Minnich 1500 Series User manual

Electric Flex Shaft Vibrator
Operator/Service Manual
Hours of Operation
8:00AM to 4:30PM Mon. – Fri. Eastern Standard Time
277 North Main Street Phone: [phone]
PO Box 367 www.minnich-mfg.com Toll Free: 800.524.1033
Mansfield, OH 44902 e-mail: [email protected] Fax: [phone]
Form: LIT-012 Revised 7/1/2007

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TABLE OF CONTENTS
Section Page #
WARRANTY-------------------------------------------------------------------------------------------------------------3
GENERAL SAFETY RULES ----------------------------------------------------------------------------------------4
WORK AREA---------------------------------------------------------------------------------------------------5
ELECTRICAL SAFETY---------------------------------------------------------------------------------------5
PERSONAL SAFETY-----------------------------------------------------------------------------------------5
TOOL USE AND CAR----------------------------------------------------------------------------------------5
SERVICE --------------------------------------------------------------------------------------------------------5
GROUNDING INSTRUCTIONS-------------------------------------------------------------------------------------6
FUNCTIONAL DESCRIPTION--------------------------------------------------------------------------------------7
ASSEMBLY--------------------------------------------------------------------------------------------------------------8
OPERATION-------------------------------------------------------------------------------------------------------------9
MAINTENANCE ------------------------------------------------------------------------------------------------------10
PERIODIC MAINTENANCE SCHEDULE -------------------------------------------------------------10
MOTORS ------------------------------------------------------------------------------------------------------10
FLEXIBLE SHAFTS----------------------------------------------------------------------------------------- 11
VIBRATOR HEADS-----------------------------------------------------------------------------------------11
SERVICE ---------------------------------------------------------------------------------------------------------------12
ELECTRIC MOTORS--------------------------------------------------------------------------------------- 12
TO REPLACE BRUSHES ------------------------------------------------------------------------12
TO REPLACE FILTER ----------------------------------------------------------------------------12
TO REPLACE MOTOR SWITCH--------------------------------------------------------------- 13
TO REPLACE ELECTRIC CABLE -------------------------------------------------------------14
TO REPLACE ARMATURE AND FIELD------------------------------------------------------15
TO REPLACE BRUSH HOLDER--------------------------------------------------------------- 16
VIBRATOR HEADS-----------------------------------------------------------------------------------------17
TO DISASSEMBLE HEADS ---------------------------------------------------------------------17
TO DISASSEMBLE ECCENTRIC WEIGHT ASSEMBLY --------------------------------17
TO REPLACE OIL SEALS -----------------------------------------------------------------------17
TO ASSEMBLE ECCENTRIC WEIGHT ASSEMBLY -------------------------------------18
TO ASSEMBLE HEADS --------------------------------------------------------------------------18
PARTS AND SERVICE NOTES----------------------------------------------------------------------------------19
ELECTRIC MOTOR PARTS SHEET---------------------------------------------------------------------------- 20
VIBRATOR HEAD AND SHAFT PARTS SHEET------------------------------------------------------------ 21
SPECIFICATIONS
1500------------------------------------------------------------------------------------------------------------- 22
2500------------------------------------------------------------------------------------------------------------- 23
3500------------------------------------------------------------------------------------------------------------- 24
SERVICE SCHEDULE---------------------------------------------------------------------------------------------- 25

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MINNICH MANUFACTURING CO.
WARRANTY AND SERVICE AGREEMENT
Minnich Manufacturing Co. warrants to the original purchaser that, if any part of the product proves defective in material or
workmanship within one year from purchase, and is returned to Minnich Manufacturing Co. within 90 days after the defect
is discovered, Minnich Manufacturing Co. will at its option repair or replace said part. Product shipped to Minnich
Manufacturing Co. freight prepaid will be returned freight prepaid. Product shipped to Minnich Manufacturing Co. freight
collect will be returned freight collect.
LIMITATIONS:
Warranty does not apply to repairs that are required because of normal wear or tear, parts or products that are damaged
as a result of misuse, neglect, accident or fire, or of lightning, flooding or other acts of God, or by improper installation or
maintenance, of which Minnich Manufacturing Co. will be the sole judge. Warranty does not apply to parts or products
that have been modified by an unauthorized party that has in Minnich Manufacturing Co.’s judgment affected their
performance or reliability. Warranty does not apply if the part or product substantially fulfills the performance
specifications.
Minnich Manufacturing Co. shall not in any event be liable for the cost of any special, indirect, or consequential damages
as a result of this product.
SERVICE:
Out of warranty service is available through Minnich Manufacturing Co.

