FLEXIBLE DRIVE POKER MANUAL

Transcription

1 FLEXIBLE DRIVE POKER MANUAL Technical Data Parts manual Product manual PM.02/03 Design File DF.02/03 Customs Tariff Codes Product Spares Poker Drive Units Petrol Poker Drive Units Diesel Poker Drive Units Assembled Flexible drive pokers GCM Ltd Ratcliffe Buildings, Tuttle Hill, Nuneaton, Warwickshire, United Kingdom. CV10 0GA Tel: 0044(0) Fax: 0044(0) Website: Dealer Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 1

2 WARRANTY We warrant that the product is free from defects in materials and workmanship. If such a fault is found within six months from date of purchase from an approved dealer, the company will replace free of charge all failed components. Any failed unit must be returned carriage paid to the factory for inspection. The warranty does not cover failure attributable to wear and tear, accidental damage, site or operator misuse or lack of maintenance. We will not accept units under warranty that third parties have attempted to repair or disassembled Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 2

3 Page Index Contents 2 Warranty 3 Index 4 Declaration of Conformity 5 Poker and Coupling Specification 6 Operating Instructions SAFETY NOTICE 7 Poker Specifications / Part Numbers 8 6 mtr 9 x 25 9 x 22 Flexible Drive Parts List and Illustration 9 6 mtr 13 x 32 & 15 x 35 Flexible Drive Parts List and Illustration 10 6 mtr 13 x 32 c/w sleeve Flexible Drive Parts List and Illustration 11 Claw, Warsop, Errut, Australian Metrix, Tremix, Macfab, JMA Coupling Parts List and Illustration 12 Fyne Coupling, Joiners and Interconnectors/Extension Drives Parts List and Illustration 13 Tag Coupling Parts List and Illustration 14 VB mm Poker Parts List and Illustration 15 VT mm Poker Parts List and Illustration 16 CE Diesel Frame Parts List and Illustration 17 Standard Diesel Frame Parts List and Illustration 18 Rubber Based Swivel Petrol Frame Parts List and Illustration 19 Sledge Petrol Frame Parts List and Illustration 20 Standard Petrol Frame Parts List and Illustration 21 CE Petrol Frame Parts List and Illustration Frame Electric Parts List Frame Electric Parts List cont. and Illustration 24 Claw, Warsop, Fyne, Metrix Parts List 25 Mikassa, Hayashi and Hexagon Parts Lists 26 Claw, Warsop, Fyne, Metrix Parts List cont and Illustration 27 VB 26/32 mm Poker Head Dismantling and Assembly Procedure 28 VT 40/45/50/60/75 Poker Head Dismantling and Assembly Procedure 29 Flexible Drive Servicing Procedure 30 Flexible Drive Servicing Procedure cont 31 Modification Record Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 3

4 EC DECLARATION OF CONFORMITY (STATIC MACHINES) We Declare under our sole responsibility that the product(s) VT AND VB FLEXIBLE DRIVE CONCRETE VIBRATORS To which this certificate relates is in conformity with the following directives Supply of Machinery (Safety Regulations) 1992 (SI 1992/3073) Supply of Machinery (Safety) (Amendment) 1994 (SI 1994/2063) Safety of Machinery BS EN292-1&2 1991, BS EN , BS EN , BS EN , BS EN , BS EN , BS EN BS EN , BS /392/EEC Machines Directive 93/44/EEC & 93/68/EEC Amendment to Machines Directive This equipment must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the above mentioned directive. Certified by Date Thursday, November 22, 2007 David Aston General Manager Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 4

