992a / 993 Service Manual
Contents
1. Ea Replace rotor assembly in head housing Apply Loctite 545 adhesive sealant or equivalent all around the threads of the end cap Tighten and wipe off excess Loctite 545 adhesive sealant involves repeatedly coiling the flex shaft from the head to the motor while the motor is running The flex shaft should be coiled and uncoiled repeatedly until the amperage to operate the vibrator is reduced and remains constant It must be reduced to a level lower than the rated amperage on the name plate If an ammeter is not available an increase in speed RPM can be heard The coiling and uncoiling should be repeated until the speed increases and remains constant If this procedure is not followed additional torque will be required from the motor thus reducing the motor life NOTE When attaching Vibrator Head to Flexible Shaft casing always use Permatex Form a Gasket No 2 on the threads One of the greatest enemies of satisfactory performance of Vibrator Heads is water As the head is submerged in the mix water and cement try to get into the head In addition to tightening the head onto the flexible shaft tightly the threads must be coated with Permatex Form a Gasket 2 This must be done each and every time that the head is removed and re installed Wyco Motor Service and Maintenance Instructions Wyco vibrator motors are designed to operate 50 to 100 hours between normal preventive maintenance intervals The service instruct2. To lubricate lightly coat the core with grease 514 B Wyco shaft lubricant while inserting it into the casing Do not over lubricate since the 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 core insuring 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 seperately shipped core amp casing This procedure 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 alignment of hex driver with respect to rotor shaft Refill with proper amount of Wyco No 514 O non foaming vibrator oil Apply Loctite 545 or equivalent to threads on both ends of rotor See Chart Below HEAD OIL REQUIREMENTS Head Size D 13 16 Square EH 1 Square Oil Required 1 2 ounce 3 4 ounce 1 ounce 1 1 4 ounces 2 ounces 3 1 2 ounces 1 38B 1 3 8 Square 1 75B 1 3 4 Square 2 00B 2 Square 2 25B 2 1 4 Square
3. 545 LOCTITE 545 L LOCTITE 545 No Description Qty 1 38B 1 75B 2 00B 2 25B No Description Qty 1 38B 1 75B 2 00B 2 25B Nut Hex Jam 432707 Washer Flat 1 887015 887016 Washer Flat 887011 Seal Oil 2 kkk 1 1 2 Bearing Ball End Cap KK Driver Hex 384446 Shim 419701 N A Manufacturer suggests using End Cap with pressed in seals 1 38B 208231 1 75B 208236 2 00B 208261 2 25B 208268 However Seal and End Cap are available separately upon request 3 Electric Concrete Vibrator Assembly Drawings 3a 19 2 20 21 23 24 26 15 32 35 z 33 Electrical Tape Taping Instructions 1 Two 75 inch strips covering spring holes on each side of toggle 2 Two 1 75 inch strips covering face plate holes and rivets extending over sides of switch 3 Two 4 inch strips covering switch wires Bottom first from edge of cord clamp Top next with tape starting about half way through switch depth 4 One 12 inch strips make two wraps around switch 30 29 Model 115V Wire 230V Wire Number Color Color Model 115V Wire 230V Wire 902A 992A Yellow Yellow mear Goo Color ext 903 993 Black Black 902A 992A White Red 903 993 White Red i OO dy NN N S ie J S B Z y KO SECTION A A Electric Conc
4. by clamping hex portion of motor connector 85 in a vise C Remove four plastic bolts 2 and lift off end cap 1 D On grounded motors remove hex nut 36 switch tent 37 and tape 38 Remove four screws that secure wire leads to switch 13 and remove it from inner motor housing 34 Note The switch terminals that each wire is connected to and the vertical slot in threaded barrel of switch 13 faces toward line cord 7 7 REPLACEMENT E Position new switch 13 on mounting lugs on inner motor housing 34 Note Vertical slot in threaded barrel of switch 13 must be toward line cord 7 in order to have ON OFF switch positions agree with marking on end cap 1 F Position each of the four wires to the same terminal location previously used G Assemble four screws through lead terminals and tighten securely to switch 13 H On grounded motors only tape switch with item 38 slide switch tent 37 on switch and secure with hex nut 36 I Replace end cap 1 filter 12 and four plastic bolts 2 POWER CORD REPLACEMENT REMOVAL A Disconnect line cord 7 from power source B Secure motor in upright position switch 13 up by clamping hex portion of motor connector 35 in a vise C Remove four plastic bolts 2 and lift off end cap 1 D Remove the two screws holding cord set 7 leads to switch 18 E Alternately loosen lock nuts 5 until they are flush with top of cord bracket 4 N
