owners manual power pack - face machinery china · • the hydraulic system is a high pressure high...

Model : All Power Packs Manual no. : PPRF040

Revision no. : -

Date of issue : 12-08-2008

Owners Manual Power Pack

INTERNATIONAL CONTRUCTION EQUIPMENT

Operation & Maintenance Instructions Power Packs

of 41 ISO-9001 : 2000 certified company subject to change without notice


of 41 ISO-9001 : 2000 certified company Subject to change without notice


All rights reserved. No part of this publication may be copied or published by means of printing, photocopying, microfilm or otherwise without prior written consent of INTERNATIONAL CONSTRUCTION EQUIPMENT BV. This restriction also applies to the corresponding drawings and diagrams.

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 changes without prior 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 damage resulting from the application of this publication to the version actually delivered to you.

For extra information as to adjustments, maintenance and repair, please contact the technical department of your supplier. This publication has been written with great care. However, INTERNATIONAL CONSTRUCTION EQUIPMENT BV cannot be held responsible, either for any errors occurring in this publication or for their consequences.

IMPORTANT!: Important safety instructions are marked as shown below:

CAUTION Indicates a potentially hazardous situation which, if not avoided MAY result in minor or moderate injury.

WARNING Indicates a potentially hazardous situation which, if not avoided COULD result in serious injury or even death.

DANGER Indicates an threatening hazardous situation which, if not avoided WILL result in serious injury or even death.




TABLE OF CONTENT

1 SAFETY INSTRUCTIONS .................................................................................6

1.1 General ............................................................................................................. 6 1.2 Safety precautions .............................................................................................. 6 1.3 Safety instructions .............................................................................................. 9

2 DESCRIPTION ..............................................................................................10

2.1 Description of the one engine power packs............................................................10 2.2 Description of the 1000RF power packs.................................................................10 2.3 Hydraulic system ...............................................................................................10 2.4 Electrical system................................................................................................11

3 ASSEMBLY AND INSTALLATION...................................................................12

3.1 Moving the equipment ........................................................................................12 3.2 Connecting the hydraulic hoses............................................................................12 3.3 Connecting the standard pendant control ..............................................................16 3.4 Connecting the optional wireless control ...............................................................16

4 OPERATION..................................................................................................18

4.1 Emergency stop.................................................................................................18 4.2 Filling the pressure and return hose......................................................................18 4.3 Bleeding/filling the clamp hoses...........................................................................18 4.4 Control panel ....................................................................................................19 4.5 Pendant remote control, cable (standard)..............................................................20 4.6 Radio remote control (optional) ...........................................................................21 4.7 Starting / stopping 200RF / 400RF / 500RF / 600RF power packs .............................23 4.8 Starting / stopping 1000RF power packs ...............................................................26 4.9 IQAN PLC System ..............................................................................................29 4.10 Troubleshooting.................................................................................................33

5 MAINTENANCE .............................................................................................34

5.1 General ............................................................................................................34 5.2 Service intervals ................................................................................................34 5.3 Daily maintenance .............................................................................................34 5.4 Inspection and change intervals...........................................................................35 5.5 Remaining service intervals .................................................................................35 5.6 Severe conditions ..............................................................................................36 5.7 Additional inspections .........................................................................................36 5.8 Draining and filling the hydraulic oil reservoir.........................................................36 5.9 Refill volumes....................................................................................................36 5.10 Recommended liquids.........................................................................................37 5.11 Welding............................................................................................................37

6 ORDERING OF PARTS...................................................................................38

6.1 Procedure.........................................................................................................38 6.2 Original equipment.............................................................................................38 6.3 Shipment ..........................................................................................................38 6.4 Shortages .........................................................................................................38 6.5 Return of parts..................................................................................................38 6.6 Screws and bolts ...............................................................................................38 6.7 Hoses...............................................................................................................39 6.8 Fittings.............................................................................................................40




Preface

This owner’s manual has been written for the users of ICE Power packs. The owner’s manual explains how to use, service and inspect the power pack, with the intention to use the power pack safe and efficiently. One copy of the present manual should at any time be at the location where the unit is in operation. When the instructions of this owner’s manual are not strictly followed, accidents may happen.

Therefore, make sure you understand all the instructions in this manual before you start using the power pack. For ordering of parts we refer to the parts manual of the relating power pack. For the operation of the machine which is attached to the power pack, we refer to the owner’s manual of the relating manufacturer.

If operational or maintenance problems arise which are beyond the scope of this manual, please contact your dealer. They are prepared to assist you in order to make the best use of your equipment. Please have the following at hand: • Model

• Equipment serial number




1 SAFETY INSTRUCTIONS

1.1 General

Power packs contain components which are under high pressure during operation. Some components

get very hot, other components have rotating parts which can cause serious injuries. Therefore pay special attention to this chapter and the operation and maintenance section in this manual. REMARK: Regular maintenance and skilful operation will not only lengthen the mechanical life, but is essential for the safety of the user and bystanders.

1.2 Safety precautions

ICE accepts no liability for any damage or physical injury caused by non-compliance with the safety instructions in this manual or by carelessness during the installation, use, adjustment or maintenance of the equipment. Regularly maintenance and skilful operation will not only lengthen the mechanical life, but is essential for the safety of the user and possible bystanders.

