Husqvarna AMG 3200 Concrete Vibrator Drive Unit: Safety and Operating Instructions

Introduction

Thank you for choosing a Husqvarna quality product. We hope that you will genuinely enjoy it. Please note that the enclosed manual contains Atlas Copco references. The Husqvarna Group is vouching for the quality of this product. If you have any questions, please do not hesitate to contact our local sales or service point.

Husqvarna AB, 561 82 Huskvarna, Sweden

Thank you for choosing a quality Husqvarna product. We hope you will enjoy it greatly. Please note that the attached manual contains Atlas Copco references. Husqvarna Group guarantees the quality of this product. If you have any questions, please do not hesitate to contact our local sales representatives or the nearest service center.

Husqvarna AB, 561 82 Huskvarna, Sweden

This manual provides knowledge on how to use the machine effectively and safely. It also provides tips on how to perform regular maintenance on the machine. Before using the machine for the first time, read these instructions carefully and understand them all.

Safety Instructions

To reduce the risk of serious injury or death to yourself or others, read and understand the Safety and Operating Instructions before assembling, operating, repairing, maintaining the machine, or changing its accessories.

Distribute these Safety and Operating Instructions to the work sites, provide copies for employees, and ensure that everyone who will work with or service the machine reads the safety instructions. Furthermore, the operator or the operator's employee must assess the specific risks that may arise as a result of any use of the machine. Save all warnings and instructions for future reference.

Signal Words for Safety

The safety signal words DANGER, WARNING, and CAUTION have the following meanings:

• DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious personal injury.
• WARNING: Indicates a hazardous situation which, if not avoided, could result in death or serious personal injury.
• CAUTION: Indicates a hazardous situation which, if not avoided, may result in minor or moderate personal injury.

Work Area

• DANGER: Explosion Hazard

An explosion may occur if a hot machine or exhaust pipe comes into contact with explosive substances. When working with certain materials, sparks and ignition may occur. Explosions will lead to severe injury or death.

• Never operate the machine in an explosive environment.
• Never use the machine near flammable materials, vapors, or dust.
• Ensure there are no unidentified sources of gas or explosives.
• Avoid contact with the hot exhaust pipe or the lower part of the machine.
• DANGER: Fire Hazard

If a fire starts in the machine, it can cause injury.

• If possible, use a dry chemical fire extinguisher of class ABC; otherwise, use a CO2 fire extinguisher of type BE.
• DANGER: Fuel Hazard

Fuel is flammable, and fuel vapors can explode when ignited, leading to serious injury or death.

• Protect your skin from contact with fuel. If fuel has penetrated the skin, consult a qualified health specialist.
• Never remove the cap and refuel the tank when the machine is hot.
• Refuel the fuel tank outdoors or in a clean and ventilated area, free from sparks and open flames. Refuel the fuel tank at least ten meters (30 feet) from the place where the machine will be used.
• Slowly release the cap to vent pressure.
• Never overfill the fuel tank.
• Ensure the cap is screwed on when the machine is in use.
• Avoid spilling fuel on the machine and wipe up any spilled fuel.
• Regularly check for fuel leaks. Never operate the machine if it is leaking fuel.
• Never use the machine near materials that can create sparks. Remove all hot or spark-producing devices before starting the machine.
• Never smoke when refueling, operating, or servicing the machine.
• Store fuel in a container specifically designed and approved for the purpose.
• Dispose of empty fuel and oil containers properly and return them to the retailer.
• Never use your fingers to check for fluid leaks.
• WARNING: Secure the work area

Cluttered workbenches and insufficient lighting can cause personal accidents and lead to serious injuries.

• Keep the work area clean.
• Maintain adequate lighting in the work area.

