9992-1020, Service Manual
Contents
1. REPLACEMENT In order to replace the shaft and casing you first have to be in load mode You can do this by firs pressing and releasing the e stop and then by pressing teach button and then the motor start button at the same time At this moment both motor start and teach but tons will flash meaning that you are in load mode When in load mode the triggers will control the forward or reverse motion in increments Remove the Side Safety Covers and lift up the Shaft Safety Cover Remove the Brush Holder and the Brush attachment from the Shaft amp Casing 1 2 3 Lock the Reel Drum with Hook Latch See next page for diagram 4 Reverse the Shaft amp Casing so it does come out of the Feed Wheel Unlock the Reel Drum and at the same time pull on the Shaft amp Casing so it does uncoil from the Drum Careful the reel drum is spring loaded so as soon as its unlocked it will try to pull the shaft amp casing When most of the shaft amp casing 15 out of the reel drum lock the Reel Drum 6 Unscrew the shaft head cut the tie straps and remove the old Shaft amp Casing 7 Re guide a new Shaft amp Casing as previously tie down with straps and screw the head back onto motor drive 9 Unlock Reel Drum and slowly let go of the shaft amp casing so it coils the new Shaft amp Casing onto the Drum 9 Guide the Shaft amp Casing tip thru the Feed Wheel lower the Shaft Safety Cover and press the forward trigger Bring the2. brush 5 ft past the gun and follow the initial set up procedures Note In case the reel drum spring load is lost follow the steps mentioned below Side Untangle any shaft amp casing f Let the reel drum loose so it will spin Shaft i Covers until its stops by it self Safety Wrap the shaft amp casing around the Cover reel drum quite tightly without turn ing the blue reel drum Turn the reel drum 8 times in the feed direction This will load up the spring The further you are among the turns the more it will get harder to turn Guide the Shaft amp Casing tip thru the Feed Wheel lower the Shaft Safety Cover and press the forward trigger Bring the brush 5 ft past the gun and follow the initial set up procedures 9992 1020 Hook Latch for locking the Reel E Drum SE Cover Feed p NW Wheel Shaft Head 1 MAINTENANCE Note Remove the plug from the power outlet before carrying out any adjustment service or maintenance Safety coupling replacement A 80 in Ib Safety Coupling 9600 0102 is supplied within the motor connection assembly as standard This will break if the shaft 1s overloaded by forcing cleaning tool within the tube A hook type removal tool 9600 0055 is supplied for removing this broken unit Engage the far end of the broken coupling with this tool and pull the coupling out Storage store disconnect water supply hose and gun assemb
3. do the job of a heavy duty tool WEAR PROPEL APPAREL No loose clothing or jewelry to get caught in mov ing parts Rubber gloves and footwear are recommended when working outdoors USE SAFETY GLASSES with most tools Also face or dust mask if cutting op eration is dusty DON T ABUSE CORD Never carry tool by cord or yank it to disconnect from receptacle Keep cord from heat oil and sharp edges SECURE WORK Use clamps or a vise to hold work It s safer than using your hands to operate tool DON T OVERREACH Keep proper footing and balance at all times MAINTAIN TOOL WITH CARE Keep tools sharp and clean for best and safest performance Follow instructions for lubricating and changing accessories DISCONNECT TOOLS When not in use before servicing when changing ac cessories such as blades bits cutters etc REMOVE ADJUSTING KEYS AND WRENCHES Form habit of checking that keys and adjusting wrenches are removed from tool before turning it on AVOID ACCIDENTAL STARTING Don t carry plugged in tool with finger or switch Remove the plug from the socket before carrying out any adjustment servicing or maintenance Do not use unit with combustible fluids or where combustible fluids or fumes may be present 9992 1020 CARRYING amp LOADING POSITION The WILS MATIC can be either pushed or pulled when holding from the handle bar and the unit tilted on its pneumatic wheels HANDLE BAR The WILS MATIC can be easily loaded on to a tr
