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Ice 18ZR Operation And Maintenance Manual

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OPERATION AND MAINTENANCE MANUAL
This manual is for ICE Model 18ZR, 25ZR, 50ZR vibrators
used with 350GZ, 450GZ, 595GZ power units
INTERNATIONAL CONSTRUCTION EQUIPMENT, INC.
Specializing in Pile Driving and Drilling Equipment
Corporate offices: 301 Warehouse Drive, Matthews NC 28104 USA
Sales & Service contacts
Phones: 704 821-8200, 888 ICEUSA1
Fax:
704 821-8201
Email:
info@iceusa.com
Operation and Maintenance Manual
www.iceusa.com
© International Construction Equipment, Inc. All Rights Reserved.
Parts Contacts
Phones: 704 821-8200, 888 ICEUSA1
Fax:
704 973-0985
Email:
parts@iceusa.com
OM-ZR-May15

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Summary of Contents for Ice 18ZR

  • Page 1 OPERATION AND MAINTENANCE MANUAL This manual is for ICE Model 18ZR, 25ZR, 50ZR vibrators used with 350GZ, 450GZ, 595GZ power units INTERNATIONAL CONSTRUCTION EQUIPMENT, INC. Specializing in Pile Driving and Drilling Equipment Corporate offices: 301 Warehouse Drive, Matthews NC 28104 USA www.iceusa.com...
  • Page 2 Lakeland, FL 33809 USA Email: sales@iceicon.nl Phones: 704-821-8200 x164 www.iceicon.nl Fax: 863-680-1540 Southeast Asia ICE Texas Branch ICE Far East Pte Ltd Texas & West 13 Pioneer Sector 2 30095 US Highway 90 Katy, TX 77494 USA Singapore 628374 Phone: 704-821-8200 x165...

  • Page 3: Warranty

    ICE upon inspection to have been defective in material or workmanship. Such parts shall be provided at no cost to the user at the business establishment of ICE or at the ICE distributor of the product during regular working hours.
  • Page 4 Operation and Maintenance Manual Page 2 OM-ZR-May15...

  • Page 5: Introduction

    INTRODUCTION Literature This manual contains parts information for your ICE equipment. This manual should be stored in or near the power unit in a literature holder or literature storage area. Read, study and keep it with the equipment litera- ture, ICE Parts Manuals, and CAT engine information. English is the primary language for the ICE publications.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS CONTENT PAGE Parts and Service Locations ........................Front End Paper Warranty ..................................1 Introduction ................................... 3 Table of Contents ................................4 Section 1: GENERAL INFORMATION Power Unit, Vibrator Driver Extractor ..........................7 Hydraulic Hoses, Clamps and Accessories, General Description of ZR Operation ..............8 Vibrator Specifications ..............................
  • Page 7 Table of Contents (continued) CONTENT PAGE Unclamp Pile, Changing Frequency, Underwater Operation .................... 34 Section 6: MAINTENANCE General, Maintenance Safety, Caterpillar Maintenance ....................37 Daily Maintenance-Power Unit, Vibrator ......................... 38 Clamp Jaws, Service Intervals, 100 Hours, 500 Hours, Power Unit Maintenance, Severe Conditions ........39 Lubrication, Crankcase-Diesel Engine, Grease Clamp Plungers ..................
  • Page 8 Table of Contents (continued) CONTENT PAGE Section 9: ELECTRICAL COMPONENTS & CIRCUITRY (continued) Electrical Components & Operation, Optional Control, Control Panel Display, Engine Monitoring ........70 Hydraulic System Monitoring, Starting Diesel Engine, Changing Engine Speed, Stopping Engine, Emergency Stop ..... 71 Hydraulic Clamp, Vibrator, Rotary Head, Other ......................

  • Page 9: Section 1: General Information

    Power Unit The ICE power unit is powered by a Caterpillar Tier 3 diesel engine and is mounted on a tubular sub-base that serves as a fuel tank. The power unit and vibrator are operated from the control panel or remote control pen- dant.

