GENERAL OPERATION AND SERVICE MANUAL HYDRAULIC VIBRATORY HAMMER EQUIPMENT GENERAL INTERNATIONAL CONSTRUCTION EQUIPMENT BV (ICE) Hefbrugweg 6 (De Vaart), 1332 AN, Almere, The Netherlands Telno.: +81 36 532 05 60, Fax no.: +31 36 532 04.01 Revision 3 - frst printing 07/96 7) Printed in Holland a Manual number: MAN.EN4O emogue 1804001 ered carya GENERAL (© 1996 INTERNATIONAL CONSTRUCTION EQUIPMENT BV (ICE) Al ights reserved. No part of this publication may be copied or published by means of printing, ‘photocopying, micrafilm or otherwise without prior written consent of INTERNATIONAL ‘CONSTRUCTION EQUIPMENT BV. This restriction also applies to the corresponding drawings ( and ciagrams. INTERNATIONAL CONSTRUCTION EQUIPMENT BV has the right to change parts of the equipment at any time without prior or direct notice to the client. ‘The contents of this publication are subject to change without notice, ‘This publication is to be used for the standard version of the equipment only ‘Thus INTERNATIONAL CONSTRUCTION EQUIPMENT BV cannot be held responsible for any ‘Gamage resulting from the application of this publication to the version actualy delivered to you. For exira information as to adjustments, maintenance and repair, contact the technical department of your supplier. This publication has beon writen with great care, However, INTERNATIONAL CONSTRUCTION EQUIPMENT BV cannot be held responsible, either for any errors ocourring in this publication or for their consequences. ‘The enclosed O.E.M. documentation has been produced and published by the manufacturer in question, INTERNATIONAL CONSTRUCTION EQUIPMENT BV cannot be held responsible for errors occurring in the ©.E.M documentation or for their consequences. =i @ new 3.0087 ei 180-601 exited companyLIST OF ACCESSORIES Vibratory hammer CLAMPS, BEAMS ADAPTOR PLATE (Turning plate) BIAS WEIGHT (Extra/Ballast weight) JAWS: Powerpack PACKAGE SUPER SILENCE RADIOGRAPHIC REMOTE CONTROL SHUT-OFF PUMP HEAD MANIFOLDS IMMERSION HEATER: Rev. 3-02/97 GENERAL ~ Universal clamps with interlock jaws = Caisson clamps for tubes and double sheet piles = Conerete clamp for displacement piles like concrete, wooden or cast-in-situ piles = Used in conjunction with 2 or 4 caisson clamps ‘and available in several lengths - Mounted between footplate of vibratory hammer and clamping system to suit any pile/sheet pile ‘configuration - Mounted on top of the suppressor head to increase the rate of penetration or limit rebound, effects = Several jaw configurations are available or can be made up to suit specific requirements ~ Reduces noise level at 10 m below 70 dB(A), | however increases weight and dimensions | - Wireless operations of main functions of hammer and powerpack ~ On most pumps itis possible to shut-off (manually or electrically) 1 or a number of inaividual pump heads to reduce the maximum flow. - Anumber of different manifolds are available for different combinations of operations, like vibratory driving, impact driving, ete. ~ Optional on some models to keep oil at a minimum temperature, e.g. in arctic areas en =I 150-001 ceed companyGENERAL 7 PREFACE ‘This manual was prepared to acquaint the owner, operator and service engineer with the operation and maintenance of the vibratory hammer with hydraulic and electrical part of the power unit. This manual is divided into the following chapters: Chapter 1: Safety instructions This chapter deals with general warnings and safety precautions ‘which should be adhered to and be known to the owner's operating personnel to reduce the risk of personal injuries or major environmental hazards. This chapter also contains an explanation on the pictographs and symbols used. Chapter Functional description Provides a brief description of the system functions. Chapter 3: Preparations for operation Describes the general preparations to be taken care of before the hammer or powerpack can be used for the purpose it was built for. Chapter 4: Operation Provides general operating instructions. Chapter : Special operations Provides special operating instructions, Chapter 6: Hydraulic circuitry Describes the main and the secondary pump circuitry. Chapter 7: Electric circuitry Desoribes the electric circuitry. Chapter 8: Maintenance Describes general maintenance instructions Chapter 9: Ordering of parts General chapter on ordering of parts, used abbreviations, list of key words, list of definitions, etc. Parts manual Hammer (if applicable) Parts manual Clamps (if applicable) Parts manual Turning Plates (if epplicable) en-IV Rov. 3-02/97GENERAL 7 Parts manual Powerpack (if applicable) Options (if applicable) Troubleshooting Troubleshooting diagrams (i applicable) Note: Dimensions are in the metric system, unless otherwise specified, Instructions for steps to perform are marked by a Take the time to thoroughly familiarize yourself with the contents of this manual before starting the operation or undertaking any maintenance work on the unit(s). (One copy of the present manual should at any time be at the location where the Unit is in operation. We sincerely hope that this manual will be a useful guide to the operation and maintenance of the equipment. If operational or maintenance problems arise which are beyond the scope of this ‘manual, please contact ICE BV at the telephone number on this page. We are prepared to assist you in order to make the best use of your equipment. {you call, please have the following at hand: = equipment serial number and model year of make = electrical specifications = hydraulic specifications INTERNATIONAL CONSTRUCTION EQUIPMENT BV Heforugweg 6 (De Vaart), 1332 AN Almere ‘The Netherlands Telno.: +31 365920560 Fax no.: +31 365320401 MAN.EN40 Revision 1 - first printing 12-95 Printed in Holland 2 A CONTRIBUTION GQ To THE PROTECTION OF OUR ENVIRONMENT The packaging material All spare parts have been packed in cardboard or wooden boxes, Disposing of the equipment ‘An equipment that has reached the end of its operating Ife stil contains valuable substances and materials. Instead of disposing of your machinery, enquite at your local authority as to the best means of recycling these materials. Rev, 8-02/97 Cy wy 1809001 certod company YYGENERAL CONTENTS page PREFACE .. A CONTRIBUTION TO THE PROTECTION OF OUR ENVIRONMENT 1 SAFETY INSTRUCTIONS ... 1.1 General 1.2. Safety precautions 4.3 Limit conditions 1.8.1 Refusal 1.3.2. Rebound 113.3 Max, bearing temperatures 1.4 Incorporated safety precautions 2 FUNCTIONAL DESCRIPTION 3 PREPARATION FOR OPERATION 3.1 Delivery of equipment... 3.2 Rigging of vibrator 3.3 Connecting the hydraulic hoses at the powerpack 3.4 Bleeding hydraulic clamp hose lines 3.5 Filing vibrator pressure hose 3.8 Hand-held remote control pendant... 3.7 Starting and warming-up diesel engine . 3.8 Control paneVdashboard : 3.9 Final check before start-up .. 8.10 Warming up hydraulic fuid... 4 OPERATION ... 4.1 Operation from remote control pencat 4.1.1 Clamping a pile .. 4.1.2 Starting vibration 4.1.3 Stopping vibration .. 4.1.4 Off-clamping from a pile 4.41.5 Emergency stop 4.2 Changing the frequency . . 4.3 Shutting down the diesel engine 42 4.4 Cooling down the vibrator gear case 242 4.5 Caisson clamp adjustment... 4.8 Hydraulically lacked caisson clamps . 5 SPECIAL OPERATIONS 5.1 Operating instructions for ICE-AF vibrators. 5.2 Driving and extracting battered piles ... 5.3 Operating the hammer at very low temperatutes .nrnronrnnnunnn 2 5.4 Compacting or continuous operation. 52 en- VI Rev. 9.02/87 180-8001 cartes companySf 5.5 Operating hydraulic vibratory hammers under water 5.6 Operating instructions for deep water (otishore) operations. 6 HYDRAULIC CIRCUITRY .. 6.1 Main pump circuitry 6.2 Secondary pump circuitry 7 ELECTRIC CIRCUITRY....... 8 MAINTENANCE 81 General 8.2 Dally maintenance 8.3 Monthly maintenance 8.4 Yearly maintenance 8.5 Recommended exchange criteria for long term wear and tear parts ... 8.5.1 Hammer 8.5.2 Powerpack . 8.5.3 Heavy duty conditions 88 Long-term storage . 8&7 Lubrication 8.7.1 Hydraulic drive oil. 8.7.2 Biodegradable hydraulic oft... 8.7.3 Lubrication oil vibratory gear CASE on 8.7.4 Lubrication of the vibration case uncer ‘extreme circumstances i 8.8 Maintenance of hydraulic circuit elements 8.8.1 Draining and filing hydraulic ol tank in powerpack 8.8.2 Cleaning the hydraulic pick-up fiter .. 8.8.3 Changing the hydraulic return fier element... 8.9 Installation of the hydromotor .... 8.10 Oil capacity 8.11 Pressure settings and lubricetion instructions chart 8.12 Lubrication intervals (powerpack running yarn 8.13 Bolt torque information nee 8.13.1. Vibrators ... 8.13.2 Powerpacks 9 ORDERING OF PARTS . 9.1 Procedure : 9.1.1 Original equipment .. 9.1.2 Shipment . 9.1.3. Shortages ..... 9.1.4 Return of parts 9.2 Screws and bolts 9.3 Hoses 9.4 Fittings Rev. 3-02/97 ee en- Vi soso T5090 ceca careany Aoretoga PARTS MANUAL HAMMER (ff applicable) PARTS MANUAL CLAMPS (if applicable) PARTS MANUAL TURNING PLATES (if applicable) PARTS MANUAL POWERPACK (f applicable) OPTIONS ff applicable) TROUBLESHOOTING (t applicable) LIST OF ILLUSTRATIONS Fig. Description 1.01 Pictographs used on ICE Equipment 1.02 Pictographs used on ICE Equipment 1.03 Pictographs used on ICE Equipment 1.04 Pictographs on Vibratory Hammer and Pile Clamp 1.05 Pictographs on Powerpack 1.08 Explanation of pictographs on equipment 1.07 Explanation of pictographs on equipment 2.01 Layout drawing 3.01 Connection of hydraulic hoses 3,02 Control panel powerpack 3,03 Remote control pendant 4.01 Measurement caisson clamp adjustment 4.02 Hydraulic circuit ICE-Hydrolocks 9.01 Fittings LIST OF TABLES Table Description 3.01 Recommended siings or grommets 5.01 Labeling of connections on powerpack 8.01 Oil capacity 8.02 Oil capacity powerpack 8.03 Pressure settings 8.04 Lubrication intervals 8.05 Torque settings for bolts SHCS 12.9 8.06 Torque settings for bolts (standard thread) en - VII 10300 ered company @® GENERAL Rev, 3-02/97GENERAL DANGER / WARNING / CAUTION MAIN SWITCH / BATTERY SWITCH STOP / START DIESELENGINE REVOLUTIONS PER MINUTE (RPMD DIESELENGINE LOWER / RAISE REVOLUTIONS PER MINUTE (RPM DIESELENGINE ENGINE OVERSPEED OPEN / STOP MOVEMENT / CLOSE CLAMP CLAMP CLOSE INDICATION START. VIBRATION LOWER / RAISE EXCENTRIC MOMENT DRIVE / BRAKE STOP VIBRATION ANPERE METER HOUR COUNTER INTERIOR LIGHT ON / TIMER SETS OFF PANEL LIGHT