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Summary of Contents for Alpha WDP-120
- Page 1 MANUAL Alpha Wet/Dry Polisher ® Instruction Manual Model No.: WDP-120 Version 3 WARNING: To reduce the risk of injury, user must read and understand instruction manual! 103 Bauer Drive, Oakland, NJ 07436 • 800-648-7229 • Fax: 800-286-0114 www.alpha-tools.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS WDP-120 Overview ....................3 Specifications ......................3 Accessories .....................4 Attachment - Guard ..................5 Introduction ........................6 About The Symbols ..................6 Electrical Symbols ..................6 General Safety Rules ....................7 Work Area ......................7 Electrical Safety ....................7 Personal Safety ....................7 Tool Use and Care ...................8 Service ......................8 Specific Safety Rules ..................9 Use Proper Extension Cords ................10 Grounding Instructions ................10 Additional Precautions For Using The WDP-120........10 Laws And Regulations Of Noise Levels ............11 Guard Installation ....................12 Attaching A Backer Pad To WDP-120 ..............13... -
Page 3: Wdp-120 Overview
WDP-120 OVERVIEW Figure-1 SPECIFICATIONS Rating ................120 V Amperage ..............7A Wattage ................800W Speed (Variable) ............500~2800 RPM Weight ................. 7.3 Lbs / 3.3kg Spindle ................ 5/8”-11... -
Page 4: Accessories
ACCESSORIES... -
Page 5: Attachment- Guard
ATTACHMENT- GUARD Half Cover Main Unit Connector Sub Cover Figure-3 COMPONENTS: Main Unit Connector Half Cover Sub Cover... -
Page 6: Introduction
INTRODUCTION Thank you for purchasing the Alpha Wet/Dry Concrete Polisher. Please read this ® instruction manual thoroughly to ensure safety and correct use of the polisher. Keep this manual in a place where operators can access it easily whenever necessary. ABOUT THE SYMBOLS According to the hazard level, all safety notes in this manual are classified into “DANGER”, “WARNING”, and “CAUTION”. DANGER! Death or serious personal injury is imminent when handling this polisher incorrectly. WARNING! There is a possibility of death or serious personal injury when handling this polisher incorrectly. CAUTION! There is a possibility of personal injury or property damage when handling this polisher incorrectly. -
Page 7: General Safety Rules
CAUTION! The following are important notes for products, operation, and maintenance appli- cable to this polisher. GENERAL SAFETY RULES WORK AREA • Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents. • Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools may create sparks which may ignite the dust or fumes. • Keep bystanders, children, and visitors away while operating a power tool. Distractions can cause you to lose control. ELECTRICAL SAFETY • Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adaptor plugs. Check with a quali- fied electrician if you are in doubt as to whether the outlet is properly grounded. If the tools should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user. • Avoid body contact with grounded surfaces, such as pipes, radiators, ranges, and refrigerators. There is an increased risk of electric shock if your body is grounded. • Don’t expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. -
Page 8: Tool Use And Care
tools with your finger on the switch or plugging in tools that have the switch on, invites accidents. • Remove adjusting keys or wrenches before turning the tool on. A wrench or a key that is left attached to a rotating part of the tool may result in personal injury. • Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations. Do not use on a ladder or unstable support. • Use safety equipment. Always wear eye protection. Dust mask, nonskid safety shoes, hard hat, or hearing protection must be used for appropriate conditions. TOOL USE AND CARE • Use clamps or other practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control. • Do not force tool, use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed. • Do not use tool if switch does not turn it on or off. Any tool that cannot be controlled with the switch is dangerous and must be repaired. • Disconnect the plug from power source before making any adjustments, chang- ing accessories, or storing the tool. Such preventive safety measures reduce the risk of starting the tool accidentally. • Store idle tools out of the reach of children and other untrained persons. Tools are dangerous in the hands of untrained users. • Maintain tools with care. Keep tools sharp and clean for better and safer perfor- mance. Follow instructions for lubricating and changing accessories. Inspect the electrical cord periodically and if damaged, have it repaired by authorized service facility. Inspect extension cords periodically and replace if damaged. Keep handles dry, clean and free from oil and grease. • Check for damaged parts. Before using the tool each day, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced by an authorized service center unless otherwise indicated elsewhere... -
