WycoTool Hydraulic Paving Vibrators User Manual

Operation and

Service Manual

for

WYCO

Hydraulic Paving

Vibrators

CHAPTER 1 - GEERAL IFORMATIO .....................................................................................................................................1

a) Purpose of Vibration ..............................................................................................................................................................1

b) Vibrator Positioning and Spacing .........................................................................................................................................1

c) Vibrator Speed (VPM) Vibrations Per Minute ......................................................................................................................1

d) Paver Travel Speed ................................................................................................................................................................1

e) Mix Design and Slump ..........................................................................................................................................................1

CHAPTER 2 - VIBRATOR DESIG FUDAMETALS ...............................................................................................................2

a) Rotor ......................................................................................................................................................................................2

b) Bearings and Bearing Cups ..................................................................................................................................................2

c) Hydraulic Motor ....................................................................................................................................................................2

d) Square Head Housing ............................................................................................................................................................2

e) Oldham Style Drive Components .........................................................................................................................................2

f) Vibration Isolator ..................................................................................................................................................................2

g) Hydraulic Hoses and Quick Disconnects ..............................................................................................................................2

h) Protective Hoses and Plugs ...................................................................................................................................................3

CHAPTER 3 - ISTALLATIO AD OPERATIG REQUIREMETS .....................................................................................4

a) Mounting Vibrators.................................................................................................................................................................4

b) Hydraulic Hose Connections ................................................................................................................................................4

c) Oil Filtration ..........................................................................................................................................................................4

d) Vibrator Performance and Oil Supply ..................................................................................................................................4

Oil Pressure .................................................................................................................................................................4

Temperature .................................................................................................................................................................4

Flow Rate ....................................................................................................................................................................5

e) Trouble Shooting ...................................................................................................................................................................5

Trouble Shooting Chart ...............................................................................................................................................6

f) Vibrator Parts Breakdown.......................................................................................................................................................7

Straight Vibrator............................................................................................................................................................7

Angle Vibrator...............................................................................................................................................................8

Vibrator Assembly Parts List........................................................................................................................................9

CHAPTER 4 - SERVICE AD ASSEMBLY ISTRUCTIOS ....................................................................................................10

a) Maintenance Interval ..........................................................................................................................................................10

b) Special Tools Required .......................................................................................................................................................10

c) Bearing Replacement ..........................................................................................................................................................10

1) Head Housing Removal .......................................................................................................................................10

2) Rotor Assembly Removal .....................................................................................................................................10

3) Rotor Disassembly ................................................................................................................................................11

4) Cleaning ...............................................................................................................................................................11

5) Bearing Replacement ...........................................................................................................................................11

6) Rotor / Square Head Housing Assembly .............................................................................................................12

d) Hydraulic Motor Seal Replacement ....................................................................................................................................13

1) Seal Removal ........................................................................................................................................................14

2) Seal Replacement .................................................................................................................................................14

e) Hose, Hydraulic Motor and Alternate Hydraulic Motor Seal Removal .............................................................................14

1) Protective Hose Removal .....................................................................................................................................15

2) Motor Housing Removal ......................................................................................................................................15

3) Hydraulic Motor Removal ...................................................................................................................................15

4) Alternate Seal Replacement ..................................................................................................................................16

f) Assembly .............................................................................................................................................................................16

1) Hydraulic Motor to Motor Housing Assembly .....................................................................................................16

g) Speed Sensing / Smart Vibrators .........................................................................................................................................17

CHAPTER 5 - PARTS DRAWIGS .....................................................................................................