4. 9992 1020 WILS MATIC ELECTRIC gite erra SELF FEED TUBE CLEANER MODEL WAM 5000 375 1 HP 1725 RPM MODEL WAM 5000 500 1 HP 1725 RPM OPERATING INSTRUCTIONS amp SERVICE MANUAL Thomas C Wilson Inc 21 11 44th Avenue Long Island City New York 11101 Tel 718 729 3360 Fax 718 361 2872 http www tcwilson com Email tcwilson tcwilson com Updated 3 03 2006 9992 1020 SAFETY INSTRUCTIONS 10 11 12 13 14 15 16 LA 18 19 LAN WARNING READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in accident fire and or personal injury SAVE THESE INSTRUCTIONS KNOW YOUR POWER TOOL Read this service manual carefully GROUNDING INSTRUCTIONS This product is equipped with a cord having an equipment grounding conductor and a grounding plug The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances KEEP GUARDS IN PLACE and in working order KEEP WORK AREA CLEAN Cluttered areas and benches invite accidents AVOID DANGEROUS ENVIRONMENT Keep work areas well lit STORE IDLE TOOLS When not in use tools should be stored in dry high or locked up place out of reach of children DON T FORCE TOOLS It will do the job better and safer at the rate for which it was designed USE RIGHT TOOLS Don t force small tool or attachment to
5. cription Brush Holder 9992 6100 For 3 8 Shaft amp Casing 9992 6150 For 1 2 Shaft amp Casing e Flexible Shaft Lubricator 9675 0000 e Safety Shaft Coupling 9600 0102 includes removal tool e Flexible Shaft amp Casing 9722 0045 Shaft amp Casing 3 81 OD 45ft e 9724 9045 Shaft amp Casing 1 21 OD 451 e Spiral Brushes 61746 Speed 1725 min e 62501 Speed 1725 min e Water Collection Attachment 9992 7000 Thomas C Wilson Inc 21 11 44th Avenue Long Island City New York 11101 13
6. ing on the trigger 12 Once you extend the brush until the end of the tube Press the Teach button CAUTION The brush will immediately retract until Home Position 13 At this point the two buttons Motor Start and Teach should be lit 14 Now by just pressing amp holding the Forward Trigger you can start the tube cleaning cycle Holding the Forward Trigger will feed the brush forward until the taught position and come back Once its back release the forward trigger switch tube and repeat cycle 15 Observe the following operation guidelines Do not force cleaning head within tube If any resistance is felt back off two inches or so and re feed shaft until it moves easily through the tube If this fails use a smaller cleaning head or one intended for plugged tube applica During the reversing of the brush if the brush doesn t stop at home position As a backup it will stop half way inside the gun assembly At this point the auto mode will be turned off and the user will be in manual mode At this point just hit forward and go to the home position then start from Operation 3 Step 10 e Only allow one inch to three inches of the brush to come out of other end of tube e In Case of Emergency hit the E Stop Once the E Stop is pressed You must first release the E Stop by turning Clockwise and then recycle the power and restart from Step 5 9992 1020 9992 1020 SHAFT amp CASING
7. ly Disconnect flexible shaft from machine Dry out the shaft with an air blast through a hose fitting optional 9614 attached to large aluminum coupling Store the tube cleaner in a dry heated place Lubrication Periodically grease ball bearing inside motor connector housing through grease fitting usually every 200 hours of services Replacement of cords or electrical components If supply cord is damaged it must be replaced by a special cord or an assembly available from the factory PARTS LIST Key Description Part No Qty 1 Shaft Exit Guide 9992 1180 1 2 Feed Unit Assembly 9992 5200 1 3 Shaft amp Casing 9724 9045 1 4 Drum Assembly 9992 4200 1 5 Feeder Gun Assembly 9992 3100 1 6 Drive Unit Assembly 9992 5100 1 7 Frame Assembly 9992 1100 1 8 Control Cabinet 9992 2100 1 9992 1020 11 9992 1020 TROUBLE SHOOTING PROBLEM CAUSE amp SOLUTION No power or E Stop when pressed not 5 not activated not Pressed 12 lit up when unit is first plugged into power outlet Power up but motor not turning when activated Motor running but Flexible Shaft not turning Motor running but no water output at end of Flexible Shaft Flexible Shaft turning but not feeding out Motor running and water drips inside unit Unit running rough and or noisy Brush goes over the taught distance Brush pulls back into gun and teach light comes off press E Stop to activate GFCI Plug not re
8. nts Motor Start button is amp White Re Load mode either forward or reverse There is no max limit or presses and released backup limit So remove any brush extension and brush at the same time before reversing all the way back OPERATION 3 Un coil electrical cord from the hook and plug it in a properly grounded outlet Press the reset button on the GFCI plug 2 Attach the brush holder piece amp the appropriate brush onto the shaft that is stick ing out of the shaft exit guide 3 Un coil Feeder Gun Assembly and connect it to the unit using the shaft connector and electrical connector 4 Connect water hose to water inlet with strainer within Turn water supply on Solenoid valve only opens to allow water through when the motor is running 5 At this point the E Stop will be lit 6 Release the 5 button by turning it Clockwise 7 At this point none of the buttons will be lit 8 Press the Forward Trigger until the tip of the Shaft amp Casing is 5 feet beyond the tip of the Gun 9 Press the Motor Start button CAUTION After 5 seconds the brush will immediately pull back in to the gun This is the Home Position 10 Hold the end of the Feeder Gun at the tube mouth making sure it is held away from your body 11 Press the Forward Trigger on the Gun to go forward Thus extend the brush until the desired length Length of the Tube to be cleaned Make sure to achieve this with the minimum puls