ON / OFF P, ae i} Fig. 1.01 Pictographs used on ICE Equipment Rev. 3-02/07 en- 1x moon 150-9001 ceried orpanyRETURN OIL FILTER CLOGGED INDICATION SHUT DOWN RESET. EXCEEDS 3 bear. AIRPRESSURE HYDROTANK PUMP INLET PRESSURE DIESELENGINE OIL PRESSURE DIESELENGINE OIL PRESSURE TOO LOW CLAMP CLOSE PRESSURE CLAMP OPEN PRESSURE SHIFT PRESSURE DECREASE EXCENTRIC MOMENT SHIFT PRESSURE INCREASE EXCENTRIC MOMENT WORKING (DRIVE? PRESSURE BRAKE (RETURN) PRESSURE ENGINE COOLANT TEMPERATURE ENGINE COOLANT TEMPERATURE TOO HIGH HYDRAULIC OIL TEMPERATURE LOW HYDRAULIC GIL TEMPERATURE TOD HIGH Fig. 1.02 Pictographs used on ICE Equipment OS) 808001 ceiacompary GENERAL TO START HOLD BUTTON UNTIL ENGINE DILPRESS Rev. 3-02/97© bya! MIN Va we De MAX em é Es ASTOP. GENERAL HYDRAULIC OIL LEVEL | Rel] LA HIGH NOISE LEVEL RISK OF BURNS TO FINGERS: (OR HANDS RESULTING FROM DANGEROUS LIQUIDS OR (CHEMICALS FIRE RISK AB! |b B [eB] le HOW TO PREVENT KEEP CLEAR FROM EXPLOSION AREA, USE ADEQUATE CLIMBING DEVICE DISCONNECT POWER SOURCE BEFORE OPENING DASHBOARD USE EAR PLUGS WEAR PROTECTIVE GLOVES KEEP MACHINE CLEAR OF OIL RESTS. BE CAREFUL WHEN HANDLING FUEL. AND HYDRAULIC O1L Fig. 1.07 Explanation of pictographs on equipment Rev. 3-02/07 150-300 cried company a ent-10GENERAL o - > Fig. 2.07 Hydraulic vibratory pile driving hammer spread with its main components en2-1 reniere TS0-s01 cored company Rey, 3-02/97ff \ GENERAL 2 FUNCTIONAL DESCRIPTION A hycraulic vibratory pile driving hammer spread consists of the following main ‘components, Also refer to the layout drawing (fig. 2.01): 1 Hydraulic Vibratory hammer 2 One or a set of pile clampis) 3 Hose bundle between hammer and powerpack 4 Diesel hydraulic powerpack ad1 The vibratory hammer itself consists of ~ A vibratory case (gear case) with an even number of eccentric weights rotating at 1,000 - 3,000 rpm around their shafts and driven by 1 or a number of hydraulic motors. ~ A suppressor (hammer head) connected to the vibratory case through rubber elastomers. ‘The suppressor isolates the vibrations from the hammer to the crane or pile driving rig. When the diesel engine is started, the hydraulic pump is automatically activated and oil is circulated through the main manifold back into the tank. After the main valve on the manifold block is activated, the oil flow will rotate the hydraulic motor(s) which in turn rotate(s) the main drive shati(s) Due to the gear synchronisation between the drive- and eccenter shafts) the eccenters will start to rotate and the hammer starts its vertical vibration, 150-9001 certegconparyL= 7 q iz ee mre a Fig. 3.07 Connection of hydraulic hoses ena-1 (A) Rev. s-0097 pevee gin 150-9001 certified company ah S GENERAL QS? 3 PREPARATION FOR OPERATION 3.4 DELIVERY OF EQUIPMENT When unloading and unpacking the vibratory diver, use extreme care. For your protection, make a thorough inspection of the unit immediately on delivery. In case of any damage or shortage notify the transit agent at once and have the delivery carrier make a notation on the freight bill. WARNING ‘Always lift powerpack by its own lifing lug(s). Use certified slings and place the powerpack on a horizontal and stable ground (surface). 3.2 RIGGING OF VIBRATOR AA stool wire rope sing must be connected to the fiting pin of the vibration suppressor. The required strength of this sing depends on the capacity of the crane land the werk to be carried out. A safety factor of five is recommended. Several turns of a smaller diameter cable will usually last longer than one turn of a larger diameter cable, Refer to the table below for recommended slings or grommets. ‘Max. line pull | Hammer type [Grommet] Allow. ‘Allow. diameter | single work load | double work load 2 tomes 18: 625 24mm 6200 Kg 12400 kg) 18 tonnes 216 33mm 11880 kg) 17820 kg, 24 tonnes 223; 1228; 39 mm 16520 kg 2aTBO kg 14280; 14RF | ‘Otonnes | 416; 420; 428;S117 | S4mm | S1820k9 7730 kg 815 (0), 5515; 2RF ‘SO tonnes | BAF; 3026; 46RF, 62AE| S7mm | S5340 kg 58040 kg 60 tonnes, “6RF comm | 402009 {60300 kg 80 tonnes 14120) Tamm | $6100 kg ‘84150 kg 720 tonnes 1212) 120mm | 60400 kg 720800kg | Tabio 3.01 3.3 CONNECTING THE HYDRAULIC HOSES AT THE POWERPACK A CAUTION ‘The powerpack must be shut down during connection of the hydraulic hoses. * Connect the vibrator and driving head to the powerpack by five hydraulic hoses (refer to fig. 3.01), Rev. 3-02/97 en 3-2 maga 150400 caries companya GENERAL © Connect the hoses to the powerpack with the help of quick-disconnect couplers. The hose couplers are arranged and sized to ensure correct connection at the powerpack. * Clean the couplers with a thread-free cloth before making the connections. ‘* Make sure that the couplers are fully run-up. They should be firmly hand-tight. If wrenches are used, do not overtighten. 3.4 BLEEDING HYDRAULIC CLAMP HOSE LINES Normally, the vibrator and hydraulic clamp(s) are shipped as a unit with all hoses attached. The hoses are usually full of fluid and may be used immeciately. However, if for any reason the clamp line hoses have been removed or if air is present in the lines, they must be bled prior to resuming operation. + Start and warm up the ciesel engine as described in section 3.7. * With the engine warmed up and running, loosen the clamp close line at the hydraulic clamp. Turn clamp switch (OPEN/CLOSE) on the remote control pendant to CLOSE. Wait until fluid flows from the connection at the hydraulic ‘clamp. When fuid flows without any traces of air, tighten the connection. ‘+ After the clamp close line has been bled, do the same for the clamp open line, Then turn the clamp switch to CLOSE and to OPEN several times to ensure that the clamp cylinder is working properly It may be necessary to bleed the hose more than once. “ 3.5 FILLING VIBRATOR PRESSURE HOSE ‘The vibrator is usually shipped with the vibrator hydraulic hose full of fluid so that, the unit may be used immediately. However, if the pressure hose has been removed from the vibrator, it should be allowed to fill with hydraulic fluid prior to full speed operation. It is not necessary to have the return hose filled with fluid, ‘+ Start and warm up the diesel engine as described in section 3.7. With the engine warmed up and running at about 1,500 rpm, the main lines will bbe automatically filed with hydraulic fluid in about 10 min. ‘Wait 10 min for the lines to fil up. Do not operate any switches on the control pendant * Check the oil level in the hydraulic oll tank. Refil when the level is below or near the minimum mark. 3.6 HAND-HELD REMOTE CONTROL PENDANT * Connect the remote control pendant with its cable plug to the dashboard of the powerpack. With the remote control pendant connected, the vibrator can no longer be operated from the dashboard, en3-3 2) Rev. 3-02/97 sete re 1504001 certodcorpary aeGENERAL CAUTION ‘The vibrator can be operated without using the remote control pendant. Safe operation of the equipment however can only be obtained if the remote control pendant is connected to the vibrator. Operation without remote control pendant is only allowed in case the connecting cable is broken provided that the operator has a clear view on the vibrator and the working area, * To allow control from the dashboard, remove the connecting-plug from the dashboard. A WARNING ‘The EMERGENCY STOP on the dashboard and the outer side of the powerpack will not be bridged when the remote control pendant is connected to the dashboard and they will always stop the equipment. 3.7 STARTING AND WARMING-UP DIESEL ENGINE ‘* Read the operator's manual of the diesel engine. CAUTION Before starting the engine, take all precautions as described in chapter 1 ‘The diesel engine must not be started if the temperature of the hydraulic fluid is below -18 °C. The fluid temperature can be read on the gauge mounted on the hydraulic reservoir or on the Hydraulic Fluid Monitor (black needie) on the control panel (ICE-780 only). It ambient temperatures below -18 °C are anticipated, an immersion heater for heating the hydraulic fluid is available. Consult ICE for detaits, e * Open the air inlet valve and the air outlet fleps on top of powerpack cover door (for ICE-870, ICE-780 and ICE-900 only). * © Turn main power switch to ON. /\ WARNING ‘Check if the vibrator switch on the remote control pendant is in OFF position. Press the STOP button on the control pendant or dashboard panel and release it. * Briefly activate the RPM+ switch on the pendant control ‘+ Press the red button of the safety switch and keep the bution depressed until the oll pressure exceeds 2 bar (30 PSI). * Press the START switch and turn it to START. If the engine fails to start after 30 s of cranking, allow the starter to cool down for several minutes before repeating the starting procedure. * As the engino starts, release the START switch. * Adjust the throttle (manually or via pendant) untl the engine is running at 1,500 rpm and allow it to warm up for about 5 min. Rev. 302/97 Fp) ene-a sone 180-900 ied cgay JGENERAL Fig. 8.02 and 3.03 Control panel and remote control pendant ona i) Reon a woman 68)we A CAUTION Allow the temperature of the hydraulic fluid to come up to at least 0°C (30°F) before starting the vibrator. 3.8 CONTROL PANEL/DASHBOARD ‘The control panel (ig. 3.02) of the powerpack contains all operating controls, gauges and switches for the hammer and the powerpack. Connected to the control panel is the remote control pendant (fig. 3.03). Note: The OPERATION AND MAINTENANCE INSTRUCTIONS on the control panel merely serve as reminders. They are not complete and therefore not intended as a substitute for a thorough understanding of the present manual. 