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GENERAL SAFETY RULES
This manual contains NOTES, CAUTIONS, and WARNINGS. These MUST be followed to
prevent the possibility of improper use, incorrect servicing, damaging the equipment, or
personal injury. Read and comply with all NOTES, CAUTIONS and WARNINGS included in
these instructions.
NOTE: Notes contain additional information important to the operation of
the equipment.
CAUTION: Cautions provide important information to prevent mistakes
that could result in damage to the equipment.
WARNING: Warnings alert one to practices or conditions that could
lead to personal injury or death!
WARNING
Read and understand all instructions.
Failure to follow all instructions listed below may result in one or all of the following;
electric shock, fire, and serious injury.
WARNING
DO NOT USE TOOL IF IT IS IN NEED OF SERVICE!
SAVE THESE INSTRUCTIONS

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- WORK AREA –
Keep your work area clean and well lit.
Cluttered and dark areas invite accidents.
DO NOT operate power tools in explosive atmospheres, such as, in the presence of flammable liquids, gases, or dust.
Power tools create sparks that may ignite the dust or fumes.
Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to lose control.
- ELECTRICAL SAFETY -
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 adapter 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.
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.
DO NOT expose power tools to rain or wet conditions.
Water entering a power tool will increase the risk of electric shock.
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.
When operating a power tool outside, use outdoor extension cords marked “W-A or “W”.
These cords are rated for outdoor use and reduce the risk of electric shock.
- PERSONAL SAFETY -
Stay alert, watch what you are doing and use common sense when operating a power tool. DO NOT use tool while tired or
under influence of drugs, alcohol or medication.
A moment of inattention while operating power tools may result in serious personal injury.
Dress properly. DO NOT wear loose clothing, or jewelry. Tie up long hair. Keep your hair, clothing, and gloves away from
moving parts.
Loose clothes, jewelry, or long hair can be caught in moving parts.
Avoid accidental starting. Be sure switch is off before plugging in.
Carrying tools with your finger on the switch or plugging in tools that have switches on invites accidents.
DO NOT overreach. Keep proper footing and balance at all times.
Proper footing and balance enables better control of the tool in unexpected situations.
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 -
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.
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.
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.
Store tools out of the reach of children and other untrained persons.
Tools are dangerous in the hands of untrained users.
Maintain tools with care. Keep tools clean.
Properly maintained tools are less likely to bind and are easier to control.
Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tools
operation. If damaged, have the tool serviced before using.
Many accidents are caused by poorly maintained tools.
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 -
Tool service must be performed only by qualified repair personnel.
Service or maintenance performed by unqualified personnel could result in a risk of injury.
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 injury.

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GROUNDING INSTRUCTIONS
The electric vibrator motors must be grounded while in use to protect the operator from electric shock. The vibrator
motors are equipped with a 3-conductor electric cord and a 3-prong grounding type plug to fit a properly grounded mating
receptacle.
115 VOLT
Models 1500 and 2500 are fitted with a 15amp NEMA Type 5-15P plug as shown in Fig. 1a. It is to be used in
conjunction with NEMA Type 5-15R grounded female receptacle as shown in Fig. 1b. Model 3500 is fitted with a 20amp
NEMA Type 5-20P plug as shown in Fig. 2a. It is to be used in conjunction with a NEMA Type 5-20R grounded female
receptacle as shown in Fig. 2b. It is also available with an optional 20amp NEMA Type L5-20P, as shown in Fig. 3a,
which is to be used in conjunction with a NEMA Type L5-20R grounded female receptacle as shown in Fig. 3b.
Fig. 1a Fig. 1b Fig. 2a Fig. 2b
Fig. 3a Fig. 3b

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FUNCTIONAL DESCRIPTION
The MINNICH line of Flex Shaft vibrators is a system of fully interchangeable components that fulfill the requirements of
any job.
The electric motors are available in three (3) sizes – 1500, 2500 and 3500 series all in 115 volts. They are designed to be
splash-proof as designated by the following symbol on the switch plate cover.
The flexible shafts are available in two (2) diameters - 7/8” and 1 3/16” and six (6) lengths – 2’, 5’, 7’, 10’, 14’ and 21’.
Couplings are available to join several lengths together.
The vibrating heads are available in six (6) sizes - 3/4”, 1”, 1 3/8”, 1 3/4”, 2” and 2 3/8” diameters.
RECOMMENDED MOTOR / SHAFT/ HEAD COMBINATIONS
MOTOR 1500 SERIES 2500 SERIES 3500 SERIES
SHAFT 2’, 5’, 7’ 2’, 5’, 7’, 10’, 14’, 21’ 2’, 5’, 7’, 10’, 14’, 21’
HEADS (DIA.) 3/4”
1”
1 3/8”
1 3/8”
1 3/4”
2”
2 3/8”
1 3/8”
1 3/4”
2”
2 3/8”
RECOMMENDED HEAD / SHAFT (CASING) COMBINATIONS
7/8” DIA. CASING 1 3/16” DIA. CASING
LENGTH HEAD SIZE LENGTH HEAD SIZE
2’
5’
7’
10’
3/4”, 1”, 1 3/8”, 1 3/4”
3/4”, 1”, 1 3/8”, 1 3/4”
3/4”, 1”, 1 3/8”, 1 3/4”
3/4”, 1”, 1 3/8”
2’
5’
7’
10’
14’
21’
1 3/8”, 1 3/4”, 2”, 2 3/8”
1 3/8”, 1 3/4”, 2”, 2 3/8”
1 3/8”, 1 3/4”, 2”, 2 3/8”
1 3/8”, 1 3/4”, 2”, 2 3/8”
1 3/8”, 1 3/4”, 2”, 2 3/8”
1 3/8”, 1 3/4”, 2”, 2 3/8”

