www.wackergroup.com

Internal Vibrator

M 1000M 2000M 3000

OPERATOR’S MANUAL

0154561en 002

0303

0 1 5 4 5 6 1 E N

HMS Table of Contents

1. Foreword 3

2. Safety Information 4

2.1 Service Safety ...................................................................................... 52.2 Operating Safety .................................................................................. 52.3 Safety & Informational Labels .............................................................. 72.4 Label Locations .................................................................................... 7

3. Technical Data 8

3.1 Motors .................................................................................................. 83.2 Vibrator Heads ..................................................................................... 93.3 Shafts ................................................................................................. 103.4 Sound and Vibration Measurements .................................................. 10

4. Operation 11

4.1 Application .......................................................................................... 114.2 Recommended HMS Combinations ................................................... 124.3 Extension Cords ................................................................................. 134.4 Connecting Motor to Power Supply .................................................... 144.5 Assembling Head, Motor and Shaft .................................................... 154.6 Operation ............................................................................................ 16

5. Maintenance 17

5.1 Periodic Maintenance ......................................................................... 175.2 Motor Brushes .................................................................................... 185.3 Motor Housing .................................................................................... 195.4 Lubricating Shaft ................................................................................ 205.5 Lubricating H-Head ............................................................................ 215.6 Checking H-Head for Wear ................................................................ 225.7 Troubleshooting .................................................................................. 235.8 Wiring Schematics .............................................................................. 24

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Table of Contents HMS

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Foreword

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1. Foreword

This manual provides information and procedures to safely operateand maintain this Wacker model. For your own safety and protectionfrom injury, carefully read, understand and observe the safetyinstructions described in this manual.

Keep this manual or a copy of it with the machine. If you lose thismanual or need an additional copy, please contact WackerCorporation. This machine is built with user safety in mind; however,it can present hazards if improperly operated and serviced. Followoperating instructions carefully! If you have questions about operatingor servicing this equipment, please contact Wacker Corporation.

The information contained in this manual was based on machines inproduction at the time of publication. Wacker Corporation reserves theright to change any portion of this information without notice.

All rights, especially copying and distribution rights, are reserved.

Copyright 2003 by Wacker Corporation.

No part of this publication may be reproduced in any form or by anymeans, electronic or mechanical, including photocopying, withoutexpress written permission from Wacker Corporation.

Any type of reproduction or distribution not authorized by WackerCorporation represents an infringement of valid copyrights and will beprosecuted. We expressly reserve the right to make technicalmodifications, even without due notice, which aim at improving ourmachines or their safety standards.

Safety Information HMS

2. Safety Information

This manual contains DANGER, WARNING, CAUTION, and NOTEcallouts which must be followed to reduce the possibility of personalinjury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potentialpersonal injury hazards. Obey all safety messages that follow thissymbol to avoid possible injury or death.

DANGER indicates an imminently hazardous situation which, if notavoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if notavoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if notavoided, may result in minor or moderate injury.

CAUTION: Used without the safety alert symbol, CAUTION indicatesa potentially hazardous situation which, if not avoided, may result inproperty damage.

Note: Contains additional information important to a procedure.

DANGER

WARNING

CAUTION

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HMS Safety Information

2.1 Service Safety

When using electric tools, basic safety precautions should always befollowed to reduce the risk of fire, electric shock, and personal injury!The guidelines following will help the user maintain operator safety.

2.1.1 NEVER use worn electrical cords. Severe electrical shock andequipment damage may result.

2.1.2 Prevent body contact with grounded surfaces such as pipes, metalrailings, radiators and metal ductwork.

2.1.3 When motor is used outdoors, use only extension cords intended forand marked for outdoor use.

2.1.4 ALWAYS keep all electrical cords away from heat, oil and sharp edgeswhich can damage them. Inspect all electrical cords before each useand have damaged cords replaced or repaired at an authorized servicecenter.

2.1.5 Make certain motor is in good working order and properly groundedbefore starting.

2.2 Operating Safety

Familiarity and proper training are required for the safe operation ofequipment! Equipment operated improperly or by untrained personnelcan be dangerous! Read the operating instructions contained in thismanual and familiarize yourself with the location and proper use of allcontrols. Inexperienced operators should receive instruction fromsomeone familiar with the equipment before being allowed to operatethe machine.

2.2.1 Keep work area clean and free of clutter.

2.2.2 ALWAYS keep work area well lit.

2.2.3 NEVER allow children or people other than the operator to handlepower cable and extension cords.

2.2.4 NEVER operate motor in areas exposed to flammable or explosiveliquids or gases! The motor brushes spark during operating and couldignite fumes.