3.9 FINAL CHECK BEFORE START-UP * Check all bolts of the clamp. if necessary tighten them. Refer to the table in section 8.13.1 for tightening torques. * Check the oil level of the vibratory hammer. The oil level must be half way the sight glass. Refer to the maintenance section for the oil type to be used. * Check all bolts of the vibratory hammer (pay special attention to the bolts of the vibration case, the cover plates and the motor guards) * Check the oil level of the hydraulic reservoir in the powerpack. The level must be in between the MAX and MIN indications on the level gauge. Refer to the maintenance section for the oll type to be used. x } * Check the fluid level and the water separator, ‘© Grease the plunger of the clamp. ‘Check the hydraulic hoses and couplings for damage, leaks, etc. Replace if necessary. © Check if the EMERGENCY STOP buttons on the dashboard, the powerpack and the remote control pendant are released. * Check the clamp pressure on the dashboard with the clamp switch in CLOSED position. Refer to the PRESSURE SETTINGS AND LUBRICATION INSTRUCTIONS CHART in chapter 8. Note: If the clamp pressure is below the specified pressure, check the pressure switch and relief valves for correct setting. © The hammer is now ready for operation. WARNING Never loosen the oil sight glass at a warm vibrator body ternperature. A pressute spray of hot oil may cause severe injury. Wait until the body has cooled down: seen Rev. 8-02/97 ‘emia3.10 Note: en3-7 GENERAL WARMING UP HYDRAULIC FLUID ‘The vibrator must not be operated at full speed if the temperature of the hydraulic fluid is below 15 °C (80 °F). Refer to the hydraulic temperature indication on the control panel. CAUTION Do not operate the vibrator if the hydraulic fluid temperature exceeds 70°C (160°). 6, Rev. 3-02/97 1S0-300 srg carpany owe 4 OPERATION A CAUTION ‘Make sure to have a good view over the vibrator and the working area. Ensure that communication with the crane driver is always possible. A WARNING Stay clear of the direct surrounding of the vibrator. 4.1 OPERATION FROM REMOTE CONTROL PENDANT 44.1 Clamping a pile * Position the vibratory hammer first over and than on the pile. * Tum the clamp switch to CLOSE. The CLAMP light will ight up when the hydraulic clamp has achieved adequate pressure to permit vibration to begin. The light should normally light up in a few seconds, 44.2 Starting vibration ‘= Tum the vibration switch to START/FORWARD or press the START button. CAUTION Do not start the vibrator until the CLAMP light in the pendant lights up indicating adequate clamping pressure. 44.3 Stopping vibration * Turn the vibration switch to STOP/REVERSE or press the STOP button. CAUTION Never use the EMERGENCY STOP button for normal stops. 4.1.4 Off-clamping from a pile * Turn the CLAMP switch to OPEN to release the hydraulic clamp so that the vibrator can be removed from the pile. CAUTION Check if lifting line is slightly under tension before the clamp pressure is released. Rov. 3-02/97 en 4-1 T5001 eed company‘CAUTION Do not turn the switch to OPEN until a visual check indicates that vibration has stopped, 44.5 Emergency stop For an emergency stop either the buttons on the dashboard, the powerpack or the remote control pendant may be used. + Press the EMERGENCY STOP button. A CAUTION Before continuing operations reset the EMERGENCY STOP button by turning it clockwise. Always reset the EMERGENCY STOP button immediately after the hammer and powerpack have been shut down completely. 4.2 CHANGING THE FREQUENCY In order to provide maximum flexibility in achieving optimum piling penetration and extraction rates, the frequency of the vibratory driver is adjustable. The frequency can bbe varied by changing engine speed. Engine speed is changed with the ENGINE THROTTLE or RPM +/- switch on the dashboard or on the hand-held pendant. 4.3 SHUTTING DOWN THE DIESEL ENGINE + Stop the vibrator. * Allow the diesel engine to run at 1,500 rpm during 5 min. * Reduce the speed to low idle for about 30 s. ‘© Stop the engine by turning the ENGINE START switch to OFF. A WARNING If the diesel engine is shut down while the vibrator is clamped to a pile, the ‘clamp check valve will keep the vibrator clamped to the pile. However, system leakage Could result in a loss of clamp pressure. Therefore it is not allowed to leave the vibrator clamped to a pile for a considerable period of time when the diesel engine is not running + Top up the fuel system immediately after operation to prevent condensation in the fuel tank. 4.4 COOLING DOWN THE VIBRATOR GEAR CASE Note: Never cool the vibrator gear case with water in order to avoid thermo- shock of the bearings. The vibration case must slowly cool down in ait. en4-2 SB) Rev 3.0207 omen isoowncantateomnny —— (2)GENERAL 4.5 CAISSON CLAMP ADJUSTMENT When using caisson clamps the adjustment of the clamps relative to the centreline of the hammer should be: © telative to the pile internal diameter Di when the clamp noses face inwards; * relative to the pile outside diameter Do when the clamp noses face outwards. The measurement from the centreline of the hammer should always be to the final position of the fixed jaw. See fig. 4.01. Fig. 4.07 Measurement caisson clamp adjustment fev 202 @) ves — 180-9001 certfied company© ace ao ea ee = Fig. 4.02 Hydraulic circuit ICE-Hyarolocks en 4-4 ventas 180-001 cared company Rey, 3-02/97@ dENeRAL we 46 HYDRAULICALLY LOCKED CAISSON CLAMPS By activating the clamp switch on the remote control, the clamp (I) closes and the wedges (IV) which clamp the pile on the beam are locked (see fig. 4.02). ‘When the manually operated flow control (Ill) remains open, the wedges are pressed in “clamp close" position (CLOSE) and open again in *clamp open position (OPEN). When the flow control (III) is closed, the wedges (IV) are pressed ir Position (CLOSE) and do not open in "clamp open" (OPEN) position. “clamp closed" By opening the flow control (Il) and by switching the clamp to open position (OPEN) (keep it shortly in open position), the wedges (IV) unlock again. When the flow control (Il) of one clamp is closed the clamp remains blocked; the other clamp can stil be moved until the clamp is switched again in “clamp closed” position (CLOSE), As with the clamp, the hydraulic set is activated when the pressure decreases, Note: Open and close the flow control (Il) by hand when it is pressureless. Operating the hycraulically locked ple clamps * Adjust the clamps to the (pite) width. ‘© Close the flow control (III) by turning it clockwise by hand, + Position the machine on the pile using the clamps. * Clamp the clamps on the pile (position "CLOSE"); the clamps are pressed on the beam. } * Loosen the clamps from the pile (position "OPEN’); the clamps remain on the correct pile width. ‘* Moving the clamps: + Open the flow control (Ill) by turing it counterclockwise by hand, ‘+ Open the clamps and keep them in "OPEN" position for a moment. Rev. 8-02/97 mee 1809007 cece company en 4-5aS GENERAL 5 SPECIAL OPERATIONS 5.1 OPERATING INSTRUCTIONS FOR ICE-RF VIBRATORS. ‘The specific feature of the IGE RESONANCE FREE Vibratory hammer is that the Upper and lower row of the eccenters can -by remote control- be shifted in such a way that the total eccentric moment of the hammer can be infinitely varied from 0- 100%. For this reason there is/are one or two additional hydraulic shift gear(s) on the hammers. ‘The clamp pump on the PTO of the engine is connected to a special manifold ( inside the powerpack. This manifold can be electronically activated to either supply the hydraulic clamp(s) or to activate the shift gear Apart from the 3 hammer operating hoses, there are: - 5 connections for the ICE-14RF, ICE-23RF and ICE-46RF ~ 6 connections for the ICE-28RF The connections on the powerpack are labelled as illustrated below. ‘Moment Clamp oh orc i o oO ° oO ° Table 6.01 Remote control pendant ‘The hammer, clamp(s) and shift gear are operated from a special remote control pendant. Proceed as follows: © Start the diesel engine and warm up as described in the operating manual. * Increase the diesel engine rpm. ‘+ Hold the ECG MOM switch on the pendant in [] position until pressure has reached 190 bar. This will take a few seconds. ‘+ Start the hammer through the pendant. * Wait until the eccenters rotate at full speed. * Hold the ECC MOM switch on the pendant in [+] position until the required amplitude or maximum vibration level is reached, * To stop the hammer proceed in reverse order. Note: Some powerpacks have an electric circuit where the eccentric moment is automatically shifted to ZERO before the hammer is stopped. en 5-1 Gey Rev. 3-02/97 sense 70 180-800 ered carpary =Ly GENERAL 5.2 DRIVING AND EXTRACTING BATTERED PILES Driving and extracting battered piles is allowed up to a batter of 1:1 without any modification to the hammer. ‘When driving battered piles one should take care that: * when using @ hammer with a splash lubrication system the gears connected to the eccentrics have to be at the lower (under) side of the rake. '* when using hammers with a forced lubrication system the suction side of the lubrication oil pump should be at the lower (under) side of the rake, Please see your parts manual whether the mentioned positions are at the hydromator side or at the opposite side. 5.3 OPERATING THE HAMMER AT VERY LOW TEMPERATURES When using the hammer at very low ambient temperatures (below -10 degrees, centigrade) please make sure that you adhere to the following instructions: ‘© when starting the hammer never run the hammer at maximum RPM. Let the hammer warm up slowly; * make sure that the bearings get enough oil by taking off one of the bearing covers (with forced lubrication hammers at the farthest position away from the ol input location); { * the lubrication oil may be changed for a lower viscosity cil, however one should check the oll viscosity also at higher temperatures as the hammer warms up rapidly once driving at full speed. 5.4 COMPACTING OR CONTINUOUS OPERATION Basically, ICE hydraulic vibratory hammers without forced lubrication cannot be Used for compaction work or continuous operation, e.g. working periods of longer than 1 hour. This would cause the bearing temperature to exceed 100 °C. Driving of heavy sections or closed ended piles (e.g. for sand pile operations) may ‘cause the hammer head (suppressor) to start bouncing, Should this happen, the suppressor head must be adcitionally ballasted. Note: ICE should be contacted prior to the actual operations on site or immediately after rebounce phenomena are experienced. ev. 3-02/97 ae 3a) ore 1S0.900 casa enpany oefo GENERAL we ICE hammers with forced lubrication may be used in two different modes: * short lubrication circuit; the oil is pumped from the gear case through the gear case coverplate straight into the bearings. * extended lubrication circuit; as above, however the pumped oil is first pumped through an cil cooler located at the backside of the powerpack before it is pressed through the bearings. Note: The extended lubrication circuit requires an adcitional oil cooler unit and 2 additional hoses. This is required for all compacting and continuous operations. 