5. 15525 415230 0 1 2 3 4 15 6 7 8 9 i 415363 415211 415209 415511 415509 415221 415219 N 415521 415539 N k N N E 415358 415212 765210 765510 175512 175612 43551 41552 41552 41531 41531 41531 41551 41552 41551 46551 415400 415367 415368 N ee 415358 415212 765210 765510 175512 175912 N wo Ne K N Oo WOWBWWBWNHND DY GN ES Of ei wo K woodoo a o0 O oO oO ee O 415400 415367 415368 415400 415367 415368 415400 415367 415368 E E E EnrnD E 0NwD EnA 9 Qj Q Co e Inspect the vibrator for damage prior to using this equipment Read understand and follow all safety and maintenance 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 use damaged equipment e Insure that the motor shaft and head are connected securely as described in the maintenance instructions e Insure that the plug is connected to the appropriate power source e Insure that the motor is not immersed in concrete and that any cord connections are not in water or fresh concrete e Turn vibrator on using switch by moving the toggle to the 1 or on position e Insert the vibrator head vertically into the concrete to be consolidated e Do not run
6. 3V Functional Description The vibrator motor is used to power concrete flex shaft vibrators which provide vibration to consolidate freshly poured concrete The vibration is created by an eccentric weight inside the vibrator head that generates a pulse once per revolution Use only the motor head and shaft combinations listed in the chart below ELECTRIC MOTOR VIBRATOR HEAD VIBRATOR SHAFT AMPS CAT NO SIZE IN CAT NO LENGTH CK SERIES 902A 992A 902A 230 992A 230 903 993 903 230 993 230 2 20 FT Assembly Drawings Marking Square Assembly Marking Square Assembly on End Cap Size Part on End Cap Size Part D 13 16 877520 1 75B 1 3 4 878540 EH ile 877526 2 00B 2a 878563 1 38B 1 3 8 878533 2 25B 2 1 4 878568 LOCTITE 545 PERMATEX 2 No Description Qty D Nut Hex Jam 435638 Holder Seal 1 Bearing Ball 097011 Seal Oil A 587320 Bushing it Rotor 717340 Driver Hex 1 382428 O Ring Buna Oss RA AN a A C ee LOCTITE 545 PERMATEX 2 No Description Qty EH Nut Hex Jam 432710 Bearing Ball 097012 587325 Rotor 717345 6 Bushing 1 177325 7 End Cap 1 k 8 Driver Hex 1 384447 Seal Oil xk End Cap Assy with seals is Part 207248 Order bushing separately 5 10 3 6 7 8 LLLLLLLLLL LLL LL ELL LLL LLL LLL PERMATEX 2 LOCTITE
7. Wyco Operator s and Service Manual Electric Flex Shaft Concrete Vibrators wyco General Safety Rules READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in electric shock fire and or serious personal injury WARNING LSAVE THESE INSTRUCTIONS 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 flammable liquids gases or dust Power tools create sparks which may ignite the dust or fumes 3 Keep bystanders children and visitors away while operating a power tool Distractions can cause you to lose control Electrical Safety 1 Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances Never remove the grounding prong or modify the plug in any way Do not use any adaptor plugs Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded If the tools should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user 2 Double Insulated tools are equipped with a polarized plug one blade is wider than the other This plug will fit in a polarized outlet only one way If the plug does not fit fully in the outlet reverse the plug If it still does not fit contact a qualified el