2.2.5 NEVER overreach. Keep proper footing and balance at all times. Makesure any supporting structures are strong enough and stable enoughto support your weight and the weight of any equipment on it.

2.2.6 ALWAYS remain aware of moving parts and keep hands, feet, andloose clothing away from moving parts of equipment.

2.2.7 ALWAYS wear protective clothing appropriate to the job site whenoperating equipment.

DANGER

WARNING

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Safety Information HMS

2.2.8 Goggles or safety glasses will protect against eye damage caused by

flying debris.

2.2.9 NEVER carry motor by cord or pull on it to disconnect it fromreceptacle. Keep cord away from heat, oil and sharp edges.

2.2.10 Keep handle, and other areas where motor and shaft are gripped, dry,clean and free from oil and grease.

2.2.11 Avoid unintentional starting! Don't carry motor around jobsite while itis connected to power source. Don't carry motor with finger on switch.

2.2.12 NEVER operate machine when you are tired. Remain alert, watchwhat you are doing and use common sense.

2.2.13 NEVER operate machine if switch does not function properly. Havedefective switches replaced by authorized service center.

2.2.14 ALWAYS replace worn or damaged components with spare partsdesigned and recommended by Wacker.

2.2.15 DO NOT overload motor. An overloaded motor will overheat. Use onlyrecommended head/motor/shaft combinations. See Table 1.

2.2.16 DO NOT allow untrained personnel to service this equipment. Onlytrained electrical technicians should be allowed to service the electricalcomponents of this equipment.

2.2.17 NEVER attach shaft to motor while it is running.

2.2.18 ALWAYS check the power supply before running motor. Using thewrong voltage supply will damage motor.

2.2.19 ALWAYS make sure motor switch is OFF before plugging motor topower supply.

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HMS Safety Information

2.3 Safety & Informational Labels

Wacker machines use international pictorial labels where needed.These labels are described below:

2.4 Label Locations

Label Meaning

Wear eye, ear, and head protection when operating machine.

Read the operator's manual for machine infor-mation.

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Technical Data HMS

3. Technical Data

3.1 Motors

Item No. M 1000 (Green) M 2000 (Yellow) M 3000 (Red)

Motors

Voltage (AC/DC) V 115 230 115 230 115 230

Current (Maximum) A 9 4,5 15 6,5 20 10

Power kW (Hp) 1.0 (1.3) 1.0 (1.3) 1.7 (2.3) 1.5 (2.0) 2.3 (3.1) 2.3 (3.1)

Speed (No-load) rpm 15500 17500 16500

Weight kg (lbs.) 5.4 (12) 5.9 (13) 8.1 (18)

Motor type Universal electric motor

Frequency Hz 50/60

Phase 1

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HMS Technical Data

3.2 Vibrator Heads

Item No. H25 H25S H35 H35S H45 H45S H55 H65

Vibrator Heads

Diameter mm(in.)

25(1.0)

25(1.0)

35(1.4)

35(1.4)

45(1.8)

45(1.8)

55(2.3)

65(2.5)

Length mm(in.)

440(17.3)

295(11.7)

410(16.2)

310(12.3)

385(15.3)

305(12.0)

410(16.1)

385(15.3)

Weight kg(lbs.)

1.2(2.6)

0.9(1.8)

2.1(4.6)

1.6(3.6)

3.2(7.1)

2.5(5.6)

4.9(10.8)

6.0(13.4)

Compaction Dia. cm(in.)

41(16)

36(14)

60(24)

56(22)

76(30)

71(28)

102(40)

122(48)

Lubrication ml(oz.)

10(0.38)

10(0.38)

15(0.5)

15(0.5)

22(0.75)

19(0.63)

30(1.0)

44(1.5)

type SAE 80W140 synthetic oil (WACKER P/N 27238)

Item No. HR 38 HR 48 HR 65 HR 70 HR 70(S)

Vibrator Heads

Diameter mm(in.)

38(1.5)

48(1.875)

65(2.5)

70(2.75)

70(2.75)

Length mm(in.)

266.9(10.5)

355.8(14)

355.8(14)

381.3(15)

152.5(6)

Weight kg(lbs.)

-- 2.7(6)

3.9(8.5)

5(11)

2.7(6)

Compaction Dia. cm(in.)

-- 48.3(19)

66(26)

66(26)

50.8(20)

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Technical Data HMS

3.3 Shafts

3.4 Sound and Vibration Measurements

The required sound specification, Paragraph 1.7.4.f of 89/392/EECMachinery Directive, is:

- the sound pressure level at operator’s location (LpA) = 84.7 dB(A)

- the sound power level (LWA) = 96.4 dB(A)

These sound values were determined according to ISO 3744 for thesound power level (LWA) and ISO 6081 for the sound pressure level(LpA) at the operator’s location.