5.5 OPERATING HYDRAULIC VIBRATORY HAMMERS UNDER WATER ‘The following should be adhered to when operating vibratory hammers under water: + Check the transmission case proceeding as follows: * Check all seals and gaskets (O-rings, gasket between vibration case and vibration case adaptor). * Check all bolt connections. Check for possible leakage by bringing the pressure in the transmission case to approx. 0.2 bar excess pressure and by checking with a mixture of water and soap. * Check all hydraulic hoses on leakage. * Check the oil level in the transmission case. + Remove the breather and replace it by a plug. ‘Should the water depth be less than 10 m, the following should suffice: + Join the transmission case to a compressor and bring the transmission case to 0.5 excess pressure, + Increase the air pressure to 1.0 bar overpressure when the hammer is at 6 m below the water ine. * In this way there is a constant excess pressure of min. 0.2 bar and max. 0.5 bar present * After completing under water working check lubrication oil and when required change it )\ CAUTION Watch carefully that hammer is not “hot” when lowered or driving through the water surface. This may cause a thermo-shook and damage the bearings. j\ CAUTION Excess pressure of more than 0.5 bar may damage the transmission case. ® eote om 130-504 exttadcarparyGENERAL Ve In case of water depths of over 10 m, always use the air regulation system for under water operation. During these operations regularly check the oil level. if the oil becomes white/grey check immediately for leakage and replace the oi A CAUTION (Check lubrication oil regularly during and in any case after completion on watercontent. Water can also enter the case as condensate from non- dried compressed air. Contact ICE for such operations. 5.6 OPERATING INSTRUCTIONS FOR DEEP WATER (OFFSHORE) OPERATIONS Air regulation system Before operating, read and check the vibrator according to 5.5 of Operation and Service Manual. Connect the air regulation system to an air compressor with an air buffer. ‘The air pressure you need under water is 1/70 of the depth in meters, For example: 200 meters under water = 200 x ho + 1.1 BAR = 21.1 BAR ‘The 1.1 BAR over-pressure is needed to avoid leaking seawater into the vibration gearbox, Note: By lowering and retrieving the hammer be aware of the maximum speed of 10. 15 mtr/min, Testing the air regulation system (se0 fig. 5.01) Disconnect the hose (b) from air valve R. = Screw a plug in the hose connector, - Start the compressor, at 1.1 bar over-pressure the safety valve S will be opened (you can hear the valve breath out), Maintenance ‘After operating under water check the oil ofthe vibration gearbox. (See also 5.5) For long-term storage fil the air regulating vaive with oil to avoid corrosion of the inside of the valve (See also 8.6) Rev. 3-02/97 nero 10-9001 csitosconparyGENERAL Check the membrane of the air regulating valve every 6 months by removing the screws of the cover. When it is damaged, replace it. (P/n 9306034) Note: Contact ICE for special operating and maintenance instructions waler pressure Fig. 5.01 Air regulation system for deepwater operation (offshore) en 5-5 Rev. 3-02/97 180-800 orifled companya GENERAL 6 HYDRAULIC CIRCUITRY ‘The hydraulic circuit of the ICE vibratory hammers and powerpacks is a so-called ‘open-loop system. There is only a very low back pressure in the return line. Each powerpack is equipped with 2 pumps: = the main pump which drives the hydraulic motors on the vibratory hammer; = the second pump which is used to open and close the hydraulic clemp\s). (On RF-type machines this pump is also used to activate the shift motor on the vibratory hammer. Both pumps are fixed displacement piston pumps. 6.1 MAIN PUMP CIRCUITRY With the diesel engine running, hydraulic fluid is taken from the reservoir by the rive pump and is pumped to the drive manifold. At the manifold the oil is either directed back to the hydraulic tank or through the hoses to the vibratory hammer. Here it drives the hydraulic motors and flows back to the powerpack through the return line. Depending on the oil temperature the oil is then either directed straight to the tank. or first (ful-flow) through the oil cooler. | When the hammer is started a hydraulic accumulator limits the initial maximum pressure to the motoris) providing a regulated increase in motor speed. Full motor speed is reached within a few seconds. When the hammer is switched OFF, a back pressure of approximately 50 bar is automatically created and causes the hammar to stop quickly. ‘The circuit is protected by means of a pressure relief valve and is provided with pressure and return line fers. ‘The hydraulic hoses can be quickly disconnected at the powerpack directly behind the manifold, Rev. 3-02/97 eng-1 soo 180001 cred companyGENERAL 6.2 SECONDARY PUMP CIRCUITRY With the diesel engine running, hydraulic fluid is taken from the oil tank by the secondary pump and pumped either to the clamp manifold or to @ combined ‘olamp/shift motor manifold Both circuits (clamp OPEN/CLOSE and shift motor) are protected by pressure relief valves. The clamp CLOSE circuit has a pressure switch that repressurizes the clamp should the clamp pressure drop below the setting of the pressure switch. ‘Al clamps are provided with a piiot-operated check valve which maintains the clamp pressure at any time until the clamp OPEN switch is activated ‘The hydraulic shift gear motor and hydraulic swivel are provided with check valves to guarantee and maintain en intial Eccentric Moment Setting. For the hydraulic circuitry diagrams, please refer to the operation manual of each separate powerpack. on6-2 GB Rew. 3-00007 soar cntesiomeya GENERAL o ELECTRIC CIRCUITRY The electric circuitry of all powerpacks is 24 VOC. All main hammer functions are electrically controlled either from the remote hand- held pendant or from the switches on the control panel. ‘Some functions are activated through a time relay, other functions are protected by fuses against short-circuit or overload. Al powerpacks are provided with the following safety switches: - EMERGENCY STOP = minimum hydraulic oil evel ~ lubrication oil pressure of diesel engine = 00! fluid temperature of diesel engine = hose burst protection control For the electric circuitry diagrams, please refer to the operation manual of each separate powerpack. Rev. 3-02/97 Cp) nts 180-9001 certied company SoGENERAL 7 8 MAINTENANCE 81 GENERAL Preventive maintenance includes normal servicing that will keep the engine, vibratory driver and power unit in peak operating condition and prevent unnecessary breakdowns. This servicing consists of periodic lubrication and inspection of the moving perts and accessories of the unit. DANGER A ‘All maintenance work is strictly reserved to qualified and authorized personnel. Except for the visual inspections, all maintenance work shall be carried out with the diesel engine stopped. ‘Take care that the main power switch is in OFF position. Install a DO NOT OPERATE or similar warning label to the main power switch, Disconnect the power cables from the battery prior to the maintenance ‘work on the electrical system. Lubrication is an essential part of preventive maintenance, determining to a great extent the useful fe of the unit ‘Some components in the unit require more frequent lubrication than others and some require different types of lubricants. Therefore, itis important that the instructions regarding types of lubricants and frequency of their application are closely adhered to. To prevent minor irregularities from developing into serious conditions that might involve shut-down and major repair, several other services or inspections are recommended for the same intervals as the periodic lubrications. The purpose of these services or inspections is to assure the uninterrupted operation of the unit. * Thoroughly clean all lubrication fitings, caps, filer plugs and level plugs and their surrounding surfaces before servicing. Prevent dirt from entering lubricants and coolants. The intervals given in the schedule are based on normal operation Perform these services, inspections, etc. more often as needed for operation under abnormal or severe conditions. 82 DAILY MAINTENANCE ‘The dally instructions apply to routine or daily starting of an engine and not toa new engine or one that has not been operated for a considerable period of time. For new or stored engines, refer to the diesel engine Operator's Manual (section “Preparation for Starting Engine, First Time’). en 8-1 « Rev, 3-02/97 180801 cetesoareany zeGENERAL we * Each day -or at the beginning of each shift- check the entire unit prior to and during start-up. * Prior to starting the diesel engine at each shift, proceed as follows: * Visibly inspect all bolts, nuts and screws, including the bolts fastening the hydraulic clamp to the vibration case. If necessary tighten, ‘+ Tighten the bolts holding the gripping jaws in the hydraulic clamp, * Grease the plunger in the hydraulic clamp with any good multipurpose grease, * Check the oil level in the vibration case and if required fil to the proper level. The cil level should be in the middle of the sight glass. Change oil fit is milky or black. * Check the fluid level in the hydraulic fluid reservoir and refi if necessary. CAUTION It is absolutely imperative that no dirt or other impurities be permitted to contaminate the hydraulic fuid. Any contamination will drastically shorten, the life of the high-pressure hydraulic system, * Visually check all hoses for signs of damage or cuts that might cause hose failure during operation. Be sure all connections are tight, especially the quick-disconnect couplers. * Visually inspect all suppressor elastomers. * Electrical components need no maintenance except periodic wiping with a clean, dry, thread-free cloth to remove’ dust. * Perform all daily maintenance checks and operations indicated in the Diesel Engine Operating Instructions (section “Preventive Maintenance Chart" ‘Check the oil level of the hydraulic tank in the powerpack. Check the diesel fual level Check the dirt indicator of the pressure- and return ter. Check the V-belts) Check the engine oil level. © Atter start-up: * Check all hydraulic hoses for leaks. Make sure they hang freely with no kinks. * Check the pump and all hydraulic manifolds and fitings for leeks. * Check the hydraulic oil fiter indicator. The return filter on the power unit must be checked with the diesel engine running * During operation * Check proper functioning of the lubrication pump on the hammer through the flow-glass in the vicinity of pump. * Be especially alert on rattling noises which indicate that one or more bolts have come loose. Check all bolts immediately and retighten them, * Handle all hoses with care and pay attention that no sharp curves or bends occur. Rev. 3-02/97 Gs ena-2 oregon TSO-800 cares campanyaS GENERAL 83 MONTHLY MAINTENANCE * Check the clamping jaws on wear. * Check the proper functioning of the pump for forced lubrication by removing a plug or a hose on the pressure side of the pump (only when the hammer has no fow-giass) Check all pressure relief valve settings. Check on the hour counter if the engine is due for inspection or maintenance. ‘Visually check the condition (dirt) of the oll cooler. Clean when necessary. Check the functioning of the temperature valve in the return line. 84 YEARLY MAINTENANCE ‘+ Have the hydraulic fluid analyzed by a local hydraulic service centre. Replace fluid if required. Refer to section 8.7 for fluid replacement data. ‘* Replace the pump for forced lubrication on the hammer. * Have the hydraulic system inspected by ICE (authorized) service personnel. 