  • Page 10: Hydraulic Hoses, Clamps And Accessories, General Description Of Zr Operation

    A hose is also provided for motor case drainage return to the hydraulic reservoir. Clamps and Accessories A variety of clamps and accessories are available for ICE vibrators. Please consult the individual Vibrator Parts Manual or the Vibrator Clamps & Accessories Parts Manual. General Description of ZR Operation Zero Resonance vibratory driver/extractors eliminate vibration in the damaging range by adjusting eccentric moment to zero during start-up and shut-down.

  • Page 11: Vibrator Specifications

    Vibrator Specifications Description Unit 18ZR 25ZR 50ZR Eccentric moment in-lbs, kg-m 1500, 18 2200, 25 4400, 51 Maximum frequency 1650 2050 1600 Driving Force tons, kN 93, 825 136, 1 210 168, 1 495 Centrifugal force tons, kN 85, 755...

  • Page 12: Power Unit Specifications

    Power Units Specifications Constant improvement and engineering progress make it necessary that we reserve the right to make specification changes without notice. Please consult ICE for the latest available information. Description Unit 350GZ 450GZ 595GZ 700GZ 800GZ Engine - Caterpillar...

  • Page 14: Section 2: Safety

    Section 2: SAFETY Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safe- ty rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

  • Page 15: Hoses, Lines, Tubes Handling Procedures & Checklist, Precaution For Oil, Fire Extinguisher Requirements

    Hazard Information Use caution when removing filler caps, grease fittings, pressure taps, breathers or drain plugs. Hold a rag over the cap or plug to help prevent being sprayed or splashed by liquids under pressure. Wear a hard hat, protective glasses, hearing protection and other protective equipment as required by job con- ditions.

  • Page 16: Fire Explosion, Crushing Or Cutting Prevention, Mounting And Dismounting

    Hoses, Lines and Tubes Handling Procedures Do not pull on, or attempt to move equipment, by force or pressure to the hydraulic hoses. The power unit will need to be moved closer to the work if hoses do not reach. Do not operate this equipment with hydraulic hoses that are damaged or kinked.

  • Page 17: Before Starting The Engine & During Engine Starting, Equipment Operation, Stopping Equipment, Stopping Engine

    Fire or Explosion Prevention (continued) Clean and tighten all electrical connections. Check regularly for loose or frayed electrical wires. Refer to mainte- nance schedules for inspection interval. Have all loose or frayed electrical wires tightened, repaired or replaced before operating the equipment. Wiring must be kept in good condition, properly routed and firmly attached.

  • Page 18: Section 3: Loading, Unloading, And Shipping

    Section 3: LOADING, UNLOADING & SHIPPING Power Unit The power unit should be loaded with the heat exchangers facing to the rear of the truck to prevent damage to the heat exchangers from flying objects. The power unit is usually held to the truck by wrapping a chain around both ends of the fuel tank sub-base.

  • Page 19: Section 4: Preparation For Operation

    Section 4: PREPARATION FOR OPERATION General When unloading and unpacking the power unit and equipment, use extreme care. For your protection, make a thorough inspection of the unit immediately upon delivery. In case of any damage or shortage, notify the transit agent at once and have the delivering carrier make a notation on the freight bill. Rigging of Vibrator A steel wire rope sling must be connected to the lifting pin of the vibration suppressor.

  • Page 20: Connection Of Hoses At Power Unit

    Connecting Vibrator Hoses to Power Unit 350GZ Quick Disconnect Panel Eccentric Moment Actuator Gear Oil to Cooler Gear Oil to Vibro Motor Case Drain Motor Return Close Clamp Open Clamp Motor Pressure The vibrator’s interconnecting hoses (in the bundle) terminate with quick disconnect couplers specific to each function and mating quick disconnect at the power unit.