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ASSEMBLY
CAUTION: Turn the switch off and unplug the motor before performing any maintenance or fitting any components to the
motor.
ASSEMBLING SHAFT TO MOTOR
1. The end of casing with the strain relief spring goes into the motor casing adapter.
2. Insert inner core of the shaft into the core adapter on motor. Make sure the core is fully inserted.
3. Coat threads on casing coupler with Permatex Form-A-Gasket #1.
4. Thread casing coupler counterclockwise into adapter on power unit and tighten securely using open end
wrenches on the flats. NOTE – These are Left-Hand Threads.
ASSEMBLING VIBRATOR HEAD TO SHAFT.
1. Coat threads on casing coupler with Permatex Form-A-Gasket #1.
2. Push core toward motor end to make certain it is still engaged in the motor. Insert exposed end of core into head
core adapter.
3. Holding casing coupler with an open end wrench on the flats, thread the head on counterclockwise and securely
tighten with a pipe wrench.
CAUTION: Put pipe wrench only on the very end of the head to which the flexible shaft is being attached.
LOOSEN
TIGHTEN

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OPERATION
Match vibrator motor, shaft and head assembly to the job. Select the shortest shaft possible to do the job to assure
maximum power at the head.
Avoid sharp bends in the flexible shaft for greatest efficiency and shaft life. This is true both in operation and storage. DO
NOT allow the flexible shaft to hang or be dragged over sharp edges of the forms during operation.
DO NOT use shaft or cord to pull motor.
To vibrate concrete, dip vibrating head vertically into the mix. Allow to vibrate until the surface around the head becomes
glossy and no large air bubbles break the surface – usually 10-20 seconds. Withdraw the head slowly, then move and
immerse vibrator head in new location.
CAUTION: Over – vibration will cause a separation of the aggregates and will weaken the concrete.
DO NOT operate the vibrating head out of the mix for more than two minutes to prevent overheating and permanent
damage to bearings and seals. Wet concrete keeps the head at safe operating temperature.
NOTE: A new head will run slightly warmer for a short time than a broken in head. Once the seals seat the temperature
of the head will drop.
The electric motors work in 115volt single phase current. They are universally wound and can be operated on either AC
or DC. The current must not exceed 60 cycles when operating on AC. 50 cycle AC current is acceptable.
DO NOT operate motors on voltages that vary more than 5% from the specified.
WARNING: Use only 3-conductor extension cords, that are equipped with 3-prong grounded plugs and 3-pole
receptacles that accept the tools plug.
Recommended AWG Wire Size For Extension Cords
Motor Rated Amps 25' [7.6m] 50' [15.3m] 100' [30.5m] 150' [45.8m] 200' [61.0m]
1500 9 18 14 12 10 8
2500 15 16 12 10 8 6
3500 20 14 12 8 6 6
Always use the proper size extension cord. Undersize cords will result in loss of power due to voltage drop.
WARNING: Running the motor on reduced voltage may result in burning up the motor.

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MAINTENANCE
CAUTION: Turn the switch off and unplug the motor before performing any maintenance or fitting any components to the
motor. When servicing use only identical replacement parts.
PERIODIC MAINTENANCE SCHEDULE
BEFORE OPERATING
1. Inspect air inlet filter and outlet vent holes. Clean or replace dirty or clogged filter.
2. Inspect electrical cords for undue wear or damage. Replace damaged cords. DO NOT use damaged cords.
EVERY 50 HOURS
Clean and lubricate the core in the flexible shaft.
EVERY 100 HOURS
1. Inspect commutator and brushes in motor.
2. Change oil in vibrator head.
MOTORS
Wipe off motor with damp rag after each use to prevent concrete build-up.
CAUTION: Never spray with or dip electric motor in water. This will increase the risk of electric shock.
Clean intake and exhaust areas to insure unrestricted air flow. Restricted air flow could cause motor to overheat.
Remove end cover over air filter and clean air filter element as often as required by working conditions. To clean filter,
remove and wash in warm, soapy water. Make sure filter is completely dry before reinstalling.
Check brushes periodically for wear. As a safety feature to protect the motor, the brushes are of such design that the
motor will shutdown if they wear and become too short. To avoid unnecessary arcing and an unexpected shutdown,
inspect the brushes every 100 hours and replace them when necessary. Always replace both brushes at the same time.
TO INSPECT OR REPLACE MOTOR BRUSHES:
1. Remove plastic brush housing covers and brush holder caps from both sides of the motor.
2. Pull out the brushes and measure the length of the graphite block portion of the brush. If the dimension is 3/8” or
less, replace with new brushes. If brushes are long enough, replace them in the same position in the motor to
avoid undue arcing.
3. Break in new brushes by running the motor less flexible shaft for about five (5) minutes or until the arcing stops.
Inspect commutator through access port in bottom of motor after every 100 hours of use. With motor running, check for
excessive arcing. If present, clean commutator with an industrially rated commutator cleaner which is available at most
motor repair establishments.

