Wacker Neuson M 1000 User manual

www.wackergroup.com
Internal Vibrator
M 1000
M 2000
M 3000
OPERATOR’S MANUAL
0154561en 002
0303
0154561EN

HMS Table of Contents
wc_bo0154561002enTOC.fm 1
1. Foreword 3
2. Safety Information 4
2.1 Service Safety ...................................................................................... 5
2.2 Operating Safety .................................................................................. 5
2.3 Safety & Informational Labels .............................................................. 7
2.4 Label Locations .................................................................................... 7
3. Technical Data 8
3.1 Motors .................................................................................................. 8
3.2 Vibrator Heads ..................................................................................... 9
3.3 Shafts ................................................................................................. 10
3.4 Sound and Vibration Measurements .................................................. 10
4. Operation 11
4.1 Application .......................................................................................... 11
4.2 Recommended HMS Combinations ................................................... 12
4.3 Extension Cords ................................................................................. 13
4.4 Connecting Motor to Power Supply .................................................... 14
4.5 Assembling Head, Motor and Shaft .................................................... 15
4.6 Operation ............................................................................................ 16
5. Maintenance 17
5.1 Periodic Maintenance ......................................................................... 17
5.2 Motor Brushes .................................................................................... 18
5.3 Motor Housing .................................................................................... 19
5.4 Lubricating Shaft ................................................................................ 20
5.5 Lubricating H-Head ............................................................................ 21
5.6 Checking H-Head for Wear ................................................................ 22
5.7 Troubleshooting .................................................................................. 23
5.8 Wiring Schematics .............................................................................. 24

Table of Contents HMS
wc_bo0154561002enTOC.fm 2

Foreword
wc_tx000001gb electric.fm 3
1. Foreword
This manual provides information and procedures to safely operate
and maintain this Wacker model. For your own safety and protection
from injury, carefully read, understand and observe the safety
instructions described in this manual.
Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker
Corporation. This machine is built with user safety in mind; however,
it can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Corporation reserves the
right 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 any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights and will be
prosecuted. We expressly reserve the right to make technical
modifications, even without due notice, which aim at improving our
machines or their safety standards.

Safety Information HMS
wc_si000104gb.fm 4
2. Safety Information
This manual contains DANGER, WARNING, CAUTION, and NOTE
callouts which must be followed to reduce the possibility of personal
injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
CAUTION: Used without the safety alert symbol, CAUTION indicates
a potentially hazardous situation which, if not avoided, may result in
property damage.
Note: Contains additional information important to a procedure.
DANGER
WARNING
CAUTION

HMS Safety Information
wc_si000104gb.fm 5
2.1 Service Safety
When using electric tools, basic safety precautions should always be
followed 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 and
equipment damage may result.
2.1.2 Prevent body contact with grounded surfaces such as pipes, metal
railings, radiators and metal ductwork.
2.1.3 When motor is used outdoors, use only extension cords intended for
and marked for outdoor use.
2.1.4 ALWAYS keep all electrical cords away from heat, oil and sharp edges
which can damage them. Inspect all electrical cords before each use
and have damaged cords replaced or repaired at an authorized service
center.
2.1.5 Make certain motor is in good working order and properly grounded
before starting.
2.2 Operating Safety
Familiarity and proper training are required for the safe operation of
equipment! Equipment operated improperly or by untrained personnel
can be dangerous! Read the operating instructions contained in this
manual and familiarize yourself with the location and proper use of all
controls. Inexperienced operators should receive instruction from
someone familiar with the equipment before being allowed to operate
the 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 handle
power cable and extension cords.
2.2.4 NEVER operate motor in areas exposed to flammable or explosive
liquids or gases! The motor brushes spark during operating and could
ignite fumes.
2.2.5 NEVER overreach. Keep proper footing and balance at all times. Make
sure any supporting structures are strong enough and stable enough
to support your weight and the weight of any equipment on it.
2.2.6 ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from moving parts of equipment.
2.2.7 ALWAYS wear protective clothing appropriate to the job site when
operating equipment.
DANGER
WARNING

Safety Information HMS
wc_si000104gb.fm 6
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 from
receptacle. 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 it
is connected to power source. Don't carry motor with finger on switch.
2.2.12 NEVER operate machine when you are tired. Remain alert, watch
what you are doing and use common sense.
2.2.13 NEVER operate machine if switch does not function properly. Have
defective switches replaced by authorized service center.
2.2.14 ALWAYS replace worn or damaged components with spare parts
designed and recommended by Wacker.
2.2.15 DO NOT overload motor. An overloaded motor will overheat. Use only
recommended head/motor/shaft combinations. See Table 1.
2.2.16 DO NOT allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to service the electrical
components 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 the
wrong voltage supply will damage motor.
2.2.19 ALWAYS make sure motor switch is OFF before plugging motor to
power supply.