  • Page 21: Connection Hoses-Models At Vibrator

    Should it be necessary to remove hoses or quick disconnect fittings, verify correct routing in reference to the power unit connection(s). If there is any confusion, contact ICE to avoid damage to equipment and risk to personnel when in operation.

  • Page 22: Attach Sheet Clamp, Attach Caisson Beam To Vibrator

    !WARNING – Safety! !WARNING – Equipment! The bottom of the vibrator and the top of the clamp or caisson beam must be clean and free of rust or paint. Dirt, rust or paint could cause bolts to loosen and the clamp or beam to come loose.

  • Page 23: Connection Of Hoses For Sheet Clamp, Connection Of Hoses Caisson Clamp

    Connection of Sheeting Clamp Hoses OPEN 1. Connect two hoses at end of the vibrator to the sheeting clamp at that end as shown at right. OPEN CLOSE 2. Connect hose from fitting marked “C” on vibrator to fitting marked “C” on clamp.

  • Page 24: Adjusting Position Of Caisson Clamps With Hydrolocks, Bleeding Clamp Hoses

    Adjusting Position of Caisson Clamps with HydroLocks 1. Lift vibrator with clamps into the air. 2. With jaws open, loosen jam nut on HydroLock holding valve (see diagram below). 3. Back out Allen-screw to relieve pressure. It may be necessary to rest the weight of the vibrator on the clamps to release the HydroLock cylinders.

  • Page 25: Bleeding Hoses For Zr Function Hoses

    Bleeding Hoses for ZR Function Hoses ZR Function/Eccentric Moment Actuator Hoses ZR Function/Eccentric Moment Rotary Joint Section 4: PREPARATION FOR OPERATION Page 23 OM-ZR-May15...

  • Page 26: Section 5: Operation

    Section 5: OPERATION Control Box & Remote-Control Pendants - Exterior MAIN CIRCUIT OPEN CLAMP CLOSE CLAMP HYD-OIL TEMP RETURN FILTER REMOTE-LOCAL DECREASE INCREASE 21 22 23 Inside Panel Section 5: OPERATION Page 24 OM-ZR-May15...

  • Page 27: Completion Of Set-Up & Maintenance, Control Panel Components

    Completion of Set-up and Maintenance Complete all preparation as described in Section 4: PREPARATION FOR OPERATION. Read Section 6: MAINTENANCE and perform any required maintenance. See Caterpillar Operation & Maintenance Manual Control Panel Components The power unit control panel contains the controls for the diesel engine and displays operating parameters and fault lights.

  • Page 28: Engine Display

    Engine Display The picture above shows the Display as it appears during normal engine operations. To change the screen for night operation, press the light button (2nd from top). The picture below shows the Display if an engine problem has occurred. One of three conditions may have occurred - 1) Warning, 2) Derate, or 3) Shutdown.

  • Page 29: Power Unit Mode Selection, Changing Mode, Local Or Remote Control, Operation Using Remote-Control, Control Panel

    Local or Remote Operation The power unit and vibrator or rotary head may be operated either from the control panel (LOCAL) or from the remote-control pendant (REMOTE). Additionally, an optional radio control is available for remote operation. Remote or Local operation is selected by using the REMOTE-LOCAL switch at the control panel. Operation using Remote-control Pendant (REMOTE) The remote-control pendant can control the operation of the vibrator or rotary head.

  • Page 30: Operation With Optional Radio Remote Control

    Operation using Optional Radio-remote Control The optional radio-remote control may be used to control the operation of the vibrator. The radio-remote control has an operating range of 100’ (30 m) to permit control from any position to best view the operation of the equipment.

  • Page 31: Starting & Warming Engine, Changing Engine Speed

    Starting and Warming Engine Before starting the engine, read the Caterpillar Operation & Maintenance Manual carefully. Follow the engine starting, operating, and maintenance procedures in the Caterpillar Manual !WARNING – Equipment! Operation with hydraulic oil below 0°F (-18°C) may result in damage to hydraulic components.

