Wacker Neuson AR 75/9/042 User manual

Operator’s manual

External vibrator

AR

2, 3, 4, 5, 6, 7

06.2013

5100002209en / 003

Manufacturer

Wacker Neuson Produktion GmbH & Co. KG

Preußenstraße 41

80809 München

www.wackerneuson.com

Tel.: +49-(0)89-354 02-0

Fax: +49-(0)89-354 02-390

Translation of the original operator's manual in German

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1 Foreword ....................................................................................................................7

2 Introduction ...............................................................................................................8

2.1 Use of the manual.......................................................................................................... 8

2.2 Storing the manual......................................................................................................... 8

2.3 Accident prevention regulations..................................................................................... 8

2.4 Further information......................................................................................................... 8

2.5 Target group................................................................................................................... 9

2.6 Symbol explanation...................................................................................................... 10

2.7 Wacker Neuson representative.................................................................................... 11

2.8 Limitation of liability...................................................................................................... 11

2.9 Identification of the machine ........................................................................................ 12

3 Safety .......................................................................................................................13

3.1 Principle ....................................................................................................................... 13

3.2 Proper use.................................................................................................................... 13

3.3 Structural modifications................................................................................................ 14

3.4 Operator responsibility................................................................................................. 14

3.5 Operating company responsibilities............................................................................. 14

3.6 Personnel qualification................................................................................................. 15

3.7 General sources of danger........................................................................................... 16

3.8 General safety information........................................................................................... 17

3.8.1 Safety in the workplace................................................................................... 17

3.8.2 Service............................................................................................................ 17

3.8.3 Safety of people.............................................................................................. 17

3.8.4 Handling and use............................................................................................ 18

3.9 Electrical safety............................................................................................................ 19

3.9.1 Electric power supply for electrical appliances of protection class I+III .......... 20

3.9.2 Extension cable and cable drum..................................................................... 20

3.10 Specific safety information – external vibrators............................................................ 21

3.10.1 Operating safety.............................................................................................. 21

3.11 Safety when using formworks...................................................................................... 22

3.11.1 Use stable formwork ....................................................................................... 22

3.11.2 Formwork and safety belt................................................................................ 22

3.12 Personal protective gear.............................................................................................. 23

3.13 Safety devices.............................................................................................................. 24

3.14 Safeguarding against switching back on...................................................................... 24

3.15 How to act in dangerous situations.............................................................................. 25

4 Safety and information labels ................................................................................26

5 Scope of delivery ....................................................................................................27

6 Structure and function ...........................................................................................28

6.1 Field of application....................................................................................................... 28

Table of contents

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6.2 Brief description............................................................................................................ 28

6.3 Variants ........................................................................................................................ 29

7 Components and operator's controls ...................................................................30

7.1 AR 2.............................................................................................................................. 30

7.2 AR 3.............................................................................................................................. 31

7.3 AR 4.............................................................................................................................. 32

7.4 AR 5.............................................................................................................................. 33

7.5 AR 6.............................................................................................................................. 34

7.6 AR 7.............................................................................................................................. 35

8 Transport and storage ............................................................................................36

8.1 Safety ........................................................................................................................... 36

8.2 Transport preparation................................................................................................... 36

8.3 Transporting the machine............................................................................................. 36

8.4 Storage......................................................................................................................... 37

9 Installation ...............................................................................................................38

9.1 Safety ........................................................................................................................... 38

9.2 Before installation......................................................................................................... 38

9.2.1 AR 2, 3, 4 Installation – power cable............................................................... 39

9.2.2 AR 5, 6, 7 Installation – power cable............................................................... 41

9.2.3 Wiring diagram ................................................................................................ 43

10 Use and operation ...................................................................................................44

10.1 Safety ........................................................................................................................... 44

10.2 Prior to starting the machine......................................................................................... 44

10.2.1 Checks before startup ..................................................................................... 44

10.2.2 Checking the mains......................................................................................... 45

10.3 Fitting the machine....................................................................................................... 46

10.3.1 Before fitting .................................................................................................... 46

10.3.2 Hole pattern..................................................................................................... 47

10.3.3 Fastening material requirements..................................................................... 48

10.4 Electrical connection..................................................................................................... 49