Personal Safety

• General: Only qualified and trained personnel may operate or maintain the machine. They must be physically capable of handling the machine's weight and power. Always use common sense and good judgment.
• Keep bystanders, children, and visitors away from the machine during operation. Distractions can cause you to lose control.
• Personal Protective Equipment (PPE): Always use approved protective equipment. Operators and other persons in the work area must wear protective equipment, including at a minimum:
• Safety helmet
• Hearing protection
• Impact-resistant safety glasses with side shields
• Protective gloves
• Suitable protective footwear
• Appropriate or similar work clothing (without loose parts) that covers your arms and legs.
• Drugs, Alcohol, or Medication:
• WARNING: Drugs, Alcohol, or Medication

Drugs, alcohol, or medication can affect your judgment and ability to concentrate. Poor reactions and incorrect judgment can lead to serious accidents and death.

• Never operate the machine when you are tired or under the influence of narcotics, alcohol, or medication.
• No person under the influence of narcotics, alcohol, or medication may operate the machine.

Electrical Hazards

• DANGER: Electrical Hazards

There is a risk of electric shock from machines with electric drive, which can lead to serious injury or death.

• Avoid body contact with earthed surfaces.
• Ensure there are no hidden cables or other power sources in the work area.
• When working outdoors, use an extension cord approved for outdoor use.
• Always check that the mains voltage matches the one indicated on the machine's data plate.

Starting Hazards

• WARNING: Forced Starting

Forced starting of the machine can cause injury.

• Keep your hands away from the start/stop device until you are ready to start the machine.
• Learn how to shut down the machine in an emergency.

Falling Parts Hazard

• WARNING: Falling Parts

Failure to comply with requirements for workpieces, accessories, or the machine itself can create flying debris at high speed. During operation, flying debris or other particles from the sealing material may detach and cause personal injury by striking the operator or other persons. To reduce these risks:

• Use approved personal protective equipment and a safety helmet, including impact-resistant eye protection with side shields.
• Ensure there are no unauthorized persons in the work area.
• Keep the work area clear of foreign objects.

Entanglement Hazard

• WARNING: Entanglement Hazard

There is a risk of being pulled in or caught by rotating machine parts from jewelry on the neck, hair, gloves, and clothing. This can cause strangulation, scalping, tearing, or death. To reduce the risk:

• Never grab or touch a rotating machine part.
• Avoid wearing clothing, neck jewelry, or gloves that can get caught.
• Cover long hair with a hair net.

Unexpected Movement Hazard

• WARNING: Unexpected Movements

The machine is subjected to heavy stress during operation. If the machine is damaged or stuck, there may be a sudden and unexpected movement, which can lead to injury.

• Always inspect the machine before use. Never operate the machine if you suspect it is damaged.
• Ensure the handle is clean and free of grease and oil.
• Keep your feet away from the machine.
• Never sit on the machine.
• Never hit or misuse the machine.
• Pay attention and watch what you are doing.

Dust and Fumes Hazard

• WARNING: Dust and Fumes Hazard

Dust and/or fumes generated or dispersed during machine use can cause serious and permanent damage to the respiratory system, diseases, or other bodily harm (e.g., silicosis or other irreversible lung disease, which can be fatal, cancer, birth defects, and/or skin inflammation).

• Some dusts and fumes generated by compaction work contain substances for which the following applies:
• Conduct a site-specific risk assessment. The risk assessment must include dust and fumes generated by the use of the machine and the potential for existing dust.
• Use appropriate engineering controls to minimize the amount of dust and fumes in the air and to minimize their accumulation on equipment, surfaces, clothing, and body parts. Examples of controls include: exhaust ventilation and dust collection systems, water sprays, and wet drilling. Control dust and fumes at the source whenever possible. Ensure that control devices are properly installed, maintained, and used.
• Wear, maintain, and use respiratory protective equipment correctly as instructed by your employer and as required by occupational health and safety regulations. Respiratory protective equipment must be effective for the type of substance (and, if applicable, approved by the relevant government authority).
• Operate in a well-ventilated area.

Vibration Hazards

• WARNING: Vibration Hazards

Normal and proper use of the machine exposes the operator to vibrations. Regular and frequent exposure to vibrations can contribute to or aggravate injuries or disorders of the operator's fingers, hands, wrists, arms, shoulders, and/or nerves and blood supply, or other body parts, including those leading to disability and/or permanent injuries or ailments that may develop gradually over weeks, months, or years. Such injuries or disorders may include damage to the circulatory system, damage to the nervous system, joint damage, and eventual damage to other body structures.