  • Page 32: Full Speed, Engine Shutdown, Emergency Stop

    Adjust the throttle so that the engine is running at the high idle rpm indicated below. The engine should maintain the full load rpm indicated below under load. Power Unit Vibrator High Idle Full Load Low Idle 350GZ 18ZR 1950 1850 450GZ 18ZR/25ZR 2100 2000 595GZ...

  • Page 33: Resetting Emergency Stop Button

    Resetting Emergency Stop Button After Use Pushing the EMERGENCY STOP button will cause all operating functions to stop. Diesel engine and vibrator will stop immediately. To reset the EMERGENCY STOP button, turn the EMERGENCY STOP button clockwise. To restart the power unit, follow normal engine start procedure. Both EMERGENCY STOP buttons (pendant and control panel) must be reset for engine start.

  • Page 34: Operation With Vibrator, Limitations, Refusal, Rebound, Bearing Temperatures, Batters, Safety Features

    Call ICE to review the planned operation before using an ICE vibrator on a batter. Use of a vibrator on a batter without discussing the operation with ICE and getting prior written approval is considered improper use and will void the vibrator warranty.

  • Page 35: Clamp To Pile, Start Vibrator, Change Eccentric Moment, Stop Vibrator, Unclamp From Pile

    Operation with Vibratory Driver/ Extractor (continued) !WARNING – Safety! Make sure that crew has a clear view of vibrator and working area. Insure good communication between vibrator operator and crane operator. !WARNING – Safety! Industry practice suggests a safety line should connect pile to crane or piling rig. Clamp to Pile Position vibrator on pile.
  • Page 36 Check gear case sight gauge frequently. For operation at depths up to 15’ (5m): Although ICE vibrators have been used at shallower depths many times without problems, it is recommended that the procedure below be used whenever operating underwater. For operation at depths below 15’ (5m): 1.

  • Page 37: Section 6: Maintenance

    Section 6: MAINTENANCE General Preventive maintenance includes normal servicing that will keep the power unit, vibratory driver/extractor and rotary head in peak operating condition and prevent unnecessary trouble from developing. This servicing consists of periodic lubrication and inspection of the moving parts and accessories of the unit. Lubrication is an essential part of preventative maintenance, controlling to a great extent the useful life of the unit.
  • Page 38 Daily Maintenance - Power Unit !WARNING – Equipment! It is absolutely imperative that no dirt or other impurities be permitted to contaminate the hydraulic oil. Any contamination will drastically shorten the life of the high-pressure hydraulic system. Before Engine Start-up Checklist: 1.

  • Page 39: General, Maintenance Safety, Caterpillar Maintenance

    Operating in excess of twelve hours per day, reduce service intervals to half of those specified. Extended Inactive Periods Consult Caterpillar Operation and Maintenance Manual. Also see Storage Procedure for Caterpillar Products (CAT Publication Number - SEHS9031-04). Consult ICE for Vibrator. Section 6: MAINTENANCE Page 37 OM-ZR-May15...

  • Page 40: Daily Maintenance-Power Unit, Vibrator

    Lubrication Crankcase - Diesel Engine Follow the engine manufacturer's maintenance schedule and the lubricating oil specifications outlined in the Caterpillar Operation & Maintenance Manual. The lubricant shall meet the performance requirements of API Service Classification CH-4. New engines are shipped with Caterpillar CH-4 (10W-30). The table below gives oil viscosity requirements for varying ambient temperature.

  • Page 41: Clamp Jaws, Service Intervals, 100 Hours, 500 Hours, Power Unit Maintenance, Severe Conditions

    Vibrator Gear Case Checking Oil Level: Check oil level in sight glass located on the lower center of the vibrator gear case. Oil level should be in the middle of the sight glass. Adding Oil: On the vibrator gear case top plate, remove the 1" pipe plug to add oil. Draining Oil: Remove ¾”...