Page 9: Specific Safety Rules
SPECIFIC SAFETY RULES • Accessories must be rated for at least the speed recommended on the tool warning label. Wheels and other accessories running over rated speed can fly apart and cause injury. • Hold tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a “live” wire will make exposed metal parts of the tool “live” and shock the operator. • Know your power tool. Read operator`s manual carefully. Learn its application and limitations, as well as the specific potential hazards related to this tool. Following this rule will reduce the risk of electric shock, fire, or serious injury. • Always wear safety glasses with side shields. Everyday eye-glasses have only impact resistant lenses; they are NOT safety glasses. •... -
Page 10: Use Proper Extension Cords
Total length of cord in feet (120V ) Ampere Rating 25ft 50ft 100ft More Not More Than Than Not Recom- mended GROUNDING INSTRUCTIONS This tool should be grounded while in use to protect the operator from electric shock. The tool is equipped with a three-conductor cord and three-prong grounding type plug to fit the proper grounding type receptacle. The green (or green and yellow) conductor in the cord is the grounding wire. Never connect the green (or green and yellow) wire to a live terminal. ADDITIONAL PRECAUTIONS FOR USING THE WDP-120 In addition to the general safety notes described on the preceding pages, please read and observe the following precautionary notes before using the polisher. DANGER! 1. Check the working voltage. Be sure the voltage available at power outlet matches specified voltage on the nameplate. If the polisher is used with higher voltage than specified, the mo- tor will burnout. Any attempts to do so may damage the polisher or cause an accident or injury. 2. Inspect all polishing discs. Never use cracked, chipped or damaged polishing discs. 3. Hold the polisher tightly at start-up. -
Page 11: Laws And Regulations Of Noise Levels
Failure to do so may cause an injury due to high impact at initial start up. 4. Stop using the polisher immediately when noticing any malfunctions or any suspicious abnormal noises. Turn the power switch OFF and contact your dealer or Alpha Professional Tools ® for repair. 5. Handle the polisher with care. If you accidentally drop the polisher, do not use it until checking that it is not cracked, deformed, or damaged in any way. 6. Do not pour water or any liquids onto or inside the polisher. It may cause electric shocks. 7. Do not hold the polisher in a vice. 8. Do not touch any rotating parts. Never touch the polishing disc of the polisher during operation with your hands. 9. Do not leave the disc while spinning on the bench, floor or surface of your workpiece. It may cause an accident or injury. WARNING! 10. Attach the backer pad and polishing disc correctly by following the procedure in this instruction manual. Attaching the polishing discs incorrectly may cause an accident. 11. Observe any suspicious abnormal noises when a polishing disc is attached for the first time and polisher is turned ON. It may cause bodily injury if the polishing disc flies off. 12. Do not touch the polishing disc while spinning. The polishing disc spins very fast and you may hurt yourself. 13. Be careful of your surroundings when working in high places. When working in high places, make sure there are no people below. Do not trap the power supply cord on anything or drop the polisher or any materials, otherwise, It may cause an accident. -
Page 12: Guard Installation
GUARD INSTALLATION Figure-4 Figure-5... -
Page 13: Attaching A Backer Pad To Wdp-120
ATTACHING A BACKER PAD TO WDP-120 Figure-6 ATTACHING RUBBER CAP TO WDP-120 Rubber Cap Rubber Cap Figure-7... -
Page 14: Wdp-120 Wet Operation
WDP-120 WET OPERATION Rubber Cap Figure-8 Insert the rubber cap to the dust gage of the main cover. WDP-120 DRY OPERATION Rubber Cap Rubber Hose Adapter S t a i n l e s s S t e e l Hose Band Figure-9 Flexible Connector Hose (optional / sold separately) -
Page 15: Wdp-120 Polish Right Up To The Wall
POLISH RIGHT UP TO THE WALL STEP 1 Change the front cover to the sub cover Figure-10 STEP 2 Loosen the screws on both sides of the C-handle and move it upward as shown in Figure 11. Figure-11 STEP 3 Figure-12... -
Page 16: Wdp-120 Wet/Dry Concrete Polisher Operation
WDP-120 WET/DRY CONCRETE POLISHER OPERATION CAUTION! Always be sure that the tool is switched off and unplugged before adjusting or checking function on tool. MAIN CONNECTION Connect only to single-phase AC current supply and only to the main voltage speci- fied on the rating plate. SWITCHING ON AND OFF CAUTION! Before plugging in the tool, always check the working voltage be sure that the voltage specified is on the name plate. Before plugging in the tool, always check to see that the slide switch actuates properly and returns to the “OFF” position when the rear of the slide switch is depressed. ON POSITION Switching on: Switch can be locked in “ ON” position for ease of operator comfort during extended use. Apply caution when locking tool in “ON” position and maintain firm grasp on tool. Push power switch to the forward position until it locks into position as shown in Figure 13. -