5 POKER AND DRIVE SPECIFICATION Model VB26 VB32 VB40 VT40 VT45 VT50 VT60 VT60 VT75 VT75 Head Diameter mm Head Length mm Head Weight kg Frequency VPM Amplitude Half Tip Acceleration G Radius of effectiveness Drive Length mtr Shaft Diameter mm Cover Diameter mm Drive Weight Unit weight c/w Claw Coupling Kg Output m³/r Vibration 1 Mtr from head 9.88m/s² 9.58m/s² 9.58m/s² 28.70m/s² 18.10m/s² 19.10m/s² 30.60m/s² 30.60m/s² 17.90m/s² 17.90m/ s² Vibration reading taken when plugged into poker drive unit, I mtr from poker head, the measurement was weighted acceleration magnitudes in all three axis simultaneously. POKER/DRIVE/COUPLING SPECIFICATION COUPLING SPECIFICATION Coupling Weight Housing Claw 2.00 kg 60 mm Metrix 0.92 kg 48.5 mm Fyne/Norton 1.40 kg 1 7/8 Warsop/Fairport 2.22 kg 65 mm Macfab JMA Tremix Specification Part Number Weight 26 mm Poker 9 x 25 Drive Claw Coupling kg 32 mm Poker 9 x 25 Drive Claw Coupling kg 40 mm Poker 9 x 25 Drive Claw Coupling kg 40 mm Poker 13 x 32 Drive Claw Coupling kg 45 mm Poker 13 x 32 Drive Claw Coupling kg 50 mm Poker 13x 32 Drive Claw Coupling kg 50 mm Poker 13 x 32 Drive c/w Sleeve Claw Coupling mm Poker 13 x 32 Drive Claw Coupling kg 60 mm Poker 15 x 35 Drive Claw Coupling kg 60 mm Poker 13 x 32 Drive c/w Sleeve Claw Coupling mm Poker 15 x 35 Drive Claw Coupling kg 75 mm Poker 13 x32 Drive c/w Sleeve Claw Coupling kg 0.92 kg 2.22 kg Errut 1.74 kg 60 mm TAG COUPLING SPECIFICATION Coupling Weight Housing Tag Campbell Harvey 0.70 kg 46.8 mm 10 mm Hexagon GCM Tag 0.70 kg 46.8 mm 10mm Hexagon CEL Square 0.70 kg 46.8 mm 7/16 Square SMG Tag 0.34 kg 34.9 mm Semi Cicular Mikassa 0.41 kg 44.0 mm 5/16 Hexagon Hayashi 0.56 kg 39.8 mm 10 mm Hexagon Dynapac Maximum Noise Levels Power Unit & Poker Poker Hatz Honda 26 mm 93 d B (A) 83 d B (A) 32 mm 93 d B (A) 83 d B (A) 40 mm VB 93 d B (A) 83 d B (A) 40 mm VT 92 d B (A) 82 d B (A) 45 mm 92 d B (A) 82 d B (A) 50 mm 92 d B (A) 82 d B (A) 60 mm 92 d B (A) 82 d B (A) 75 mm 92 d B (A) 82 d B (A) Noise levels vary subject to weather conditions, background noise etc Always wear noise protective gear 0.70 kg Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 5

6 OPERATING INSTRUCTIONS IMPORTANT SAFETY INFORMATION READ THIS MANUAL BEFORE OPERATING VIBRATORS. IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PLACE THE INFORMATION IN THIS MANUAL INTO THE HANDS OF THE OPERATOR 1. The VB and VT Flexible Drive immersion Vibrators are precision tools manufactured specifically for hand compaction of wet concrete. 2. Always wear eye protection when operating this vibrator. 3. Always wear ear protection when operating this vibrator. 4. The vibrator must be free to vibrate and not become trapped between shuttering and reinforcements. 5. Always operate, inspect and maintain this vibrator in accordance with all regulations (local, state, federal and country) which may apply to hand operated tools. 6. The vibrator head must not be held under any circumstances, when holding the vibrator always hold by the drive as near the power source as possible. 7. Excessive vibration, repetitive motions or uncomfortable positions are harmful to your hands and arms. Stop using the vibrator if discomfort, tingling feeling or pain occurs. Seek medical advice before resuming use. 8. Always read motor manual before using equipment and observe all safety recommendations in engine/motor manual. 9. DISCONNECT ELECTRICAL SUPPLY BEFORE SERVICING UNITS 10. ONLY A QUALIFIED ELCTICIAN MAY SERVICE ELECTRIC DRIVE UNITS OPERATING INSTRUCTIONS 1. Do keep the flexible drive shaft as straight as possible and ensure that it does not twist or knot. 2. Never engage a poker vibrator drive to an engine that is running. Many accidents have been caused because operators have not switched off the engine. 3. When vibrating concrete avoid leaving poker vibrators in the same place for excessive periods. 4. When concrete vibration is finished switch off the machine. 5. The vibrator should not be laid on the ground and left running while waiting for the next batch of concrete, it will overheat the bearings 6. Never leave the vibrator drive hung over scaffolding or such resting places. 7. Do not drive over the flexible drive 8. Never drag the power unit around the site by the flexible drive. 9. Never run the poker vibrator at speeds in excess of 3000 rpm, this will cause the vibrator to fail. Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 6