  • Page 42: Lubrication, Crankcase-Diesel Engine, Grease Clamp Plungers

    Gear Case Oil Lube Pump The hoses on the gear case lube pump hoses should be bled when Lube Pump first placed in operation to ascertain Filter proper function and to purge air from system. The filter should be checked and cleaned when servicing gear oil.

  • Page 43: Hydraulic System, Draining & Filling Hydraulic Oil Reservoir, Changing Return Filters

    Hydraulic System To maintain the maximum operating efficiency in the precision parts of the hydraulic system, it is extremely important to eliminate factors that can cause breakdowns or unsatisfactory performance in the system. Among the most common of these factors are rust, corrosion, contamination and products of oil deterioration. Most problems can be minimized or avoided simply by maintaining a disciplined preventive maintenance pro- gram.

  • Page 44: Recommended Hydraulic Oil, Operating In Sub-Freezing Conditions

    Recommended Hydraulic Oil ICE power units are shipped with CHEVRON Clarity™ AW46 hydraulic oil. CHEVRON Clarity hydraulic oil exceeds the requirements of both the E.P.A. and U.S. Fish and Wildlife Service for non-toxicity and is inherently biode- gradable.

  • Page 45: Setting Clamp Relief Valve

    Setting Clamp Relief Valve for Vibrator The Clamp Pressure Relief Valve (RV2 on hydraulic schematic) must be set at 4,800 psi (330 bar). The clamp relief valve is located on the power unit clamp manifold that is located on the right behind the quick- disconnect couplers at the power unit.

  • Page 46: Setting Zr Function Relief Valve (Eccentric Moment Control Actuator Relief)

    Setting ZR Function Relief Valve (Eccentric Moment Control Actuator Relief) The Clamp Pressure Relief Valve (RV2 on hydraulic schematic) limits eccentric pressure for the ZR function (eccentric moment control actuator). This relief valve must be set at 1,500 psi (100 bar). To set relief valve for eccentric moment actuator: 1.

  • Page 47: Setting Clamp Restore Pressure, Setting Clamp Temperature Relief

    Setting Clamp Restore Pressure The Clamp Pressure Switch (PS1 on hydraulic schematic) monitors clamp pressure when the clamp is closed. If clamp pressure drops below 4500 (310 bar), the pressure switch activates the clamp control valve to restore clamp pressure. To set clamp pressure switch: 1.

  • Page 48: Setting Main Circuit Relief Valve

    Setting Main Relief Valve The Main Relief Valve (RV1) on hydraulic schematic) must be set at 5500 psi (380 bar). The Main Relief Valve is near the bottom of the main manifold that is located behind the quick-disconnect couplers at the power unit (see drawing below). To set main relief valve: 1.

  • Page 49: Setting Pilot Relief Valve & Setting Reservoir Pressure Regulator (595G, 700G, 800G)

    Adjusting Screw Pilot Relief Valve Jam Nut 595GZ, 700GZ, 800GZ 840774 Setting Pilot Relief Valve 595G, 700G & 800G The Pilot Relief Valve (RV1 on hydraulic schematic) must be set at 6000 psi (415 bar). The Pilot Relief Valve is located on the hydraulic reservoir (see drawing above left). To set pilot relief valve: 1.

  • Page 50: Section 7: Torque Specifications

    !WARNING – Equipment! !WARNING – Safety! A torque wrench is strongly recommended for assembly and maintenance of ICE equipment. Torque is measured in terms of force and distance. Force is the amount of pushing or pulling applied at the end of the lever.

  • Page 51: Torque Value Chart

    Torque Specifications (continued) Torque values are for lubricated fasteners. Increase torque by 1/3 for dry fasteners. Allen Allen Standard Standard Screw Wrench Screw Wrench Torque Torque Size Size Size Size Ft-lbs Ft-lbs 1/4-20 3/16 1/4-28 3/16 5/16-18 5/16-24 3/8-16 5/16 3/8-24 5/16 7/16-14...