Page 17: Ground Fault Circuit Interrupter (Gfci)
GROUND FAULT CIRCUIT INTERRUPTER (GFCI) A Ground Fault Circuit Interrupter is built in-line with the power supply cord to protect the operator from electric shock. 1. GFCI Information. – Alpha Wet Polisher is provided with an in-line GFCI as a standard acces- ® sory for your safety, and to prevent possible electric shocks. It is strongly advised to test the GFCI on a regular basis. DANGER! Never attach a damaged extension cord to the polisher. NOTE: Use the appropriate extension cord, see table on page 9. CAUTION! When the GFCI trips, this could be the result of water entering the polisher housing. 1. Turn OFF the power switch, disconnect polisher from power supply and blow dry air inside the motor cover through the air vents. 2. Re-connect power supply and press the GFCI reset button. The polisher is ready to start working once the reset button is pressed down. DANGER! Always check that the GFCI unit is working correctly (reset, test, and reset) before using this tool. Do not use the tool if the GFCI is not working correctly. Do not bypass the GFCI if this condition occurs, a real shock hazard may exist. WARNING! If the GFCI fails to trip when the test button is pressed, or fails to reset, the device is defective and should replaced. CAUTION! 1. The GFCI is a safety device, do not use as an on/off switch. 2. The GFCI on the tool will not protect you if you cut into another current carrying conductor. 3. Do not use where water may enter GFCI case. -
Page 18: Testing In-Line Gfci Unit (Before Each Use Of The Polisher)
TESTING IN-LINE GFCI UNIT (Before Each Use Of The Polisher) 1. Connect polisher to a single phase AC power supply. 2. Verify that the indicator lens shows red (indicating output voltage). 3. Press the test button to verify that the red in the indicator lens disappears. 4. Press the reset button to verify the red indicator is visible. 5. The GFCI is now ready for use. WARNING! DO NOT USE IF ABOVE TEST FAILS! Indicator viewing lens. RED lens shows power to polisher. CLEAR lens shows no pow- er to polisher. RESET BUTTON TEST BUTTON Figure-16 Figure-15 VARIABLE SPEED ADJUSTMENT This polisher is equipped with a Variable Speed control DECREASE SPEED that will allow the spindle speed to be adjusted from 500 RPM to 2800 RPM. Speed adjustment is controlled by rotation of the wheel as shown in the Figure 14. INCREASE SPEED NOTE- Wheel numbers are for reference point of mo- tor speed (#1 is 500 RPM and #6 is 2800 RPM). Adjust the RPM of the tool to match the recom- Figure-17 mended RPM of the product being used. -
Page 19: Speed Pot Feedback Sensor
SPEED POT FEEDBACK SENSOR This polisher is equipped with a Closed Loop Feedback sensor that is attached to the speed pot. When a load is applied to the tool, the sensor will re-adjust the RPM to maintain a constant speed. WATER CONTROL VALVE CAUTION! Adjust the water flow to wet the stone and remove waste, excessive spray and mist will get inside the tool and cause premature failure of the tool and/or cause the GFCI to trip. This polisher is equipped with a center water-feed system. Water flow to the spindle shower bolt can be controlled by throttling the valve stem as seen in Figure 18, Figure 19 and Figure 20. Water Valve in Water Valve in closed position half open position Figure-19 Figure-18 Water Valve in full open position Figure-20... -
Page 20: Water-Feed Attachment
WATER-FEED ATTACHMENT Attach the polisher water-line fitting to any garden hose connection. OPERATION WARNING! To reduce the risk of electric shock, check the tool’s water supply system to ensure there is no damage to the seals or hoses. A damaged water supply system may result in abnormal water flow to the tool which could be dangerous. CAUTION! Always wear safety goggles or a face shield during operation. Never switch on the tool when it is in contact with the workpiece, it may cause an injury to operator. Never run the tool without properly installed accessories. Make sure that the water valve is closed. Connect the garden hose adapter to the water source. Make sure that water comes out when the water valve is opened. Hold the tool firmly. Turn the tool on and begin your application. Apply slight pressure only. Excessive pressure will result in poor performance and premature wear. MAINTENANCE CAUTION! Always be sure that the tool is switched off and unplugged before attempting to perform inspection or maintenance. DAILY Before daily start-up inspect tool, power cord, GFCI, and backer pad or other spindle attachments. If damage has occurred, repair affected areas before use. Connect the tool to the correct power source and test the Ground Fault Circuit Interrupter (GFCI) before using the tool. Push the RESET button and confirm that the red light is on, push the TEST button and confirm that the red run light is off and push the RESET button to use the tool. Turn the unit on and run in a no-load condition to ensure that backer pad or other spindle attachment is balanced. -
Page 21: Bearings And Gears
