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They must be well trained in the use of this machine. • All safety controls must be in place before startup. • Operators and owners must read this manual and other supporting material provided by the Manufacturer. This manual provides best practices for operating and maintaining your Quantum Pile Driver...
INTRODUCTION .............................. 4 1- Quantum INFORMATION ..........................4 2- WARRANTY ..............................5 3- ABOUT THIS INSTRUCTION MANUAL OF Quantum PILE DRIVER ............10 4- Quantum PILE DRIVER ..........................11 5- STANDARD EQUIPMENT AND ACCESSORIES ON REQUEST ................12 6- MANUFACTURING ELEMENTS ........................12 7- MAIN COMPONENTS AND TECHNICAL DATA ....................
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APPENDIX C ..............................70 QUANTUM QUICK HITCH - INSTRUCTIONS ....................70 Appendix D - RISK ASSESSMENT WORKSHEET ( EXAMPLE ONLY) ..............72 Appendix E - Quantum PILE DRIVER PRE START UP CHECK LIST .............. 86 Appendix F - Warranty Claim Form ......................87...
INTRODUCTION 1- GENERAL INFORMATION The Quantum pile driver is a new machine for the driving of guardrail/solar posts. It is precisely designed as a self-propelled machine able to use a remote control or GPS location system. The machine is very stable because it is supplied with a safe and reliable rubber crawler track. The...
2- WARRANTY The company İnnosis guarantees that the Pile Driver is exempt from defects. It has been submitted to testing before its delivery to the Customer. The warranty has a one-year validity starting from the indicated date on the fiscal document of delivery. The accessories and tools of the machine are not covered by the warranty.
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• Filters, and all fluids • Any item that has not been operated in accordance with this Operators Manual. Warranty Period • For all equipment sold, the warranty period for the engine is 12 months or 1000 hours, whichever comes first. Starting from the date of delivery to the first user. •...
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User Responsibilities The user is responsible for: Provide daily precheck start-up sheets. • Transportation costs to an approved repair contractor. • Parts shipping charges above those that are considered usual and customary. • Local taxes, if applicable. • Costs to investigate complaints unless the problem is caused by a defect in İnnosis •...
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Manufacture; In the case that the defect parts won’t be returned to the Manufacture within 30 (thirty) days (from the date of receipt of the new ones), the company Quantum keeps the right to invoice the new parts shipped.
The expected maintenance is not carried out; 3- ABOUT THIS INSTRUCTION MANUAL OF QUANTUM PILE DRIVER This manual should be kept safe, clean and complete in every part of it and kept in an appropriate package, placed on the machine chassis, ready for any consultation.
It is highly recommended users contact local authorities in this matter. 4- Quantum PILE DRIVER The Pile driver has a metallic plate, placed well in sight on which the identification data of the machine are punched. It contains: •...
5- STANDARD EQUIPMENT AND ACCESSORIES ON REQUEST Standard Equipment Accessories • Supporting foot on column base • Hydraulic Rock Drill • Extractible and reversible pile guide bearing • Hydraulic Concrete Core Barrel • Hydraulic Tracks with automatic brakes • Full functional remote control •...
wheels and two rubber crawler tracks, which receiving the motion and being the only components that adhere to the ground, are the ones which definitely move the pile driver. Engine: This is mounted on the base level of the chassis group and an engine bonnet, which protects it and can be locked but can be opened manually.
The Pile Driver must be entrusted to a competent, qualified, and trained personnel. The Manufacturer is not responsible for accidents caused by carelessness of the personnel, improper or incorrect use of the Quantum Pile Driver, or the failure of the safety rules. Furthermore, the warranty of the machine would immediately be void.
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The loading and unloading of the machine on the vehicle happens with the help of ramps (showed in the figure 3) anchored on the vehicle. Using a Crane is not recommended for loading or unloading the machine This process can be done via two different functions, manually or with the remote control unit. We highly recommend using remote control, as it is deemed to be the safest practice.