............................................18

.TABLE OF COTETS

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CHAPTER 1
GEERAL IFORMATIO

a) Purpose of Vibration

The use of internal vibration is required to
improve the workability of low slump con­crete used in slip form paving. Low slump
concrete reduces edge slump conditions,
which allows the concept of slip form paving
to work. Also, lower slump concrete general­ly means a lower water to cement ratio, which
increases pavement strength. Vibration
increases the workability of concrete by flu­idizing it and helps to provide a smooth work­able surface. Equally important, it consoli­dates the concrete reducing entrapped air,
honey combing, cold jointing and other inter­nal flaws which would reduce pavement
strength.

b) Vibrator Positioning and Spacing

Proper positioning and operation of vibrators
in the paving slip form molds is important to
provide proper consolidation of the concrete.
Generally, the distance between vibrators
should be between 12 and 24 inches depend­ing on mix design, paver speed, vibrator speed
and numerous other factors.

The proper position of the vibrators should be
with their tips angled downward slightly and
as close to the center of the slab as possible.
With the vibrator tip angled down into the
center of the slab, the opening created by the
vibrator will have a tendency to fill with a
more uniform mixture. Also, the highly
vibrated concrete directly next to the vibrator
will be spread over a larger area reducing the
chance of localized over-vibration. The angle
also helps to increase the area vibrated by not
directing vibration straight down into the
subbase.

c) Vibrator Speed (VPM) Vibrations per

Minute

Historically, vibrator speed has been between
5,000 and 10,800 VPM, although in some
areas, the trend is to reduce speeds to

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between 5,000 and 8,000 VPM. As with
vibrator spacing, the optimum vibrator speed
depends on many factors. These include,
but are not limited to mix design, paver speed
and vibrator spacing. Regardless of what
optimum speed is required it is important to
closely monitor vibrator speed to ensure a
consistent quality and more uniformly
consolidated pavement.

d) Paver Travel Speed

Paver travel speed will affect consolidation.
If the paver speed is too high, the vibrators
may not be vibrating in the mix for a long
enough duration to adequately consolidate it.
If the paver travel speed is too slow, over­vibration will occur, driving entrained air out
and segregating the mix.

e) Mix Design and Slump

Mix design and slump have an influence on
concrete consolidation. A high slump concrete
will consolidate easier than a low slump
concrete. However, if the slump is too high
it will cause edge slump problems and lower
the strength of the concrete. If the mix
consists of fine aggregate and one size of large
coarse aggregate, it will be harder to
consolidate and finish the slab. It is
recommended to use a mix that uses at least
two aggregate sizes, one large and one small.
The smaller aggregate mixed in with the larger
aggregate will fill some of the larger voids,
thus making finishing and consolidation
easier.

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CHAPTER 2
VIBRATOR DESIG FUDAMETALS

a) Rotor

The rotor is the component that generates
vibration. A vibration impulse is generated
every revolution. It is essentially a shaft with
material removed from one side to create an
unbalance. The greater the unbalance, the
greater the centrifugal force that can be gener­ated. The following lists the potential cen­trifugal forces generated by the rotor at differ­ent speeds:

Speed

VPM Force 2000# 2500#

5,000………… 448 562
6,000………… 677 809
7,000………… 877 1,101
8,000………… 1,145 1,438

9,000………… 1,450 1,820
10,000………… 1,790 2,247
10,800………… 2,088 2,621

b) Bearing and Bearing Cups

Two bearings are located on each end of the
rotor. Each bearing is individually sealed and
lubricated with high temperature grease. The
bearings are separated from each other by a
shim, which prevents interaction between the
bearing outer races. The bearing inner races
and shims are clamped together on both ends
of the rotor using threaded components. The
bearings fit into high precision ground bearing
cups. The clearance between the bearing
outer diameters and the bearing cup inner
diameters is extremely small. A hardened cup
is permanently pressed into the head housing.
The other cup is slotted to prevent rotation
and it mates with the motor housing.

c) Hydraulic Motor

Forcing hydraulic oil through it operates the
Hydraulic Motor. The oil passes between two
gears, causing the output shaft to turn. The
output shaft is centered on the motor. A gear
is internally mounted on the output shaft and
mates with an idler gear. A lip seal assembly

is used to seal between the aluminum
hydraulic motor housing and the output shaft.
Controlling the oil flow through the motor can
control the motor speed.