8.5 RECOMMENDED EXCHANGE CRITERIA FOR LONG TERM WEAR AND TEAR PARTS 85.1 Hammer AWS When teeth are worn 3 - 4 mm ELASTOMERS + When small hair cracks are visible on the outer surface FORCED LUBRICATION PUMP : Every 500 operating hours of hammer BEARINGS Every 1500 operating hours of hammer {normal operating conditions) Every 1000 operating hours of hammer (heavy driving circumstances) HOSES ‘When outer cover disappeared and stool braiding is visible AT LEAST: every two years 85.2 Powerpack QUICK LOCK COUPLINGS —: When the inserts are worn BATTERIES ‘When the battery loader needs a long period for loading PRESSURE RELIEF VALVES —: When the standard pressure setting cannot be reached, en 8-3 Eeme woror artrcmey — (4)ma GENERAL 8.5.3 3.3 Heavy duty conditi ns Note: The service intervals specified are based on NORMAL operating conditions. Operation under unusual conditions requires some agjustments in service intervals. ‘+ When the average temperature is above +27 °C or below -23 °C, reduce service intervals as specified (see table 8.04). ‘+ When operating in the presence of dust or sand, reduce service intervals as specified (see table 8,04) * When operating in excess of 12 hours per day, reduce service intervals as specified (see table 8.04) * When operating in an environmental air with high salt or moisture content, the service intervals need not to be changed, However, the unit should be thoroughly inspected weekly to determine what additional servicing, if any, might be required * During stand-by or inactive periods, the service intervals may be extended twice from those specified. 8.6 LONG-TERM STORAGE ‘Should the hammer not be used for eny extended period of time (approximately 2 - 8 months), the gear case lubrication oil should be removed and the complete gear case be filed by any type of oll. The hammer should preferably be stored vertical, otherwise with the hydraulic motors facing downwards, When laid down the a hammer head should be supported slightly higher than the clamp to ensure that the bearings facing upwards are filed with oil as well and are not trapped in an air gap. Ifit is not possible to fil up gear case with oil at least the vibration hammer should, ‘ be run at least every 3 to 4 weeks. 87 LUBRICATION 8.7.1 Hydraulic drive oil New power units are shipped with MOBIL DTE-18M or hydraulic cil, unless otherwise specified by the client. Check label in powerpack for actual oil type, When replacing fluid other than this, use a fluid with the following specifications: Viscosity index | 150 Viscosity (mnv/s) | 48.6 @ 40°C 313 @ 50°C 82 @ 100°C 1SONG 46 DIN 51524) HLP 25 Rev. 3-02/97 en 8-4 sree 150-3001 ceri companywe ‘The recommended fluids were chosen based on the system operating temperature range being 15 °C (oold - ambient - start up) to 71 °C (maximum operating) ‘When operating in arctic conditions, itis recommended to use an immersion heater to preheat the oil prior to starting, It may also be necessary in extreme cold or hot climates to use a different viscosity oil which is better adapted to adverse conditions. ‘+ Contact the nearest oll supply representative for suggested procedures, 8.7.2 Biodegradable hydraulic oll Unless the biodegradable oil is an ester-type oil with the same specifications as the mineral oi, it is allowed to use it in combination with ICE equipment. Operating the vibratory hammer with other types of biodegradable oil is not allowed. ‘Should you have any doubt, please contact ICE before using the oil. 87.3 Lubrication oil vibratory gear case ‘The fluid level is easily read through the sight-glass located at the lower centre of the long side of the vibratory case (motor side). Under normal gear case temperatures the level of the lubrication oil should be at mid-level of the sight glass. Lubrication gear oil may be added when necessary through the special filing plug or through the vibration case top plate, above the motor recess. The oil may be Gained by removing the plug at the motor end of the base plate, The most preferred lubrication oil is @ synthetic lubricant, since synthetics were designed for applications where service conditions are more severe due to high operating temperatures. Moreover they have good oxidation stability, Synthetics also provide considerably longer service life than natural, petroleum- based lubricants consequently resulting in less maintenance hours spent on the mechanic service of the unit. ‘The vibration case lubricant (a synthetic lubricant) installed at the factory is MOBIL. SHG-630 or MOBIL SHC-634, ‘When replacing the lubricant, a gear oil with the following specifications must be used: HOB SHC-SSO MOBIL HO-658 Tcasiy rae rT 1s ‘Viscosity (mm*/s) 218 @ 40 430 @ 40°C ors @ 50° wis @ so 296 100° as @ 100% 1SO.VG_ L 220 460 (9 en8-5 oo — Rev. 3-02/97 te un 180-001 ceifed companyff \ GENERAL Note: _SHO-634 is used for most conventional hammers, whereas SHO-630 is Used for high frequency hammers and hamimers with forced lubrication. ‘When other lubricant ol is used, please check above data with your supplier and have lubrication intervals confirmed, 8.7.4 Lubrication of the vibration case under extreme circumstances Note: When a vibratory hammer is working under extreme circumstances, only the lubricant installed at the factory must be used! Extreme circumstances are €.9.: ~ Outside temperature over 30 °C. = Soil compaction, semi-continuous operations like installation of drains, installation of diaphragm walls, etc. ‘The vibratory hammer is working continuously. The temperature in the vibration case wil rise to 60 °C to 70°C. At 70°C, SHC-634 has a viscosity of 100 mm/s (cSt), SHC-630 : 60 cSt. = Long driving times at high operating pressure. = When much eneray is reflected at the pile tip (teboune), 88 | MAINTENANCE OF HYDRAULIC CIRCUIT ELEMENTS Note: Check al ines, hoses and connections regularly for leaks and obvious damage. Repair damage immediately; splashed oil may cause injuries, fre and contaminations, 8.8.1 Draining and filling hydraulic oil tank in powerpack * To crain the hydraulic reservoir remove the plug on the bottom of the reservoir, * To ill the hydraulic reservoir use the filer pipe mounted on the engine side of the reservoir. LA wT Only clean, fitered hydraulic uid should be pumped into the reservoir. Any contamination carried into the system by the fuid will drastically shorten the Ife of the high-pressure hydraulic system. Cleaning the hydraulic pick-up filter * Drain the hydraulic reservoir * Remove the side cover of the reservoir, Rev. 3-02/97 eng-6 ones Is0.a001 ores companyrm we CAUTION It is absolutely imperative that no dirt or other impurities be permitted to contaminate the hydraulic fuid. Any contamination will drastically shorten, the life of the high-pressure system. Refer to section 8.7. ‘+ The pick-up fiter is connected to the input pipe for the hydraulic drive pump. Remove the entire filter assembly by unscrewing it from the pipe. * Disassemble and clean the entire fiter in clean solvent or diesel fuel. ‘* Replace the fiter. Carefully replace the side cover of the reservoir after cleaning so that no dirt is allowed to enter the reservoir opening, Refll the reservoir with recommended hydraulic fluid. 8.83 Changing the hydraulic return filter element The return filter is located on the hydraulic reservoir wall on the pump side. ‘+ To remove element, screw off the element, ‘+ Clean the fiter housing interior and all component parts with a thread-free rag, ‘+ Install the new element. 8.9 _ INSTALLATION OF THE HYDROMOTOR The following procedures should be carefully followed when replacing the hydraulic. motor(s) on the ICE vibratory hammers with either new or rebuit units. Extra care should be exercised at every step of these procedures to prevent any dirt from entering either the hydraulic motors or the transmission case. ‘+ Remove the motor guard. ‘+ Remove the hydraulic hoses from the motor. Plug the hose ends to prevent dirt entry and excessive oll loss. Tag hoses when removing to ensure correct reconnection location, * Remove the old motor and remiove the appropriate hydraulic fitings from the motor, Drain the hydraulic oil from the motor and plug the ports for shipping, * Inspect the pinion shaft bearing and the female spline in the pinion shaft for weer. ‘+ Fil the new motor completely with clean hydraulic oil by pouring into the case drain port. Temporarily plug the case drain port to prevent oil loss during installation * Install the new O-ring on the motor pilot diameter. Install the hydraulic fittings in the appropriate ports, Be sure the motor and motor mounting area are clean * Align the shaft splines and slide the new motor completely into the transmission case. Do not allow weight to “hang” on the splined shaft. Instal the motor ‘mounting bolts and tighten them to proper torque (see ICE manual) + Re-attach the hydraulic hoses to the proper location. Make sure the hoses are not rubbing the transmission case. Rev. 3-02/07 en8-7 1S04001 ceed cermary> we Install the motor guard and torque motor guard mounting bolts. ‘Suspend the complete hammer from a crane but not attached to a pile. Set the power unit at 1,400 rom and run the hammer for 15 min. Next stop the hammer and check for leaks. Let the hydraulic motoris) cool down to 30 °C (85 °F) The unit is now ready for work and full power operation, 8.10 OIL CAPACITY ‘SHC-634 ol! ‘SHC-630 oll ‘Model Quantity Model Quantity (1) 1GE-418(5) 25 10E-428 24 ICE116 z7 1CE-625 24 ICE216 27 1Ge-228 =7 1GE-1228 215 ICEa16 210 ICE-1423-6 218 ICE815 12 ICE-420 £10 1CE-5515 212 1CE-423 245 105-8514 214 ICEB15-0 +66 1GE1412 215 ICE-3025 #36 I ICE-1412.V 286 ki ICET4RF 250 ICE-23RF 240 IGE-289F 240 ICE-46RF/62RF 273 Table 8.01 Note: When an oil cooler for forced lubrication is used: 25 I extra for cooling system, POWERPACK HYDR. TANK ENGINE OIL PAN | ENGINE COOLING Mobil DTE 15, Mobil Delvac 13/90 ‘SYSTEM Model o o wo 70 300 75 30 115 570 14 36 175 1050 13 40 180 650 29 60 278/300(RF) 1050 28 85 330(RF) 1050 28 55. 