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FLEXIBLE SHAFTS
LUBRICATION – After every 50 hours of operation, remove the inner core and wipe it clean. Coat core with a 1/16” layer
of MINNICH #002120-00000 high temperature grease.
CAUTION: DO NOT use solvents. Solvents trapped in the core or casing will breakdown the new grease and risk
premature failure.
Reverse the core in the casing at every lubrication to even the wear and extend service life.
Replace worn or broken casing to prevent damage to core and head.
To insure long life of flexible shafts, avoid putting undue bends in them. Whenever a casing becomes kinked, or worn to
extreme, replace with original equipment.
Never install a new core in a kinked casing or a kinked core in a new casing. This will cause the new parts to fail
prematurely.
Core and casing assemblies are shipped from the factory pre-lubricated. However, separate cores and casings are
shipped without lubrication and must be lubricated with MINNICH #002120-00000 high temperature grease at assembly
as noted above.
Always apply Permatex Form-A-Gasket #1 to the threads of the casing adapter when reassembling the core and casing
assembly to the vibrator head and motor.
Break in a newly lubricated core and casing assembly before putting it to work. During this break-in the core will turn
slower than normal, could rattle a little bit and draw the motor speed down, causing the motor to draw more current. After
this break-in period, the unit will run smoothly.
VIBRATOR HEADS
The vibrator heads require very little maintenance since they are lubricated with oil and sealed at the factory.
Wash concrete and dirt from heads after each job or at the end of a workday – whichever occurs first.
To extend the bearing life in the head, change the oil in the head after every 100 hours of operation.
TO CHANGE OIL IN HEADS:
1. Secure tip of vibrator head in vise and use a chain or pipe wrench on the casing adapter, rotating adapter
counterclockwise for a right hand thread. Remove head from vise and drain out old oil in a container and dispose
properly.
2. Insert open end of head into the appropriate size bump tube. With open end facing down, strike bottom end of
bump tube on a block of wood until eccentric weight assembly drops out.
3. Flush eccentric weight assembly and housing with clean solvent and wipe all parts clean.
4. Inspect bearings, core adapter and seals for signs of wear. If parts pass inspection, reassemble eccentric weight
assembly into the housing. Clamp head vertically in a vise and refill with proper amount of MINNICH #002119-
00000 long life oil (see chart on page 19).
NOTE: If there are signs of wear (grooving) from the seals on the core adapter, worn seals or looseness in the
bearings see the service portion of the manual for further instructions.
5. Put oil on core adapter for ease of assembly of casing adapter containing the two (2) seals. Start thread of
adapter into housing for a turn or two. Stop and apply a generous coating of Permatex Form-A-Gasket #1 all
around the threads on the casing adapter.
NOTE: It is very important that the casing adapter fits tightly against the housing. In order to guarantee a
waterproof seal, allow 15 minutes for sealant to set up.

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SERVICE
ELECTRIC MOTORS
CAUTION: Turn the switch off and unplug the motor before performing any maintenance to the motor. When servicing
use only identical replacement parts.
TO REPLACE BRUSHES #19
TO REMOVE:
1. Disconnect electric cable #24 from power source.
2. Remove plastic brush housing covers #21 from both sides of motor housing #13.
3. Using a blade point screwdriver, unthread brush holder caps #20 from brush holders #18.
4. Remove brushes #19. In most cases, the brush #19 will automatically partially eject from brush holder #18.
TO REPLACE:
1. Align the carbon portion of the new brush #19 with brush holder #18 and insert.
NOTE: Be careful not to chip the edges of the brush.
2. Feed spring end of brush #19 into brush holder #18 until the round stop at the end of the spring is flush with the
brush holder #18.
3. Hold stop in place and slide brush holder cap #20 into opening of motor housing #13.
4. Using a blade point screwdriver, thread and tighten brush holder cap #20 into brush holder #18.
5. Replace plastic brush housing cover #21 onto motor housing #13.
6. Break in new brushes by running the motor less flexible shaft for about 5 minutes or until the arcing stops.
TO REPLACE FILTER #28
TO REMOVE:
1. Set motor in upright position and secure with end cover #30 up.
2. Using a blade point screwdriver, remove end cover #30 by removing four (4) screws #31 and four (4) lockwashers
#3.
3. Remove filter #28 leaving end cover spacer #29 in the middle.
TO REPLACE:
1. Place filter #28 over centered end cover spacer #29.
2. Place end cover #30 on spacer #29 so as to align the four (4) holes with tapped holes in motor housing #13.
3. Using a blade point screwdriver, replace the four (4) lockwashers #3 and four (4) screws #31. Tighten into motor
housing #13.