• Before starting any loading and movement, it is essential to assure cleanliness of the ramp surfaces from trace of oil, grease, ice or soil • Make sure that ramps are firmly anchored to the vehicle, placed parallel to each other and positioned with an angle of maximal 30°...
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Fig.5 Configuration of transport and movements For any transporting, on a flat surface as well as on inclined surface, the pile driver has always to assume the transport configuration or movement configuration, as showed in the Page 18 figure The following precautions are necessary for the displacement of the pile driver on inclined surfaces:...
2-3 Starting and Controls Before start-up the following checks must be carrying done by the assigned operator: ➢ Check if all the control levers are in the neutral position ➢ Make sure that the emergency button is operational. To reactivate rotate a little clockwise ➢...
Quantum only. Therefore, different functions such as application of inadequate or not-tested equipment and not of Quantum manufacturer are considered as improper and are consequently forbidden.
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Before placing the machine in the construction site and starting to use it, it is essential to establish where the pile driving or the drilling should be done. Make sure there are no underground service lines, as for example, water conduction pipelines, gas or combustible oil lines, electrical lines, optical waveguide nets, phone lines or other kind of service nets.
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Concerning the movements of the rubber crawler tracks, the operator must observe the following indications: • Normally the Quantum Pile Driver moves with its rubber tracks. The correct position is to have the back sprocket teeth positioned at the back, as the driving direction should be in the forward direction.
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on the horizontal level and the other one on the inclined level figure 8 (2). Always travel with the sliding blocks on the same horizontal level, in order not to damage the rubber crawlers. • When the machine proceeds in reverse (figure 8. 3), an empty space is created between the carrying roller, the front wheel, and the rubber crawler track, with the risk that this last one comes out of its seat.
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Fig.9 Possible seat movement in reverse movement of the crawler Every movement of the Pile Driver, although it is affected inside the operative zone or construction site, must always be carried out with the fitted Flashing Light on. This light is placed on the rear of the machine and will auto start when the machine is running see figure 10.
3- PEOPLE SAFETY PRECAUTIONS 3-1 General The Quantum pile driver is designed to operate extremely safe, however it must be operated by qualified, trained, adult personnel who is very well aware of the instructions in this manual. Safety is of primary importance for the personnel who use the machine or who carry out reparations or maintenance tasks on the machine.
standard operational procedures in compliance with the rules and regulations of the country of use. All of the functions of the pile driver are subject to activation of the corresponding levers that are placed on a hydraulic control device. The only exception is starting of the engine. Before starting the engine, the operate shall complete a daily check sheet or follow your company guidelines.
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Fig 12 Adhesive Labels The safety labels are as follows: Crushing danger and/or shearing danger to upper limbs. Pay maximum attention during the movements. Use protective gloves. Corrosion danger. The battery contains a corrosive substance that irritates the skin. Use protective gloves. Burning, Parts of the engine achieves high temperatures and that is why the engine itself has a lockable.
Obligation to wear protective shoes. Use only approved ones. Obligation to wear protective gloves. Use only approved ones that fit well. Obligation to wear a safety visor. Use only the approved ones. Obligation to wear a protective helmet. Use only the approved ones. All operators are obligated to use approved ear protection.
5) In case of emergency, the engine must be stopped by pushing the emergency stop button next to the control levers or by activating the emergency stop button on the remote Control. Following stopping the engine, the hydraulic oil pump and all controls will be deactivated.
• Burning risk for contacts with the endothermic parts of the engine (label #3) • Face and eye injuries for projection of solid parts (label #10) • Abrasion further to collision with metallic parts (label #8, #9 and #11) • Injuries to the auditory apparatus for not having used the proper and proper protection (label #12) (For labels refer to figure 12 at page 27)
in very cold climate, with temperatures between –20° and +5°C the following requirements are necessary Use oils suitable to those temperatures (engine and hydraulic), it is advisable to consult a lubrication list for the choice of suitable oils. The machine is fitted with standard anti-freeze at the factory and the operator should check that the antifreeze is suitable for the environment.