7 POKER SPECIFICATIONS Specification Claw Warsop Fyne Errut No Coupling JMA Metrix 26 mm 9 x mm 9 x mm 9 x mm 13 x mm 13 x mm 13 x mm 13 x 32 c/w sleeve mm 15 x mm 13 x mm 13 x 32 c/w sleeve mm 15 x mm 13 x mm 13 x 32 c/w sleeve mm 15 x Specification SMG POKER SPECIFICATIONS Tremix Hexagon Hayashi Mikassa CEL Square Macfab 26 mm 9 x mm 9 x mm 9 x mm 13 x mm 13 x mm 13 x mm 13 x 32 c/w sleeve mm 15 x mm 13 x mm 13 x 32 c/w sleeve mm 15 x mm 13 x mm 13 x 32 c/w sleeve mm 15 x Pokers with Rubber Nose Caps change third digit to 3 Different lengths change suffix 6000 = 6 mtr, 5000 = 5 mtr Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 7

8 NB 9 x 22 mm Drive has now been replaced by 9 x 25 which is interchangeable as an assembly Mikassa conversion Cover is standard, shaft has different shaft connection and tag FLEXIBLE DRIVE PARTS LIST (Drawing ) Item Description Qty 9 x 22 9 x mtr Drive Complete mtr Drive Complete mtr Drive Complete Retaining Washer a Retaining Washer to suit Mikassa Hexagon Tag a Hexagon Tag to suit Mikassa Shaft Connection a Shaft Connection to suit Mikassa Cover Adaptor Poker End Cover Adaptor Motor End Nitrile O Ring 70/80 SRDH Cover Spring Grease BP Lithium LS3 As Req mtr Cover c/w Cover Adaptors mtr Cover c/w Cover Adaptors mtr Cover c/w Cover Adaptors a 4 mtr Cover w/o Cover Adaptors a 5 mtr Cover w/o Cover Adaptors a 6 mtr Cover w/o Cover Adaptors mtr Shaft c/w shaft connections mtr Shaft c/w shaft connections mtr Shaft c/w shaft connections a 4 mtr Shaft w/o connections a 5 mtr Shaft w/o connections a 6 mtr Shaft w/o connections b Shaft c/w shaft connections to suit Mikassa Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 8

9 FLEXIBLE DRIVE PARTS LIST (Drawing /1011) Item Description Qty 13 x x mtr Drive Complete mtr Drive Complete mtr Drive Complete Retaining Washer a Retaing Washer to suit Mikassa Hexagon Tag a Hexagon Tag to suit Mikassa Shaft Connection ( One on Mikassa) a Shaft Connection to suit Mikassa Cover Adaptor Poker End Cover Adaptor Motor End Cover Spring Grease BP Lithium LS3 As Req mtr Cover c/w Cover Adaptors mtr Cover c/w Cover Adaptors mtr Cover c/w Cover Adaptors a 4 mtr Cover w/o Cover Adaptors a 5 mtr Cover w/o Cover Adaptors a 6 mtr Cover w/o Cover Adaptors mtr Shaft c/w shaft connections mtr Shaft c/w shaft connections mtr Shaft c/w shaft connections a 4 mtr Shaft w/o connections a 5 mtr Shaft w/o connections a 6 mtr Shaft w/o connections b Shaft c/w shaft connections to suit Mikassa Cover Adaptor Washer Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 9

10 FLEXIBLE DRIVE PARTS LIST (Drawing ) Item Description Qty 6 mtr 13 x 32 c/w Sleeve 400 Drive Complete Retaining Washer Hexagon Tag Shaft Connection Cover Adaptor Poker End Cover Adaptor Motor End Cover Spring Grease BP Lithium LS3 As Req Cover c/w Cover Adaptors a Cover w/o Cover Adaptors Shaft c/w shaft connections a Shaft w/o connections Cover Adaptor Washer Rubber Sleeve 45mm x 35mm x 1mtr Cover Sleeve Reducer Band-It Buckle C mm a Band it Strapping C mm Black Silicon Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 10