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TO REPLACE MOTOR SWITCH #32
TO REMOVE:
1. Disconnect electric cable #24 from power source.
2. Using a wrench, remove motor switch weather cap #36 and motor switch nut #35 from barrel of motor switch #32.
NOTE: The vertical groove in the threaded barrel of the switch is toward the electric cable #24.
3. Using a blade point screwdriver, remove the four (4) screws #2 and four (4) lockwashers #3 that hold the switch
cover plate #34 onto motor housing #13 and remove. Remove #33 switch sleeve.
4. Using a blade point screwdriver, disconnect the two (2) lead wires from the electric cable #24 and two (2) from the
field #12 from the motor switch #32.
5. Remove switch.
TO REPLACE:
1. Before beginning, refer to “TO REPLACE FILTER #28” and remove end cover #30 and filter #28. This is done to
see the lead wires of field #12 and lead wires of electric cable #24 after they are connected to motor switch #32,
to insure they are not coming in contact with the commutator bars on armature #8.
NOTE: Once you remove end cover #30 be certain to clean and inspect filter #28.
2. With the vertical groove on threaded barrel of motor switch #32 facing toward electric cable #24, to insure
“ON/OFF” will agree with markings on motor switch cover plate #34, connect two (2) lead wires from electric cable
#24 and two (2) lead wires from field #12 to motor switch #30. Install switch sleeve #33 around switch.
3. When pushing motor switch #32 into motor switch opening in the motor housing #13, position lead wires to allow
motor switch #32 to lie flat.
4. Position motor switch cover plate #34 on motor switch #32 by inserting the key in the center hole into the vertical
groove in the threaded barrel of the switch. This will locate the “OFF” position on motor switch cover plate #34
toward the electric cable #24. Secure switch cover plate with four (4) screws #2 and four (4) lockwashers #3 onto
motor housing #13.
5. Replace motor switch nut #35 and motor switch weather cap #36 onto the barrel of motor switch #32 and tighten
securely. NOTE: A small amount of silicone dielectric compound placed inside motor switch weather cap #36 will
ease installation of it and provide additional sealing.
6. Install filter #28 and end cover spacer #29.
7. Replace end cover #30 and secure with four (4) screws #31 and four (4) lockwashers #3.

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TO REPLACE ELECTRIC CABLE #24
TO REMOVE:
1. Disconnect electric cable #24 from power source.
2. Using a wrench, remove motor switch weather cap #36 and motor switch nut #35.
3. Using a blade point screwdriver, remove four (4) screws #2 and four (4) lockwashers #3 from motor switch cover
plate #34. Remove cover plate.
4. Refer to “TO REPLACE FILTER #28” and remove end cover #30 and filter #28.
5. Remove switch sleeve #33.
6. Using a blade point screwdriver, disconnect the two (2) lead wires from electric cable #24 from motor switch #32.
Disconnect ground wire (green) from motor housing #13 by unthreading screw #26 with lockwasher #25 from
motor housing #13.
7. Using a wrench, unscrew the spiral flex nut (part of strain relief #23) from the strain relief body.
8. Turn the electric cable #24 until it becomes free and pull it out.
TO REPLACE:
1. Take electric cable #24 and install and crimp terminal #22 on all three (3) wires.
2. Slip spiral flex nut (round end first) onto electrical cable #24.
3. Slip electric cable #24 through the rubber sleeve in the strain relief body so that ¼” of outside covering extends
inside the motor housing #13 with the ground wire (green) facing in the down position toward opening for brush
holders in motor housing #13.
4. While holding the electric cable #24 in position, screw the spiral flex nut onto the strain relief body and tighten with
wrench.
5. Feed ground wire (green) through vent hole and secure to motor housing #13 with screw #26 and lockwasher
#25. Make sure ground wire does not interfere with commutator on the armature #8.
6. Connect the two (2) shorter lead wires of electric cable #24 to motor switch #32 and tighten screws.
7. Install switch sleeve #33 over the switch terminals.
8. Refer to steps “3” through “5” of “TO REPLACE MOTOR SWITCH #32” to finish installation.