400 1500 34 70 SOORFYS7O 1500 45.5 85 700(RFV7B0/900(RF) 2080 60.5 115 Table 8.02 Note: As a standard the cooling system has been protected to -20 °C, Rev. 3.02/97 yy en8-8 (S001 elecwe 8.11 PRESSURE SETTINGS AND LUBRICATION INSTRUCTIONS CHART PRESSURE SETTINGS Powerpack mope.| 70 | 115 | 175 | 160 |so0iRA| 400 [So0(RF]] 7ooRRM] 780 | SOOIRF) 20(RF)| s70 Main eit valve VI bs) zo | 170 | 170 | 260 | a50 | a40| a0 | s40 | oo] o40 Brake pressure v6 (oe) «| wo} wo} 0 | 0 | | 0 | 0 | o| so ‘Clamp rele valve v2 fs 200 | 170 | 190 | s20 | s20 | s40| 240 | a00 | o40| 340 ‘Clamp press. switch PS toa 120 | 150 | 100 | 205 | 255 | s20| 320 | s20 | 320 | _a00 ce. moment + bat . =~ | 0 | - | 10 | ro | - | 100 Eee. moment = (oat a [ies |= | a ro | 10 | - | 100 Full load speed (com 2,600 | 2,200 | 2400 | 2.000 | 2.200 | 1.800) 2.100 | 2.100 | 2.100] 1,980 Full oad flow (oie 100 | 250 | 380 | 200 | seo | a0 | sro | reo | rao} aco Table 8.03 8.12 LUBRICATION INTERVALS (POWERPACK RUNNING HOURS) ” DESCRIPTION NORMAL DRIVING] HEAVY DRIVING | MIN. CONDITIONS | CONDITIONS. First_| Interval | First _| Interval HAMMER Lubrication oll yoo [400 [50 [150 | yay Main hye iter 100 [00 [ s0_| 300 yoary Fiterforced ute gytem | 100 | 200 | 50 | 150 | year POWERPAGK | Olan soo | 200 | 100] 200 yest Fuliriocior 300 | 200 | 100_| 200 yealy vec ret fer wo | 400 | 50 | 00 yesty Hyg ol = - =| sample yeary ‘COOLER UNIT | Luts. ter | 10 | 200 | 50 | 160 vyeaty freed ut system Table 8.04 foes ame uGENERAL Note: The oil filters etc. should be checked visually half-way the above- mentioned CHANGE- intervals. 8.13 BOLT TORQUE INFORMATION ‘Torque (in kN) is determined by the length of the wrench handle (in meters) muttipied by the force (in KN) applied at the end of the handle. For example, if the wrench is 1 m long and 50 N (6 kg) of force is applied at the end of the handle, the total torque applied would be 50 Nm (© kam). Proper use of the torque wrench is important. To obtain the listed torques, a steady pull should be exerted to the handle until the desired torque is reached. 8.13.1 Vibrators The following torque specifications apply to the bolts from the component assemblies listed. Whenever any of these bolts are replaced, the given torque specifications should be adhered to. Refer to the table below. Rev. 3-02/97 en 8-107 GENERAL ‘TORQUE INFORMATION FOR BOLTS SHOS 12 THREAD DIAMETER TORQUE (inches) (eam) (wm) ibs.f) ot 18 7.94 42 31 AB 3.53) 70 52 het 14 41.14 | 12 83 Ye AS 12.70 471 126 wt 15.88 ‘324 7239 10 19.05 ‘S76 425, 18 25.40, 1.479 7,092 THAT 31.75. 2,008 1.497 18 38.10 3,482 2,570 MB. 46 34. M10. 89 66 Mi2. 150 TT Mi6 373 276 M20. 727 | M24 1,250 22, M30) 1,753 1,294 Table 8.05 8.13.2 Powerpacks Use the torques given in the table below for bolts and nuts with standard threads (conversions are approximate): THREAD DIAMETER TORGUE inches mom iba iim me 6.35 23 Ted 7 7.98 1835 2527 7h 953 225 4527 7h 711 50210 70+ 18 ss 12.80 75310 700216 he 14.29 T0215 150220 iE 75.88 150220 200s 25, " 19.05 265 2 95 360 = 60 v7 22.23 220+ 60 370 = 60 7 25.40 640+ 60 875 = 100 Tabie 8.05 eng-14 (SA Rev, 3-02/97 |S0-8001 cred companyGENERAL 7 9 ORDERING OF PARTS 9.1 PROCEDURE * When ordering parts, be sure to include the model and serial number of the unit ‘or component. Confirm all telephone orders immediately to avoid duplicating shipment. 9.4.1 Original equipment ‘+ Where serial numbers are given, these numbers only apply to equipment and components originally furnished with the unit. Where equipment has been changed or added to, these numbers may not necessarily apply. 9.41.2 Shipment * State to whom shipment is to be made and method of shipment desired, otherwise our own judgement will be made, 9.1.3 Shortages | * Claims for shortages or errors should be made immediately on receipt of parts, No responsibilty will be assumed for delay, damage or loss or material while in transit. Broken, damaged or loss of material should be refused or a full description made of damage or loss to the carrier agent on the freight or express bill. 9.1.4 Return of parts If for any reason you desire to return parts to the factory or to any distributor from ‘whom these parts were obtained, frst secure permission to return the parts. Shipping instructions will be given along with this permission \ ) fev. 9-02/87 CES) not rater |503001 erie companyGENERAL 9.2 SCREWS AND BOLTS ‘Amost all connections on the units are made with socket-head cap (Allen) screws. These high-strength screws are available at most industrial supply houses. Screws and bolts are designated in the PARTS LIST in abbreviated form (see below). The information, in parenthesis, immediately following the bolt or screw designation shows the size as follows: a= 13x1'% + Vs" Diameter, 18 Threads Per Inch, 1'/:" Length Note: Some screws or bolts require a specific torque when replacing. For identification of these bolts and a more thorough understanding of torque, refer to section 8.13. ABBREVIATIONS USED BHCS Button Head Cap Screw FHCS Flat Head Screw Cap FLCS Flanged Head Screw Cap Ho High Collar HHCS Hex. Head Gap Screw HHPP Hox. Head Pipe Plug HSSS Hex. Socket Set Screw PHMS Philips Head Machine Screw RHMS Round Head Machine Screw SHCS Socket Head Cap Screw SHPP Socket Head Pipe Plug SHSS Socket Head Shoulder Screw end-2 (SB) rev s-02/97 ost eieeoneyGENERAL 93 HOSES Example of hose ion a |b Ca a [oh iT i Hose| 125 | Ror | F | 9 | 24 | p | o | 20 | Loss| s a, HOSE LD. (8 algits) (125=1'/") (050=""), etc. In inches; 2 place decimal b, SAE or MANUFACTURER RATING (3 digits) (PT4 = Power Track) (RO1 = SAE Rating 100R1), etc. ©, FIRST END - TYPE OF FITTING (1 digit) (F = 3000 PSI Flange) (P = NPT male) (H = 6000 PSI Flange) (M = JIC-male) = JiC-female swivel ete. d. FIST END - BEND ANGLE (1 aigit) (0 = None) (3 = 805) (9 = 90%, ete. @. FIST END - SIZE (In ‘/eth) (2 digits) {. SECOND END - TYPE OF FITTING (1 digit) (See codes for frst end) g. SECOND END - BEND ANGLE (1 digit) (See codes for first end) h. SECOND END - SIZE (in “/xth) (2 digits) i, LENGTH In inches; 1 place decimal (0395 = 391") (1240 = 124"), etc, j. SPECIAL CODES None) Spring Guard) S.S.Braid) Offset) } ev. CY eno- Rev. 9-02/07 iy 9-3 ome cetaceanGENERAL 94 FITTINGS Example of fitting designation ah 8 lapel t)¢ehn fot | 2[/t -16| Mm | i2/ y [oo] 0 -onf of olol1 3 a, SELECTOR INDEX 2: inch fittings 9: metric fittings b. CONFIGURATION OR SHADE OF FITTING S: straight fitting C: Cap L: 90° elbow P: Plus V: 45° elbow U: Union, pipe T: Tee X: Cross (fourth end fi ©, FIRST END SIZE in sixteenth of an inch (index 2)" in millimetres (index 9) "Exceptions: 90 = 10° 8: 92 = 12" ot 14" e 99 = non code size See general specification sheet for sequence of order. d. FIRST END FITTING STYLE bee See fitting style selector chart @, SECOND END SIZE If applicable. See first end size. {. SECOND END FITTING STYLE if applicable. See first end fitting style. g. THIRD END SIZE If applicable. See first end size. h. THIRD END FITTING STYLE If applicable. See first end fitting style. i. LENGTH CODE {pipe nipples ((ong] only, in decimal inches for index 2) 050 = 5.0 inches 105 = 10.5 inches en 9-4 renter Woot ertedcargey Rev. 8-02/97in millimetres for index 9 120 = 12.0 inches 084 = 8.4 inches, LENGTH CODE (elbows/nipples) OL - long (elbow) 006 - close (nipple) 0X - extra long (elbow) 008 - short (nipple) FOURTH END SIZE and FOURTH END FITTING STYLE (crosses only) See first end fitting size or end style. j._ INSTALLATION AID OR STYLE OF HEAD not applicable H: regular hex. W:wide or large hex. Qi square head (ext) Ri square head (int.) S: hex, head (int. socket) i hex. head (ext.) k, PRESSURE RATING 0: not applicable 3: standaid weight (40) 4: 125 Ib 4: extra heavy (80) |. SPECIAL NOTATIONS 0: none A; tapped hole in fitting 8: office F: special fab., non-stock item M: magnetic m. MATERIAL carbon steel brass cast brass : stainless steel AAR. mal. iron maleable iron cast iron : forged steel aluminium S2NOTKONA Also refer to fig. 9.01 Rev. 3-02/97 en9-5 1802001 ested cmany@Q ss © JIC MALE JIC FEMALE “ 3° FLARE J SWIVEL 37° FLARE IC MALE BSP FEMALE 8 BULKHEAD T SWIVEL 37? FLARE BSP MALE BSP FEMALE aw eae iat NPTF MALE NPTF FEMALE D ‘SWIVEL, N a ‘SWIVEL NPTF MALE — NPTF FEMALE . : al UNF MALE UNF FEMALE Rg (SAE) K al ‘SWIVEL {SAE} METRIC WETRISCH tu) tu 2m HETRISCH —— METRISCH u | | MALE (O-RING) Ww — FEMALE wu a wu HETRISCH NETAISCH c) Ee pase +] Bp frmesine {s} {s) METRISCH NETRISCH x Fl MALE [0-RING) z ae FEMALE (s) (sh FLANGE : FLANGE F COUPLING K esi) 4 COUPLING (standard) = lhugh pressurel Fig. 9.01 on 9-6 Ge) Peu.3.0207 pena ge 130804 cated camparyVIBRATORY HAMMER 7 RF MKII Manual 7RFO0041 Rev. : Date January 2000 From Machine No. 7990610 and up ‘TABLE OF CONTENTS CONNECTIONS OF HYDRAULIC HOSES. VIBRATORY HAMMER ASSEMBLY. ‘SUPPRESSOR HOUSING ASSEMBLY WELDING SUPPRESSOR HOUSING ASSEMBLY. VIBRATION CASE ADAPTER ASSEMBLY. VIBRATION CASE ASSEMBLY...... HYDRAULIC ASSEMBLY .. BOTTOM VIEW OF VIBRATION CASE. HOSE ASSEMBLIES INTERCONNECTING (80 meter), QUICK DISCONNECT 4" onieone 180-001 caries caanyUNWRITTEN PAGE "S000 ered companyPeges ansaid Ag ‘7RFOO005 2 fi 8 2 g S 5 3 ~ : 8 5 - 5 = 2 i So | 6 wl S es B a z = 8 o ca . te e 5 i: a2VIBRATORY HAMMER ASSEMBLY ‘TRFOOO11 CQ vmarrr Ome Page a pve goo . TSO.80t cored eaganyVIBRATORY HAMMER ASSEMBLY ‘7RFOOO1T DESCRIPTION Part No. 1 1 SUPPRESSOR HOUSING ASSEMBLY 7RF1000 1 WELDING ASSEMBLY SUPPRESSOR HOUSING 7RF1100 2 1 VIBRATION CASE ADAPTER ASSEMBLY ‘7RF2000 3 1 VIBRATION CASE ASSEMBLY 7RF3001 4 1 HYDRAULIC ASSEMBLY 7RF4001 5 1 STICKER ASSEMBLY 6259000 6 2 LOGO"7RF* g80st21 7 1 SINPLATE 9170014 anual 7AFOOO81 Rayan 2000 —— ase pe 180-2001 certtiag company i:ia @ SUPPRESSOR HOUSING ASSEMBLY ‘7RF1000 Manual 7RFONOH Fev.