Buyers Products Company DBV2500 User manual

1
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Installation Instructions
1. When selecting the vibrator’s mounting location
always follow safe working procedures including, but not
limited to: Engaging parking brake, chocking truck tires
in both directions, locking dump body safety prop in
place and turning off truck engine.
2. The vibrator should be mounted as close to ¼ the
body’s length from the front of the body as possible. It
should be centered between the body's long members/
sills.
3. Check for proper clearance between the
vibrator and: hoist, truck frame, oil tanks, air tanks, fuel
tanks etc.
4. The dump body will need to be reinforced to accept
the force of the vibrator. For bodies with traditional
channel, I-beam or tubing cross members select and
cut a 4" to 6" wide channel long enough to cover the
length of three cross members (typically 36"-38") as
shown in Figure "A". Position the channel perpendicular
across the three cross members and stitch weld in
place.
Locate the supplied (threaded) vibrator plate over the
middle of the three cross members and weld in place. It
should run the same direction of the mounting channel
Fig. B
so the vibrator is bolted perpendicular to the cross
members. For cross memberless bodies refer to Figure
"B". Cut two 4" to 6" wide channels (typically 32"-34"
long) to serve as cross member supports for the vibrator
mount. Locate channels approximately 24" apart (or as
space permits) and weld to long members and dump
body floor as shown in Figure "B". Cut another 4" to 6"
wide channel to join cross members. Weld the supplied
(threaded) vibrator plate to the channel. Weld this
assembly to the dump body floor and cross members.
5. Place vibrator on threaded mounting plate. On one
side of vibrator insert bolt and retainer lock, and apply
medium/strong thread locker to bolt and tighten. Inspect
vibrator mounting plate for any warping from welding. If
there is any warping, shim (over shim a little) the other
mounting foot so mounting surface and feet are flush.
Note: Failure to mount vibrator on flat surface can crack
the housing and/or affect vibrator performance. Insert
second bolt and retainer lock, and apply medium/strong
thread locker to bolt and tighten. Torque mounting bolts
to 280 ft. lbs. Note: When vibrator is wired, run for 10+
minutes in 15 seconds on/30 seconds off intervals
(Caution! Vibrator will be hot), retighten and torque each
Mount 1/4 body length
from front of body
DBV2500 & DBV3500
Dump Body Vibrator
Fig. A
Threaded
vibrator plate
4"-6" Channel
For Bodies with Cross Members For Cross Memberless Bodies
CAUTION
Read and follow these instructions for proper
installation of a TruckSTAR dump body vibrator model
DBV2500 OR DBV3500.
—continued