• If at any time you experience numbness, persistent and recurring discomfort, burning sensation, stiffness, tingling, pain, clumsiness, loss of grip, skin whitening, or other symptoms while operating or not operating the machine, stop operating the machine, notify your employer, and seek medical attention. Prolonged use of the machine after the onset of such symptoms may increase the risk of symptoms becoming more severe and/or permanent.
• Participate in health surveillance or monitoring, medical examinations, and training programs offered by your employer and as required by law.
• When working in cold conditions, wear warm clothing and keep your hands warm and dry.
• Refer to the "Exposure Declaration for Noise and Vibration" for the machine, including the declared vibration value. This information can be found at the end of these safety and operating instructions.
• Operate and maintain the machine as recommended in these instructions to prevent unnecessary vibration increase.
• To reduce operator exposure to vibration impact, the following may help:
• If the machine has shock-absorbing handles, hold them in the central position and avoid pressing them against the end stops.
• When the impact mechanism is activated, your only body contact with the machine should be your hands on the handle(s). Avoid any other contact, such as resting any part of your body against the machine, or leaning over the machine in an attempt to increase the feed force.
• Ensure the machine is well maintained and not worn.
• Stop working immediately if the machine suddenly starts to vibrate strongly. Before resuming work, find and eliminate the cause of increased vibrations.

Noise Hazard

• WARNING: Noise Hazard

High noise levels can cause permanent hearing loss and other problems, such as tinnitus (ringing, buzzing, whistling, or humming in the ears). To reduce risks and prevent unnecessary noise level increases:

• The primary step is to assess these hazards and implement appropriate control measures.
• Operate and maintain the machine as recommended in these instructions.
• If the machine has a muffler, check that it is in place and in good working order.
• Always use hearing protection.

Hot Oil Hazard

• WARNING: Hot Oil Hazard

There is a risk of burns when changing the oil or oil filter on a hot machine. Wait for the machine to cool down before changing the oil.

Accessory Hazards

• WARNING: Accessory Hazards

Accidental activation of accessories during maintenance or assembly can cause serious injury when the power source is connected. Never check, clean, install, or remove accessories when the power source is connected.

Operation

Preparation Before Vibrating

Operating Speeds

The maximum engine speed must not exceed the factory setting of 3,600 rpm. During maintenance, the engine speed must be checked and adjusted to a maximum of 3,600 rpm. For more information on adjusting, starting, and stopping the engine, refer to the engine instructions.

Connecting the Flexible Shaft to the Drive Unit

1. Lift the lock lever (A) on the drive unit (D).
2. Insert the flexible shaft (B) into the drive unit.
3. Ensure the square fitting on the flexible shaft (C) fits into the square tube of the drive unit (D).
4. Attach the vibrator tube to the flexible shaft by screwing it on with your left hand.
5. Plug the drive unit (D) into the socket and start the machine.

Starting the Engine (Honda)

1. Turn the main switch to the ON position.
2. Open the fuel cock (B).
3. Close the choke valve (D) if the engine is cold. If the engine is warm or the ambient temperature is high, close the choke valve halfway, or leave it open.
4. Turn the starter switch (E) to the ON position.
5. Grip the recoil starter handle (F) and pull it until you feel resistance. Release the handle to its initial position, then pull it until the engine starts.
6. Move the throttle lever (G) gradually to the fully open position.

Note: When starting the engine, let it run for a few minutes to warm up before loading the generator.

Refueling

Stop the engine and open the fuel cap.

• Refuel. Always use a fuel filter when refueling.
• Close the fuel cap and wipe up any spilled fuel before starting the machine.

Vibrating

1. Allow the vibrator to penetrate about 15 cm (6 inches) into the nearest lower layer to ensure good bonding of the different layers.
2. Fill the formwork evenly with concrete in layers of 30–50 cm (12–19 inches) thick.
3. Insert the vibrator vertically at a distance of 8-10 times the tube diameter between insertions.
4. Vibrate systematically.
5. Withdraw the vibrator slowly to allow the concrete to fill the voids left by the vibrator.
6. The concrete is thoroughly vibrated when the area around the vibrator becomes shiny and there are no air bubbles on the surface. This usually takes about 10-20 seconds.