d) Square Head Housing

The Square Head Housing has four flat sides
which are beneficial for transmitting vibration
to the mix. It supports the rotor through the
bearings and bearing cups. The external sur­faces are case hardened for wear resistance.

e) Oldham Style Drive Components

The components that transmit rotation from
the hydraulic motor to the rotor are of a
design known as Oldham drive. These com­ponents allow for a slight misalignment
between motor and rotor axes of rotation. The
output shaft from the hydraulic motor has two
flat parallel surfaces. These flat surfaces mate
with a slot in the driver. The driver also has
flat surfaces, which mates with the slot in the
driver sleeve. The driver sleeve screws on to
the end of the rotor. The drive slots are
located 90 degrees from each other. Small
amounts of misalignment are compensated for
with a small amount of relative motion
between the flats and the slots.

f) Vibration Isolator

The rubber vibration isolator is used to
reduce transmission of vibration to the mount­ing bar of the paver. It allows for a small
amount of relative motion required to create
vibration while maintaining support for the
vibrator.

g) Hydraulic Hoses and Quick Disconnects

Two hydraulic hose connections are required.
The pressure hose is the smaller diameter hose
and it supplies hydraulic oil to the vibrator.
The return hose is the larger diameter hose
and hydraulic oil exits through it. Quick
disconnects are used on the end of each
vibrator hose. Generally, the female quick
disconnect is attached to the pressure line.

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The quick disconnects can be attached to each
other when removed from the machine to
prevent contamination.

h) Protective Hoses and Plugs

A rubber protective hose surrounds the
hydraulic hoses leaving the vibrator,
preventing wear due to concrete abrasion.
This protective hose is attached to the vibrator
with hose clamps. A rubber plug supports the
hydraulic hoses where the hydraulic hoses
leave the vibrator, preventing it from rubbing
against metal. Another plug is located where
the hydraulic hoses leave the protective hose.
This plug primarily is used to prevent foreign
material from entering the protective hose.

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CHAPTER 3
ISTALLATIO AD OPERATIG
REQUIREMETS

a) Mounting Vibrators

See figure line art drawings for illustrations of
item numbers listed in parenthesis.

Angle bracket mounted vibrators are intended
to be mounted on a round bar having an
outside diameter of 2” to 2-7/8”. Generally
the vibrator tip should be angled downward 15
to 30 degrees. Attach the top clamp (23)
around the mounting bar and tighten the two
bolts (24), nuts (20) and lock washers (19).

Straight bracket mounted vibrators (page 9)
should be mounted with two isolators.

b) Hydraulic Hose Connection

The hydraulic hoses exiting the vibrator are
supplied with quick disconnects. Normally
the male quick disconnect is attached to the
pressure line, but this can vary. The smaller
diameter hose is the pressure. Always ensure
that these hoses are attached accordingly or
the oil seal in the hydraulic motor will fail
very quickly.

THE SEAL O THE HYDRAULIC
MOTOR WILL FAIL QUICKLY IF THE
HOSES ARE IMPROPERLY
COECTED.

ESURE THAT THE QUICK
DISCOECTS ARE CLEA PRIOR TO
ASSEMBLY OR LEAKAGE MAY
OCCUR. WHEEVER A VIBRATOR IS
OT COECTED TO A PAVER,
COECT THE PRESSURE AD
RETUR LIES TOGETHER TO AVOID
COTAMIATIO.

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IT IS IMPORTAT TO MIIMIZE THE
AMOUT OF HOSE COECTED TO
THE RETUR LIE. EXCESSIVE
AMOUTS OF RETUR HOSE WILL
ICREASE BACK PRESSURE O THE
HYDRAULIC MOTOR SEAL, CAUSIG
PREMATURE HYDRAULIC MOTOR
SEAL FAILURE.

c) Oil filtration

The hydraulic oil must be properly filtered to
ensure proper operation and to prevent wear
and damage due to contaminates.