WARNING It is the responsibility of the user or operator to ensure that the local health and safety regulations are observed before and during the use of the equipment.

Operators

• Only trained personnel shall be permitted to operate the machine. • Temporary employees and trainees shall only be permitted to work with the equipment under the

supervision and instruction of trained personnel.

Owner’s manual

• Everyone who works at or with the equipment should be familiar with the contents of this manual and the manuals of the machines which are driven by the power pack and should follow the instructions accurately.

• One copy of the present manual should at any time be at the location where the unit is in operation.

• The management is under obligation to inform the personnel of the contents of this manual and is obliged to observe all of the regulations and directions.

• Additional manuals are available on request.

Always

• Lead exhaust fumes outside when operating in a closed area. Continued breathing-in of exhaust fumes may be fatal.

• Pay attention to irregular or unusual noises and analyse where they come from.

• Remove all tools and electrical cords before starting the power pack. • Warn colleagues when you feel uncomfortable with the way the power pack or the driven machine

is functioning.

Never

• Make adjustments or repairs while the system is under pressure. • Make adjustments or repairs while the engine is working • Continue operation when service inspection is due, or when a repair is necessary.




• Continue operation when it is known that one of the safety provisions is out of order or not working properly.

• Leave the remote control pendant unattended. • Attempt to (dis)connect the quick-disconnect couplers when the engine is running.

Tools

• Never use defective (maintenance) tools. • Only use a tool for the purpose it was designed for.

Clothing and footwear

• When working with the equipment, do NOT wear rings, watches, jewellery or any loose clothing which could be caught in moving or rotating parts.

• Always wear protective goggles, a safety helmet, protective footwear and hearing protection specially suited for the work.

• Keep hands away from moving or rotating parts. Wear working gloves. • Take appropriate measures for the protection of hearing if the sound level of 85 dB(A) is

exceeded; always use ear protection when working close to a machine in operation.

Water and moisture

• NEVER direct a jet of water at electrical parts. • Make sure all protective devices of the electric installation have been installed to guarantee

adequate protection from moisture and water. Failure to do so can result in malfunction of safety circuits and cause harm to personnel and equipment components.

Technical specifications

• The permissible tolerances as mentioned in the present manual shall NOT be exceeded.

Safeguards

• All safeguards must be correctly installed and may only be removed for maintenance and service purposes by qualified ICE service engineers.

• The equipment should never be switched ON when the protective covering is incomplete or when the safeguards are not in place.

• All safeguards must be checked at regular intervals and repaired immediately in case of malfunction.

Safety directions and warnings

• Any safety direction, warning or instruction fitted on the equipment shall NOT be removed, rendered illegible or covered. They shall be present and legible throughout the entire operating life of the equipment.

• Illegible, damaged or covered safety directions, warnings or instructions shall immediately be

replaced or repaired.

Service and maintenance

• The service and maintenance activities shall only be carried out by qualified ICE personnel or one

of ICE’s appointed and certified dealers in full compliance with all safety instructions and service intervals.

• Use original ICE Parts and liquids.

Electrical system

• Work on the electrical system or equipment may only be carried out by skilled electricians or by specially instructed personnel under the supervision of such electricians and in accordance with the applicable electrical engineering rules




Hydraulic system

• The hydraulic system is a high pressure high oil flow system. Work on the hydraulic equipment shall only be carried out by persons having special knowledge and experience in high pressure

hydraulic systems. • When bleeding hoses or looking for leaks, take protective measures. Escaping oil under pressure,

even a pin-hole size leak, can penetrate body tissue, causing serious injury.

Use according to purpose

• In order to guarantee correct operation, the equipment should only be used in accordance with the purpose as described in this owner’s manual.

Fire or explosion prevention

• Hydraulic oil and diesel fuel are flammable. Therefore: o Do not weld or flame-cut on pipes or tubes that contain flammable fluids. Clean them

thoroughly with non-flammable solvent before welding or flame cutting on them. o Clean and tighten all electrical connections. Check regularly for loose or frayed electrical

wires. Wiring must be kept in good condition, properly routed and firmly attached. Routinely inspect wiring for wear or deterioration. Loose, unattached, or unnecessary wiring must be

eliminated.

WARNING Never smoke when filling the fuel tank or use flames in the vicinity. Never store flammable liquids near the engine.

Work area

• Place the power pack in a safe place.

• Position the power pack in such a matter that eye contact with the power pack is assured. • Keep the work area clean. Keep the equipment accessible and make sure that the area

surrounding of the equipment is kept clean. • Always be extremely careful when using a carbon tetrachloride fire extinguisher in a closed area,

as it may produce toxic vapours and/or deplete the area from oxygen.

Incorporated safety precautions

In case a vibratory hammer is used in combination with the power pack, a number of safety provisions are built-in. These safety provisions ensure that the risk for failures, human injuries and environmental pollution is reduced to a minimum: • Dual operating functions, either by hand-held pendant or on the control box in the power pack

• Emergency stop on hand-held pendant. • Emergency stop on radio remote control. (with a 5 second delay) • Emergency stop on outer side of the power pack.