-/Jan 2000 Pages a tego TS0-600 artes eraniTEM = Qty 1 1 2 1 3 2 4 1 5 1 6 1 7 2 8 4 9 4 10 2 1" 4 2 4 13 4 14 4 15 4 enol 7RFOOOY Fev.-/ Jen 2000 SUPPRESSOR HOUSING ASSEMBLY DESCRIPTION WELD. ASSY, SUPP, HOUSING MANIFOLD. ‘STOP BLOCK VALVE GUARD ‘CHECK VALVE BODY ‘CHECK VALVE O-RING #214 HHS M8 x 25 HHCS M12 x 65 ‘SHCS M2 x40 SHCS Mi2 x65 SHCS M16x30 SHCS M16 x40 FLATWASHER MB M12 SPRINGWASHER, 180800 ered comsany Bb) 7RF1000 Part No, 7RFI100 g704tt17 grate 9408101 110.723 110731 100.097 790.078 110.683 100.505 110.678 9107015 110.103 790.103, 110.637 Page?WELDING ASSEMBLY SUPPRESSOR HOUSING ‘7RF1100 aa! TAFODOS Fav fn 2000 sec 8 180-9001 cred companyWELDING ASSEMBLY SUPPRESSOR HOUSING TRF1100 ITEM QTY DESCRIPTION Part No, 1 1 SUPPRESSOR HOUSING 9402120 2 1 HOSE GUIDE 130.297 3 1 HOSE CLAMP 97041118 4 1 HOSE CLAMP 97081127 5 2 *LOGO"ICE™ SMALL" 790.09 64 Manat TAFOOOY - Fev.-/Jan 2000 = Pages tage TS. ceric companyVIBRATION CASE ADAPTER ASSEMBLY ‘7RF2000 UU G0 do. ose Meml7AFO00t Fev Jan2000 Page 10 a penta |S0400 ated argany@ VIBRATION CASE ADAPTER ASSEMBLY 7RF2000 ITEM QTY —_ DESCRIPTION Part No, 1 1 VIBRATION CASE ADAPTER 9201104 & 8 ELASTOMER 130.023 3 16 SHCS M12 x45 790.013 4 32 SHCS M12 x 55 100.507 5 20 SHCS M16 x 60 790.085 6 + FITT2P 16P000000-00SS001 . 7 20 TFRING-17-St 8 Be LOCKNUT M12 aren Aa Maul arn @)) evan age 11 postegon oe 180-9001 cried company iiVIBRATION CASE ASSEMBLY ‘7RF3001 a at Fn Page 12 —__. {f Feta 2200 nteooe ‘Sout ced companyVIBRATION CASE ASSEMBLY ‘7RF3001 em gry PTI Part No, 1 1 VIBRATION CASE 97041130 2 4 ECCENTRIC SHAFT 97041103 3 1 MOTOR-PUMP SHAFT SPLINED 97041133, 4 1 SPLINED SHAFT 9507041 5 1 MOTOR GEAR 97041134 6 4 ECCENTRIC 97041102 7 2 ECCENTRIC GEAR 97041105 8 2 ECCENTRIC GEAR 97041106 8 2 ACTUATOR GEAR 97041110 10 4 BEARING COVER 94021110 " 2 BEARING COVER 97041109 2 1 BEARING COVER 97041126 13 1 BEARING COVER 97041115 4 1 BEARING COVER 97041120 5 1 COVER 9210102 6 1 COVER 7041119 7 1 SEAL HOUSING COVER 9704t112 18 4 MOTOR MOUNTING PLATE 97081132 19 + PUMP MOUTING PLATE 970a1131 20 1 ADAPTER RING g70aitit 2 1 MOTOR GUARD 97041135 2 1 ACTUATOR GUARD 97041136 23 + PUMP GUARD 97041137 | 24 4 ROTARY ACTUATOR 9705116 25 1 SWIVELING COUPLER 9711034 6 1 FILTER ELEMENT 9711036 a7 1 MOTOR F12-80 798,008 28 1 PUMP 182 ga0t021 r 29 2 BEARING NJooaEC 9711037 30 10 BEARING NJ2312 9401038 31 1 BEARING H) 220 geoe024 32 1 CENTR, BREATHER 810.208 33 2 KEY 16x10x60 Sper. 34 4 KEY 2ax14x200 9705001 35 1 KEY 20x12x40 9901008 36 2 DOWEL PIN 9711035 37 4 FILTERPIN 9808103 38 5 PARALLEL PIN 12m6x 28 9202022 38 10_—_-FITT2P.04P000000-008S001 100.845 40 1 FITT2P-12P900000-008SoM1 100.187 Manu 7O084 Fata 2000 Page 13 sete 180-001 corto companyria @ VIBRATION CASE ASSEMBLY 7RF3001 @ i J Qe i 4 y ee log - t Yj Manual 7AFOOO8Y Pogo 4 av Jan 2000 vem ron 1804001 ceriedcompary@ VIBRATION CASE ASSEMBLY ‘TRF3001 ITEM «QTY — DESCRIPTION Part No. a 48 _FITT9P-14A000000-008S001 9107030 42 7 FITT9P-18A000000-00ss001 ‘9805019 48 2 FLANGE RECHT 9805068 4 1 GASKET 97041125 45 1 O-RING #025 ‘9505008 48 2 O-RING #110 . 400.92 47 1 O-RING #159 110.197 48 2 O-RING #230 110.829 49 1 O-RING #237 9604001 50 9 O-RING #259 120.154 51 1 O-RING #267 100.194 52 1 O-RING #271 9202039 53 1 O-RING #274 110.097 54 1 OILSEALS5x70x8 9711039 55 4 HHCS 6x25 790.06 56 6 SHCSM8x20 100.465 57 12 SHCSM8 x25 s202034 58 4 SHCSMBx30 790.061 59 24 SHCS M8 x40 st07007 60 10 SHCS M10 x30 790.066 a 71 SHCS M1230 110.685 2 4 SHCS M12 x35 ser1024 63 6 — SHCSM16x40 110.103, 64 1 SIGHT GAUGE — 100.185 65 8 RETAINING RING 794.069 66 10 RETAINING RING 9303007 67 1 RETAINING RING 9711040 8 1 RETAINING RING. ‘9806025 69 6 FLATWASHER M16 110.081 70 4 SPRINGWASHER M6 790.086 n 6 SPRINGWASHER M16 790.088 nm 13 Lirshe 630 790.894 QFNOZS - The Arn Olea. Vaheulos S Grain brea ‘Manua 7FO0081 Fav. dan 2000| PagesHYDRAULIC ASSEMBLY TRFAO01 6 ‘Morus 7RFo004t at ev.-/Jan 2000, Page 16 ——______ 2 180-9001 ceria company LeHYDRAULIC ASSEMBLY ‘7RF4001 TEM «QTY —_—DESCRIPTION Part No, 1 1 RELIEF VALVE = 790.989 2 1 FITT9P-22A00000-008S001 9203013 3-20 _FITTaS-14U16A000-000H001 9109041 4 3 FITT9S.04816A000-000H001 9809025 5 1 FITT9S-18U16A000-000H001 9805020 6 2 FITT9S-08S164000-000H001 9802087 7 1 FITT2S.08M10R000-000H001 300.088 8 1 FITT9S-18V16A000-000H001 9802058, 9 4 FITT9S-20842C000-000H001 8109060 10 2 —_FITT9s-220244000-000H001 9202029 "1 2 FITT8S-42¥36C000-000H001 9111008 2 5 FITT9L-16V16A000-000H001 a 13 1 FITT@L-08P18A000-000H001 9802056 14 2 SPLIFLANGE KIT #16 6000 psi 100.927 15 2 O-RING #219 100,081 16 8 — SHCS7ite'14x1 122" 100.125 7 1 HOSE aseRo2votevoteLO0750 9809010 18 1 HOSE ageROzva1evoteLoaEoo 9809011 19 1 HOSE ageRo2vatevoteLoogso 909012 20 1 HOSE oaRo2votevoteLoos00 9511003 : at 1 HOSE a3aRo2VorevoteLo1000 9112016 2 2 HOSE o3eRO2VOtevoTELOaT70 9802004 23 3 HOSE 038R02V016V416L05500, 9802003, 24 5 HOSE o38Ro2VOtevO16L11400 9907008 25 1 HOSE 050R02J008v024L05200 9802007 26 1 HOSE os0R02Yo2avozal.11400 9109053 a 2 HOSE O75PTavos6Y436L11400 9403017 28 1 HOSE 100PT4Y042H016L05000 9802008 29 1 HOSE 100PT4Yo42H016L05240 9802005 30 2 HOSEO38R INMETEN Monae 7AFOOD6Y Fev. =/an2000 aE mmo 180-001 centedeoroany age 17Page 18 UNWRITTEN PAGE S000 cred company ® ‘Maral 7AFO0081 Fer Jan2000Varual7AFOOOAY Fay /Jan 2000 BOTTOM OF VIBRATION CASE T5600 cared creamy ‘7RFOO007 PagePage20 HOSE ASSEMBLIES INTERCONNECTING (30 METER) ‘700020 180-9001 cera company Mant 7aFa0041 ev Jan2000,HOSE ASSEMBLIES INTERCONNECTING (30 METER) « ITEM QTY ~—_DESCRIPTION 1 1 FITT2S-06060000-00H001 2 d FITT2S-06008P000-000H001 3 i FITT2S-08012P000-000H001 4 5 FITT9S-06P 16A000-000H001 5 1 FITT9S-08P22A000-000H001 6 10 FITT9S-16A16A000-000H001 7 2 FITT9S-20P42C000-000H001 8 2 FITT9S-22422A000-000H001 9 2 FITT9S-36C42C000-000H001 10 2 FITT9S-42C42C000-000H0001 1" 1 ‘COUPLER FEMALE 918" 12 1 ‘COUPLER FEMALE 318" 13 1 COUPLER FEMALE 1° 14 1 COUPLER MALE 3/8" 8 { COUPLER MALE is" 16 1 COUPLER MALE 1 a 1 DISCONNECT MALE 3/8" 18 i DISCONNECT MALE %" 19 1 DUST CAP 3/8" 20 1 DUST CAP 3/8" a 1 DUST CAP 12" 2 1 DUST CAP 3/4” 23 1 DUST CAP 1 14° 24 1 DUST PLUG 318" 2% 1 DUST PLUG 316" 26 1 DUST PLUG 1 14" az 10 HOSEo3sR02V016V016L62000 2B 2 HOSEos0R02voz2v022L.62000 29 4 HOSE100PT4Y042¥042L.60000 po! Ja000 EE EY 180-604 cored company 7RFO0020 Part No. 110.143 400.357 400.409 9403018 sitt022 9403020 9403019 9109058 9403024 9409025, 9404007 100.777 9404023, ‘9404008, 9406014 4o4a2a 100.245 400.251 100.257 9404010 9408016 400.253 9404026 100.737 9404009 9404025 9403023, 9403021 9403022 PageatHOSE ASSEMBLIES QUICK DISCONNECT 1 ” aru! 7AF000st ——— D\ v. a af HOSE ASSEMBLIES \ J QUICK DISCONNECT 1 14” ITEM QTY DESCRIPTION Part No. t i FEMALE DISCONNECT 1 1/4" 9404023 2 1 DUST PLUG 9404025 3 : MALE DISCONNECT 1 1/4" 9404024 4 1 DUST CAP 9404026 5 1 O-RING KIT 9802062 6 1 QUICK DISCONNECT REPAIRKIT 9802063 nese @) oe @) re T0001 cried company180-9001 cated company(A info 35-50 TU a ( asTUoo12 35 TU 35TU0O13 200 A [8a] 260. © T9000 ered csanyinfo 35-50 TU serena S Daten - Spécifications techniques - Specificaties oe 357U ee ssTu ce soTu Ice soTU ssTuoni2 ssruno13 soTuoo10 soTuoo1s lam model Universal Sheetpie Universal Sheeiplo Clarging Foro 350 350 500 500 iw ax, operating pressure 320 320 320 320 bar Wight 165 165 20 250 kg lee asTu Ice ssTu Ice soTu lee soTu ssTuoo12 ssTuan13 soTuo10 soTuoots emmeange Universal Spudwand Universal Spudwan hemmkratt 350 350 00 500 a Max Beviebssiuck 320 20 z= 320 bar ‘Gewicht 185, 165 250 250 kg Joe 357U cess TU Ice soTu Joe soTu ssTuonte ssTuno1a soTuga1o soTuon1s ince Universal ince Palplanche Universal inc pllanche Fores de serage 350 350 500 500 ia Pression de travail may. 320 320 x0 0 bar , Poids 165, 185 250 250 'g NL ce 35 TU Ices TU IcesoTu Ice soTu stunt asTuno1g soTuoo1o soTuons Wommedel Universe! Overt Universee! Overt amkracht 350 350 500 500 i Max, were 20 20 320 20 bar Gowers 165 185 250 20 ‘9 180-800 ceed companyUniversal clamp 35TU, 50TU Parts Manual 3550TU43 Revision te Date August 2000, Model ‘s6TUO012 From Machine No, : 3U950101 and up Model : gsTUO018 From Machine No: XXXXXXXX and up Moda! + S0TUO010 From Machine No. SU950101 and up Model : soTuoo18 From Machine No. : XXXXXXX and up ‘TABLE OF CONTENTS PAGE CLAMP ASSEMBLY 35TU0012 CLAMP ASSEMBLY 35TUO0018 .. CLAMP ASSEMBLY 50TU0010..... I CLAMP ASSEMBLY 50TU0018 BJ CHAIN ASSEMBLY... steve 1804001 cried companyCLAMP ASSEMBLY 35TU0012 1504001 ertescareany 35TUOO12 Manel e507 Us3 Pwr 2000,f \ CLAMP ASSEMBLY QS? 35TU0012 = TEM QTY —_DESCAPTION aN 1 1 CLAMP BODY 9112101 2 1 PISTON END CAP 9112105 3 1 PISTON 9112104 4 1 ROD BUSHING 9112102, 5 1 CYLINDER ROD 9112103, 6 1 FKEDJAW ti2t06 e 1 PILE FEED GUIDE 9203107 8 1 PIO CHECKVALVE 9201201 9 4 SHCS M8 x70 9109072 10 6 HHCS M12 x 35 9203029 1 5 SHCS M16 x 50 790.369, 12 1 HHCS M16 x 50 9111006 13 2 ‘SHCS M16 x 100 9107034 14 4 SHCS M30 x 90 520.208 15 4 M8 LOCKWASHER: 790.087, 16 8 M16 LOCKWASHER 790.088. 