Flextool VP38 User manual

CONCRETE VIBRATOR
PENDULUM TYPE
VP38 - VP44 - VP57
OPERATING INSTRUCTIONS
WARNING
To reduce the risk of injury, all operators and maintenance personnel must read and understand
these instructions before operating, changing accessories, or performing maintenance on Flextool
power equipment. All possible situations cannot be covered in these instructions. Care must be
exercised by everyone using, maintaining or working near this equipment.
38 mm
44 mm
57 mm

Introduction ............................................................................ 2
Functions and controls........................................................... 2
Accessories ........................................................................ 2-3
Hazards and risks ................................................................. 3
Operation ............................................................................... 3
Care and preventive maintenance.......................................... 3
Cleaning and storage............................................................. 3
Service ................................................................................... 4
Trouble shooting .................................................................... 4
Specifications ......................................................................... 4
Warranty................................................................................. 4
Spare parts and service ........................................................ 4
Thank you for your selection of Flextool equipment.
Flextool have specialised in the design and manufacture of
quality products since 1951.
We have taken care in the design, manufacture and testing of
this product. It is covered by a six month warranty. Should ser-
vice or spare parts be required, prompt and efficient service is
available from our branches.
General Safety Instructions for the Operation of Power
Equipment
The goal of Flextool is to produce power equipment that helps
the operator work safely and efficiently. The most important
safety device for this or any tool is the operator. Care and good
judgement are the best protection against injury. All possible
hazards cannot be covered here, but we have tried to highlight
some of the important items, individuals should look for and
obey Caution, Warning and Danger signs placed on equip-
ment, and displayed in the workplace. Operators should read
and follow safety instructions packed with each product.
Learn how each machine works. Even if you have previously
used similar machines, carefully check out each machine
before you use it. Get the "feel" of it and know its capabilities,
limitations, potential hazards, how it operates, and how it stops.
This vibrator is designed for the compaction of concrete by
immersion of the vibrator head. Compaction improves the
strength and finish of concrete by driving out entrapped air.
High frequency vibration allows the efficient compaction of low
slump concrete mixes.
The vibrator head is driven by a rotating flexible drive shaft that
transmits the drive from a coupling, engaged with a separate
portable drive unit.
The vibrator head uses a unique principle to produce vibration.
A single self aligning ball bearing supports a rotor at one end.
The other end of the rotor is hardened and free to roll inside the
hardened barrel (38, 44 mm) or nose cap (57 mm). When dri-
ven, the difference in diameters of the rotor and its mating sur-
face, coupled by friction and centrifugal force, causes the rotor
to describe an epicyclic motion and roll around inside the bar-
rel or nose cap. Each time the rotor rotates once on its own
axis it rolls almost four times around the axis of the vibrator
head. As a result, the low flexible shaft speed of 3,000 r/min
produces a high frequency vibration of 11,000 vibration/min.
The rotor motion is like a conical pendulum with the greatest
vibration produced at the nose of the vibrator head.
Vibrator models are available with a range of vibrator head
diameters and flexible shaft lengths. For effective vibration
select the largest diameter vibrator head that the job will
accommodate. The flexible shaft should be selected with the
shortest standard length (3, 6 or 9 m) that best suits the most
common applications. Non standard flexible shaft lengths are
available to order.
The vibrator is fitted with a quick action 60 mm (2.36 in) diam-
eter flexible shaft coupling for operation from a drive unit fitted
with a 45 mm (1.75 in) diameter 3-tooth dog drive.
A petrol or diesel drive unit with a minimum of 3.7 kW (5 hp)
or an electric drive unit with a minimum rating of 2.2 kW (3 hp)
is required.
Nose caps with resilient polyurethane tips are available to
extend the life of form boards and improve off-the-form finish.
Drive units are available with petrol, diesel, air and electric
motor drives.
Extension flexshafts (3 & 6 m) extend the length of an existing
vibrator flexshaft and are available to enable vibrating within
formwork to a depth of 12 m.
NEVER allow any person to operate equipment without ade-
quate instruction.
ENSURE all operators read, understand and follow the operat-
ing instructions.
SERIOUS INJURY may result from improper or careless use of
this machine
! MECHANICAL HAZARDS
DO NOT operate the machine unless all protective guards are
in place.
DO NOT leave the equipment in operation while it is unattend-
ed.
ENSURE that the equipment will remain stable and will not
move or fall while in operation.
EXERCISE CARE when handling vibrators. Exposure to vibra-
tion or repetitive work actions may be harmful to hands and
arms.
DO NOT hold the vibrator head in your hands while it is run-
ning. Hold the vibrator by the flexible shaft to isolate your hands
from the vibration.
NEVER stand on the vibrating head while it is operating.
DO NOT place your foot on the vibrator head while it is running
unless it is done momentarily and the vibrator head is resting
on a resilient support such as a car tyre.