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TO REPLACE ARMATURE #8 AND FIELD #12
TO REMOVE ARMATURE #8
1. Refer to steps “1” through “4” in “TO REMOVE” section of “TO REPLACE BRUSHES #19.”
2. Using a blade point screwdriver, remove four (4) screws #2 and four (4) lockwashers #3 from end cap #4.
3. With plastic mallet, tap casing adapter #1 on alternating sides until end cap #4 becomes loose from motor
housing #13. It may be necessary to use a blade point screwdriver to pry end cap #4 away from motor housing
#13.
4. Because of tight tolerances in bearing seat of end cap #4, armature #8 will be removed with end cap #4.
5. To remove armature #8 from end cap #4, hold laminations of armature #8 with end cap #4 facing in down
position. Tap inner face of end cap #4 with plastic mallet on alternating sides until it becomes free of armature #8.
NOTE: When armature #8 is free from end cap #4 be certain not to lose spring washer #5.
TO REMOVE FIELD #12
1. Using a blade point screwdriver, remove the four (4) screws #2 and four (4) lockwashers #3 that hold the switch
cover plate #34 onto motor housing #13 and remove out of the way. Remove switch sleeve #33. Remove the
two (2) field leads from motor switch #32.
2. With motor housing #13 standing in upright position, field leads will become visible. With blade point screwdriver,
pry the two (2) field leads that are inserted in sides of brush holders #18 free. When lead wires are free, notice
that the two (2) terminals on the lead wires are flag shaped. This allows them to slide into sides of brush holders
#18.
3. Using a Phillips screwdriver or 1/4” socket, remove the two (2) field screws #9 and lockwashers #10.
4. Turn motor housing #13 upside down and tap on hard surface until field #12 becomes free of motor housing #13,
being careful not to damage field windings.
TO REPLACE FIELD #12
1. Take field #12 and install and crimp terminal #22 on the two (2) wires without terminals.
2. With switch opening on motor housing #13 facing away from you, stand motor housing #13 in an upright position.
3. Examine field #12. NOTE: A section of one of the lead wires will be over or very near to one of the field holes that
the field screws #9 will pass through. Position field #12 so this is on the right side as you look down on field #12
for models 2500 and 3500 (2 and 3 HP) and on left for model 1500 (1 HP) with single field lead facing away from
you. CAUTION: Position this wire so it is clear of the boss for hole in field #12. A screwdriver may be used to
hold the wire out of the way when installing field #12 into motor housing #13.
4. Place alignment tool into right-hand threaded hole in motor housing #13. NOTE: Threaded holes are located in
bosses near the bottom of motor housing #13 and accept the field screws #9.
5. Position the wire connection end of the field down with the right hand field hole over alignment tool and slide into
motor housing #13. CAUTION: While sliding field #12 into motor housing #13, be sure all field wires are clear
and will not be in the way of the field #12 seating itself on flange in motor housing #13.
6. Remove alignment tool and insert field screws #9 and lockwashers #10. Tighten securely.
7. Insert two (2) field leads with flag shaped terminals into sides of brush holders #18, being sure they are tightly in
place. NOTE: you will feel a slight snap when this is accomplished. It is quite apparent which flag shaped
terminal goes to the right brush holder #18 and which to the left brush holder #18.
8. Connect the remaining two (2) lead wires to motor switch #32.
9. Install switch sleeve #33 over the switch #32 terminals.
10. Refer to steps “3” and “4” on “TO REPLACE MOTOR SWITCH #32” for replacing motor switch over plate #34.

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TO REPLACE ARMATURE #8
1. Before replacing armature #8 into motor housing #13, be sure core adapter #6 is securely threaded onto the
armature shaft at fan end.
2. With motor housing #13 standing in an upright position, hold armature #8 with commutator bars facing down and
insert through field #12 into bearing seat of motor housing #13. NOTE: It may be necessary to tap the core
adapter #6 with plastic mallet in order to properly seat armature bearing #11 into bearing seat of motor housing
#13.
3. With the tabs of spring washer #5 facing down, place it on upper armature bearing #7.
4. With five (5) screws #2 in casing adapter #1 facing switch opening of motor housing #13, place end cap #4 over
spring washer #5 and armature bearing #7 and press into place. NOTE: It may be necessary using a blade point
screwdriver to tighten four (4) screws #2 and four (4) lockwashers #3 before end cap #4 is seated properly in
place.
5. Refer to steps “1” through “5” of “OF REPLACE BRUSHES #19” to finish installation.
TO REPLACE BRUSH HOLDER #18
TO REMOVE:
1. Disconnect electric cable #24 from power source.
2. Remove four (4) bolts #16 and four (4) lockwashers #15 disconnecting motor frame #39 from motor assembly.
Remove motor assembly from frame.
3. Remove two (2) isolators #15 located under brush holders from motor housing #13.
4. Refer to steps “2” through “4” of “TO REMOVE BRUSHES #19” for brush removal
5. Refer to steps “2” through “5” of “TO REMOVE ARMATURE #8” for armature removal.
6. Using an Allen wrench loosen set screws #17 in motor housing #13 to release brush holders #18. Remove brush
holders #18.
TO REPLACE:
1. Set motor housing #13 down on appropriate brush holder spacing fixture.
2. Install brush holders #18 into motor housing #13. Slide alignment bar through both brush holders #18 and slot in
fixture. NOTE: Some brush holders #18 have only one (1) slot to receive the terminal from the field #12. Make
certain these brush holders are installed with this slot towards the bottom of the motor housing #13 and not up
towards the switch opening.
3. Hold right amount of pressure on each brush holder #18 when tightening the cup point set screw #17. Seat the
set screw #17 lightly, back out a partial turn and reseat making sure the set screw cup point seats in, but not so
tight that it would crack the brush holder #18.
4. Refer to steps “1” through “5” of “TO REPLACE ARMATURE #8” for armature #8 and brush #19 replacement.
5. Install the two (2) isolators #14 previously removed.
6. Reinstall motor assembly into motor frame #39. Install four (4) bolts #16 and four (4) lockwashers #15 securing
motor frame #39 to isolators #14.