WARNING Never change the electrical wiring or hydraulic safety setting, which changes the above safety provisions. In most countries the hammer and power pack are not allowed to operate in explosion-risk areas without modifications. Always contact ICE when special requirements are compulsory.




1.3 Safety instructions

HAZARD DESCRIPTION

Safety sign Risk for short circuit

9501049

Read the operation manual

9501051

Disconnect power source before opening dashboard

Make sure the machine is in good condition

High noise level

9501058

Read the maintenance instructions in the owners manual for proper service procedures

9501050

Use ear protection

Surface can be hot Fire risk

9501052

Do not touch, allow the surface to cool down.

9501054

Keep machine clear of oil rests, be careful when handling fuel and hydraulic oil

Component is pressurised

Risk of burns to fingers or hands resulting from dangerous liquids or chemicals

9501049

Depressurise before maintenance

9501053

Wear protective gloves




2 DESCRIPTION The power pack can be used for the following purposes:

• To drive an (ICE) vibratory hammer • To drive an auger, impact hammer, cutter, winch or shear • To drive a sand pump

2.1 Description of the one engine power packs

This part of the manual contains the description of the following power packs

Power packs

ICE – 200RF ICE – 400RF ICE – 500RF ICE – 600RF

The power packs are powered by a CATERPILLAR or VOLVO engine. The engine is mounted on a tubular sub-base which serves as a fuel tank. The power unit and the driven machine are operated from the control panel or remote control

pendant. The standard remote control pendant is connected by cable or optional by a wireless pendent. Hydraulic oil is stored in the reservoir. Oil cooling is accomplished by an air-to-oil temperature exchanger. All of the above components are contained in a sheet metal enclosure with lockable doors and air

vents.

2.2 Description of the 1000RF power packs


Power packs

ICE – 1000RF

The 1000RF power packs are powered by one CATERPILLAR or two VOLVO engines. The engines are

mounted on a tubular sub-base which serves as a fuel tank. The power unit and the driven machine are operated from the control panel or remote control pendant. The standard remote control pendant is connected by cable or optional by a wireless pendent. Hydraulic oil is stored in the reservoir. Oil cooling is accomplished by air-to-oil heat exchangers.

All of the above components are contained in a sheet metal enclosure with lockable doors and air vents.

2.3 Hydraulic system

(for the circuitry, refer to the parts manual) The hydraulic circuitry of the ICE power pack is a so-called open-loop system. This means that the oil is taken from a reservoir. The pressure in the return line is low. Each power pack is equipped with several hydraulic pumps. The main pump(s) are variable

displacement pumps and drive the vibratory hammer. The secondary pump(s) can be used to open/close a clamp to adjust the centrifugal force of a RF vibratory hammer and drive the oil coolers.

The main pump




When the diesel engine is running and the forward/start button is activated, hydraulic fluid is taken from the reservoir by the drive pump and is pumped to the drive manifold. The oil is directed through the hoses to the driven machine (vibratory hammer). It flows back to the power pack through the return line. The circuit is protected by means of a pressure relief valve and is provided with a return line filter. The hydraulic hoses can be disconnected at the power pack directly behind the manifold.

The secondary pump

When the diesel engine is running, and the clamp or RF actuator buttons are activated, hydraulic fluid is taken from the reservoir by the secondary pump and pumped directly to the mentioned hydraulic parts. It flows back to the power pack through the return line.

Optionally this circuit may be protected by means of a pressure relief valve and return filter.

The reservoir

The hydraulic oil is stored in the hydraulic reservoir. The oil flows into the reservoir via a filter. The reservoir may be closed with a butterfly valve.

Optional lube oil cooler

Optionally the lube oil from the vibratory hammer may be cooled in the power pack for 500RF series and upwards.

2.4 Electrical system

(for the circuitry, refer to the parts manual) The power pack contains a 24V DC electrical installation.

All main hammer functions are electrically controlled either from the remote control or from the main control panel. The power pack is equipped with a control module, which will warn the operator in the following cases: • Hydraulic oil temperature too high.

• Hydraulic oil level too low. • Engine coolant temperature too high. • Engine coolant level too low. • Engine Over speed. • Engine lubrication oil pressure too low.

• Emergency stop • Lube oil pressure low(optional) • Lube oil pressure high(optional) • Lube oil temperature high(optional)

If necessary, the Power Pack will stop the main oil flow automatically. The power pack is also equipped with the following safety measures: • Emergency stop. (Enclosure, radio remote, cable remote) • Safety switch on the butterfly valve. If the oil supply to the main oil pump has been shut off by

means of the butterfly valve, the engine can not be started.

Optional warning

• Warm up active.




3 ASSEMBLY AND INSTALLATION

3.1 Moving the equipment

The power packs are equipeed with lifting logs.

WARNING Always lift the power pack by its own lifting lugs. Use certified slings and place the power pack on a horizontal and stable ground (surface).

3.2 Connecting the hydraulic hoses

CAUTION Never connect or disconnect the hoses while the engine is still running.