Fig.13 Starting frame 3.2 Hydraulic Safety All controls on the Quantum Pile Driver are fitted with a pressure relief valve. All the levers, apart from the first one (the one indicated in the figure 14 items 1.), can be activated in two positions. The levers will automatically return to their starting or neutral position.
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Fig.14 Controls and Checking Components Emergency button: If the operator notices a dangerous situation or simply needs to stop immediately, he can push the button and the pile driver will block totally. With the engine being off and the pump being deactivated, all the functions in action will fully stop at that moment.
80°C. Under this temperature the exchanger doesn’t work. Watching the appropriate thermometer, placed outside the tank, can easily carry out the temperature check. 3.3 Remote Control Operating procedure for Quantum Remote Control Unit • All controls are clearly marked with the function.
3-4 Pile Driving Before starting work, the operator has to limit the area of the construction site in which the pile driver will be moving and in which piles will be installed (standard work). Same goes to supplementary functions with different accessories. Afterwards, the operator will bring the pile driver to the place where he wants to carry out the work and will position it accordingly.
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Fasten Pins Pile Guide bearing Fig.15 Level Fig.16 Pile Guide Bearing Once the machine is set on the location, the pile driver should be prepared for the driving with the help of the pile guide bearing, showed in figure 16. The operator unthreads the two pins, placed in the side part of the column as showed in the figure 17.
Pile Driving The operator places the pile into the guide bearing, as showed in the figure (phase 1). Then he will lower the hammer (phase 2) until the pile hammer template covers the headstock of the pile, which prevents the pile against coming out (phase 3). After that, still activating the same lever for another few seconds, he lowers the hammer group so the hammer group will unhook.
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Fig.18 Phase 4 of driving Pile Extraction A metallic bar will be inserted in the lateral holes of the pile, as shown in the figure. The bar will be the connection pin for the extraction. Attached to this and to the lateral hooks of the hammer group will be the pile extraction chain, as shown in figure 19, operating as a tie rod.
Both accessories are produced by the company Quantum and are delivered to the Customer only on request. The instructions for the substitution of the pile hammer template and the pile hammer are described as follows:...
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• To make the transporting phase easier, it is necessary that the machine assumes the transport configuration, as showed in figure 20, and then the engine has to be switched Fig.20 Configuration of transport and movement • Insert one hand in the pile hammer template (1) so the pile hammer will be pushed up with the purpose of inserting a bearing pin (2) in the appropriate hole, as shown in the fig.21, in order to block the descent of the pile hammer;...
Fig.21. Hammer group structure 1-5 • Holding the pile hammer template still with one hand, extract the two pins that fix it to the hammer group structure (6). After that, remove the template out of its seat (7), as showed in figure 22. •...
• Carefully clean the parts of the undercarriage • Remove the closing tally (1) on the backstay, shown in fig.23 • Loosen the tightening valve (2) inside the space as shown in fig 23. Next when it is certain there isn’t any grease Fig.23 pressure left, remove the Sketch of the crawler...
Adjustment All the moving parts slide on Teflon plugs. They are constructed in Teflon and therefore self-lubricated. There are two types: rectangular ones (nonadjustable), and round ones (adjustable). The round unit, plugs adjust for the wear on the structure. These Teflon plugs are pushed towards the running part by a plug with a hexagonal head, by (fig 25) To Tighten 1.
4. Follow the steps to tighten on page 43 4.3 Trailer Tow Bar The Quantum Pile Driver is supplied with a towing coupler. It is placed on the rear of the machine with the purpose to permit the towing of a suitable trailer.
Maintenance 1- INSTRUCTIONS 1.1 Overview The Manufacturer has foreseen a maintenance schedule, which if carried out with care by the customer will maintain the efficiency of the machine. This will preserve the equipment of any possible damage for many hours. The operator must be a qualified and trained person in the care of the machine.