11 Claw Metrix The Claw Coupling is the industry standard. This coupling is interchangeable with CEL, Sovemat, Dynapac, Winget, Wacker, GCM, GCM/Bartell, Seddon Johnson. COUPLINGS (Left Hand Illustration) Item Description Qty Claw Warsop Errut Australian Body Diameter 60 mm 65 mm 60 mm 60 mm 500 Assembly Housing Spindle Spacer Bearing RS Circlip Adaptor COUPLINGS (Right Hand Illustration) Item Description Qty Metrix Tremix Macfab JMA Body Diameter 48.5 mm 59.8 mm 500 Coupling Housing Spindle Spacer Claw Bearing RS Circlip Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 11

12 INTERCONNECTOR COUPLINGS Item Description Qty Metrix 500 Coupling Housing Spindle Spacer Claw Bearing RS Circlip Adaptor Spindle Adaptor O Ring Adaption to fit 26 and 32mm poker onto a 13 x 32mm Poker Drive (Not Recommended) Item Description Qty Spindle Adaptor 1 Cover Adaption 1 Part No FYNE COUPLING Item Description Qty Metrix Body Diameter 1 7/8 500 Assembly Housing Spindle Spacer Claw Bearing RS Circlip Screw Repair Joiner/Sleeve Item Description Reference 550a 8 mm Shaft Sleeve b 9 mm Shaft Sleeve c 12 mm Shaft Sleeve d 13 mm Shaft Sleeve a 22 mm Cover Sleeve b 25 mm Cover Sleeve c 32 mm Cover Sleeve d 35 mm Cover Sleeve Extension Drives Item Description 13 x x mtr Extension Drive c/w Tag and Washer a 6 mtr Extension Drive c/w Tag and Washer b 9 mtr Extension Drive c/w Tag and Washer Interconnector Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 12

13 TAG COUPLINGS 9 X 25 DRIVES Item Description Qty CEL Square GCM Hex Johnson SMG Dynapac Mikassa Hayashi Housing Dia 46.8 mm 46.8 mm mm 39.8 mm mm Tag 7/16 Sq 10 mm Hex 500 Assembly mm Hex Semi Circular 10 mm Hex 5/16 Hex mm Hex Housing Washer Tag Shaft Connection Shaft Assembly Standard Standard Standard Standard Standard Standard TAG COUPLINGS 13 X 32 DRIVES Item Description Qty CEL Square GCM Hex Johnson SMG Dynapac Mikassa Hayashi Housing Dia 46.8 mm 46.8 mm mm 39.8 mm mm Tag 7/16 Sq 10 mm Hex 10 mm Hex Semi Circular 10 mm Hex 5/16 Hex 10 mm Hex 500 Assembly Housing Washer Tag Shaft Connection Shaft Assembly Standard Standard Standard Standard Standard Standard Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 13

14 VB POKER PARTS LIST Item Description Qty VB26 mm VB32 mm VB40 mm 100 Poker Assembly 50 hz Poker Assembly 60 hz Nose a Neoprene Covered Nose b Neoprene Nose Insert Nitrile O Ring 70/80 SRDH Rotor 50 hz a Rotor 60 hz Body Removal Ring Not Fitted 106 Oil Seal Bearing Oil Seal Bush Bearing Housing 1 Not fitted Not fitted Oil Seal Carrier (Not Illustrated) 1 Not fitted Not fitted Nitrile O Ring 70/80 SRDH 1 Not fitted Not fitted Grease As Req Poker Speed Label Spares Kit Drive O Ring Loctite 243 As Req Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 14

15 VT POKER PARTS LIST Item Description Qty VT40 mm VT45 mm VT50 mm 200 Poker Assembly 50 hz a Poker Assembly 60 hz Nose a Neoprene Covered Nose b Neoprene Nose Insert Nitrile O Ring 70/80 SRDH Rotor 50 hz a Rotor 60 hz Body Oil Seal Bearing Oil Seal Bush Bearing Housing Oil Seal Carrier Nitrile O Ring Nitrile O Ring Grease Poker Speed Label Spares Kit VT60 mm VT75 mm Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 15