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Fig. C Wiring Diagram
Ground
4 AWG
wire
4 AWG
wire
4 AWG wire
16 AWG
wire
16 AWG
wire
cab push button
switch SW900
to ignition switch
power source (fused)
13063171
Solenoid, 12V,
Motor Relay,
Continuous
manual reset
circuit breaker
CB150PB
vibrator
DBV2500/DBV3500
self grounding
through feet
Ground
install and bend lock
tabs as shown
apply medium/strong thread locker
torque to 280 ft. lbs.
Note: For wire lengths
exceeding 50 ft. it is
recommended to use
2 AWG wire.
bolt to 280 ft. lbs. Bend both bolt retainer lock tabs (as
shown in Fig. "C") to prevent bolts from loosening. Chain
vibrator to body for added safety (chain not included).
6. Wire vibrator per Figure "C" wiring schematic.
7. Install a chassis grounding strap for a more positive
ground. Adequate (4) AWG wire and (2) additional
terminals have been provided for this purpose.
8. Optional Timer Installation: (Figure "D" or Figure "E")
a. Push button and timer should be mounted in the
cab in a convenient location.
b. The operating time (ON time) of the vibrator is
preset to 15 seconds for the optional timer.
c. To operate: press and release push button. The
vibrator will run for 15 seconds and stop. To run the
vibrator again wait 30 seconds, then press button
again.
d. Wire the timer and push button to truck’s ignition
for secured operation.
Trouble Shooting Guide
1. Vibrator runs slow: Measure motor voltage. If less
than 12 volts DC, increase wire size from standard 4
AWG to 2 AWG. Installations requiring over 50’of wire
use 2 AWG wire.
Inspect motor brushes and change as needed. Brush
life varies with duty cycle.
2. Loud, unusual vibrator noise: Make sure vibrator bolts
are tight. Inspect mounting plate for cracks. Reinforce
mounting plate and weld as needed. If vibrator casting is
cracked replace with new parts.
3.
Vibrator fails to operate: Check vibrator to make sure
it is getting power. Check all electrical connections (and
ground) for secure corrosion free connections. Vibrator
is grounded through its foot. Install grounding strap for
a more positive ground. Check cab push button switch,
solenoid and circuit breaker for proper operation. Note:
150 Amp circuit breaker requires manual reset. If tripped,
reset. Maximum continuous run time is 15 seconds
followed by 30 seconds cooling time before operating
again.
Although the vibrator has o-ring seals and the
bearings are permanently lubricated, avoid spraying
vibrator directly with water and do not pressure
wash.
Optiona l 3 011111
Timer Diagram
Optional 3022840
Timer Diagram
Fig. D Fig. E
16 AWG
wire
cab push button
switch SW900
Timer
3011111
to ignition switch
controlled power source
Ground (-) GROUND
INITIION SWITCH CONTROL
POWER SOURCE (+)
16 AWG WIRE
CAB PUSH BUTTON
SWITCH SW900
12 V SOLENOID MOTOR RELAY
TIMER 3022840
see Fig D or E for
optional timer
installation
—continued

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ITEM PART NO. QTY. DESCRIPTION
Bill of Materials
Vibrator Parts List
1
2
4
5
3
8
13
7
7
7
11
10
12
6
9
1 3011078 1 Vibrator Housing
2 3011080 2 Eccentric Shaft Bearings
3 3011081 2 Snap Rings
4 3011082 2 Eccentric Weights
5 3011083 1 Housing Cover "O" Ring
6 3011084 1 Housing Cover
7 3011086 4 Sets Vibrator Housing Cover
Fasteners M10-1.5 x 35 mm
8 3011087 1 Motor "O" Ring
9 3011089 1 12 Volt Motor
10 3011090 1 Brush Assembly Replacement
11 3011091 1 Each Motor Bearing w/Spring Washer
12 3011092 1 Motor End Cover
13 3011093 2 Tie Rod Fasteners M10-1.5 x 180 mm
14 3009255 1 Mounting Kit, Steel
14A 3011239 1 Mounting Bracket, Steel
14B 3011079 2 Screw Hex Cap .75-16 x 3.5 Grade 8 Zinc
14C 3011238 2 Washer, 1/4" Split Lock Zinc
14B
14A
14C
14
—continued

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3010634 Rev. F
1 2
3
4
5
6
3010636 Vibrator Installation Mounting Kit
1 CB150PB 1 Breaker, 150 AMP.
2 13063171 1 Solenoid, 12V, Motor Relay, Continuous
3 SW900 1 Switch, Momentary, 12V
4 3010629 50 ft. Wire, Copper, 4 AWG, 50'
5 3010631 20 ft. Wire, 16 Gage, MTW, 20'
6 3010635 1 Hardware, 2500 & 3500 VIB.
– BTN040 4 Nylon Cable Tie, 4" x .100"
– 3010634 1 Instruction Sheet, Vib Kit
ITEM PART NO. QTY. DESCRIPTION
Bill of Materials
Warranty
Buyers Products Co. warrants all truck/trailer hardware manufac-
tured or distributed by it, to be free from defects in material and
workmanship for a period of one year from date of shipment. Parts
must be properly installed and used under normal conditions.
Any product which has been altered, including modification, mis-
use, accident or lack of maintenance will not be considered under
warranty. Normal wear is excluded. The sole responsibility of Buyers
Products Co. under this warranty is limited to repairing or replacing any
part or parts which are returned, prepaid, and are found to be defective
by Buyers Products Co. Authorization from Buyers Products Co. must
be obtained before returning any part. No charges for transportation
or labor performed on Buyers’ products will be allowed under this
warranty.