The weighted effective acceleration value, determined according toISO 8662 Part 1, is 5.1 m/s2.

The sound and vibration measurements were obtained with the unitoperating at nominal speed.

Item No. SM1-E SM2-E SM4-E

E - Shafts

Length m(ft.)

1(3)

2(6.5)

4(13)

Weight kg(lbs.)

1.4(3)

2(5)

4.3(10)

Lubrication WACKER Flex-shaft Lube - P/N 26880

Item No. SM0-S SM1-S SM2-S SM3-S SM4-S SM5-S SM7-S SM9-S

S - Shafts

Length m(ft.)

0.5(1.5)

1(3)

2(6.5)

3(10)

4(13)

5(16.5)

7(23)

9(29.5)

Weight kg(lbs.)

2.3(5)

3(7)

5(11)

6.7(15)

8.5(19)

10.5(23)

14(31)

17.7(39)

Lubrication WACKER Flex-shaft Lube - P/N 26880

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HMS Operation

4. Operation

4.1 Application

The HMS series of internal vibrators can be used over a wide rangeof applications for the consolidation of concrete.

WACKER internal vibrators are typically used for on-site vibration ofconcrete for foundations, walls, columns, slab work, etc. Additional in-plant applications include vibration of concrete during the production ofpipes, slabs, beams, double T columns, walls, etc.

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Operation HMS

4.2 Recommended HMS Combinations

See Graphic: wc_gr001210

The HMS Sytem has three basic parts:

(a) motor, (b) shaft, (c) head

These three pieces can be assembled in various combinations to meetjob requirements. Choosing the correct combination is important toproduce good results and protect the parts from excessive wear anddamage. Selecting too large a head/shaft combination will overload themotor.

Refer to Table 1 below when selecting motor, shaft, and headcombinations.

Table 1 Recommended HMS Combinations

Shafts (b)

SM1-E SM2-E SM4-E SM0-S SM1-S SM2-S SM3-S SM4-S SM5-S SM7-S SM9-S

Length m (ft.) 1 (3) 2 (6.5) 4 (13) 0.5 (1.5) 1 (3) 2 (6.5) 3 (10) 4 (13) 5 (16.5) 7 (23) 9 (29.5)

Head (c) Motor (a)

H 25 M 1000 X X X X X X X X

M 2000 � � � X X X X X X X X

M 3000 � � � X X X X X X X X

H 35 M 1000 X X X � �

M 2000 X X X

M 3000 X X X

H 45 M 2000 X X X

M 3000 X X X

H 55 M 2000 X X X

M 3000 X X X

H 65 M 2000 X X X

M 3000 X X X

HR 38 M 3000 X X X

HR 48 M 3000 X X X

HR 65 M 3000 X X X

HR 70 M 3000 X X X

HR 70(S) M 3000 X X X

Acceptable Combinations

� Not Recommended - On small diameter shafts, motor may overspeed shaft and head. On long shafts, motor may overload.

X Not compatible.

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HMS Operation

4.3 Extension Cords

Extension cords are often required on jobsites to connect the motor.When choosing an extension cord make sure it has adequate wire sizefor safety. An undersized cord will cause a drop in line voltage resultingin a loss of power and overheating. Refer to Table 2 when selectingextension cords. It shows the correct wire size to use depending oncord length. If in doubt, use the next heavier cord size.

On motors being used outdoors, use extension cords rated for outdooruse.

Improper use of extension cords can cause overheating or createserious fire or shock hazards. Never use worn or damaged cords!

Table 2 Minimum wire size for extension cords - AWG (mm2)

MAXIMUM CORD LENGTH - m (ft.)

7.5 (25) 15 (50) 30 (100) 45 (150) 55 (175) 60 (200)

115V

M 1000 1.5 (16) 1.5 (16) 2.5 (14) 2.5 (14) 4 (12) 4 (12)

M 2000 1.5 (16) 1.5 (16) 2.5 (14) 4 (12) 6 (10) 6 (10)

M 3000 1.5 (16) 2.5 (14) 4 (12) 6 (10) 10 (8) 10 (8)

230V

M 1000 1.5 (16) 1.5 (16) 1.5 (16) 1.5 (16) 2.5 (14) 2.5 (14)

M 2000 1.5 (16) 1.5 (16) 1.5 (16) 2.5 (14) 2.5 (14) 2.5 (14)

M 3000 1.5 (16) 1.5 (16) 2.5 (14) 2.5 (14) 4 (12) 4 (12)

WARNING

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Operation HMS

4.4 Connecting Motor to Power Supply

See Graphic: wc_gr001211

To reduce the risk of electric shock, motors equipped with 3-wiregrounded plugs must be properly grounded. On these motors use only3-wire grounded plugs, receptacles, and extension cords.