10.4.1 Connecting to a generator............................................................................... 49

10.4.2 Connecting to mains power............................................................................. 49

10.5 Switching on the machine............................................................................................. 50

10.6 Switching off the machine............................................................................................. 50

10.7 Activities after use ........................................................................................................ 50

11 Maintenance ............................................................................................................51

11.1 Safety ........................................................................................................................... 51

11.2 Maintenance personnel qualifications .......................................................................... 51

11.3 Maintenance schedule.................................................................................................. 52

11.4 Cleaning the machine................................................................................................... 52

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11.5 Lubricate machine........................................................................................................ 53

12 Troubleshooting ......................................................................................................54

12.1 Safety........................................................................................................................... 54

12.2 Table – malfunctions.................................................................................................... 54

13 Disposal ...................................................................................................................55

13.1 Disposal of waste electrical and electronic equipment................................................. 55

14 Accessories .............................................................................................................56

14.1 Fastening clamps......................................................................................................... 56

15 Technical data .........................................................................................................57

15.1 Performance data......................................................................................................... 57

15.1.1 AR 26.............................................................................................................. 57

15.2 Extension cable............................................................................................................ 61

16 Technical data .........................................................................................................63

16.1 Performance data......................................................................................................... 63

16.1.1 AR 34.............................................................................................................. 63

16.2 Extension cable............................................................................................................ 67

17 Technical data .........................................................................................................69

17.1 Performance data......................................................................................................... 69

17.1.1 AR 4................................................................................................................ 69

17.2 Extension cable............................................................................................................ 71

18 Technical data .........................................................................................................73

18.1 Performance data......................................................................................................... 73

18.1.1 AR 52.............................................................................................................. 73

18.1.2 AR 53.............................................................................................................. 74

18.1.3 AR 54.............................................................................................................. 76

18.2 Extension cable............................................................................................................ 77

19 Technical data .........................................................................................................79

19.1 Performance data......................................................................................................... 79

19.1.1 AR 62.............................................................................................................. 79

19.1.2 AR 63.............................................................................................................. 81

19.1.3 AR 64.............................................................................................................. 82

19.2 Extension cable............................................................................................................ 84

20 Technical data .........................................................................................................86

20.1 Performance data......................................................................................................... 86

20.1.1 AR 75.............................................................................................................. 86

20.2 Extension cable............................................................................................................ 90

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21 Glossary ...................................................................................................................92

Declaration of Incorporation ..................................................................................95

Declaration of Incorporation ..................................................................................97

Declaration of Incorporation ..................................................................................99

Declaration of Incorporation ................................................................................101

Declaration of Incorporation ................................................................................103

Declaration of Incorporation ................................................................................105

Declaration of Incorporation ................................................................................107

Declaration of Incorporation ................................................................................109

Declaration of Incorporation ................................................................................111

DIN EN ISO 9001 Zertifikat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1 Foreword

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1Foreword

This operator's manual contains information and procedures for the safe opera-

tion and maintenance of your Wacker Neuson machine. In the interest of your

own safety and to prevent accidents, you should carefully read through the safety

information, familiarize yourself with it and observe it at all times.

This operator's manual is not a manual for extensive maintenance and repair

work. Such work should be carried out by Wacker Neuson service or authorized

specialists.

The safety of the operator was one of the most important aspects taken into con-

sideration when this machine was designed. Nevertheless, improper use or in-

correct maintenance can pose a risk. Please operate and maintain your Wacker

Neuson machine in accordance with the instructions in this operator's manual.

Your reward will be troublefree operation and a high degree of availability.

Defective machine parts must be replaced immediately!

Please contact your Wacker Neuson representative if you have any questions

concerning operation or maintenance.

No part of this publication may be reproduced in any form or by any means, elec-

tronic or mechanical, including photocopying, without the expressed written per-

mission of Wacker Neuson.

Any type of reproduction, distribution or storage on data media of any type and

form not authorized by Wacker Neuson represents an infringement of copyright

and will be prosecuted.

We expressly reserve the right to make technical modifications – even without

special notice – which aim at further improving our machines or their safety stan-

dards.

2 Introduction

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2 Introduction

2.1 Use of the manual

This manual is considered as part of the machine and must be kept in a safe

place throughout the entire lifecycle. This manual must be handed over to every

subsequent owner or user of the machine.

