bends reduce shaft life.

Remove the vibrator head from concrete and turn

the rocker switch to the “O” (o) position. (See

Figure 3.0 for switch location.)

Variable Speed Control Models Only

The variable speed option allows the operator to

choose between 8,000, 10,500, and 12,000 VPM

(Vibrations Per Minute).

NOTE: This instruction only pertains to model numbers that

start with WV):

20 sec

Power Switch

Turned ON

8,000

7,000

10,500

12,000

VPM

Speed Control

Button Held for

At Least 1 sec

1 sec

Ramp-up

Speed Control

Button Held for

At Least 1 sec

Speed Control

Button Held for

At Least 1 sec

FIGURE 2.0  VARIABLE SPEED CONTROL TIMING

ENGLISH

Page 6 Form No. W160 02/10

PREVENTIVE MAINTENANCE

Wyco vibrator motors are designed to operate 50

to 100 hours between normal “preventive main-

tenance” intervals. The service instructions below

should be followed to perform the preventive

maintenance.

NOTE: There are no user serviceable parts

contained within the motor housing. Open-

ing the motor housing may be dangerous

and will void the warranty. Any repairs that

require opening the motor housing should

be performed at an authorized Wyco service

center or at the Wyco factory. Use only factory authorized

replacements parts.

Brush Removal

For the location of the parts used in the following

procedures refer to Figure 3.0.

1. Disconnect the line cord from power source.

2. Lay the motor on its side with brush cap (6)

facing upwards.

3. Use a ⁄ inch (6-sided) socket to unscrew the

plastic brush cap (6) from the motor half.

4. The brush spring (5) will pop out. Carefully re-

move the brush spring by gently pulling on the

spring.

5. Repeat steps for the opposite side.

WARNING

ENGLISH

Brush Replacement

NOTE: Brushes should be replaced in pairs.

1. Align new brush (5) with brush holder and

insert.

2. Push the spring into the holder as the brush cap

is screwed back into the housing.

NOTE: The O-ring must be on the brush cap before screwing

into the housing.

3. Repeat steps for opposite side.

Filter Replacement

1. Pull the old lter down from the housing with

your ngers.

2. Place the new lter (2) in the housing, tapered

side up. (See Figure 3.0.)

Form No. W160 02/10 Page 7

Item Description Qty WVD1 WVG1 WSD1 WSG1 WSG2

1D-Ring 2 819014 819014

2Filter, Intake 1 423132 423132

3Carriage Screw; 10-32, ¾” 9 423140 423140

4Acorn Nut, Self-locking; 10-32 UNF 9 423141 423141

5Assembly, Brush & Spring; 115V 2 423112 --------

5Assembly, Brush & Spring; 230V 2 -------- 423113

6Brush Cap with O-Ring 2 423114 423114

7Quick Disconnect Body 1 113715 113715

8Core Plug 1 764733 764733

Strap, Carry (not shown) 1 819013 819013

514-O Non-foaming Vibrator Oil 14 oz W655-143 W655-143

514-B Shaft Lubricant 14 oz W655-140 W655-140

Permatex 11 oz W657055 W657055

See Figure 3.0 for Parts Locations

TABLE 2.0  SURE SPEED REPLACEMENT PARTS

On/O

Switch

Quick Disconnect

Ring

Variable Speed

Button

FIGURE 3.0 − PARTS LOCATIONS

ENGLISH

Page 8 Form No. W160 02/10

ELECTRIC VIBRATOR HEAD SERVICE & MAINTENANCE

Installing or replacing vibrator head quick

disconnect tting.

The Sure Speed motor is shipped with a Quick Dis-

connect Body (P.N. 113715 ) and a Core Plug (P.N.

764733). If the vibrator shaft assembly hasn’t been

converted to quick disconnect ttings, the conver-

sion will have to be preformed before the shaft can

be connected to the Sure Speed motor.

1. Remove the protective cap from the motor end

of the vibrator shaft. Remove any dirt or corro-

sion from the threads.

2. Place the nylon core plug into the open end of

the core casing with the ange side up.

3. With a rubber mallet begin to tap the core plug

into the casing. Stop when the plug just reaches

the tip of the core.