16 WARNING Do not run your poker out of concrete Poker power unit must not exceed 3000 rpm ( 60 hz Pokers run at 3600 RPM) Check engine speed daily before use Check engine oil daily before use CE DIESEL FRAME C/W LIFTING BARS (Orange Powder Coat) Drawing No Item Description Qty Hatz 1B20 Robin DY23 Yanmar L40 Lombardini 800 Frame Assembly a Frame assembly c/w swivel Engine Frame a Frame for Swivel Bedplate Engine Mounts Locknut M Plain Washers M Spring Washers M Nylon Insert Nut M Plain Washer M Hex Head Bolt M10 x Swivel Base Bronze Bush Plain Washer M Nylon Insert Nut M Hex Head Bolt M16 x Serial No Plate Logo Label Machine Label CE Warning label Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 16

17 WARNING Do not run your poker out of concrete Poker power unit must not exceed 3000 rpm ( 60 hz Pokers run at 3600 RPM) Check engine speed daily before use Check engine oil daily before use STANDARD DIESEL FRAME C/W LIFTING BARS (Yellow Powder Coat) Item Description Qty Hatz 1B20 Robin DY23 Yanmar L40 Lombardini 800 Frame Assembly a Frame assembly c/w swivel Engine Frame a Frame for Swivel Bedplate Engine Mounts Locknut M Plain Washers M Spring Washers M Nylon Insert Nut M Plain Washer M Hex Head Bolt M10 x Swivel Base Bronze Bush Plain Washer M Nylon Insert Nut M Hex Head Bolt M16 x Serial No Plate Logo Label Machine Label CE Warning label Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 17

18 WARNING Do not run your poker out of concrete Poker power unit must not exceed 3000 rpm ( 60 hz Pokers run at 3600 RPM) Check engine speed daily before use Check engine oil daily before use RUBBER BASED SWIVEL PETROL FRAMES( Black Powder Coat Black) Item Description Qty Std Rubber Based Swivel Tall Rubber Based Swivel 800 Frame Assembly a Honda GX120 Oil Alert b Honda GX160 Oil Alert c Honda GX d Honda G Frame Rubber Swivel Nylon Insert Nut M Plain Washer M Stud M8 x Hex Set Screw M8 x Plain Washer M Spring Washer M Serial No Plate Logo Label Machine Label CE Warning label Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 18

19 WARNING Do not run your poker out of concrete Poker power unit must not exceed 3000 rpm ( 60 hz Pokers run at 3600 RPM) Check engine speed daily before use Check engine oil daily before use SLEDGE FRAME (Yellow Powder Coat) Item Description Qty Sledge 800 Frame Assembly Frame Engine Straps Engine Mounts Locknut M Plain Washers M Spring Washers M Nylon Insert Nut M Plain Washer M Hex Head Bolt M8 x Serial No Plate Logo Label Machine Label CE Warning label Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 19

20 WARNING Do not run your poker out of concrete Poker power unit must not exceed 3000 rpm ( 60 hz Pokers run at 3600 RPM) Check engine speed daily before use Check engine oil daily before use STD TOTALLY ENCLOSED BOX PETROL FRAMES (Yellow Powder Coat) Item Description Qty Std Box w/o Swivel Std Box c/w Swivel Tall Box w/o Swivel 800 Frame Assembly Honda GX160 Oil Alert a Robin EY20 DU Oil Alert b Honda G c Briggs and Stratton Frame Bedplate Engine Mounts Locknut M Plain Washers M Spring Washers M Nylon Insert Nut M Plain Washer M Hex Head Bolt M8 x Swivel Base Bronze Bush Plain Washer M Nylon Insert Nut M Hex Head Bolt M16 x Serial No Plate Logo Label Machine Label CE Warning label Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 20

21 WARNING Do not run your poker out of concrete Poker power unit must not exceed 3000 rpm ( 60 hz Pokers run at 3600 RPM) Check engine speed daily before use Check engine oil daily before use C E TOTALLY ENCLOSED BOX PETROL FRAMES (Orange Powder Coat) Item Description Qty Std Box w/o Swivel Std Box c/w Swivel 800 Frame Assembly Honda GX160 Oil Alert a Robin EY20 DU OA Frame Bedplate Engine Mounts Locknut M Plain Washers M Spring Washers M Nylon Insert Nut M Plain Washer M Hex Head Bolt M8 x Swivel Base Bronze Bush Plain Washer M Nylon Insert Nut M Hex Head Bolt M16 x Serial No Plate Logo Label Machine Label CE Warning label Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 21