ENSURE that repairs to machinery are carried out by COM-
PETENT personnel.
! ELECTRICAL HAZARDS
THE RISK OF SERIOUS OR LETHAL INJURY from electrical
shock may arise from the combination of electricity and mois-
ture.
! FIRE & EXPLOSION HAZARDS
HAZARDS AND RISKS
ACCESSORIES
FUNCTIONS AND CONTROLS
INTRODUCTION
CONTENTS
2

PETROL is extremely flammable and explosive under certain
conditions.
! CHEMICAL HAZARDS
CARBON MONOXIDE exhaust gases from internal combus-
tion motor driven units can cause death in confined spaces.
! NOISE HAZARDS
EXCESSIVE NOISE can lead to temporary or permanent loss
of hearing.
WEAR an approved hearing protection device to limit noise
exposure. as required by Occupational Health and Safety reg-
ulations. Noise levels in excess of 85dB(A) may be produced
by engines and vibrators.
PROTECTIVE CLOTHING
ALWAYS wear protective clothing and footwear to prevent the
skin coming into contact with wet concrete.
PROTECTIVE FOOTWARE should be worn to reduce injuries
from penetration through the sole, contact with cutting objects,
slipping, contact with wet concrete and electrical hazards.
GOGGLES for eye protection may also be necessary.
USE waterproof protection for hands and knees (if kneeling)
when concreting. If your clothing becomes wet from concrete
contact make sure you change the clothing. Do not walk about
waiting for it to dry.
USE GLOVES when handling and inspecting the flexible shaft
outer casing. Excessive wear of the rubber cover can expose
the wire braided reinforcement, allowing it to project and cause
injury.
! ADDITIONAL HAZARDS
Slip/Trip/Fall is a major cause of serious injury or death.
Beware of the flexible shaft and water left on the walking or
work surface.
Exercise caution and ensure that the perimeter of elevated
formwork or platforms is protected.
Exercise care when working in the vicinity of unprotected holes
or excavations
ADDITIONAL INFORMATION
Refer to the drive unit operation instructions for additional safe-
ty and operation information on the appropriate drive unit.
These are supplied free of charge by mail or fax.
Information regarding compaction of concrete using immersion
vibrators is available in a FLEXTOOL FACT SHEET.
Check that a petrol or diesel engine is running at 3,000 r/min.
If it is not, the frequency of the vibrator head will be incorrect.
If the speed is low, compaction will not be as quick or as effi-
cient as it should. if the speed is excessive, wear of the motor,
flexshaft and vibrator will be greater. Continued operation at
higher speed may result in failure of the vibrator and flexshaft
components.
Do not engage the drive coupling in a motor that is already run-
ning.
For information on correct starting procedures refer to the
engine manufacturers operation manual.
Before engaging the flexshaft with a petrol drive unit start the
motor using the recoil starter, increase the speed to full throt-
tle and allow it to warm up for a few minutes.
If using an electric motor, switch on and check the motor rota-
tion is in an anti-clockwise direction when viewing its drive dog
front on.
Stop the motor.
Turn the bell housing trigger 180 degrees. Insert the flexshaft
coupling fully into the housing of the drive unit and release the
trigger. Push the coupling into the housing and twist the flexi-
ble shaft until the drive dogs are fully engaged and the trigger
returns to the horizontal position.
The motor may now be started.
It is not uncommon for a pendulum-type vibrator head to fail to
vibrate when the motor is switched on or started. If the vibrat-
ing head does not commence vibrating immediately, tap the tip
of the vibrator head sharply against a solid surface or try rat-
tling the vibrator head.
Do not operate the flexshaft in a coiled condition. Avoid sharp
bends in the flexshaft, particularly when it is in use.
Do not use a pendulum-type immersion vibrator head as an
external vibrator by applying it to the outside of formwork.
Do not operate the vibrating head out of concrete for extended
periods. Do not leave it running while you wait for fresh sup-
plies of concrete to be placed. Vibrator heads are designed to
be cooled by the concrete in which they are immersed.
Vibrators must be handled with care, and be properly main-
tained in order to avoid unnecessary breakdowns. Check reg-
ularly for signs of wear and rectify any faults immediately.
Hire operators should examine and test run the vibrator on
return from hiring.
The exterior of the flexshaft and the vibrator head are subject
to abrasion and wear. If the vibrator is operated unchecked,
concrete will eventually enter the vibrator head or the flexshaft.
Naturally, the cost of repairing, a vibrator which has been
allowed to deteriorate in this way will be greater.
Regular inspection of the vibrator and the flexible shaft will
avoid these problems.
Check the 3-tooth dog on the drive coupling to ensure that it is
fully meshed and not worn.
Check the flexible shaft for kinks and external damage by lay-
ing it out straight on a workbench or the floor. Although it still
operates a badly kinked flexible shaft may result in a broken
inner core.