2.2 Storing the manual

This manual is part of the machine and must be stored in the immediate vicinity

of the machine and be available to staff at all times.

In the case of loss or if a second copy of this manual is required, there are two

options for obtaining a replacement:

 Download from the Internet - www.wackerneuson.com

 Contact your Wacker Neuson representative.

2.3 Accident prevention regulations

Local accident prevention regulations and national occupational safety provi-

sions apply in addition to the notes and safety information contained in this man-

ual.

2.4 Further information

This manual is valid for different machine types from a product range. As such,

some illustrations may differ from the appearance of your machine. Variant-de-

pendent components may also be described that are not included in the delivery.

The information contained in this manual is based on machines which have been

manufactured at the time of printing. Wacker Neuson reserves the right to amend

this information without notification.

It must be ensured that any potential amendments or supplements from the man-

ufacturer are included immediately in this manual.

2 Introduction

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2.5 Target group

Note: Persons working with this machine must receive regular training about the

risks and hazards of this machine.

This operator's manual is aimed at the following persons:

Operatives:

These persons are introduced to the machine and informed about potential haz-

ards arising from improper behavior.

Specialist staff:

These persons have specialist training, as well as additional knowledge and ex-

perience. They are able to assess the tasks entrusted to them and recognize po-

tential risks and hazards.

2 Introduction

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2.6 Symbol explanation

This manual contains prominent safety information relating to category types:

DANGER, WARNING, CAUTION and NOTE.

Before commencing any work on or with this machine, notes and safety informa-

tion must be read and understood. All notes and safety information contained in

this manual must also be shared with maintenance, repair, and transport staff.

Notes

Note: Further information.

DANGER

This combination of symbol and signal word indicates a hazardous situation,

which, if ignored, will lead to death or serious injuries.

WARNING

This combination of symbol and signal word indicates a hazardous situation,

which, if ignored, may lead to death or serious injuries.

CAUTION

This combination of symbol and signal word indicates a potentially hazardous

situation, which, if ignored, may lead to minor injuries and damage to the ma-

chine.

2 Introduction

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2.7 Wacker Neuson representative

Depending on your country, the Wacker Neuson representative is a Wacker

Neuson service, a Wacker Neuson affiliate or a Wacker Neuson dealer.

On the Internet at www.wackerneuson.com.

The address of the manufacturer is located at the beginning of this manual.

2.8 Limitation of liability

Wacker Neuson will refuse to accept liability for injuries to persons or for damage

to materials in the following cases:

 Failure to comply with this manual.

 Improper use.

 Use of untrained staff.

 Use of non-authorized spare parts and accessories.

 Improper handling.

 Any type of structural alteration.

 Non-compliance with with the General Terms and Conditions of Business

(T&C).

2 Introduction

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2.9 Identification of the machine

Nameplate data

The nameplate lists information that uniquely identifies this machine. This infor-

mation is needed to order spare parts and when requesting additional technical

information.

X Enter details on the machine in the following table:

Item Designation Your information

1 Group and type

2 Construction year

3 Machine no.

4 Version no.

5 Item no.

3 Safety

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3 Safety

3.1 Principle

State of the art

This machine has been constructed with state-of-the-art technology according to

the recognized rules of safety. However, improper use can pose a risk to life and

limb of the user and/or third parties, or cause damage to the machine and other

equipment.

3.2 Proper use

This machine, depending on its type, can be used only for the excitation of all

types of molds and formworks, vibratory tables, vibratory stands, compaction of

fresh concrete and for mounting on conveyor belts (silo).

Other special applications must be checked and released by Wacker Neuson.

Proper use also includes the observance of all notes and safety information

contained in this manual, as well as complying with the prescribed service and

maintenance instructions.

Any other use is regarded as improper.

Any damage resulting from improper use will void the warranty and the liability

on behalf of the manufacturer. The operator assumes full responsibility.

Misuse particularly applies to:

 Immersing the machine in fresh concrete.

 Using the machine and the components of this machine as climbing aids.

 Failure to observe instructions for vibratory tables, frequency converters, etc.

NOTE

Notes and safety information in this chapter apply to all machine types de-

scribed in this manual.