22 WARNING Only a qualified electrician should wire up electric power units. In the event of failure only a qualified electrician should inspect the unit. Do not remove switch gear cover or motor cover on site. All motors must have motor overload fitted at power source as the motor switch does not have overload protection. 90 Frame Electric Power Unit (Yellow Powder Coat) Item Description Qty 2 HP 110/1/50 2 HP 240/1/50 2 HP 380/415/3/50 3 HP 240/1/50 3 HP 380/415/3/ Frame Assembly Frame Handle Nylon Insert Nut M Penny Washer 5/ Nylon Insert Nut M Plain Washer M Hex Head Bolt M8 x Lafert/AEG Electric Motor a Invensys Electric Motor b Unspecified Electric Motor Ring Tongue Terminals Motor Cable Gland M20 Elkay Motor Cable Gland Nut M20 Elkay Motor Cable Gland Seal 22mm ID Elkay SY Cable 3 Core 1.5 mm² (Motor to switch) a SY Cable 3 Core 2.5 mm² (Motor to switch) b SY Cable 4 Core 1.0 mm² (Motor to switch) c SY Cable 4 Core 1.5 mm ²(Motor to Switch) a Klockner Moeller Switch 25 amp P1/25/I2/ SVB 840b Klockner Moeller Switch 32 amp P1/32/I2/ SVB c DOL Starter (Only fitted on Request) Cheese Head Screw M4 x Plain Washer M Nylon Insert Nut M Switch Cable Gland & Nut M20 CMP CXT Switch Cable Gland M25 Elkay Switch Cable Gland Nut M25 Elkay Switch Cable Gland Seal 26 mm ID Elkay Plugs only fitted to models supplied to the UK Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 22

23 848 Trailing Cable SY 3 Core 1.5 mm² 2 mtr a Trailing Cable SY 3 Core 2.5 mm² 2 mtr b Trailing Cable SY 4 Core 1.0 mm² 2 mtr c Trailing Cable SY 4 Core 1.5 mm² 2 Mtr a Plug 3 Pin (UK Specification only) 110/1/50 Yellow b Plug 3 Pin (UK Specification only) 240/1/50 Blue c Plug 3 Pin (UK Specification only) 415/3/50 Red Voltage Label / /4 851 Rotation Label Serial No Label Logo Label Wiring Diagram Motor Amperage HP Voltage Manufacturer Amperage Cable 2 110/1/50 Lafert mm² 2 240/1/50 Lafert mm² 2 220/240/3/50 AEG mm² 2 380/415/3/50 AEG mm² 3 240/1/50 Lafert mm² 3 220/240/3/50 AEG mm² /3/50 AEG mm² Max lgth 11 mtr 30 mtr 69 mtr 138 mtr 24 mtr 47 mtr 83 mtr WARNING Always check motor amperage different models of motor may have different amperage. Do not use a cable longer than the maximum length indicated. Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 23

24 Petrol and Diesel Power Take Off (4Holes on 92 mm P C D) 3/4 Keywayed Drive Dog Item Description Qty Claw Warsop Fyne Metrix 600 Assembly Plunger Knob Plunger Housing MK Plunger Spring Flexo M Plunger Pin Housing a Hex Head Set Screw 5/16 UNC x b Hex Head Set Screw 5/16 UNF x c Hex Head Set Screw M8 x Socket Screw M10 x 10 Nylon patch E E E E 608 Drive Dog 3/4 Keyway Bore Key 3/16 Sq x 1 1/ Plain Washer M Spring Washer M Plunger Assembly Loctite (Always Loctite Pin and Knob) Frame Electric Power Take Off (4 Holes on 112 mm P C D) Item Description Qty Claw Warsop Fyne Metrix 600 Assembly Plunger Knob Plunger Spring M Plunger Pin Plunger Housing MK Housing Hex Head Set Screw M8 x Socket Screw M10 x 10 Nylon Patch E E E E 608 Drive Dog 24 mm Keyway Bore Key 8 x 7 x Plain Washer M Spring Washer M Plunger Assembly Loctite (Always Loctite Pin and Knob) Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 24