Check the outer casing rubber cover for damage where it
enters the ferrule at the vibrator head. Damage is caused by
operators using a crane to retrieve a vibrator trapped in con-
crete reinforcing bars.
It is advisable to wash the vibrator head and flexshaft with
clean water after use each day and before storing. This will
ensure that concrete does not accumulate on the exterior.
SERVICE
CLEANING AND STORAGE
CARE AND PREVENTIVE MAINTENANCE
OPERATION
3

Vibrating heads are fitted with left hand screw threads on the
nose cap, barrel and flexible shaft casing.
Dismantle the vibrating head and the flexible shaft every 500
working hours. Inspect for wear before re-assembling. Apply a
thin coating of grease to the core assembly inserting it into the
casing assembly from the drive coupling end.
The most critical part of the vibrator is the seal which excludes
the flexible shaft and bearing grease from the vibrator head.
The ingress of grease into the vibrator head will prevent its
operation. The mating surfaces of the rotor and barrel (38, 44
mm) or nose cap (57 mm) must be clean and dry.
Replace the seal and all o-rings at each overhaul.
Pendulum-type 38, 44 & 57 mm epicyclic action vibrators have
a rotor supported by a single ball bearing. The bearing and the
adjacent seal should be lightly greased only. All other compo-
nents (barrel, rotor and nose cap) should be internally clean
and free from finger prints and grease.
Polish the mating surface of the rotor and barrel (38, 44 mm)
or nose cap (57 mm) with fine emery cloth and wipe with a
cloth moistened with methylated spirits to ensure optimum
cleanliness.
It is recommended that only genuine FLEXTOOL replacement
bearings are used. These are specially manufactured to meet
the arduous operating conditions.
Frequency
11,000 vib/min
Amplitude in Air VP38 VP44 VP57
1.7 mm 1.8 mm 2.1 mm
Flexshaft Dia
Std 13 x 32 mm
HD 13 x 35 mm
Weight VP38 VP44 VP57
3 m Flexshaft 13Kg 14 Kg 16 Kg
6 m Flexshaft 21Kg 22 Kg 24 Kg
9 m Flexshaft 29 Kg 30 Kg 32 Kg
FLEXTOOL products are covered by warranty for a period of
six (6) months from the date of purchase against defects in
material or workmanship provided that:
• the product concerned has been operated and maintained
in accordance with the operating instructions.
• has not been damaged by accident, misuse or abuse.
• has not been tampered with or repaired by any unautho-
rised person.
The owner is responsible for the cost of transportation to and
from the authorised repairer and the unit is at the owners risk
while in transit to and from the repairer.
Flextool (Aust.) Pty. Ltd. ABN 53 116 784 626
Melbourne Head Office
400 Victoria Street Tel: [phone]
Brunswick Vic. 3056 Fax: [phone]
Australia
Sydney
Unit 1, 52 Heathcote Road Tel: [phone]
Moorebank N.S.W. 2179 Fax: [phone]
Brisbane
14 Manton St Tel: [phone]
Mornington QLD 4170 Fax:[phone]
Adelaide
68 Daws Road Tel: [phone]
Edwardstown S.A. 5039 Fax: [phone]
Perth
Unit 3, 47 Tate Street Tel: [phone]
Bentley W.A. 6102 Fax: [phone]
Free Call
Outside the above Tel: [phone]
metropolitan areas.
Internet www.flextool.com.au
[email protected]
SPARE PARTS AND SERVICE
WARRANTY
TROUBLESHOOTING
SPECIFICATIONS
Symptom Possible Causes and Correction
Vibrator does not vibrate. Flexible shaft is rotating
• Tap the tip of the vibrator head sharply against a solid surface or try rattling the vibrator head.
• Check electric motor direction of rotation using arrow on bell housing.
Three phase motors can run in reverse due to incorrect phase rotation.
Single phase motors can run in reverse due to incorrect internal connection after rewinding.
If rotation is incorrect check that the core ends have not unscrewed.
• If the vibrator head has just been serviced the mating surfaces of the rotor and the
barrel (38, 44 mm or nose cap 57 mm) may not be clean.
• Check the vibrator barrel for wear or fine cracks that allow the ingress of moisture.
• Grease has leaked into the vibrator head. Check for over greasing of the core or over
speed of the petrol motor. Replace seal, remove core and wipe excess grease from
the core with a clean cloth.
Flexible shaft is not rotating
• Check that the vibrator coupling is fully engaged in the drive unit bell housing
Rotor / Core / Barrel is broken • Petrol drive unit motor is running in excess of 3,000 r/min.
• Outer casing or inner reinforcing spring is kinked or collapsed.
Grease in vibrator barrel • Petrol drive unit motor is running in excess of 3,000 r/min.
• Core has been over greased.
Replace seal, remove core and wipe excess grease from the core with a clean cloth
F2476 Issue 031207