4.4.1 Check that switch on motor is off before connecting motor to powersource.

4.4.2 Make sure power supply matches voltage requirements listed on motorlabel. Running a motor at a low voltage will cause it to run slow. Thiswill reduce perfomance and may cause motor to overheat.

4.4.3 On motors equipped with a three wire grounded plug use three-wiregrounded receptacles (d) when connecting the motor. If a 3-wiregrounded receptacle is not available, then a grounded adapter must beinstalled as shown in illustration (e) to ensure a proper groundconnection.

Note: Not all countries require the use of a three-wire grounded plugfor this piece of equipment. In these countries, motors are equippedwith a two-wire plug which can be plugged into a standard electricaloutlet.

WARNING

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HMS Operation

4.5 Assembling Head, Motor and Shaft

See Graphic: wc_gr001212, wc_gr001247

4.5.1 H Heads:

Apply pipe sealant to threads on head (a). Attach head onto end offlexshaft (left hand thread) and tighten using a wrench.

HR Heads:

Slide the casing coupling protective sleeve (d) onto the end of theshaft. Apply pipe sealant to shaft threads (c), attach Vibrator head toshaft and tighten using wrenches.

Apply a uniform 9.5 mm (3/8 in.) bead of silicone adhesive about 102mm (4 in.) long over casing coupling. Push casing coupling protectivesleeve (d) over coupling, rotating sleeve as you push, until end ofsleeve enters recess on vibrator head. Let silicone dry forapproximately one hour.

4.5.2 The shaft is attached to motor using a quick disconnect coupler. Thecoupler may vary depending on the type of shaft being used. All newWACKER flexshafts come equipped with a coupler and do not requireany additional coupling device. Refer to parts manual for shaftsequipped with couplers.

If you are using a shaft from another manufacturer, or are attaching anolder WACKER shaft, refer to parts manual to order the correctcoupling to use. If a coupler must be installed on the shaft, apply pipesealant to threads (a) before assembling.

4.5.3 Lubricate shaft core. See Lubricating Shaft.

4.5.4 To attach shaft to motor, pull adapter pin (b) on motor up and slidecoupler in place. Rotate coupler until pin falls into coupler socket.

wc_gr001247d d

c

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Operation HMS

4.6 Operation

Hold head in air or place it on soft surface when starting motor. Thiswill prevent it from bouncing on hard surfaces which could damagebearings. During use, insert the head quickly into the mix and then pullit out slowly. Rapid removal is the main cause of poor concreteconsolidation. For best results submerge head completely and try toestablish a symmetrical pattern for inserting and removing the head.

Avoid sharp bends in the shaft. This can create hot spots.

When moving around jobsite do not drag head and shaft on ground.

Avoid touching forms and rebars when inserting head in mix. This cantransmit vibration to other areas of the mix which may already besetting.

CAUTION: DO NOT run the motor with the head out of the mix for longperiods of time. This can cause the bearings to overheat.

For more detailed information on the use, selection and application ofWACKER equipment for concrete consolidation, order Wackerpublication WCW 982 “CONCRETE CONSOLIDATION”.

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HMS Maintenance

5. Maintenance

5.1 Periodic Maintenance

Before starting

Every50

hrs.

Every100 hrs.

Every300hrs.

Inspect air filter and vent holes. Clean or replace dirty or clogged filters.

•

Inspect electrical cords for wear or damage. Do not use damaged cords.

•

Inspect brushes in motor. •

Clean and lubricate core in shaft. •

Change oil in H-head. •

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Maintenance HMS

5.2 Motor Brushes

See Graphic: wc_gr001213

To protect the motor, the brushes are designed to automatically shutoff the motor if they become too short. If the motor stops duringoperation, the brushes may need to be replaced. To avoid having thebrushes shut down the motor unexpectedly, inspect brushes every 50hours and replace them when necessary. Always replace both brushesat the same time.

To inspect or replace brushes:

5.2.1 Remove brush caps (a) from both sides of motor.

5.2.2 Pull brushes (b) out and measure length. Install new brushes if length(c) is less than 10 mm (3/8 in.) long. If brushes are still long enough,place them back in motor. Make sure they are installed in the samepositions they were removed, to avoid arcing.