  • Page 52: Section 8: Troubleshooting

    When difficulties arise, please first use this troubleshooting guide and the Caterpillar Operation & Maintenance Manual. If the difficulty cannot be corrected, contact your Caterpillar dealer, the local ICE service location or International Construction Equipment, Inc. at 888 ICEUSA1 or 704 821-8200. Components in CAPITAL LETTERS are shown on the Electrical and Hydraulic Schematics (see Sections 9 &...

  • Page 53: Engine Problems Indicated On Engine Display

    Engine Problems Indicated on Engine Display If there is an engine problem, a screen similar to the one on the left below will appear on the engine display. There are three levels of engine conditions that may be indicated - 1) warning, 2) derate, and 3) shutdown. Warning Derate Shutdown...

  • Page 54: Other Engine Screen Displays

    Service screen History screen The screen in the center shows certain engine information that may be useful to the job mechanic, ICE serviceman, or Caterpillar service person in diagnosing engine problems. This screen may be assessed by pressing the upper arrow key. To return to the normal operating engine screen, press the lower arrow key.

  • Page 55: Hydraulic Problems Indicated On Control Panel, Emergency Stop Indicated At Control Panel

    Hydraulic Problems Indicated on Control Panel The engine may be shut down by a hydraulic problem. If the engine is shut down by the following hydraulic problems, a red light on the control panel will illuminate. Hydraulic return filter clogged - Filter is clogged and oil is bypassing or faulty filter pressure reading Hydraulic oil level low - Low hydraulic oil level or faulty oil Warning Lights...

  • Page 56: Diesel Engine Does Not Start

    Diesel Engine Does Not Start Shutdown Lights Main power switch must be ON. All other switches on control panel and pendant must be in central (neutral) position. EMERGENCY STOP BUTTON must be disengaged (turned clock- Engine Display wise). Check if any of four shutdown lights on control panel are on. Shutdown light is on No Shutdown lights are on Correct problem or bypass hydraulic shutdown.

  • Page 57: Diesel Engine Does Not Run At Full Speed

    Diesel Engine Will Not Run at Full Speed See normal engine speeds in table below. Use engine speed switch (SLOW - FAST) to set high-idle speed. The Caterpillar engine control module (ECM) reduces speed (derates) if a condition occurs that could damage the engine. Derate speed is typically 50% of normal engine speed.

  • Page 58: Clamp Closes But Close Light Does Not Come On

    Clamp Closes But CLOSED Light Does Not Come ON Engine is running. Hoses are connected. Clamp switch to CLOSE Check CLOSED lights on both pendant and control panel.  Both CLOSED lights out One CLOSED light out Hold clamp switch on OPEN for 20 Replace bulb or fix wiring.

  • Page 59: Clamp Will Not Close

    Clamp Will Not Close Engine is running Hoses are connected Clamp switch on CLOSE Clamp pressure is above zero Pressure on clamp gauge is Go to next page zero Manually shift clamp solenoid Reservoir end Engine end valve Close solenoid Clamp pressure is zero Clamp pressure builds Check voltage to close-clamp...
  • Page 60 Shut down engine Shut down engine Reconnect close-clamp hose at clamp Recheck clamp quick-disconnect couplers Disconnect open-clamp hose at clamp If problem not solved, call ICE Restart engine Clamp switch to CLOSE Clamp does not close Shut down engine Clamp closes...

  • Page 61: Clamp Does Not Open

    Clamp Will Not Open Engine is running Hoses are connected Clamp is closed Turn clamp switch to OPEN, hold for 20 seconds and read Clamp pressure is 4800 psi Pressure on clamp gauge is Engine end Reservoir end Go to next page zero Open solenoid Manually shift clamp solenoid...
  • Page 62 Disconnect close-clamp hose at Recheck clamp quick-disconnect clamp couplers Restart engine If problem not solved, call ICE Turn & hold clamp switch to OPEN Clamp does not open Use bleed valve to release close-clamp Clamp opens pressure Shut down engine CAUTION –...