3Safety

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3.3 Structural modifications

Structural modifications must not be undertaken without the written consent of

the manufacturer. Structural changes without the consent of the manufacturer

can pose a risk to users and/or third parties, and also damage the machine.

The manufacturer's liability and warranty will also cease in the event of

unauthorized structural modifications.

Especially the following are cases of structural modifications:

 Opening the machine and the permanent removal of components.

 Installing components that do not originate from Wacker Neuson and are not

equivalent in terms of design and quality to the original components.

 The addition of any type of accessory that does not originate from Wacker

Neuson.

3.4 Operator responsibility

The operator is the person who operates this machine for commercial or eco-

nomic purposes, or who hands it over for use/application by a third party, and

who bears legal product responsibility during operation for the protection of staff

or third parties.

The operating company must make the manual available to staff at any time and

ensure that operatives have read and understood the manual.

3.5 Operating company responsibilities

 Know and implement applicable occupational safety provisions.

 Investigate dangers in a risk assessment based on working conditions at the

site.

 Produce operating instructions for this machine.

 Regularly check that the operating instructions are up-to-date with the latest

guidelines.

 Clearly regulate and specify responsibilities for installation, use, trouble-

shooting, maintenance and cleaning.

 Train staff at regular intervals and inform them about potential hazards.

 Provide staff with the required protective gear.

3 Safety

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3.6 Personnel qualification

This machine may only be operated and used by trained staff.

Incorrect application, misuse or use by untrained staff threaten the health of the

users and/or third parties and risk damaging the machine or causing a failure.

The following requirements also apply to the user:

 Physically and mentally fit.

 Reactions not impeded by drugs, alcohol or medication.

 Familiarity with the safety information in this manual.

 Familiarity with correct operation of this machine.

 The minimum age to use the machine has been reached.

 Instructed in how to operate the machine independently.

3Safety

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3.7 General sources of danger

The following section lists dangers based on the risk assessment. Residual risks

are particular risks associated with handling machinery which, despite compli-

ance with the standards of safe construction, cannot be eliminated.

Residual risks are not obviously recognizable and can be the source of a poten-

tial injury or risk to health.

If unforeseeable residual risks occur, the machine must be switched off immedi-

ately and the competent manager informed. The manager will make further de-

cisions and do everything necessary to eliminate the risk.

The manufacturer of the machine must be informed if necessary.

DANGER

Risk of fatal injury from electrical voltage!

There is an immediate danger to life from touching live parts. Damaged

insulation or individual parts can be dangerous to life.

Therefore:

X If the insulation is damaged, immediately disconnect the power supply and

arrange repair work.

X Only allow qualified electricians to perform work on the electrical system.

X The electrical system must be disconnected from the mains power and test-

ed to ensure no voltage.

X The power supply must be switched off before maintenance, cleaning and

repair work and fused before being switched on again.

X Do not bypass fuses or decommission. Use the correct number of amps

when changing fuses.

X Protect live parts from wet conditions. Danger due to short circuit.

WARNING

Noise-induced hearing damage!

Noise in the area where work is performed can cause serious hearing damage.

Therefore:

X Suitable ear protection must be worn during all work that generates noise.

X Only remain in the danger zone for as long as is necessary.

WARNING

Heat-induced risk of burning!

The machine can become extremely hot during long use and cause burns on

contact with skin.

Therefore:

X Allow the machine to cool down after use.

X If the cooling down stage cannot be complied with (e.g. in an emergency),

always wear heat-resistant gloves.

3 Safety

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3.8 General safety information

The safety information in this chapter contain the "General Safety Information",

which must be listed in the manual in accordance with applicable standards.

Information may be included that does not apply to this machine.

3.8.1 Safety in the workplace

 Keep work space tidy. Untidy or unlit work spaces can lead to accidents.

 Working with this machine in an explosive environment is forbidden. Electri-

cal tools produce sparks, which can ignite dust or vapor.

 Keep children and other persons away from work performed on this machine.

Distraction while using the machine can cause loss of control.

 Working with this machine among dry vegetation is forbidden. Danger of fire!

 Always secure the machine against tipping over, rolling, sliding, and falling.

Danger of injury!