PERIODIC WARNING! Preventive maintenance preformed by unauthorized personnel may result in mis- placing of internal wires and/or components which voids the warranty and could cause serious hazards. We recommend that tool service and repairs not covered in the manual be preformed by an Alpha Repair Center. ® Periodic maintenance is done to check the tool and to minimize down time. These checks are done based on hours of operation and operating conditions. Operating condition can vary depending on the work surface and job being preformed. If the tool is not used for a long period of time the carbon brushes should be checked and the commutator cleaned, before putting the tool back into operation. BEARINGS AND GEARS To minimize your tool’s down time and expensive tool repairs, it is recommended to send the tool back to an Alpha Repair Center after about 300 to 400 hours of opera- ® tion or every second carbon brush set change. The bearings should be replaced and the gears should be checked. If your tool starts to sound differently, this could be an indication of a worn bearing; continuing to use the tool in this condition could result in over heating or motor failure. CARBON BRUSH REPLACEMENT Carbon brushes wear out over time, based on the polisher usage. If a carbon brush is worn out, it may cause the motor to malfunction or fail to run. Whenever the length of the carbon brush reaches the wear limit, replace with a new set. NOTE - To maintain even wear, both brushes should be replaced at the same time. Figure-21 The carbon brushes in this polisher are located underneath the Rear Cover (Part # 210053) as shown in Figure 21. -
Page 22: Rear Cover Removal
REAR COVER REMOVAL 1. Gently pull water tube away from holder. Figure-22 2. Release the tube from the holder. Figure-23 3. Unwrap 3 inches of the coiled harness. Figure-24 4. Remove the 2 screws from the valve bracket. Figure-25... - Page 23 5. Pull the valve assembly away from mount. Figure-26 6. Remove the rear case screw. Figure-27 7. Hold polisher with one hand and pull the rear case straight back with the other hand. NOTE: Do not twist case in a side to side motion when pulling back. Figure-28 8. Pull back the rear case until the carbon brush assembly is exposed. NOTE: Do not pull rear case further back from this point. Figure-29...
- Page 24 Carbon Brush Spring Carbon Brush Holder Carbon Brush Wire Figure-30 9. Lift the spring from the carbon brush and place on the side of the brush holder. Figure-31 10. Remove the carbon brush wire spade connector from the terminal post and then remove the carbon brush. Spade Connector Figure-33 Figure-32...
- Page 25 11. You can also remove the carbon brush by removing the screw and pulling the holder out with a pair of needle nose pliers. 12. With the carbon brush holder removed, you can check and clean the armature commuta- tor. The commutator is the contact points that the carbon brushes ride on when the motor is running. Figure-34 NOTE: Each polisher has 2 carbon brushes located on opposite sides of each other. After the replacement of the two brushes, assemble the polisher by reversing disassembly procedure.
- Page 26 16. The commutator should be clean and shiny; if it is dull and black, you can clean it with a commutator cleaning stone. Clean Dirty Figure-36 Figure-37 17. To clean the commutator, press the commutator cleaning stone against the com- mutator and rotate the armature by turning the spindle shaft by hand. Continue for a minute or until commutator is clean and shiny. Figure-38 18. Reconnect the power wire, ensuring that the wire path is correct. Reinstall the carbon brush holder into the slot on motor housing and slide in until the tab for the screw hits the stop. Install the screw using light pressure to prevent it from stripping. 19. After both carbon brushes have been replaced you can reassemble the rear cover. Make sure the power wires are in the tool to prevent pinching of the wires.
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Page 27: Alpha Wdp-120 Schematic
® ALPHA WDP-120 SCHEMATIC Revised: 12/2013... -
Page 28: Alpha Wdp-120 Guard Schematic
® ALPHA WDP-120 GUARD SCHEMATIC Optional Accessory Flexible Connector Hose... -
Page 29: Alpha Wdp-120 Parts List
® ALPHA WDP-120 PARTS LIST DRAWING NO. PART NO. DESCRIPTION QUANTITY 310025 Output Shaft with Nitriding (5/8"-11) 210006 Key (3x10) 210001 Screw M4x14 210002 Spring Washer M4 210003 Plane Washer M4 310002 Aluminum Gear Case Cover 210010 Ball Bearing 6201 310003 Bearing Cover 310004 Screw M4x10 310005 Gear Washer 210016 Gear 210017 Wave Spring Lock Washer 10 210018 "C" Clip for Shaft 10 210019 Oil-impregnated Bearing 8x12x8 210021 Self-tapping Screw 4.2x40 210022... - Page 30 ® ALPHA WDP-120 PARTS LIST DRAWING NO. PART NO. DESCRIPTION QUANTITY 210042 Field Coil 120V 310015 Brand Label 210091 Field Coil Case 310006 Data Label 210046 Carbon Brush Holder 210047 Coil Spring 210048 Carbon Brush 120V 210049 SST Self-tapping Screw ST2.9×8 210094 Terminal Block 210093 Speed Pot w/Speed Feed Back Sensor 120V 210053 Rear Cover 210054 Self-tapping Screw 4.2x14 210055 Cord Jacket 210056 Twist Strip 210057 Rubber Washer 210058...