• Make sure the connectors are not under pressure.

• Clean the couplers with a lint-free cloth. • Check the couplers and hoses for any damage. • Connect the hoses with the help of quick-disconnect couplers. Avoid kinking and chafing. The

couplers are sized to ensure correct connection.

• Make sure the couplers are FULLY tightened. The drive pressure coupler (1) and drive return coupler (2) can be tightened with a chain-wrench, the others should be tightened by hand.

3.2.1 Connecting the hydraulic hoses on a 200RF


Power packs

ICE – 200RF




Connections

1 Drive pressure hose 6 Drain hose 2 Drive return hose 7 Eccentric moment + 3 Clamp hose (close) 8 Eccentric moment -

4 Clamp hose (open) 9 Pendant remote control connector 5 Drain hose



Power packs

ICE – 400RF

Connections:

1 Drive pressure hose 6 Drain hose 2 Drive return hose 7 Eccentric moment + 3 Clamp hose (close) 8 Eccentric moment – 4 Clamp hose (open) 9 Remote control 5 Drain hose



Power packs

ICE – 500RF

2 1

7 8

5 6

3 4 9




Connections

1 Drive pressure hose 7 Eccentric mom.+ 2 Drive return hose 8 Eccentric mom.- 3 Clamp hose (close) 9 Cooler in 4 Clamp hose (open) 10 Cooler out

5 Drain hose 11 Pendant remote control connector 6 Drain hose



Power packs

ICE – 600RF

Connections

1 Drive pressure hose 7 Eccentric moment +

2 Drive return hose 8 Eccentric momment - 3 Clamp hose (close) 9 Cooler in 4 Clamp hose (open) 10 Cooler out 5 Drain hose 11 Pendant remote control connector 6 Drain hose






Power packs

ICE – 1000PP/RF

Connections

1 Drive pressure hose 7 Eccentric moment +

2 Drive return hose 8 Eccentric moment - 3 Clamp hose (close) 9 Cooler in 4 Clamp hose (open) 10 Cooler out 5 Drain hose 11 Pendant remote control connector 6 Drain hose

1 2

11

3

8 7

4

5

10

9

6




3.3 Connecting the standard pendant control

Connect the cable plug to the control panel of the power pack (see illustration, item A).

A

When the pendant / wireless control cable is: Connected: The hammer can only be activated by means of the pendant / wireless control. Disconnected: The hammer can only be activated by means of the control module at the control panel, or radio remote control.

3.4 Connecting the optional wireless control

Connect the cable plug to the control panel of the power pack (see illustration, item A).

A

When the pendant / wireless control cable is: Connected: The hammer can only be activated by means of the pendant / wireless control.




Disconnected: The hammer can only be activated by means of the control module at the control panel, or radio remote control. REMARK The EMERGENCY STOP on the power pack housing is always operational. The EMERGENCY STOP on the pendant control and the radio remote control are operational only

when they are connected.




4 OPERATION

WARNING Make sure you are familiar with the SAFETY INSTRUCTIONS as described in chapter 1 before you operate the power pack. Make sure the operator has a clear view on the working area, the power pack and the machine which is driven by the power pack. Make sure that communication with other involved persons (crane driver) is always possible.

4.1 Emergency stop

Check if the emergency stop buttons on the remote control pendant / radio remote control and the outside of the power pack are released. If not, turn the button clockwise. IMPORTANT! Always reset the emergency stop button immediately after the hammer and power pack have been

shut down completely.

4.2 Filling the pressure and return hose

When the driven machine is shipped with all hoses attached, the hoses are usually full of oil and may be used immediately. However, if any of the hoses are connected at the jobsite or if air is present in hoses, they must be bled prior to operation. • Start and warm up the engine (read chapter 4.7.1. or 4.8.1 depending on the power pack type) • Keep the engine running at 1500 rpm.

• Press the forward button for appr. 2 seconds and than stop, to build up some pressure without running the machine(vibratory hammer). Do this 2 or 3 times and the hoses are filled.

• Check the oil level in the hydraulic oil tank. Refill if necessary.

4.3 Bleeding/filling the clamp hoses

When the vibrator and hydraulic clamp are shipped with all hoses attached, the hoses are usually full of oil and may be used immediately. However, if the clamp hoses are connected at the jobsite or if air is present in hoses, they must be bled prior to operation.

• Start and warm up the engine (read chapter 4.7.1. or 4.8.1 depending on the power pack type) • Turn the clamp switch (OPEN/CLOSE) on the remote control to the position OPEN. The pressure in

the clamp hoses will go down to almost zero. • Shut down the engine (read chapter 4.7.2 or 4.8.1 depending on the power pack type)

Caution When bleeding hoses or looking for leaks, take protective measures. Escaping oil under pressure, even a pin-hole size leak, can penetrate body tissue, causing serious injury.

• Loosen the clamp-close-connector a little bit at the clamp (with a tray under the connector). • Start and warm up the engine (read chapter 4.7.1. or 4.8.1 depending on the power pack type) • Turn the clamp switch (OPEN/CLOSE) on the remote control to the position CLOSE. • Wait until fluid flows without any traces of air, then tighten the connector.