25 Petrol and Diesel Power Take Off (4Holes on 92 mm P C D) 3/4 Keywayed Drive Dog Item Description Qty Hayashi Mikassa Hexagon 600 Assembly Plunger Knob Plunger Housing MK Plunger Spring Flexo M Plunger Pin Housing a Hex Head Set Screw 5/16 UNC x b Hex Head Set Screw 5/16 UNF x c Hex Head Set Screw M8 x Socket Screw M10 x 10 c/w Nylon Patch E E E 608 Spindle 3/4 Bore Keywayed a Spindle Adaptor Key 3/16 Sq x 1 1/ Plain Washer M Spring Washer M Plunger Assembly Loctite (Always Loctite Pin and Knob) Frame Electric Power Take Off (4 Holes on 112 mm P C D) Item Description Qty Hayashi Mikassa Hexagon 600 Assembly Plunger Knob Plunger Spring M Plunger Pin Plunger Housing MK Housing Hex Head Set Screw M8 x Socket Screw M10 x 10 c/w Nylon Patch E E E 608 Spindle 24 mm Keyway Bore a Spindle Adaptor Key 8 x 7 x Plain Washer M Spring Washer M Plunger Assembly Loctite (Always Loctite Pin and Knob) Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 25

26 Claw PTO Fyne PTO Petrol and Diesel Power Take Off (4Holes on 92 mm P C D) Alternative DriveDog Item Description Qty Claw 20 mm Claw 1 Claw 5/8 UNF Claw Taper 600 Assembly Drive Dog Key Not Required Not Required NB 1) An alternative PTO Housing is used fro the Taper Drive Dog 103. Or alternatively 2 adaptor plates 2) When using the 12 Drive Dog it may be necessary to shorten the engine spindle PLUNGER ASSEMBLY IDENTIFICATION Item Description Qty Aluminium Casting Fabrication Cast Iron Casting Plunger Housing Thread M20 x 1.0 Not Fitted M20 x Plunger Knob Plunger Spring Plunger Pin Plunger Housing Not Fitted Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 26

27 ASSEMBLY / DISMANTLE INSTRUCTIONS 26/32 mm POKER DISMANTLING PROCEDURE 1. Hold the poker body in a vice. 2. Unscrew the poker nose (left hand thread). 3. Using a suitable drift, drive the rotor out through the nose end, taking care not to damage the thread. 4. From the nose end, drive out the removal ring, two oil seals and bearing. 5. Discard the oil seals and bearings as these must be replaced with new items on re-assembly ASSEMBLY PROCEDURE 1. Thoroughly clean the body paying particular attention to the bore and the O ring diameters. 2. Fit new removal ring and new oil seal into the poker body with the open side of the oil seal facing out wards, using the oil seal fit tool. 3. Fit new bearing and oil seal bush. 4. Thoroughly clean the rotor and insert it into the nose end of the poker body ensuring not to damage or disturb the oil seal. 5. Fit the second new oil seal with the open side facing outwards. This operation should be carried out using the oil seal fitting tool. The purpose of the oil seals is to prevent the ingress from the drive into the poker body, therefore both seals face the same direction. 6. Thoroughly clean the nose and fit a new O ring over the thread into position against the shoulder. 7. ENSURE THE TAPER AT THE END OF THE ROTOR AND THE BORE OF THE POKER NOSE ARE CLEAN, DRY AND FREE OF ANY LUBRICANT. 8. Screw the nose (left hand thread) into the poker body. Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 27