5.2.3 Break in new brushes by running motor for about 5 minutes with noshaft attached.

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HMS Maintenance

5.3 Motor Housing

See Graphic: wc_gr001214

Clean motor housing immediately after use, using a damp cloth toremove dust or concrete. Inspect rear air filter, front screen, and ventson motor housing to make sure they are open. Replace or cleanclogged air filter before operating motor to prevent overheating.

To clean rear filter: screw out knob and remove cover (d) from motor.Remove filter (e) and wash in warm, soapy water. Allow filter to drycompletely before using.

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Maintenance HMS

5.4 Lubricating Shaft

See Graphic: wc_gr001215

Remove wire core (f) from shaft casing and wipe with a clean cloth.

Apply a liberal amount of flex-shaft grease to the entire length of thecore by hand (g). Insert core into casing and rotate it. Repeat thisprocedure several times.

CAUTION: DO NOT try to force the casing full of grease. A tightlypacked casing will put a heavy load on the motor and could cause it tooverheat.

CAUTION: DO NOT clean casing or core with solvents. Excesssolvent on casing or core may cause grease to break down, resultingin damage to shaft.

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HMS Maintenance

5.5 Lubricating H-Head

See Graphic: wc_gr001216

The bearings in the head are lubricated with oil. To extend bearing life,change oil in head every 300 hours of operation.

To change oil:

Place head in a vise and remove tip from casing. If necessary, add acouple of small spot welds (h) on tip to provide a better grip for wrench.Drain old oil from casing and add correct quantity of new oil. Refer tosection Technical Data. Apply pipe sealant to threads on tip and attachit tightly on casing.

Note: In the interests of environmental protection, place a plastic sheetand a container under the machine to collect any liquid which drainsoff. Dispose of this liquid in accordance with environmental protectionlegislation.

Use only SAE 80W140 synthetic oil or equivalent.

CAUTION: DO NOT overfill. Too much oil in the head will overload themotor.

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Maintenance HMS

5.6 Checking H-Head for Wear

See Graphic: wc_gr001217

Periodically measure the outside diameter of the head casing (a) in thearea of most noticeable wear.

Replace head if measured diameter is less than the minimum weardiameter.

NEWDIAMETER

mm (in.)

MINIMUMWEAR DIAMETER

mm (in.)

H 25 25 (1.00) 22 (0.88)

H 35 35 (1.38) 32 (1.25)

H 45 44 (1.75) 41 (1.63)

H 55 57 (2.25) 54 (2.13)

H 65 64 (2.50) 60 (2.38)

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HMS Maintenance

5.7 Troubleshooting

Problem / Symptom Reason / Remedy

Motor does not start. • Open circuit breaker or blown fuse on power supply.

• Brushes are worn too short. Replace.

• Switch on motor bad or wire connections loose.

Motor runs at normal speed but overheats.

• Air filter, screen, or vents clogged, blocking air flow.

• Too much grease in shaft.

• Too much oil in head.

Motor runs at slow speed and overheats.

• Line voltage too low.

• Extension cord too small.

• Head/shaft combination too large.

• Shaft not lubricated, core running dry.

• Head bearings binding. Inspect and replace.

• Rotor in motor rubbing.

• Motor bearings failed. Inspect and replace.

Motor noisy • Worn brushes. Brushes installed incorrectly.

• Worn motor bearings.

• Rotor in motor rubbing.

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Maintenance HMS

5.8 Wiring Schematics

See Graphic: wc_gr001218

M 1000 M 2000 M 3000

115V 5843 630571597653

5845

230V 5041 6551* 5800

* NO GROUND WIRE

1. SWITCH B BLACK or BROWN

2. STATOR G GREEN or GREEN W/ YELLOW STRIPE

3. ROTOR W WHITE or BLUE

4. LH BRUSH

5. RH BRUSH

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HMS Maintenance

See Graphic: wc_gr001219

M 1000 M 2000

230V 5494 54325495

1. SWITCH B BLACK or BROWN

2. STATOR G GREEN or GREEN W/ YELLOW STRIPE

3. ROTOR W WHITE or BLUE

4. LH BRUSH Y YELLOW

5. RH BRUSH

6. RFI CAPACITOR

7. INDUCTION COIL

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Maintenance HMS

See Graphic: wc_gr001220

M 3000

230V 6590

1. SWITCH B BLACK or BROWN

2. STATOR G GREEN or GREEN W/ YELLOW STRIPE

3. ROTOR W WHITE or BLUE

4. LH BRUSH Y YELLOW

5. RH BRUSH L BLUE

6. RFI CAPACITOR

7. INDUCTION COIL

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