• Repeat the above instruction for the clamp-open-connector. • Turn the clamp switch to CLOSE and OPEN several times to ensure the clamp cylinder is working

properly.




4.4 Control panel

The control panel contains a control module from which the operator can control the vibratory hammer, the clamp and the power pack.

Caution Make sure the operator has a clear view on the connected machine(s) and the working area, when operating via the control panel.

IMPORTANT: The operation / maintenance / safety instructions on the inside of the control panel door serve as quick reference. They are not complete and therefore not intended as a substitute for a thorough

understanding of the present manual.

4.4.1 Control panel power packs 200RF / 400RF / 500RF / 600RF

This paragraph contains the description of the control panel of the following power packs

Power packs


2

3 4

5

6

1

Control panel Items

1 IQAN PLC control 4 Remote control battery charging adapter (option) 2 IQAN PLC module 5 Start switch 3 Remote control battery charger (option) 6 Remote control connector




4.4.2 Control panel power packs 1000RF


Power packs

ICE – 1000PP/RF

12

3 4 5 6

Control panel Items

1 IQAN PLC control 4 Stop button engine 1 2 IQAN PLC module 5 Start button engine 2 3 Start button engine 1 6 Stop button engine 2

4.5 Pendant remote control, cable (standard)

The remote control pendant contains the following functions:

1 2 3 4 5 6 7




Remote control functions

1 Emergency stop 5 Stop operation 2 Clamp open / close 6 Eccentric moment switch 3 Warning lamp: clamp closed 7 RPM switch

4 Start operation

4.6 Radio remote control (optional)

4.6.1 How to switch on the radio remote control:

Make sure the emergency stop is pulled out.

3

1

2




The following steps must be taken in a few seconds. Step 1. Press the no. 1-button. Red led starts flickering Step 2. Press the no. 2-button. Green led up once.

Step 3. Press the no. 3-button. Green led starts flickering. Remote control is ready for use.

4.6.2 The radio remote control contains the following functions:

2 4 6 8 10

119753

1

Radio remote control functions

1 Emergency stop 7 Eccentric moment + 2 Clamp open 8 Remote start switch 3 Clamp close 9 Remote stop switch 4 Start operation 10 RPM- 5 Stop operation 11 RPM+

6 Eccentric moment -




4.7 Starting / stopping 200RF / 400RF / 500RF / 600RF power packs

The paragraphs 4.7 until 4.7.2 contain the start and stop procedures of the following power packs

Power packs


1

3

4 2

Start / Stop controls

1 Earth switch 3 IQAN PLC control

2 Start switch 4 Remote control

4.7.1 Start-up procedure 200RF / 400RF / 500RF / 600RF power packs

Step 1

Turn earth switch (No.1) to “ON” position.(clockwise) Turn on remote control Make sure the emergency stop is not switched on.




3

1

2

The following steps must be taken in a few seconds. Step A. Press the no. 1-button. Red led starts flickering

Step B. Press the no. 2-button. Green led up once. Step C. Press the no. 3-button. Green led starts flickering. Remote control is ready for use.

Step 2

Turn start switch (no 2) to “I “position. The “WAIT“ screen will popup.




After a few seconds the “START ENGINE “ sign will popup.

Step 3

Turn start switch (No.2) to “START “position.

4.7.2 Stop procedure 200RF / 400RF / 500RF / 600RF power packs

• Stop operation.

• Allow the engine to run at idle speed for at least 5 min. • Turn start switch (No. 2) to “О” (OFF). • Turn earth switch (No. 1) to “OFF”. • Turn off the radio remote control (stop button).

CAUTION Vibrator may fall from pile. 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 over time. Therefore, it is not recommended to leave the vibrator clamped to a pile when the diesel engine is not running.




4.8 Starting / stopping 1000RF power packs

The paragraphs 4.8 until 4.8.2 contain the start and stop procedures of the following power packs

Power packs

ICE – 1000PP/RF

3

2 4 2 41

Start / Stop controls

1 Earth switch 3 IQAN PLC control

2 Start buttons 4 Stop buttons

4.8.1 Start-up procedure 1000RF power packs

Step 1

Turn earth switch (No.1) to “ON” position.(clockwise) Turn on remote control Make sure the emergency stop is not switched on.




3

1

2

The following steps must be taken in a few seconds. Step A. Press the no. 1-button. Red led starts flickering

Step B. Press the no. 2-button. Green led up once. Step B. Press the no. 3-button. Green led starts flickering. Remote control is ready for use.

Step 2

Wait for the preheat indication to dissappear.




After a few seconds the “START ENGINE “ sign will popup.

Step 3

Push the start buttons (No.2) one by one to start the engines.

4.8.2 Stop procedure 100RF power packs

• Stop operation. • Allow the engine to run at idle speed for at least 5 min. • Push the stop buttons (No. 4) one by one to stop the engines. • Turn earth switch (No. 1) to “OFF”.

• Turn off the radio remote control (stop button).

CAUTION Vibrator may fall from pile. 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 over time. Therefore, it is not recommended to leave the vibrator clamped to a pile when the diesel engine is not running.