Note: Never use the vibrator to move concrete sideways.

Taking a Break

• During all breaks, the machine must be placed in such a way that there is no risk of it being accidentally started. Ensure the machine is placed on the ground so it cannot fall over.
• Turn off the power during longer breaks or when leaving the work area.

Maintenance

Regular maintenance is a fundamental requirement for the continued safe and effective use of the machine. Follow the maintenance instructions carefully.

• Before starting maintenance on the machine, clean it to avoid exposure to hazardous substances. Refer to "Dust and Fumes Hazard".
• When cleaning mechanical parts with solvent, comply with relevant health and safety regulations and ensure adequate ventilation.
• For more serious service work on the machine, contact the nearest authorized service center.
• After each service, check that the machine's vibration level is normal. If not, contact the nearest authorized service center.

Every 10 Hours of Operation (Daily)

Maintenance Practices:

• Clean the machine. After each work shift, concrete splashes must be removed from the surfaces while they are still fresh.
• Ensure that the control devices are not damaged or stuck. Replace them if necessary.
• Check bolts and nuts.

After the First 20 Hours of Operation

Engine Check (Honda)

• Check the oil level on the dipstick.
• Check the fuel level (A).
• Check the machine before starting it. Inspect the entire machine to detect leaks or other defects.
• Check the ground surface under the machine. Leaks are easier to detect on the ground than on the machine itself.
• To ensure the machine remains within the specified vibration level values, the following checks must be performed:
• Check and refuel.
• Check and top up engine oil.
• Check for oil leaks.
• Check the tightness of all nuts and bolts.
• Clean the machine.
• Check and clean the engine cooling fins. Refer to the engine manual for more information.
• Regularly check the engine's air filter indicator. Refer to the engine manual for more information.
• Clean and reinstall the air filter.
• Check the engine for oil leaks.

Every 50 Hours of Operation (or Weekly)

Maintenance Practices:

• Change engine oil. (First change after 20 hours).
• Clean the spark plug.
• Clean the air filter.

Engine Oil and Air Filter Change (Honda)

Drain engine oil only when the engine is warm.

1. Remove the oil drain plug (A) and drain all the oil. Use a drain hose (B).
2. Install and tighten the drain plug (A).
3. Fill the engine with engine oil up to the maximum oil level mark (C).
4. Unscrew and replace the air filter (D). Refer to the engine manual for more information.

Every 100 Hours of Operation (or Every Second Week)

Maintenance Practices:

• Change engine oil. Refer to the engine manual for more information.
• Check and clean the spark plug. Refer to the engine manual for more information.
• Check the shock absorbers.

Every 200 Hours of Operation (or Monthly)

Maintenance Practices:

• Check the air filter.
• Check engine speed. Refer to the engine manual for more information.
• Clean the fuel cock on the carburetor. Refer to the engine manual for more information.
• Clean the spark arrestor in the muffler. Refer to the engine manual for more information.

Spark Plug Check (Honda)

• Check, clean, and replace the spark plug.

Shock Absorber Check

1. Check all shock absorbers (A) for cracks or wear.
2. Replace shock absorbers (A) if they are damaged.

Every 500 Hours of Operation (or Annually)

Maintenance Practices:

• Clean and adjust the carburetor.
• Clean the cylinder head.
• Adjust valve clearance.

Disassembly and Assembly

Disassembly

Diagram showing the components of the vibrator head assembly, including the flexible shaft, end cap, tail, vibrator shaft, and bearings.

1. Clamp the vibrator in a pipe vise.
2. Unscrew the end cap (H) and the tail (B) (left-hand thread).
3. Unscrew the flexible shaft (A) from the vibrator shaft (G) (right-hand thread).
4. Use pliers on the ends of the vibrator shaft and the flexible shaft.
5. Remove the vibrator shaft from the front of the tube.
6. Remove the ball bearing (D) and the sealing gasket (E) if necessary.