7 6 ‘M12 TABWASHER 9201027 18 4 ‘M30 LOCKWASHER 520.207, 19 1 ‘SHPP 14” 100.845 20 1 ‘M14 PLUG 9107030 2 1 GREASE FITTING 100,229 22 1 CLAMPING SLEEVE 9112014 23 1 CLAMPING SLEEVE 9112015 % = 2 ONG FIS6 ‘0.781 25 1 ‘SEAL KIT 9112006 25.1 1 ROD SEAL 9112007 252 1 ROD WIPER: 9112008 25.3 ie PISTON BEARING 9112009 25.4 1 PISTON SEAL 9112010 25.5 1 O-RING #247 9112012 25.6 1 BACKUP RING #256 9112013 26 8 ‘STRAIGHT ADAPTER 9109063 7 1 ‘STRAIGHT ADAPTER 9109041 28 1 ADAPTER - 90° 9206016 29 a 3 WAY ADAPTER 9109043, 30 1 HOSE 3/8" 9112016 ra Tvs . Bar /ieh 208 ee i) res ‘Soot eedha (oe CLAMP ASSEMBLY 35TU0018 O® Pages —— 180-9001 cariad company asTUO0I enue 50759 ov =a 2000,1 i 1 1 1 1 1 1 4 6 8 241 242 243 244 aS 46 5 26 7 28 29 Manual S550TUDS athe 2000 CLAMP ASSEMBLY DESCRIPTION CLAMP BODY PISTON END CAP PISTON ROD ROD BUSHING MOVABLE JAW FIXED JAW PILE FEED GUIDE PIO CHECKVALVE SHCS MB x 70 HHCS M12 x35 SHCS M16 x40 ‘SHCS M16 x50 HHCS M6 x50 ‘SHCS 16x70 ‘SHCS M30 x 90 M8 LOCKWASHER M16 LOCKWASHER, M12 TABWASHER Ma0 LOCKWASHER, SHPP 1° M14 PLUG GREASE FITTING O-RING #188 SEALKIT ROD SEAL ROD WIPER PISTON BEARING PISTON SEAL O-RING #247 BACKUP RING #258 STRAIGHT ADAPTER STRAIGHT ADAPTER ADAPTER - 90° SWAY ADAPTER, HOSE 9" 180001 aries crany 35TU0018 Part No, (0005101 gn12105 9705104 gr2i02 9705102 o0st02 9705105, 9201201 ‘9109072 9203028 110.108 790369 9111008 790.087 500.208 790.087 790,088 9201027 520.207 100.845 107030 100.229 100.781 9112008, 9112007 9112008 9112009 9112010 9112012 9112013, 9109063, 109041 9206016 9109043, 3112016 Poaes:CLAMP ASSEMBLY 50TU0010 ‘s0TUO010 @) oaigsoues era 2000 Page 130-8001 crag companyEM ory 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 4 10 4 1 7 2 2 8 2 4 4 8 4 6 1 7 4 18 4 19 1 20 1 a 1 2 1 23 1 = 4 2 25 1 251 1 it 252 1 32 yn 255 1 258 1 8 2 ar 1 28 1 29 1 30 1 Manual ss0TU04s a= Mr 2000 CLAMP ASSEMBLY DESCRIPTION ‘CLAMP BODY PISTON END CAP PISTON OD BUSHING CYLINDER ROD FIXED JAW — PILE FEED GUIDE PIO CHECKVALVE SHCS M8 x70 HHCS M16 x40 SHCS M16 x50 HOS M16 x 50 SHCS M16 x 100 SHCS M30 x90 MB LOCKWASHER M16 LOCKWASHER M16 TABWASHER M30 LOCKWASHER, SHPP ie" M14 PLUG GREASE FITTING CLAMPING SLEEVE CLAMPING SLEEVE O-RING #160 SEALKIT ROD SEAL ROD WIPER PISTON BEARING PISTON SEAL. O-RING #256 BACKUP RING #256 STRAIGHT ADAPTER STRAIGHT ADAPTER ADAPTER - 80° ‘SWAY ADAPTER HOSE 38" 150-5001 cored company s0TUO010 Part No, 9106105 790.414 s107t17 9201101 9108105 107115 9203108 9201201 9109072 360.079 790.369 9111008 9107034 520.208, 790.087 790.088 9203030, 520.207 100.845 9107030, 400.209 9109066 9107035 9201001 790.415 grti028 420.345 790.413 790.412 100.158 790.883, 9109063 109041 9206016 9109043 9112016 Poe?CLAMP ASSEMBLY 50TU0018 ‘S0TU0018 Maal 580 U3 Fr Mare 2000 1809001 crag company1 1 1 1 1 1 1 1 4 2 Manual ss0TUDKS Fete Maren 2000 CLAMP ASSEMBLY DESGRIPTION CLAMP BODY PISTON END CAP PISTON ROD BUSHING MOVEBLE JAW FIXED JAW PILE FEED GUIDE PIO CHECKVALVE. ‘SHCS MB x 70 SHCS M16 x30 HHCS 16x40 ‘SHCS M16x50 HHCS M16 x50 SHCS M16x70 SHCS M30 x90 M8 LOCKWASHER M16 LOCKWASHER M16 TABWASHER M30 LOCKWASHER SHPP 1/4" M14 PLUG GREASE FITTING O-RING #160 SEALKIT ROD SEAL ROD WIPER PISTON BEARING PISTON SEAL O-RING #256 BACKUP RING #256 STRAIGHT ADAPTER STRAIGHT ADAPTER 90° ADAPTER SWAY ADAPTER, HOSE 218" oD ( IS0-800 cried anpany S0TU0018 Part No, 0008107 790.414 gai 9201101 santti7 0004106 9412106 9201201 109072 9107015 350.079 790,369 9111006 790.087 520.208 790.087 790.088 9203030 520.207 100.845 107030 100.229 9201001 790.415 9111029 120.345 790.413, 790.412 100.159 790.883 9109063 109041 9208016 9109043 9112016 PaesUNWRITTEN PAGE Manual sssoTUs9 Fev.-/ne 2000 Pago 10 S000 ered carpary(q3 CHAIN ASSEMBLY TEM QTY ~—_—DESCRIPTION Part No, 1 1 CHAIN SHACKLE 9110008 2 1 CONNECTION LINK 203043 + CHAIN 110008 @) ents WY ow Maron 2000 —— Page tt 150-S00 arte company© @)( \ POWERPACK 180 PP/RF Parts Manual: 180RFO44 Revision : Date August 2000, Model 180RFO13. From Machine No. : 18PRO00811 and up TABLE OF CONTENTS PAGE ENCLOSURE INTERNAL... DRIVE PUMP ASSEMBLY. DRIVE MANIFOLD ASSEMBLY. RF MANIFOLD ASSEMBLY. CONNECTION OF HYDRAULIC HOSES... CONTROL PANEL. CONTROL PANEL - INSIDE. PENDANT... PENDANT - OPTION A QUICK DISCONNECT 1 MAGNETIC CLAMP LIGHT (COMPLEET) RELAY BOX RADIO CONTROL (COMPLET) REMOTE CONTROLS - TERMINAL WIRING CHART. HYDRAULIC CIRCUITRY ~ RF MANIFOLD... 34 HYDRAULIC CIRCUITRY — DRIVE MANIFOLD, ELECTRICAL CIRCUITRY... vn @) 150.800 carted earpanyENCLOSURE G80 OD © ia J t | O@ aus! 80RFO40 Page? = = av. Aug 2000 180800 ontogenyg 8 9 10 nt 1 12 6 13 6 14 1 15. 1 16 1 a 18 32 B 20 1 21 1 22 2 23 6 * OPTIONAL ) ZT 4 sat oeF:0 Fer Agus 2000, ENCLOSURE DESCRIPTION ‘ASSEMBLY 180 PP AIR INLET COVER AIR OUTLET COVER TOP PLATE RADIATOR INSPECTION COVER INSPECTION COVER: EXHAUST SILENCER, RAIN CAP ‘MANIFOLD DOOR ENGINE DOOR PUMP DOOR DOORLOCK DOORKEY DRIPPAN EMERGENCY-STOP EMERGENCY-STOP BOX PUSH BUTTON ELEMENT HHCS M10 x25 GREASE FITTING LOGO "ICE" SMALL STICKERS "CE GASKET DOORLOCK CILINDER EXHAUST SILENCER incl spark arrestor o 180-001 cried company ((o!) ae Part No, 9604202 9710008 ‘710004 9710001 3608030 9608031 g7i1024 9711025 9710006 710002 9710007 790.109 5/-e0 9802059 9711029 9407035 9407036 9407037 9608042 100.209 790.090 9504202 9802060 06002 9901005 Pagesae “| ett 1 Aug 2000 anal 80540 Pot @ iH 1S0-s00t cores company ® a mA Cs ef aoe 6 jus J Zz Zz & oi z = ©TEM = QTY Manat 1808FO40 Fv.-/ August 2000 INTERNAL DESORIPTI DIESEL ENGINE OILCOOLERIRADIATOR FAN BATTERY DRIVEPUMP MANIFOLD. CLAMP PUMP RETURN FILTER ‘STARTER MOTOR ALTERNATOR TEMP, SENDER AIRFILTER ELEMENT AIRINTAKE ELBOW HOSE CLAMP FUELFILTER FUELFILTER ELEMENT O-RING SPLITFLANGE SHCS 14° X 11/4" FUEL LEVEL METER FILTER ELEMENT FILTER GAUGE BULLY BULB BREATHER, FLUID LEVEL TEMP. GAUGE FLOAT SWITH TEMP SWITCH FUEL SOLENOID FUEL FILTER ELEMENT SERVO MOTOR LUBE OILFILTER, EARTH SWITCH BUTTERFLY VALVE WELDING FLANGE CHECK VALVE MANUAL PUMP FLEX. COUPLING BALL VALVE ACCUMULATOR @ 15001 artes orpany Part No, 9606004 604035 9708008 9704002 ‘9604005 3604201 9805066 100.583 srit027 s7i1028 9906010 9707003 100.9 9609019 790.093, 790.919 110.119 100.596 400.119 790.593 at.tg 100.75 9507005 9507006 100.485 9606001 100.314 ge10044 9707006 9707004 790.373 9707005 790.924 9404017 9709048 ‘0001008 9206012 400.195 se02012 810.295 PaesA (ds INTERNAL fo Ho (on C ana 09 7 —E pens aga 180-9001 ceed companySISHLBR ae 400 Manual e0RFOs0 Fav Augit 2000 ieM = QTY. ase a4 48 4 44 6 4 6 4 7 4 a 4 9 4 co 4 INTERNAL DESCRIPTI FEMALE DISCONNECT" DUST PLUG. FEMALE DISCONNECT 11" DUST PLUG MALE DISCONNECT 114" DUST CAP MALE DISCONNECT ae" DUST CAP FEMALE DISCONNECT afet DUST PLUG BONDED SEAL BONDED SEAL PICK UP FILTER (CHECK VALVE BREATHER BALL VALVE O-RING O-RING MOTOR SUPPORT DISTRIBUTION BELT BONDED SEAL%’ BSP, OIL PRESSURE SENDER " 340 081 O1IFC FITT9S-24845A000-000H001 FITT2L-16M16R000-000H001 FITT2L-06M08RO00-000H001 FITT2L-06M06PO00-o00H001 FITT2S-16P06C000-000H001 FITT2S-08°040000-000H001 FITT2L-04P064000-000H001 FITT2T-1212M12R-000H001 FITT2C-08Q000000-000H001 FITT2P-t2Po00000-000H001 FITT2P-16P000000-000H001 FITT9S-16P36A000-000H001, FiTT2L-12M112P000-000H00t FITT9L-06P184000-000H001 FITT2S-05R06M000-000H001 FITT9S-06Mt14U000-000H001 FITT9L-06\14U000-000H001 FITT9S-20845A000-000H001 FITT28-12h128000-000H001 FiTT2¢-12G000000-000H001 'S0-St ered cangany Pari No. 490.095 400.121 9404023 9404025 ‘404024 9404026 100.245 100.257 100.777 100.737 ‘9411008 sm2004 400.087 110.864 790.524 9307002 110.179 140.255 9907031 002013 9411010 9908009 ‘9608011 100.783 9410002 400.227 100.715 110.389 400.717 100.771 100.727 9308056 100.063 702001 100.489 9609013 702002 9107028 9709003 9701015, 790.804 9002014 Page?(ds INTERNAL ® 26) (2) 25 24Sos ERT 195 136 197 138 140 141 142 143 144 145 146 147 ena! 10RFO80 Fev.» / gust 2000 INTERNAL DESCRIPTION FITTSPEC. ORIFICE 2M FITT9S-04S20C000-000Ha01 FITT2S-12B12P000-000H001, FITT2S-20P208000-000H001, FITT2S-06P068000-000H001 FiTT2L-06P060000-000H001 FITT2S-06@060000-000H001 FITT2S-06M06R000-000H001 FITT9S-06R18C000-000H001 DUSTPLUG ¥" FEMALE DISCONNECT 1" FITT2S-06Q08P000-000H001 FITT2S-06B06P000-000H001 FEMALE DISCONNECT 3/8" DUST PLUG MALE DISCONNECT 3/8" DUST CAP ENDPLATE PUMP SPLIT FLOW FITT2s-oeht124000-000H001 FITTaL-06M06J000-000H001 HOUSING RELIEF VALVE FITT9S-06S18A000-000H001 FITT2S-12812? FiTT2s-12M12P |S000 eradconseny XXxX2000 Part No, 790.4441 9203031 9609010 100.387 9401028 sait016 9903021 110.143 100.053 9206018 9406015 9406013 400.387 9408017 9404007 ‘9404009 ‘9404008 9404010 9805009 790.637 400.411 9805007 9501041 9609008 9501027 400.187 Pageshea INTERNAL oe we206 207 208 R 210 an 212 213 24 215 216 217 218 219 FLUID QUANTITIES 28 Lt, 450 Lr 15 Lt, Manual 120RFDA0 Fev.-/ August 2000, INTERNAL DESCRIPTION HOSE125R02F92¢V045L05500 HOSE100R01J016Ve36L.09400 HOSE0seR0ZU006Ye20L07900 HOSE038R014006/006L06400 HOSE036R01006/906L05900 HOSE038R01.I006J006L01500 HOSE050RO1Po08v0z2L04000 HOSEO7SRO1J012912L04930 HOSE125R02F920F024L06700 HOSEO75RO1JOtZ/st2L02900 HOSE038R01Vo1avoraL.02950 HOSE038RO1.1906/906L01400 HOSE038R01.1006/906L02700 HOSE 125R02F420V445L08860 HOSE075R01J912S012L07880 HOSE0asRO2v920¥9201.02560 HOSE025R02Y016Y918L09500 HOSE03BR01J006,908L07100 HOSE038R01V018V418L06500 ENGINE OIL HYDRAULIC FLUID ANTI FREEZE |S0.400 cred omeny 9611006 400.723 100.726 Page 11DRIVE PUMP ASSEMBLYDRIVE PUMP ASSEMBLY ITEM QTY DESCRIPTION 1 DRIVE PUMP 4 DRIVE COUPLING (COMPLETE) 1 FLEX ELEMENT 4 FITT9S-12830C000-000H001 2 HOSEO63R03¥a30v930L03160 1 HOSE0saR03Yoa0vas0L.02560 1 HOSE0saR03Y930¥430L02170 8 SHCS38%18 X14" 2 LOCKWASHER aia" 2 SHCS3B"- 16X14" LOCKWASHER M18 SHCS M18 X50 anal 108040 ex Agus 2000 10-8001 coated conpry Part No. 9604005 ‘9608011 9711026 9609008 ‘9609022 9609023 609024 130.117 400.149 100.143 790.088 790.369 Page 13a @ DRIVE MANIFOLD ASSEMBLY AH XH) 4 e Iso-0t centedompary anal t0FO40 ev Aut 2000> (GQ: DRIVE MANIFOLD ASSEMBLY « (TEM QTY _DESCRIPTION art No, 1 1 DRIVE MANIFOLD 9604201 2 2 32VALVE Vea, V2B 731.135 3 1 SRVALVE v8 731.136 4 1 RELIEF VALVE VIB 731.138 5 1 RELIEF VALVE AVIA 791.137 6 1 RELIEF VALVE (COMPLETE) 9711018 7 1 RELIEF VALVE Ava 9711019 8 1 CONTROL VALVE vt 9711016 9 1 CHECK VALVE ova 731.134 10 1 CHECK VALVE ov g7ii017 1 1 PRESSURE SWITCH Pst 100.827 2 1 CARTRIDGE CART. 1 g71t020 13 3 CARTRIDGE CART.25 a7it021 14 2 — CARTRIDGE CART. 56 a7it022 18 8 SPACER E25 9711023 16 2 PINBUSHING 9208015 7 2 O-RING 100.087 18 1 O-RING 790.081 19 2 sHcstoaext" 110.167 20 8 SHCSMI0X35 9205035 at 2 SPLITFLANGE (1 ¥"-3000) 100,045 2 4 MEASURE COUPLING 790.909 28 1 FIT 9S-04818A00-000H001 9609009 24 1 FIT 98-04820C00.000H001 9609010 : 25 1 FITT'9S-06820C00-000H001 9609007 26 4 ITT 9S-12830C00-000H001 ‘9609008 7 1 HOSE03eROtVotavatéloesso 9609027 28 1 HOSEaseR02¥920¥920L02560 9609028 29 1 HOSE03eR02Jo06Ys20L.07900 9702008 30 2 HOSE0s3R03Y030Y9s0L.03150 9609022 31 1 HOSEO63RO3¥030¥430L02560 9609023 2 1 HOSEO6sRO3¥990¥490L02170 9609024 3 1 HOSEt2sRo2F920F024L06700 9609021 4 1 HOSE125R02F420V446L08860 9609020 5 1 MEASURE HOSE 9507021 % 1 MEASURE HOSE 9607009 7 1 MEASURE HOSE 9507022 38 1 MEASURE HOSE 9603004 39 1 CORD ADAPTOR 110235 40 4 SHCSMBx 110 9201035 a 1 ORING PLATE 9208001 st 3, Manga 805FO40 Fa! Augst 2000 —____ Pages 1504001 ceria company