  • Page 63: Vibrator Does Not Start

    Pressure is less than 1500 psi Pressure is above 1500 psi Vibrator does not start Resume normal operation Call ICE to discuss checking Turn main switch to OFF Check main pressure gauge reading Repair or replace damage pendant vibrator anti-cavitation check valve...
  • Page 64 Turn main switch to FOR Pressure is zero vibrator cavitation check valve Call ICE to discuss checking Check main pressure gauge reading Call ICE to discuss main pump vibrator motors or gear case Section 8: TROUBLESHOOTING Page 62 OM-ZR-May15...

  • Page 65: Vibrator Does Not Come Up To Speed

    Vibrator Does Not Come Up to Speed Check that engine is running at proper speed  Engine is running at proper speed Engine is not running at proper speed Vibrator appears slow Increase speed to proper speed Check engine for derate condition  ...

  • Page 66: Vibrator Does Not Stop

    Vibrator still does not stop Replace or repair pendant REMOTE Stop diesel engine to stop vibrator. Repair control panel After repairs, resume normal operation  Call ICE to discuss repair of main After repairs, resume normal operation  control valve  Section 8: TROUBLESHOOTING Page 64 OM-ZR-May15...

  • Page 67: Case Drain Relief Valve Leaks

    Coupler loose or hose pinched QD Coupler and hose OK After correcting problem, resume Replace case drain relief valve (RV3)  operation  Leak stopped. Case drain relief valve still leaks. Resume normal operation.  Call ICE Case Drain Relief (RV3) Section 8: TROUBLESHOOTING Page 65 OM-ZR-May15...

  • Page 68: Vibrator Gear Case Runs Hot, Vibrator Gear Case Fills With Oil

    Check if oil is milky or dirty Correct oil level Milky or dirty Oil Clean Change oil. Call ICE to discuss operating or bearing problem. Proper oil level Oil Level Sight Gauge Vibrator Gear Case Fills With Hydraulic Oil Call ICE...

  • Page 69: Eccentric Moment Actuator Control (Decr - Incr) Is Not Operational

    Moment Actuator Control Pressure is low Pressure is high Control does not function functions Call ICE to discuss checking Turn main switch to OFF Check main pressure gauge reading Repair or replace damage pendant Moment actuator control system Shutdown engine...

  • Page 70: Electrical Components

    Section 10: Electrical CIRCUITRY Electrical Schematic The electrical control circuitry presented in this section’s diagrams is for trouble shooting reference. The control system is packaged in a control cabinet with various switches and controls. Major components of the system are listed in the table below. Electrical Components Item Part Number...
  • Page 71 Electrical Components ZR Controller DECREASE INCREASE 595GZ, 700GZ & 800GZ Eccentric Moment Actuator Control 350GZ & 450GZ Section 9: ELECTRICAL COMPONENTS AND CICUITRY Page 69 OM-ZR-May15...

  • Page 72: Electrical Components & Operation, Optional Control, Control Panel Display, Engine Monitoring

    Electrical Components and Operation Components indicated in CAPITAL LETTERS below are shown on the Electrical Components Diagram and the Electrical Schematics. Optional Control Duplicate vibrator and clamp switches are located on the CONTROL PENDANT and on the CONTROL PANEL. Turning the REMOTE-LOCAL switch on the control panel to REMOTE permits operation of the clamp and vibrator from the PENDANT.

  • Page 73: Hydraulic System Monitoring, Starting Diesel Engine, Changing Engine Speed, Stopping Engine, Emergency Stop

    Hydraulic System Monitoring The control system monitors the hydraulic system for any of the following abnormal operating conditions: 1. Clogged hydraulic return filters 2. Low hydraulic oil in reservoir 3. High hydraulic oil temperature If either of these conditions occurs, a signal is sent to the ENGINE CONTROL MODULE (ECM) to shut down the engine.