- 17 -
VIBRATOR HEADS
All vibrator heads are equipped with seals in the casing adapter to keep the grease from the flexible shaft out of the
vibrator head and to retain the oil in the vibrator head.
TO DISASSEMBLE HEADS:
1. Secure tip of vibrator head in vise and use a chain or pipe wrench on the casing adapter #51, rotating adapter
counterclockwise for a right hand thread. Remove head from vise and drain out old oil in a container and dispose
of properly.
2. Insert open end of head into the appropriate size bump tube. With open end facing down, strike bottom end of
bump tube on a block of wood until the eccentric weight assembly drops out.
3. Flush eccentric weight assembly, casing adapter #51 and housing #44 with clean solvent and wipe all parts clean.
Inspect bearings #46, core adapter #48, and seals #50 for any signs of wear. If there are signs of wear on the polished
part of the core adapter #48, both core adapter #48 and seals #50 must be replaced. If the bearings #46 show any signs
of looseness, they must be replaced. Replace both pairs.
TO DISASSEMBLE ECCENTRIC WEIGHT ASSEMBLY:
1. Place eccentric weight assembly in vise. If you have a 1/4” drive ratchet, place square driver inside the female
end of core adapter #48, and turn counterclockwise for a right hand thread. If a 1/4” drive ratchet is not available,
place vise grips or locking pliers on the back end of core adapter #48 (next to the bearing), where the material is
the heaviest and remove, being very careful not to damage or mar the polished portion of the core adapter #48.
2. On opposite end use a wrench or spanner wrench (vise grips or locking pliers if spanner is not available) to
remove bearing locknut #45.
3. Slip bearings #46 off eccentric weight #47.
TO REPLACE OIL SEALS #50:
NOTE: To replace the oil and grease seals #50 in the casing adapter #51, an arbor press is ideal for this operation. If a
press is not available, a properly sized socket wrench will work. The casing adapters #51 are machined with a step inside
the I.D. to insure the seals #50 are properly seated when installed.
CAUTION: In all cases the oil and grease seals #50 are inserted into the casing adapter #51 back to back. Also, it is
advisable to press one seal #50 into place, then the other. Apply a light coating of grease to the outside diameter of seal
#50 before pressing into casing adapter #51. Some plastic sealing material may be shaved off the outside diameter of
seal #50 as it is pressed into place. Remove this after pressing each seal to avoid any chance of this residue entering
into the seal area or the bearings and resulting in a premature failure.
1. On the 3/4 in. (19mm) and 1 in. (25mm) heads, the oil and grease seals #50a and #50b are removed by pushing
them out of the female end of the casing adapter #51 and replaced by pushing oil seal #50a in first (lip down) 1
9/16 in. deep for the 3/4 in. head and 1 1/2 in. deep for the 1 in. head followed by the grease seal #50b (lip up)
through the female end of the adapter.
2. On the 1 3/8 in. (35mm), 1 3/4 in. (45mm) and the 2 in. (50mm) heads, the oil and grease seals #50 are removed
by pushing them out of the male end of the casing adapter #51 and replaced by pushing them in through the male
end of the adapter, being sure they have been properly seated against the step described earlier.
3. On the 2 3/8 in. (59mm) head, the oil and grease seals #50 are removed by pushing them out through the female
end that the head housing threads into, and replaced through the same end, being sure they have been properly
seated against the step described earlier.

- 18 -
TO ASSEMBLE ECCENTRIC WEIGHT ASSEMBLY:
1. Place eccentric weight #47 in vise.
2. Install two (2) bearings #46 on one end and secure with locknut #45 using either a wrench or spanner wrench
(depending on type of locknut used).
3. Install two (2) bearings #46 on other end and secure with core adapter #48. If you have a 1/4” drive ratchet, place
square driver inside the female end of core adapter #48 and tighten turning clockwise for a right hand thread. If a
1/4” drive ratchet is not available, place vise grips or locking pliers on the back end of core adapter #48 (next to
the bearing), where the material is the heaviest and remove, being very careful not to damage or mar the polished
portion of the core adapter #48.
TO ASSEMBLE HEADS:
1. Place housing #44 in vise vertically with open end up.
2. Take eccentric weight assembly and put a light coating of head lubricating oil MINNICH #002119-00000 and
lubricate the bearing #46 outer races.
3. With core adapter #48 pointing up, take the eccentric assembly and slide into the housing #44. You may have to
tap the core adapter #48 to properly seat the bearings into the housing #44.
4. Refill vibrator with the proper amount of MINNICH #002119-00000 long life oil (see chart on page 19).
5. Put a light coat of oil or grease on polished surface of core adapter #48 for ease of assembly of casing adapter
#51 containing the two seals #50. Start thread of adapter into the housing for a turn or two. Stop and apply a
generous coating of Permatex Form-A-Gasket #1 all around the threads on the casing adapter #51. Tighten
adapter with a chain or pipe wrench and remove excess sealant. NOTE: It is very important that the casing
adapter #51 fits tightly against the vibrator housing #44. In order to guarantee a water proof seal, allow 15
minutes for sealant to set up.
When threading vibrator head back on to the flexible shaft casing, always put Permatex Form-A-Gasket #1 on casing end
to insure a water tight seal. Thread head on and tighten with a chain or pipe wrench on head and open end wrench on
flats on casing.