8. are less likely to bind and are easier to control 7 Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the tools operation If damaged have tool serviced before using Many accidents are caused by poorly maintained tools 8 Use only accessories that are recommended by the manufacturer for your model Accessories that may be suitable for one tool may become hazardous when used on another tool Service 1 Tool service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury 2 When servicing a tool use only identical replacement parts Follow instructions in the Maintenance section of this manual Use of unauthorized parts or failure to follow Maintenance Instructions may create a risk of electric shock or injury Specific Safety Rules and or Symbols volts amperes hertz alternating current Class II Construction splash proof construction Ground Terminal protective earthing ON OFF o eme F gt lt Identification Symbol For identification in case the name plate has been removed a code has been stamped on the die cast housing as shown in Figure 1 below Order only identical replacement parts Be sure to include part number description and quantity when ordering FIGURE 1 I D Symbol Model 415V Stamp 230V stamp 902 992A 2A 2V 903 993 3
9. e 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 5 Do not overreach Keep proper footing and balance at all times Proper footing and balance enables 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 Tool Use and Care 1 Use clamps or other practical way to secure and support the workpiece to a stable platform Holding the work by hand or against your body is unstable and may lead to loss of control 2 Do not force tool Use the correct tool for your application The correct tool will do the job better and safer at the rate for which it is designed 3 Do not use tool if switch does not turn it on or off Any tool that cannot be controlled with the switch is dangerous and must be repaired 4 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 5 Store idle tools out of reach of children and other untrained persons Tools are dangerous in the hands of untrained users 6 Maintain tools with care Keep cutting tools sharp and clean Properly maintained tools with sharp cutting edges
10. ectrician to install a polarized outlet Do not change the plug in any way Double Insulation Glelimates the need for the three wire grounded power cord and grounded power supply system 3 Avoid body contact with 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 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 5 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 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 influence of drugs alcohol or medication A moment of inattention while operating power tools may result in serious personal injury 2 Dress properly Do not wear loose clothing or jewelry Contain long hair Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts UL LISTED 3LFS Personal Safety continued 3 Avoid accidental starting Be sure switch is off before plugging in Carrying tools with your finger on the switch or plugging in tools that hav
11. f the cord must be selected from the following table Extension Cord Wire Minimum Size Requirements Motor Rated Number Volts Amps AWG WYCO TO 0 L Tel 262 639 6770 or 800 233 9926 Fax 262 639 2028 or 888 992 6872 8635 Washington Avenue Website www wycotool com E Mail wycosales wycotool com gt W co Racine WI 53406 3738 USA 2008 Racine Federated Inc all rights reserved FORM NO W150 KB PRINTED IN USA 6 08
12. ions below should be followed if it becomes necessary to replace brushes switch or cord NOTE Use only factory authorized replacement parts BRUSH REPLACEMENT REMOVAL A Disconnect line cord 7 from power source B Secure motor in upright position switch 13 up by clamping external portion of motor connector 35 in a bench vise C Remove four plastic bolts 2 and lift off end cap 1 D Loosen the pan head screw 9 that holds brush retainer 16 by a 1 4 turn E The brush spring will pop out Carefully remove the brush 18 by gently pulling on the spring F Repeat steps for the opposite side Note If brushes are worn to 3 8 9 mm or less they should be replaced REPLACEMENT G Align new brush 18 with brush holder 17 and insert Note Avoid chipping brush edges when inserting Note Ensure that milled slot on brush holder 17 mates with brush clamp 11 and longer end of brush holder 17 is toward armature 21 H Feed spring into brush holder 17 hold spring in place and reposition brush retainer 16 Tighten pan head screw 9 while holding brush retainer 16 firmly against brush holder 17 J Repeat steps for the opposite side K Replace end cap 1 and four plastic bolts 2 See illustration on bottom of Page 4 Note Do not over tighten bolts SWITCH REPLACEMENT REMOVAL A Disconnect line cord 7 from power source B Secure motor in upright position Switch 13 up