9. pressed it will continue from the point it was stopped Will spin the brush clockwise and then counter clockwise on the pull back Reverse Trigger Will pull back the brush until home position is No matter in what motion the brush is reached Home Position Brush tip sticking Forward or Reverse it will always reverse out of the gun about 2 3 inches the brush until home position Will spin the brush counter clockwise Will spin the brush counter clockwise Neither the motor Initial start up mode Do not operate the unit in this mode Just use this mode start or teach is when e stop is released and initially setting up the pressed brush See Operation 3 Item 5 Motor Start button is Solid Green Manual mode In this mode the brush can be moved forward with the Pressed forward trigger until shaft amp casings max limit and re versed with the reverse trigger until home position In this mode the user can clean the tubes by going forward until desired distance and then reversing it until brush comes back in to home position Teach button is Solid Green amp Auto mode In this mode the brush can be moved forward and re pressed White versed with only holding the forward trigger In this mode the user will hold the forward trigger and the brush will be sent until the taught distance and then come back until the home position Teach button and Flashing Green Shaft amp Casing Load The triggers will move the brush in small increme
10. set press reset button on GFCI GFCI Plug defective Power cord defective E Stop 15 activated Pressed Trelease E Stop by turning it Blown Fuse replace fuse 1 Defective motor Defective wiring in unit Broken Safety Coupling Broken Shaft Cable Water supply not turn on Defective Solenoid Valve Jamming at feed wheel Broken belt Brush head is jamming inside the gun Worn Teflon seal inside Motor Connector Leakage in tube or tube fittings Lack of lubrication in Motor Connector ball bearings inside Motor Connector through grease fitting through access hole in bot tom of unit worn or corroded ball bearings in Motor Connector To many pulsing while teaching Come out of teach mode go back to home posi tion and re teach Sensor is skipping the brush head Make sure the brush attachment is in place Make sure no wires coming into the gun is cut or broken Shaft feeds out when motor start is pressed during the initial set up Brush is not far enough from the gun s tip Feed the flexible shaft out 5ft after the gun 9992 1020 SPECIFICATIONS MODEL 5000 375 5000 500 VOLTAGE 115 115 FREQUENCY 60 60 HORSEPOWER 1 1 1725 1725 SELF FEED RATE 4 FT PER SECOND 4 FT PER SECOND SHAFT amp CASING 3 8 O D 1 2 DIMENSION 41 in x 33 in x 18 in 41 in x 33 in x 18 in WEIGHT 150 LBS 150 LBS LIST OF ACCESSORIES Item Part No Des
11. uck bed or a cargo van s back by first dropping the loading wheels on to it and then by lifting the unit by its handle and at the same time by pushing it forward This way the unit will easily roll on its four wheels LOADING WHEELS N CAREFUL OTHER THAN THE NECESSARY LOADING AND UNLOADING DO NOT ROLL THE WILS MATIC ON FOUR WHEELS 9992 1020 OPERATING POSITION The WILS MATIC tube cleaner at all times should be operated with the safety covers in place In addition it should be operated only with the top side side with eyebolt up as illustrated below EYEBOLT N DANGER IF YOU ARE OPERATING THE UNIT WITHOUT THE SAFETY COVERS SERIOUS RISK OF INJURY MAY RESULT 9992 1020 GETTING ACQUAINTED WITH WILS MATIC LOADING WHEELS EYEBOLT SHAFT EXIT N GUIDE HANDLE BAR CONTROL MOTOR BUTTONS CONNECTOR OPERATION 1 Step 2 amp 3 Step 1 Shaft Exit GFCI Plug Guide amp Feeder Gun Connection Step 3 Water Hose Inlet StepS 0 6 F EN Forward Trigger Step 8 Brush Reverse Holder Trigger MINIMUM GAUGE OF EXTENSIONCORD REQUIRED USE ONLY 10 AWG UP TO 100 FT 9992 1020 9992 1020 OPERATION 2 Manual Mode Teach Mode Forward Trigger Will send the brush forward until max limit of Will send the brush forward until taught dis the shaft amp casing is reached tance and pull back the brush until home posi Will spin the brush clockwise tion If let go anytime and then re
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