4.9 IQAN PLC System

This power pack is provided with an IQAN PLC system. All controls, settings, parameters, etc. are set and can be read out of the display.

4.9.1 Button descriptions

Button descriptions

Press

for ICE info. Press

for main menu.

Press

for engine parameters. Press

to enter.

Press

for hydraulic parameters. Turn

to scroll

Press

for internal light. Press

for previous screen.

4.9.2 Language selection

1

2




Select menu. Press

Select preferences. Press

Select language. Press

Rotate scroll button to select language, press scroll button to confirm selected language.

Press previous screen button 4 times to return to main screen.

4.9.3 Menu structure

Press to enter the main menu.

Main menu Button descriptions

Press

for adjust menu. Press

for main menu.

Press

for measure.. Press

to enter.

Press

to adjust preferences. Turn

to scroll

Press

for machine information. Press

for previous screen.

3

4




4.9.4 Adjustment / Settings

Go to main menu and select adjust The following settings are adjustable:

Pump flow Accessible. Control setting ICE qualified personnel only. Pump setting ICE qualified personnel only. Sensor setting ICE qualified personnel only. Engine setting ICE qualified personnel only. Maintenance reset ICE qualified personnel only. Lube oil cooler Option.

Warm - up system Option. Flow selection (key switch) Option. Pump flow is accessible, for the rest of the settings you need to contact ICE, or your nearest ICE dealer.

4.9.5 Adjust pump flow

With this setting you can choose to drive your machine at normal operation or full power operation. For example: 36RFts at normal operation : 2000 rpm 36RFts at full power operation : 2300 rpm Other speed settings are possible on request.

Go to main menu and select adjust

Enter pump flow by pressing .




Enter Hammer high/low by pressing the button.

Choose NORMAL OPERATION or FULL POWER OPERATION by turning the button.

Enter the setting by pressing the button.

4.9.6 Warm-up procedure

Warning Make sure the vibratory hammer stands up straight, before the warm-up system is activated.

Warm-up procedure

• Start the engine. • The eccentric moment will automatically be locked at minimum. • Close the clamp. • Start the vibratory hammer (forward).




• The warm-up system is now activated. • During warm–up this pop-up screen will appear in display. • The engine speed is limited/set at intermediate speed during warm–up. • During warm–up it is not possible to adjust the eccentric moment.

• When the hydro–oil temperature and coolant water temperature are accurate, the pop-up screen will fade and the hammer will stop.

• The engine speed will toggle down to low idle. • Machinery will be ready for use now.

CAUTION To prevent severe damage to the hammer, please check if the flow selection (key-switch) is set at the correct parameter as the type of hammer to be driven.

4.10 Troubleshooting

Most breakdowns and or malfunctions can be prevented by proper periodic inspection, lubrication and

maintenance. If the malfunction cannot be corrected, contact your local ICE service location. For malfunctions of the hammer or the clamp, we refer to the relating owner’s manuals.

Engine does not start

Check if the IQAN PLC display shows a message. Solve the cause if necessary. If the engine does not turn over, check the battery and check if the connectors of the battery are fully tightened. If the engine turns over, check the fuel supply and the fuel filter. Consult the Caterpillar Operation & Maintenance Manual. Call your local Caterpillar dealer.

Engine does not stop

If there is an emergency, push the emergency stop button. Check the electrical components and connections.




5 MAINTENANCE

DANGER All maintenance work is strictly reserved to qualified and authorized personnel. Except for the visual inspections, all maintenance work must be carried out with the diesel engine stopped. Make sure that the main power switch is in OFF position. Install a DO NOT OPERATE or similar warning label to the main power switch.

5.1 General

Preventive maintenance includes normal servicing that keeps the power pack in good operating condition and prevents unnecessary breakdown. Lubrication is essential for the system, determining to a great extent the useful life of the vibratory hammer. Therefore it is important that the instructions regarding types of oils and exchange intervals are

closely adhered to. • Prevent dirt from entering lubricants and the system. • Thoroughly clean all lubrication fittings, caps, filter plugs and level plugs and their surrounding

surfaces before servicing.

Caution Regularly maintenance increases the life span and the output of the power pack, and is essential for the safety of the user and possible bystanders. Before starting maintenance, make sure the machine has cooled down, the working area is safe and clean, and the system is depressurized. Install a DO NOT OPERATE or similar warning label to the ignition switch. Turn off the mass switch prior to maintenance work on the electrical system.

5.1.1 New or stored power packs

For new or stored power packs, refer to the diesel engine Operation’s Manual (section “Preparation

for Starting Engine, First Time”).

5.2 Service intervals

Every 250 Service hours, the MAINTENANCE WARNING SIGN will appear on the display. • Contact ICE or your nearest ICE dealer for a service appointment or more information • For more detailed information regarding the engine, refer to the “Operation and maintenance

manual” of the Caterpillar engine.

5.3 Daily maintenance

The daily instructions apply to routine or daily starting of a vibratory hammer.

Before start-up, proceed as follows:

• Engine: o Check the coolant level in the radiator (engine should be cooled down).

o Check the air filter service indicator. o Check the engine oil level. o Inspect the water separator of the Fuel filter. Drain if necessary. o Check for leaks and loose connections.




o Check the fuel level.