13. ote Do not remove nuts 5 from cord bracket 4 F Remove cord 7 from under cord clamp 3 G Note approximate position of bend relief 8 on old cord 7 and remove it for reuse REPLACEMENT H Position bend relief 8 on new cord 7 in approximate position to fit into grooves in inner motor housing 34 J Insert new cord 7 through open cord clamp 8 K Position cord 7 so the screw terminals on cord leads are aligned with screws and lead colors match the drawing L Assemble two screws through lead terminals and tighten securely to switch 13 as shown M Hold switch 18 firmly in position on inner motor housing 34 lugs Firmly position cord 7 and bend relief 8 into their molded nests in the inner motor housing 84 Reposition bend relief 8 if necessary to eliminate stretching or kinking of cord 7 between switch terminals and bend relief 8 N Hold cord 7 and bend relief 8 firmly in place and alternately tighten the two lock nuts 5 until switch 18 cord 7 and cord clamp 3 are tightly secured Note Be sure cord clamp 3 is clamping outer jacket of cord 7 and not on the wire leads P Replace end cap 1 and four plastic bolts 2 EXTENSION CORDS When selecting an extension cord for use with Wyco electric motor cord sets using a 2 prong polarized plug double insulated motors an equivalent plug set must be used Extension cords must be approved for outdoor use and the wire gauge o
14. rete Vibrator Drawing Parts List Parts List see drawings on page 4 115V 115V 115V 12 AMP 12 AMP 15 AMP 902A 115V 230V 15 AMP 6 AMP 992A 903 993 902A 415335 415308 415324 415326 415512 415309 415399 415306 415335 415330 415359 415360 415322 415554 415361 415333 099909 415323 415515 230V 230V 230V 6 AMP 7 5 AMP 7 5 AMP Item 992A 903 993 Description End Cap Plastic Elect Motor Gold Screw Hex Head Plastic 1 4 20 x 1 2 Clamp Cord Bracket Cord Clamp Nut Lock 8 32 Nylon Insert Zinc Stud Motor Housing Cord Set w Plug Bend Relief Screw Pan Head 8 32 x 3 8 Long Washer Lock 8 Clamp Brush Holder Filter Switch Toggle Spring Loading Bearing Ball 1 18OD 394 Bore Retainer Brush Holder Brush Assy Brush amp Spring Nut Hex 10 32 Field Assy Armature Washer Lock 10 Screw Field 10 32 x 3 5 8 Screw Field 10 32 x 3 Sleeve Field Grounding Insert Screw Hex Thd Cut 1 4 20 x 5 8 Frame Tube Inner Frame Tube Outer Support Rubber Frame Rivet Pop Steel Plated Bushing Driver Hex Motor Black Oxide Housing Motor Painted Housing Inner Motor Connector Motor Zinc Plated Hex Panel Nut Switch Tent Electrical Tape 75 wide Operation 415304 415330 415399 415338 415304 415330 415401 415338 415306 415330 415401 415338 OANOOARWDN rg 4 1 ry n n 1 ro 4
15. the vibrator head outside of fresh concrete for an extended period of time since the vibrator depends on moving concrete to cool the bearings e Avoid sharp bends in the flex shaft during operation Sharp bends reduce shaft life e Remove head from concrete and turn switch to the off position Service and Maintenance Instructions Service the vibrator head after every 50 hours of operation to insure trouble free running on the job When servicing always replace hex driver seals and bearings Or bushing for D amp EH Heads See drawings Page 3 All heads are equipped with seals at the flexible shaft end All heads contain oil the seals serve a double purpose to keep the oil in the head and to keep the grease from the flexible shaft out of the head 1 Hold the nose end in a vise and unscrew the end cap counter clockwise with a chain wrench or a good pipe wrench N Pull the eccentric rotor assembly out of the housing If the bearings are stuck and you have difficulty removing them from the housing screw 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 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
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