3.8.2 Service

 Machine must only be repaired or maintained by qualified specialist staff.

 Only use original replacement parts and accessories. This ensures that the

operational safety of the machine is maintained.

3.8.3 Safety of people

 Working under the influence of drugs, alcohol or medication can lead to seri-

ous injuries.

 Suitable protective gear must be worn for all work. Suitable protective gear

significantly minimizes the risk of injury.

 Ensure that the machine is switched off before connecting to a power source.

Unintended setup can lead to serious injuries.

 Remove tools before starting up the machine. A tool left on a moving part

could be hurled out and lead to serious injuries.

 Always ensure your position is safe.

 Wear suitable clothing. Keep loose or baggy clothing, gloves, jewelry, and

long hair away from moving or rotating parts. Risk of entanglement!

NOTE

All notes and safety information in this manual must be read and complied with.

Failure to comply with these instructions can result in electric shock, fire and/or

serious injuries, damage to the machine, and/or damage to other objects. Keep

safety information and notes for future reference.

3Safety

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3.8.4 Handling and use

 Do not exceed the operating limits of the machine or allow it to operate for

longer periods. Risk of damage to the machine.

 Never start up machines with defective switches. Replace defective switches

immediately. Machines with defective switches conceal a high risk of injury.

 Avoid unintended machine startup. Remove plug from plug receptacle before

making adjustments to the machine settings. Unintended startup can lead to

serious injuries.

 Keep unused machines out of reach of children. Machine may only be used

by trained staff.

 Handle machine with care. Replace defective parts immediately before start-

ing up this machine. Defective machines conceal a high accident risk.

 Use the machine, accessories, tools, etc., in accordance with these

instructions.

3 Safety

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3.9 Electrical safety

The safety information in this chapter contain the "General Safety Informations",

which must be listed in the manual in accordance with applicable standards.

Information may be included that does not apply to this machine.

 Machine connector plug must fit plug receptacle. Connector plug must not be

altered in any way. Do not use adapter plugs with grounded machines. Unal-

tered plugs and plug receptacles minimize the risk of electric shock.

 Avoid body contact with grounded surfaces. There is an increased risk of

electric shock if the body is grounded.

 Keep machine away from wet conditions. Penetrating moisture increases the

risk of electric shock.

 Do not use cables other than for their intended purpose. Protect cables from

heat, oil, and sharp objects. Damaged or tangled cables increase the risk of

electric shock.

 When working outdoors, only use cables suitable for outdoor spaces. Using

a cable for outdoor spaces minimizes the risk of electric shock.

 A fault current protective switch must be used if working in a damp environ-

ment cannot be avoided. Fault current protective switches minimize the risk

of electric shock.

 Safety devices, switches, or easily damaged parts must be checked to

ensure that they are functioning perfectly and according to regulations before

this machine is used. Defective safety devices conceal a high risk of injury

and must be replaced immediately by specialist staff.

NOTE

All notes and safety information in this manual must be read and complied with.

Failure to comply with these instructions can result in electric shock, fire and/or

serious injuries, damage to the machine, and/or damage to other objects. Keep

safety information and notes for future reference.

NOTE

The rated voltage is located on the nameplate of this machine.

Observe relevant national safety regulations!

3Safety

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3.9.1 Electric power supply for electrical appliances of protection class I+III

This machine must be in perfect condition before it is connected to an electric

power supply. The following parts must be particularly checked for damage

before use.

 Plug.

 Entire length of power cable.

 Power cable.

One of the following safety devices must be present when connecting to local or

mobile power generators:

 Transformer with safe separation.

 Motor generator with equally separated windings.

3.9.2 Extension cable and cable drum

Compliance with the following points is required to minimize the risk of injury, fire,

electric shock, and material damage:

 Extension cables and cable drums must be checked and undamaged.

 Only use extension cables with grounded conductor and grounded conductor

connection on plug and coupling.

 Only use extension cables and cable drums that are tested and suitable for

use on the construction site.

 Damaged extension cables and cable drums must not be used and must be

replaced immediately.

 Cable drums and multiple plug sockets must display the same requirements

as extension cables.

 Protect extension cables, cable drums, multiple plug sockets and connection

couplings from wet conditions.

 Extension cables and cable drums must be fully unwound before startup.

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