• Other components: o Clean the bottom plate of the power pack o Inspect hydraulic system for leaks.

o Visually check all couplers and hoses for signs of damage or cuts. o Make sure all connections are tightened fully, especially the quick-disconnect couplers. o Check the oil level of the hydraulic tank on the level gauge.(should be in between min. and

max. indication).

After start up:

• Check hoses for leaks. Make sure they hang freely with no kinks. • Check the pump, hydraulic manifolds and fittings for leaks. • Check the return filter service indicator. Oil must be flowing through the filter. Change the filter

when the dial is in te red area.

5.4 Inspection and change intervals

INSPECTION INTERVALS BASED ON OPERATING HOURS POWER PACKS

Description Normal driving conditions

Heavy driving conditions

Min.

First Interval First Interval Powerpack Engine:

oil pan / fuel filter / air

filter / lubrication filter

According engine service manual Yearly

Hydraulic return filter 25 100 10 50 Every 3 months

Hydraulic oil - - - - Sample Yearly

Cooler unit Lubrication filter 25 100 50 50 Yearly

Hoses Check for damaged steel wire Daily

cHANGE INTERVALS BASED ON OPERATING HOURS POWER PACKS

Description Normal driving conditions

Heavy driving conditions

Min.

First Interval First Interval

Powerpack Engine: oil pan / fuel filter / air filter / lubrication filter

According engine service manual Yearly

Hydraulic return filter 50 3000 25 2000 Every 6 months

Hydraulic oil Sample Yearly Sample every 6

months

Sample

Yearly Cooler unit Lubrication filter 50 200 25 200 Yearly Hoses Exchange when first steel layer is damaged Every 5 years

5.5 Remaining service intervals

Engine:

• Refer to the diesel engine “Operation & maintenance manual”.




Other components:

• Have the hydraulic fluid analysed by a local hydraulic service centre. Replace fluid if required. • Have the hydraulic system inspected by ICE (authorized) service personnel.

The intervals are based on normal operation. Perform these services more often as needed for operation under abnormal or severe circumstances.

5.6 Severe conditions

The intervals specified are based on normal operating conditions. Operating under severe or unusual conditions will require some adjustments in service intervals.

In the following circumstances, the service time intervals should be reduced by one-half of those specified. • when the average temperature is above 35°C (80°F) or below -23°C (-10°F) • when operating in the presence of dust or sand • when operating in excess of twelve hours per day

When operating in air with high salt or moisture, the service intervals do not need to be changed. However, the unit should be inspected weekly to determine if additional servicing is required. Also, have the hydraulic oil tested quarterly. For extended inactive periods, the engine should be started at least once a week and run until thoroughly warm. Service intervals may be extended from those specified. For stored power packs,

refer to the diesel engine Operation’s Manual (section “Preparation for Starting Engine, First Time”).

5.7 Additional inspections

Additional inspections Action Polonged inactive period Inspect before operation Environment with high salt and/or moisture content

Weekly inspection

Heavy driving conditions Inspect engine filters every 250 hours

5.8 Draining and filling the hydraulic oil reservoir

The hydraulic reservoir is drained by removing a plug on the bottom of the of the reservoir.

The hydraulic reservoir is filled by a manual pump. All oil is pumped to the reservoir through the return filter to insure no dirt enters the hydraulic system. For exact location of the hydraulic reservoir pump, refer to the parts manual. The engine pan is filled by a manual pump. For exact location of the pump, refer to the parts manual.

5.9 Refill volumes

The refill volumes of the engine oil, diesel oil & hydraulic oil can be found in the parts manual of the power pack.




5.10 Recommended liquids

TEMPERATURES NORMAL AMBIENT

HIGH AMBIENT LOW AMBIENT

EXTREME LOW AMBIENT

-10°C < T < 55°C T > 55°C -20°C < T < 20°C -35°C < T < 20°C

VIBRATION CASE FORCED LUB

Total Carter 75W140

Total Carter 75W140

Total Carter 75W90

Total Carter 75W90

VIBRATION CASE SPLASH LUB

Total Carter SH 460

Total Carter SH 460

Total Carter SH 460

Total Carter SH 460

HYDRAULIC OIL Total EQUIVIS ZS 46 Alt. Total

EQUIVIS XV 46

Total EQUIVIS ZS 68

Total EQUIVIS ZS 32

Total EQUIVIS XV 32

BIO OIL Total BIOHYDRAN TMP 46

Total BIOHYDRAN SE 46

not recommended not recommended

ENGINE OIL Total Rubia TIR 7400 5W30 ENGINE COOLANT 50% Total GLYCOLFREEZE + 50% water + additive

Severe circumstances:

• Engine: refer to the “Operation and maintenance manual” of the Caterpillar or Volvo engine. • Hydraulic system: contact your local specialist

5.11 Welding

Do not weld or flame-cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with non-flammable solvent before welding or flame cutting on them. Proper welding procedures are

necessary in order to avoid damage to the engine’s computer, sensors and associated components. When possible, remove the component from the unit and then weld the component. If this is not possible, follow the instructions below: • Stop the engine. Turn the ignition switch to the “OFF” position. • Disconnect the negative battery cable from the battery. • Disconnect the connectors from the Engine Control Module. Move the harness to a

position that will not allow the harness to accidentally move back and make contact with any of the ECM pins.