  • Page 74: Hydraulic Clamp, Vibrator, Rotary Head, Other

    Hydraulic Clamp With the diesel engine running, turning the clamp switch (OPEN-CLOSE) on the PENDANT to CLOSE energizes the CLOSE-CLAMP SOLENOID (CS) on the hydraulic CLAMP CONTROL VALVE. The clamp closes. When the pressure in the close-clamp hydraulic circuit reaches 4,500 psi (310 bar), the CLAMP PRESSURE SWITCH (PS1) de-energizes the CLOSE-CLAMP SOLENOID and turns on the on the clamp CLOSED lights on the PENDANT and CONTROL PANEL.

  • Page 75: Electrical Schematics And Wiring

    Electrical Schematic and Wiring A Section 9: ELECTRICAL COMPONENTS AND CICUITRY Page 73 OM-ZR-May15...
  • Page 76 Electrical Schematic and Wiring B (Vibrator) ZR Function Eccentric Moment Actuator DECR - INCR Section 9: ELECTRICAL COMPONENTS AND CICUITRY Page 74 OM-ZR-May15...
  • Page 77 Electrical Schematic and Wiring B (Rotary Head) Section 9: ELECTRICAL COMPONENTS AND CICUITRY Page 75 OM-ZR-May15...
  • Page 78 Electrical Schematic and Wiring C Section 9: ELECTRICAL COMPONENTS AND CICUITRY Page 76 OM-ZR-May15...
  • Page 79 Electrical Schematic and Wiring D Section 9: ELECTRICAL COMPONENTS AND CICUITRY Page 77 OM-ZR-May15...
  • Page 80 Electrical Schematic and Wiring E ECCENTRIC MOMENT DECR ECCENTRIC MOMENT INCR Section 9: ELECTRICAL COMPONENTS AND CICUITRY Page 78 OM-ZR-May15...
  • Page 81 Electrical Schematic and Wiring F Section 9: ELECTRICAL COMPONENTS AND CICUITRY Page 79 OM-ZR-May15...

  • Page 82: Section 10: Hydraulic Circuitry

    Section 10: HYDRAULIC CIRCUITRY Hydraulic Components - Vibrator Section 10: HYDRAULIC CIRCUITRY Page 80 OM-ZR-May15...

  • Page 83: Hydraulic Schematic Vibrator

    Hydraulic Schematic - Vibrator Section 10: HYDRAULIC CIRCUITRY Page 81 OM-ZR-May15...

  • Page 84: Clamp And Vibrator Operation

    The quick disconnect couplers (QD3 & QD4) permit de-coupling of the clamp hoses at the power unit. The clamp circuit on all ICE power units can be configured to operate auxiliary equipment, such as spotters, pile gates, etc. Contact ICE for instructions.

  • Page 85: Vibrator (Continued), Zr Operation

    Vibrator (continued) Turning the vibrator switch on the control pendant to OFF, de-energizes the CONTROL VALVE (V2) and “vents” (opens) cartridge C1 allowing pump flow to go directly back to the RESERVOIR. When pressure is removed from the main FORWARD system, the BRAKE COUNTER-BALANCE VALVE (RV5) closes and blocks the pilot flow from BRAKE VALVE (BV) cartridge causing the BRAKE VALVE cartridge to close.

  • Page 86: Zr Operation Continued, Other

    Eccentric moment is controlled from the vibrator remote-control pendant. Shifting between zero and maximum eccentric moment occurs simply and quickly. Zero eccentric moment 180° out of phase Other If the hydraulic oil level in the RESERVOIR gets low, the HYDRAULIC OIL LEVEL switch (HOL) shuts down the diesel engine and turns on the HYD.

This manual is also suitable for:

25zr50zr350gz450gz595gz

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