- 19 -
PARTS AND SERVICE NOTES
Part numbers shown in BOLD type are recommended spare parts. These parts are subject to wear under normal
operating conditions and may need periodic replacement. It’s suggested that these items be stocked to satisfy the
expected service needs of this model. The actual stocking quantities of these and other service parts used in more
extensive repairs will be dependent upon the service practices of each customer.
Grease - Flexible Shaft-----------------------------------Part No. 002120-00000
Oil - Lubricating--------------------------------------------Part No. 002119-00000
Lubricating Oil Capacities
Head Dia. Oil Capacity
3/4” 1/4 oz.
1” 1/2 oz.
1 3/8” 1/2 oz.
1 3/4” 3/4 oz.
2” 1 oz.
2 3/8” 1 oz.

- 20 -
Electric Motor Parts Sheet
Fig. No. 1500 2500 3500 Description
1 002189-00000 002189-00000 002189-00000 Casing Adapter
2 006703-00.62 006703-00.62 006703-00.62 Screw, 10-24x5/8" Long Pan Hd. Th'd. Cutting (14)
3 006145-00000 006145-00000 006145-00000 Lockwasher #10 (18)
4 002088-00000 002014-00000 002081-00000 End Cap
5 002061-00000 002061-00000 002061-00000 Spring Washer
6 002678-00000 002678-00000 002678-00000 Core Adapter
7 002037-00000 002037-00000 002037-00000 Bearing
8 002089-00000 020121-00000 002082-00000 Armature, 115 Volt
9 002092-00000 Screw, 8-32x2 3/4" Long Th'd. Forming (2)
9 020123-00000 Screw, 8-32x3 1/2" Long Th'd. Forming (2)
9 002086-00000 Screw, 8-32x4" Long Th'd. Forming (2)
10 006144-00000 006144-00000 006144-00000 Lockwasher #8 (2)
11 002101-00000 002037-00000 002037-00000 Bearing
12 002091-00000 020122-00000 002084-00000 Field, 115 Volt
13 0A2087-00001 0A2015-00001 0A2080-00001 Housing, Motor
14 002042-00000 002042-00000 002042-00000 Isolator (4)
15 006148-00000 006148-00000 006148-00000 Lockwasher 5/16" (4)
16 006037-00.62 006037-00.62 006037-00.62 Bolt, 5/16"-18x5/8" Long (4)
17 006320-00.38 006320-00.38 006320-00.38 Set Screw, 10-24 x 3/8" Long (2)
18 002093-00000 002030-00000 002030-00000 Brush Holder (2)
19 002094-00000 020291-00000 002029-00000 Brush (2)
20 002095-00000 002031-00000 002031-00000 Brush Holder Cap (2)
21 002049-00000 002049-00000 002049-00000 Brush Housing Cover (2)
22 020352-00000 020352-00000 020352-00000 Terminal - Electric Cable (3)
22 020352-00000 020352-00000 020352-00000 Terminal - Field (2)
23 A10210-00001 A10210-00001 A10212-00001 Strain Relief
24 002035-00001 002035-00001 010073-00000 Electric Cable, 115 Volt
24 010906-00000 Electric Cable 115 Volt Opt Twist-Lock Plug
25 006143-00000 006143-00000 006143-00000 Lockwasher #6
26 002067-00000 002067-00000 002067-00000 Screw, 6-32 x 1/2" Long Pan Hd. Th'd Cutting
27 002033-00000 002034-00000 002034-00000 Retaining Ring
28 008150-00000 008150-00000 008150-00000 Filter
29 002109-00000 002109-00000 002109-00000 Spacer, End Cover
30 002106-00000 002103-00000 002104-00000 End Cover
31 002108-00000 002108-00000 002108-00000 Screw, 10-24 x 1" Long Stainless Steel Pan Hd. (4)
32 020361-00000 020361-00000 020361-00000 Motor Switch
32-1 A20361-00001 A20361-00001 A20361-00001 Motor Switch (Includes Part No. 33, 35 & 36)
33 020364-00000 020364-00000 020364-00000 Motor Switch Sleeve
34 002050-00000 002050-00004 002050-00000 Motor Switch Cover Plate, 115 Volt
35 020362-00000 020362-00000 020362-00000 Motor Switch Nut (2)
36 020363-00000 020363-00000 020363-00000 Motor Switch Weather Cap
37 002098-00000 002059-00000 002085-00000 Air Vent Cover
38 002048-00000 002048-00000 002048-00000 Pop Rivet, Air Vent Cover
39 0A7596-00000 0A7595-00000 0A7914-00000 Motor Frame
40 010214-00000 010214-00000 010214-00000 Plug-Inspection