• Disconnect the connectors from the IQAN PLC in the control panel. • Connect the welding ground cable directly to the part that will be welded. Place the ground cable

as close as possible to the weld.

• Protect the wiring harness from welding debris and spatter. • Use standard welding practices to weld the materials.

Disconnect before welding




6 ORDERING OF PARTS

6.1 Procedure

When ordering parts, be sure to include the model and serial number of the unit or component.

confirm all telephone and/or e-mail orders immediately to avoid duplicating shipment.

6.2 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.

6.3 Shipment

State to whom shipment is to be made and method of shipment desired, otherwise our own judgement will be made.

6.4 Shortages

Claims for shortages or errors shall be made immediately on receipt of parts. No responsibility will be assumed for delay, damage or loss of material while in transit. Broken, damaged or loss of material

shall be refused or a full description made of damage or loss to the carrier agent on the freight or express bill

6.5 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, first secure permission to return the parts. Shipping instructions will be given along with this permission

6.6 Screws and bolts

Almost all connections on the unit 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. The information, in parenthesis, immediately following the bolt or screw designation shows the size as follows: ½ - 13 x 1 ½ ½” Diameter 13 Threads Per Inch

1 ½" 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 5.14

ABBREVIATIONS USED

BHCS Button Head Cap Screw HSSS Hex. Socket Set Screw FHCS Flat Head Cap Screw PHMS Philips Head Machine Screw FLCS FLanged head Cap Screw RHMS Round Head Machine Screw HC High Collar SHCS Socket Head Cap Screw HHCS Hex. Head Cap Screw SHPP Socket Head Pipe Plug HHPP Hex. Head Pipe Plug SHSS Socket Head Shaller Screw




6.7 Hoses

EXAMPLE OF HOSE DESIGNATION

A B C D E F G H I J HOSE 125 R01 F 9 24 P 0 20 LO395 S

Explanation of hose codes

A HOSE I.D. (3 digits) (125 = 1/14”) (050 = ½”), etc. In inches; 2 place decimal

B SAE or MANUFACTURER RATING (3 digits) (PT4 = Power Track) (R01 = SAE Rating 100R1), etc.

C FIRST END – TYPE OF FITTING (1 digit) (F = 3000 PSI Flange) (P = NPT-male)

(H = 6000 PSI Flange) (M = JIC-male) (J = JIC-female swivel), etc.

D FIRST END – BEND ANGLE (1 digit) (0 = None) (3 = 30°) (9 = 90°),etc.

E FIRST END – SIZE(2 digits) (In 1/16th)

F SECOND END – TYPE OF FITTING (1 digit) (See codes for first end)

G SECOND END – BEND ANGLE (1 digit) (See codes for first end)

H SECOND END – SIZE (2 digits) (in 1/16th)

I LENGTH In inches; 1 place decimal (0395 = 39 ½”) (1240 = 124”), etc.

J SPECIAL CODES (0 = None) (S = Spring Guard) (L = S.S.Braid) (D = Offset)




6.8 Fittings

EXAMPLE OF FITTING DESIGNATION

A B C D E F G H I J K L M FITT 2 L 16 M 12 J 0 0 00L 0 0 0 1

Explanation of fitting codes

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

fitting required). C FIRST END SIZE

In sixteenth of an inch (index 2) In millimetres (index 9) Exceptions: 90 = 10” 94 = 14” 98 = 8” 92 = 12” 96 = 6” 99 = none code size

See general specification sheet for sequence of order.

D FIRST END FITTING STYLE See fitting style selector chart.

E SECOND END SIZE If applicable. See first end size.

F 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.

FOURTH END SIZE (crosses only) See first end fitting size or end style.

FOURTH END FITTING STYLE (crosses only)

See first end fitting size or end style. I LENGTH CODE pipe nipples (long) only

(in decimal inches for index 2) 050 = 5.0 inches 105 = 10.5 inches In millimetres for index 9 120 = 12.0 inches 084 = 8.4 inches

LENGTH CODE (elbows / nipples) 00L – long (elbow) 00C – close (nipple) 00x – extra long (elbow) 00S – short (nipple)

J INSTALLATION AID OR STYLE OF HEAD 0: not applicable. H: regular hex. W: wide or large hex. Q: square head (ext.) R: square head (int)

S: hex. head (int. socket) T: hex. head (ext.)

K PRESSURE RATING 0: not applicable

1: 125 lb 3: standard weight (40) 4: extra heavy (80)

L SPECIAL NOTATIONS 0: none

A: tapped hole in fitting B: orifice F: special fab., non-stock item. G: galvanized M: magnetic

M MATERIAL 1: carbon steel2: brass

3: cast brass 4: stainless steel 5: A.A.R. mal. Iron 6: maleable iron 7: cast iron 8: forged steel 9: aluminium

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