- Page 31 ® ALPHA WDP-120 PARTS LIST DRAWING NO. PART NO. DESCRIPTION QUANTITY 210105 Pin Wrench not shown 210087 Blow Mold Case 500032 Main Cover 500033 Sub Cover 500034 Half Cover 500041 Brush-A 500042 Brush-B 500037 Screw M4x10 500005 Rubber Hose Adapter 310008 Stainless Steel Hose Band 310009 Rubber Cap 310010 Water Hose-A 6x8x510(mm) 310011 Hose Connector 310012 Water Hose-B 6x8x35(mm) 310013 Water Hose-C 6x8x40(mm)
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Page 32: Loaner Program
® workmanship for a period of 180 days from the date of original retail purchase (proof of purchase required). If Alpha Professional Tools receives notice of such defects ® during the warranty period, our obligation assumed under this warranty is limited to the repair or replacement of parts, without charge. -
Page 33: Frequently Asked Questions
APPENDIX A FREQUENTLY ASKED QUESTIONS Q. What applications is the Alpha WDP-120 recommended for? ® A. The Alpha WDP-120 is recommended for wet or dry polishing. ® Q. What is the warranty for this WDP-120? A. Alpha Professional Tools warranties the WDP-120 against defects in material ® and workmanship for a period of 180 days from the date of original retail purchase (proof of purchase required). Please complete the warranty registration card upon receipt and mail immediately for prompt warranty service. Our obligation assumed under this warranty is limited to the repair or replacement of parts without charge. The warranty does not apply to tool accessories. The warranty for repairs is 30 days on the parts and labor. Q. Does the WDP-120 have a maintenance program? A. Alpha Professional Tools does not offer any type of maintenance program. ® However, we do recommend periodic checking and/or replacement of the carbon brushes for extended service life. If you should hear or detect unusual noise during the operation of the WDP-120, we recommend that you send it in to our repair department for some preventative maintenance. Q. What is the RPM of the WDP-120? A. This polisher is a variable speed polisher with an RPM range of 500 – 2,800. Q. What shall I do if my WDP-120 breaks down and I need to complete the job immediately? A. This largely depends upon the time frame involved. The first step would be to check and replace the carbon brushes. Alpha Professional Tools... - Page 34 ® provide the optimum polish on engineered stone material. Alpha does not ® recommend dry polishing on engineered stone. Q. What is the largest diameter accessory that the WDP-120 will accept? A. The WDP-120 will accept accessories up to 5”. Do not attempt to use accessories larger than 5” for safety reasons. In addition, large accessories require more torque than the WDP-120 can provide. Operating the WDP-120 under these conditions will result in overheating failure. Q. Can I use the WDP-120 for drilling applications such as faucet holes? A. No. The WDP-120 cannot be used with Alpha Core Bits to drill faucet mounting ® holes. We recommend using the VSP-120 with the provided C-Handle attachment and a template. Q. How many gallons of water does the Alpha WDP-120 use per minute? ®...
- Page 35 PRODUCT REGISTRATION CARD Model No. Serial No. Company Name: ______________________________________________ Name: ______________________________________________________ Address: ____________________________________________________ City: _______________________State: ________Zip: ________________ Telephone: ___________________________________________________ Purchase Date: _______________________________________________ Dealer’s Name: _________________________________ Note: Serial & Model Number must be included for proper registration. (800) 648-7229 Register online at: www.alpha-tools.com/productregistration.aspx Mail or Fax to: Alpha Professional Tools ® 103 Bauer Drive, Oakland, NJ 07436 Fax: 800-286-0114...
- Page 36 103 Bauer Drive, Oakland, NJ 07436 • 800-648-7229 • Fax: 800-286-0114 www.alpha-tools.com Copyright 2013 Alpha Professional Tools. All rights reserved. © Assembled in China Revised: 12/2013...
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