28 ASSEMBLY / DISMANTLE INSTRUCTIONS 40/45/50/60/75 mm POKER DISMANTLING PROCEDURE 1. Hold the poker body in a vice. 2. Unscrew the poker nose (left hand thread). 3. Using a suitable drift, drive the rotor out through the nose end, taking care not to damage the thread. 4. Unscrew the bearing housing from the poker (left hand thread) 5. Retain the oil seal bush if undamaged. 6. From the nose end drive out the oil seal. 7. Drive out the bearing and oil seal from the bearing housing and discard the oil seals and bearings as these must be replaced with new items on re-assembly ASSEMBLY PROCEDURE 1. Thoroughly clean all the components paying particular attention to the bore and the O ring diameters. 2. Fit a new O ring over the thread into position against the shoulder at the drive end of the poker body. 3. Fit a and new oil seal into the poker body with the open side of the oil seal facing out wards, using the oil seal fit tool. 4. Fit new bearing and oil seal bush. 5. Thoroughly clean the rotor and insert it into the nose end of the poker body ensuring not to damage or disturb the oil seal. 6. Fit a new oil seal to the bearing housing with the open side facing outwards. This operation should be carried out using the oil seal fitting tool. The purpose of the oil seals is to prevent the ingress of grease from the drive into the poker body, therefore both seals face the same direction. 7. Screw the bearing housing into the body (left hand thread). 8. Thoroughly clean the nose and fit a new O ring over the thread into position against the shoulder. 9 ENSURE THE TAPER AT THE END OF THE ROTOR AND THE BORE OF THE POKER NOSE ARE CLEAN, DRY AND FREE OF ANY LUBRICANT. 10. Screw the nose (left hand thread) into the poker body. Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 28

29 REMOVAL / FITTING OF POKER FROM DRIVE / TO DRIVE 1. Hold the poker body in a vice and remove the poker nose (left hand thread). 2. Unscrew the poker end cover adaptor (left hand thread). 3. Withdraw the cover adaptor to expose the inner core connector. 4. Hold the inner core by clamping a pair of pipe grips onto the inner core connector. Using a suitable open ended spanner over the flat of the nose end of the rotor, turn the rotor in a anti-clockwise direction thus disconnecting the inner core from the poker (right hand thread). 5. If no work is to be carried out to the poker loosely refit the poker nose including a new 0 ring. FITTING OF POKER TO DRIVE 1. Hold the poker body in a vice. 2. Remove the poker nose from the body (left hand thread). 3. On the 25mm drive only fit a new 0 ring over the thread against the shoulder of the drive cover adaptor. 4. Clamp the inner core connector with a pair of pipe grips. 5. Screw the connector onto the rotor by turning the rotor in a clockwise direction (right hand thread) using a suitable open ended spanner over the flat of the nose end. 6. Attach the drive cover to the bearing housing and fully tighten (left hand thread). 7. ENSURE that the taper at the end of the rotor and the bore of the nose are clean, dry, and totally free of any grease or lubricant. 8. Replace the poker nose and fully tighten ensuring a metal contact at the mating faces (left hand thread) Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 29

30 FLEXIBLE DRIVE SERVICING 1. Remove the coupling from the flexible drive by clamping the motor end cover adaptor on the spanner flats provided and unscrew the claw coupling, this has a left hand thread. 2. Withdraw the inner core from the drive end ensuring that it does not contact any dirt. 3. Wipe the inner core clean and examine it for any kind of damage and/or wear. If either is evident then it must be replaced. 4. Examine the outer cover for damage and kinking and replace if necessary. 5. Remove the hexagonal drive tag and wear washer from the inner core and fit them to the other end. This will extend the working life of the inner core by equally distributing wear. 6. Apply the Grease (Lithium BP LS3) sparingly to the inner so that a fine film remains on its surface. Be particularly careful to leave only the lightest coating within 500 mm of the poker end. 7. Replace the inner core inside the cover. 8. On the 25mm drive only refit a new O ring. Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 30

31 MODIFICATION RECORD Date Page No Modification 29/01/ Mikassa Shaft with ends added 29/01/ Adoption 26 and 32 mm Poker to 32 mm drive added 19/02/ Electric PTO kit Part no corrected 12/05/2002 7,8 Pages 7 and 8 added 07/7/ Inserted 09/08/2002 Various Illustrations rescanned 09/08/ /23 Socket Set Screw specification and part no amended 12/12/04 20 Electric Motors changed Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 31

32 GCM Ltd Ratcliffe Buildings, Tuttle Hill, Nuneaton, Warwickshire, United Kingdom. CV10 0GA Tel: 0044(0) Fax: 0044(0) Website: Dealer Flexible Drive Poker Manual Thursday, November 22, 2007 Manual Reference Page 32