IT IS IMPORTAT THAT THE
HYDRAULIC FLUID BE PROPERLY
FILTERED TO 10 MICRO ABSOLUTE
(ISO 17/13 FLUID CLEALIESS). OIL
THAT IS OT PROPERLY FILTERED
MAY CAUSE DAMAGE TO THE
HYDRAULIC MOTOR.

d) Vibrator Performance and Oil Supply

Oil Pressure

Oil pressure will vary depending on oil tem­perature, flow rate, oil viscosity and the
amount of hose connected between manifold
and vibrator. A vibrator in good condition
should operate with a pressure of 700 PSI to
1200 PSI at 4 GPM and 140° F.

Temperature

The hydraulic oil temperature should be
maintained between 100° F and 180° F
with 140° F being optimum.

UDER 100°F, EXCESSIVE PRESSURE
IS REQUIRED TO OPERATE THE
VIBRATOR AT ORMAL SPEEDS.
TEMPERATURES ABOVE 196° F

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the most. The rule then can be read giving the
operating speed.

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COULD CAUSE SERIOUS DAMAGE.
WHE EXCESSIVE TEMPERATURES
ARE ECOUTERED, FOLLOW THE
PAVER MAUFACTURIG RECOM­MEDATIOS TO REMEDY THE
SITUATIO.

Flow Rate

The flow rate of the hydraulic oil through the
vibrator directly affects the speed of the vibra­tor. When the flow is increased or decreased
the vibrator speed increases or decreases,
respectively. Oil temperature, oil viscosity
and the condition of the vibrator can affect the
relationship between flow and vibrator speed.
Typical vibrator speed at 4 GPM is approxi­mately 10,800 VPM and typical vibrator
speed at 3 GPM is approximately 8,100 VPM.

e) Trouble Shooting

To aid in trouble shooting the following tools
are available from Wyco Tool:

Hydraulic Test Kit

(Wyco PN 419850)

This kit can measure pressure and flow in
either the pressure or return line of the
vibrator. It mates with the standard vibrator
quick disconnects.

Vibrating Reed-Type Tachometer
(Wyco PN 419855)

This is a reed type tachometer that quickly
measures vibration speed when put in contact
with the rubber protective hose close to the
vibrator. When put in contact, the reed that
vibrates the most is the operating speed.

Slide Rule Tachometer
(Wyco PN 001000)

This is a less expensive alternative to the
tachometer above. It is slightly more
difficult to use and more fragile, but it will
provide an accurate reading. When put in
contact with the rubber protective hose near
the vibrator, a wire is extended until it deflects

TROUBLE SHOOTIG CHART

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Trouble Possible Causes Solutions

Vibrator not running 1) Required oil flow and pressure not supplied 1) Supply required oil flow and pressure

2) Failed bearings 2) Replace eccentric bearings per Chapter 4,
Section c

3) Hydraulic motor locked up 3) Replace hydraulic motor per Chapter 4,
Section e

Vibrator running slow 1)Vibrator head full of oil 1) Replace hydraulic motor shaft seal per Chapter 4,

Section d and bearings per Chapter 4, Section c

2) Required oil flow and pressure not supplied 2) Supply required oil flow and pressure; Check
pressure setting on relief valve

3) Hydraulic motor worn internally 3) Remove and replace hydraulic motor

Oil found in protective hose 1) Hydraulic hose connections loose near vibrator 1) Check NPT threads, apply Teflon tape and tighten

2) Hydraulic hose or hose fittings damaged 2) Replace damaged hose or hose fittings

3) Hydraulic motor shaft seal leaking and seal 3) Replace hydraulic motor shaft seal per Chapter 4,

around outside of motor also leaking Section d and replace seal on outside of motor

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