4. Align the core with the hole in the core cap and

continue to tap the cap until the ange is resting

on the top edge of the casing.

5. Apply some oil to the casing threads and thread

the quick disconnect body onto the casing over

the core plug.

6. Tighten the quick disconnect body nger tight

and then an additional quarter turn with a pipe

wrench or channel lock pliers.

Service the vibrator head after every 50 hours

of operation to ensure trouble-free running on

the job.

When servicing, always replace hex driver, seals and

bearings (or bushing for 750-D & 750-EH heads).

(See drawings on pages 12 and 13.)

All heads are equipped with seals at the exible

shaft end and contain oil. The seals serve a double

purpose; to keep the oil in the head and to keep the

grease from the exible shaft out of the head.

1. Hold the nose end in a vise and unscrew the end

cap (counterclockwise) with a chain wrench or a

good pipe wrench. (See Figure 4.0.)

FIGURE 4.0 − END CAP REMOVAL

2. Pull the eccentric rotor assembly out of the hous-

ing. If the bearings are stuck and you have di-

culty removing them from the housing, screw the

end cap partly back into the housing and bounce

the head and cap down on a block of wood in

order to loosen the bearings from their seat, then

pull out the rotor assembly. (See Figure 5.0.)

FIGURE 5.0 − BEARING REMOVAL

NOTE: Hexagon driver has left-hand threads.

3. Flush rotor assembly and housing with solvent

and wipe all parts clean. Replace bearings, seals

and hex driver. Maintain concentric align-

ment of hex driver with respect to rotor shaft.

Refill with proper amount of Wyco No. 514-O

non-foaming vibrator oil. (See Table 3.0.) Apply

Loctite® 545 adhesive/sealant or equivalent to

threads on both ends of rotor.

ENGLISH

Form No. W160 02/10 Page 9

Head Model Head Size Oil Required

750-D ⁄” Square ½ ounce

750-EH 1” Square ¾ ounce

750-FI 1⁄” Square 1 ounce

750-GI 1¾” Square 1¼ ounces

750-LI 2” Square 2 ounces

750-MI 2¼” Square 3½ ounces

750-SBI 2½” Round 1¼ ounces

TABLE 3.0 − HEAD OIL REQUIREMENTS

4. Replace rotor assembly in head housing. Apply Loctite® 545 adhesive/sealant or equivalent all around

the threads of the end cap. Tighten and wipe o excess Loctite® 545 adhesive/sealant.

Flexible Shaft - Lubrication

When vibrators are shipped completely assembled from the factory, the shafts are lubricated and

broken-in. If separate cores and casings are shipped, they require the following lubrication and break-in

procedure. Core and casing combinations should be checked for lubricant levels at least every 50 hours.

To lubricate, lightly coat the core with grease (Wyco 514-B shaft lubricant) while inserting it into the cas-

ing. Do not over lubricate. Surplus lubricant may get past the seal in the vibrator head. Over lubrication

will also increase the amount of torque required to operate the vibrator, resulting in additional stress on

the motor and possibly early core and casing failure.

When adding lubricant on the job, after each 50 hours of operation, loosen the casing from the motor

and pull out the core about 15 to 18 inches. Apply lubricant as above to the exposed section of core.

Reinstall the core ensuring that it engages with the vibrator head. During operation the grease will travel

the full length of the casing.

A break-in procedure is required after the assembly of separately shipped core and casing. This proce-

dure involves repeatedly coiling the ex shaft from the head to the motor while the motor is running.

The coiling and uncoiling should be repeated at least 3 times to ensure proper break-in.

NOTE: For shorter core and casing combinations coiling isn’t possible. Break-in for short core and casings requires bending into a

“U” shape instead of a coil.

Water is one of the greatest enemies of satisfactory performance of vibrator heads. As the head is sub-

merged in the mix, water and cement can inltrate into the head unless precautions are taken. In addi-

tion to securely tightening the head onto the exible shaft, the threads on the head and shaft must be

coated with Permatex® Form-A-Gasket® No. 2. This must be done each and every time that the head is

removed and reinstalled.

ENGLISH

Page 10 Form No. W160 02/10

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