HMS Safety Information
wc_si000104gb.fm 7
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.
w c _ g r 0 0 1 2 0 8
F O R S A F E O P E R A T I O N R E A D
O P E R A T O R  S M A N U A L .
P O U R U N E O P E R A T I O N S Û R E
L I S E Z L A N O T I C E D  E M P L O I .
S I C H E R H E I T S A N L E I T U N G E N I N
E T R I E S V O R S C H R I F T L E S E N .
P A R A O P E R A C I O N S E G U R A L E A
M A N U A L D E O P E R A C I O N .
C A U T I O N
V O R S I C H T
P R E C A U T I O N
P R E C A U C I O N

Technical Data HMS
wc_td000103gb.fm 8
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) A9 4,5156,520 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

HMS Technical Data
wc_td000103gb.fm 9
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)

Technical Data HMS
wc_td000103gb.fm 10
3.3 Shafts
3.4 Sound and Vibration Measurements
The required sound specification, Paragraph 1.7.4.f of 89/392/EEC
Machinery 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 the
sound power level (LWA) and ISO 6081 for the sound pressure level
(LpA) at the operator’s location.
The weighted effective acceleration value, determined according to
ISO 8662 Part 1, is 5.1 m/s2.
The sound and vibration measurements were obtained with the unit
operating 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

HMS Operation
wc_tx000265gb.fm 11
4. Operation
4.1 Application
The HMS series of internal vibrators can be used over a wide range
of applications for the consolidation of concrete.
WACKER internal vibrators are typically used for on-site vibration of
concrete for foundations, walls, columns, slab work, etc. Additional in-
plant applications include vibration of concrete during the production of
pipes, slabs, beams, double T columns, walls, etc.
w c
_ g
r001210
a
b
c

Operation HMS
wc_tx000265gb.fm 12
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 meet
job requirements. Choosing the correct combination is important to
produce good results and protect the parts from excessive wear and
damage. Selecting too large a head/shaft combination will overload the
motor.
Refer to Table 1 below when selecting motor, shaft, and head
combinations.
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.

HMS Operation
wc_tx000265gb.fm 13
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 size
for safety. An undersized cord will cause a drop in line voltage resulting
in a loss of power and overheating. Refer to Table 2 when selecting
extension cords. It shows the correct wire size to use depending on
cord length. If in doubt, use the next heavier cord size.
On motors being used outdoors, use extension cords rated for outdoor
use.
Improper use of extension cords can cause overheating or create
serious 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

Operation HMS
wc_tx000265gb.fm 14
4.4 Connecting Motor to Power Supply
See Graphic: wc_gr001211
To reduce the risk of electric shock, motors equipped with 3-wire
grounded plugs must be properly grounded. On these motors use only
3-wire grounded plugs, receptacles, and extension cords.
4.4.1 Check that switch on motor is off before connecting motor to power
source.
4.4.2 Make sure power supply matches voltage requirements listed on motor
label. Running a motor at a low voltage will cause it to run slow. This
will reduce perfomance and may cause motor to overheat.
4.4.3 On motors equipped with a three wire grounded plug use three-wire
grounded receptacles (d) when connecting the motor. If a 3-wire
grounded receptacle is not available, then a grounded adapter must be
installed as shown in illustration (e) to ensure a proper ground
connection.
Note: Not all countries require the use of a three-wire grounded plug
for this piece of equipment. In these countries, motors are equipped
with a two-wire plug which can be plugged into a standard electrical
outlet.
WARNING

HMS Operation
wc_tx000265gb.fm 15
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 of
flexshaft (left hand thread) and tighten using a wrench.
HR Heads:
Slide the casing coupling protective sleeve (d) onto the end of the
shaft. Apply pipe sealant to shaft threads (c), attach Vibrator head to
shaft and tighten using wrenches.
Apply a uniform 9.5 mm (3/8 in.) bead of silicone adhesive about 102
mm (4 in.) long over casing coupling. Push casing coupling protective
sleeve (d) over coupling, rotating sleeve as you push, until end of
sleeve enters recess on vibrator head. Let silicone dry for
approximately one hour.
4.5.2 The shaft is attached to motor using a quick disconnect coupler. The
coupler may vary depending on the type of shaft being used. All new
WACKER flexshafts come equipped with a coupler and do not require
any additional coupling device. Refer to parts manual for shafts
equipped with couplers.
If you are using a shaft from another manufacturer, or are attaching an
older WACKER shaft, refer to parts manual to order the correct
coupling to use. If a coupler must be installed on the shaft, apply pipe
sealant 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 slide
coupler in place. Rotate coupler until pin falls into coupler socket.
wc_gr001247
dd
c

Operation HMS
wc_tx000265gb.fm 16
4.6 Operation
Hold head in air or place it on soft surface when starting motor. This
will prevent it from bouncing on hard surfaces which could damage
bearings. During use, insert the head quickly into the mix and then pull
it out slowly. Rapid removal is the main cause of poor concrete
consolidation. For best results submerge head completely and try to
establish 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 can
transmit vibration to other areas of the mix which may already be
setting.
CAUTION: DO NOT run the motor with the head out of the mix for long
periods of time. This can cause the bearings to overheat.
For more detailed information on the use, selection and application of
WACKER equipment for concrete consolidation, order Wacker
publication WCW 982 “CONCRETE CONSOLIDATION”.

HMS Maintenance
wc_tx000266gb.fm 17
5. Maintenance
5.1 Periodic Maintenance
Before
starting
Every
50
hrs.
Every
100
hrs.
Every
300
hrs.
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. •

Maintenance HMS
wc_tx000266gb.fm 18
5.2 Motor Brushes
See Graphic: wc_gr001213
To protect the motor, the brushes are designed to automatically shut
off the motor if they become too short. If the motor stops during
operation, the brushes may need to be replaced. To avoid having the
brushes shut down the motor unexpectedly, inspect brushes every 50
hours and replace them when necessary. Always replace both brushes
at 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 same
positions they were removed, to avoid arcing.
5.2.3 Break in new brushes by running motor for about 5 minutes with no
shaft attached.