Assembly

• Replace O-rings, sealing gaskets, and bearings whenever the vibrator is repaired.
• Clean and grease the flexible shaft. Refer to the "Lubrication" section.
• Assemble the vibrator in the reverse order of disassembly.
• Be careful with the tube, vibrator shaft, and end cap, as these parts should not be lubricated. Ensure the components are clean and dry to guarantee the vibrator's operation.

Lubrication

The flexible shaft must be greased every 500 hours of operation.

Storage

• Clean the machine before storage to avoid hazardous substances. Refer to "Dust and Fumes Hazard".
• Always store the machine in a dry place.
• Empty the fuel tank before storing the machine.
• Clean the machine.
• Clean the air filter.
• Gently pull the starter handle until slight resistance is felt.
• Wipe off any oil and dirt that has accumulated on the rubber parts.
• Cover the machine and store it in a dry, dust-free area.

Disposal

A used machine must be treated and disposed of in such a way that the largest possible part of the material can be recycled and any negative impact on the environment is kept as low as possible and in accordance with local regulations.

Before a fuel-powered machine can be disposed of, it must be emptied and cleaned of all oil and fuel. Remaining oil and fuel must be handled in a way that does not adversely affect the environment.

Always send used filters and drained oil and fuel residues for environmentally sound disposal.

Troubleshooting

Technical Data

Machine Data

* Weighted effective acceleration, measured in water (m/sec²), according to EN ISO 5349 and EN ISO 20643.

Data for Tool AA

* Weighted effective acceleration, measured in water with one vibrator driven, on the hose, 2 m from the end of the vibrator column (m/sec²), according to EN ISO 5349-1.

Data for Tool AZ

* Weighted effective acceleration, measured in water with one vibrator driven, on the hose, 2 m from the end of the vibrator column (m/sec²), according to EN ISO 5349-1.

Weights and Dimensions

AMG3200 Dimensions

Diagram showing the overall dimensions of the AMG3200 unit:

• Length: 427 mm (16.81 in)
• Width: 390 mm (15.35 in)
• Height: 454 mm (17.87 in)

Working Weight: 30 kg (60.14 lbs)

Exposure Declaration for Noise and Vibration

Guaranteed sound power level Lw according to EN ISO 3744 in accordance with Directive 2000/14/EC.

Sound pressure level Lp according to EN ISO 11201, EN 500-4:2011.

Vibration value determined according to EN 500-4:2011. Refer to the "Noise and Vibration Data" table for values and more.

These declared values were obtained from laboratory type tests in accordance with the specified directive or standards and are suitable for comparison with declared values of other machines for testing in accordance with this directive or standards. These declared values are not suitable for use in risk assessments, and actual exposure values and the risk of injury experienced by an individual may be higher. Actual exposure values and the risk of injury experienced by an individual are unique and depend on how users work, the material in which the machine is used, as well as exposure time and the user's physical condition and the machine's condition.

We, Construction Tools EOOD, cannot be held liable for the consequences of using the declared values instead of values reflecting actual exposure in an individual workplace risk assessment over which we have no control.

This machine may lead to hand-arm vibration syndrome if its use is not managed adequately. The EU Guide for the management of hand-arm vibration can be found at: http://www.humanvibration.com/humanvibration/EU/VIBGUIDE.html

We recommend a health surveillance program to detect early symptoms that may be related to vibration exposure, so that management procedures can be modified to help prevent future injury.

Noise Data

Noise level, measured at 4 meters from the engine, in dB(A), according to EN ISO 6081. Uncertainty: ±3 dB.

EC Declaration of Conformity

We, Construction Tools EOOD, declare that the machines listed below comply with the provisions of Directive 2006/42/EC (Machinery Directive) and the harmonized standards mentioned below.

The following harmonized standards have been applied: EN12649

Authorized Representative for Technical Documentation:

Emil Alexandrov
Construction Tools EOOD
7000 Rousse
Bulgaria

General Director:
Nick Evans

Manufacturer:
Construction Tools EOOD
7000 Rousse
Bulgaria

Place and Date:
Rousse, 05.12.2012