Be careful concerning the loss of fluids under pressure and the excess vibration of the pipes. This means that the nitrogen in the hammerhead is not sufficient. Proceed immediately with the loading process as described in the appropriate manual of the hammer. 1.2- Programmed maintenance Daily check, (please use the Start Up Check List supplied on Page 86 or your company document) Daily check (Example)
• Check all the nuts and bolts for tightness. Check all rollers on the track frame for oil leaks and wear. • • Check the state and the integrity of the pile extractor • Consult the engine and hammer manual for relative tasks Maintenance to carry out after 50 operating hours: All Engine and Hydraulic Oil Filters must be changed.
Do the following maintenance after 500 operating hours and every 500 working hours: • Change the diaphragm in the hammer head and restore the nitrogen level The checks and maintenance to be carried out every 250/500 hours have to be done regularly, consulting the present manual of use and maintenance as well as the one concerning the hammer.
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The three-point turn: Whenever possible, make a three-point turn in your machine rather than swinging in a 180-degree arc, especially if you’re working in a compact track loader. Why? It reduces side wear on the tracks, which is a real issue when you’re working on pavement or some other form of hard surface.
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Don’t look back: Always keep your machine moving in a forward direction. If you start to travel in reverse, especially at a higher speed, this will stress your tracks. Remember, rubber tracks are primarily designed for forward use. Rotate your tracks: In the same way it’s a good idea to rotate tires on your car, it’s also smart to rotate rubber tracks on your machine periodically.
Your tracks are filthy, and you don’t clean them regularly. As we noted above, the cleaner your tracks are, the longer they last. Tracks that are dirty and full of rocks and debris will wear out much faster than tracks you clean every day after the job. You clean your tracks but pay no attention to your undercarriage.
Place the machine on flat ground and check the level and temperature indicator on the side of the Hydraulic Tanks. When the oil arrives at half sight (between the blue and red traces, as in figure 29), the quantity inside the tank is sufficient. But if the oil is nearby the red trace, it will be necessary to restore it by adding other oil, following the instructions described later.
The hydraulic oil tank is equipped with an averaging device for the purification of the contained fluid. Such device is provided with a cartridge (filter) with a high filtering power. It purifies the oil on its return to the tank (unloading phase). To check the filter, it is necessary to remove the lid, unscrew the three screws and extract it from its seat, as showed in figure 30.
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Fig 31(1) Checking Oil Fig 31(2) Changing Oil Note: the oil contained in the motor drives is the same one that lubricates the brakes (represented by the whole gear system inside every drive motor driver). Therefore, when you check or replace the oil in the drives, you automatically check or replace the oil of the brakes. Replacement Let the motor drives turn until you bring the plugs in one of the configurations shown in figure 31(2).
IMPORTANT: To avoid pollution, it’s absolutely forbidden to disperse oils, lubricants, filter cartridges or other noxious materials in the environment. Comply strictly with the instructions in force for the disposal of liquids or solid substances. 4- ENGINE AND HAMMER CHECK Engine For the oil level check of the engine and/or its substitution, for the check and/or the substitution of the concerning filter and for all the other checks concerning the engine, we...
6- TROUBLESHOOTING FAILURES CAUSES REMEDIES Crawler tracks: Lack of grease Apply Grease to tighten Loosening of the crawler track Tightening valve defect Replace the valve The seal on the slack adjuster is Replace the seals in the slack damaged adjuster Replace the worn-out components The superior part of the crawler Guide slide crawler track worn-out...
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The diesel engine doesn’t start Electric stop device broken Replace electric stop device (battery and oil indicators on) If the electric stop device has Carry out the connections been removed, the connections following the electrical schedule are wrong enclosed Replace the wiring After having checked the emergency button and/or the electric stop device it will be...
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The Arm move in jerks Air in the hydraulic circuit Make the machine work unoccupied for a while, using each function until the air exit the hydraulic circuit. The Arm moves without activating Blocking valve jammed Change the lever and maybe the lever the gaskets Jack gasket wear-out...
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The diesel engine starts, but after a Emergency button activated Deactivate emergency few seconds it turns off button (rotate slowly clockwise) Release the lever from position A The lever for hammer activation lever or B (it returns automatically in has been left in position A or B (see the neutral position) figure 14 page 33) and blocked at the end point...
Oil leak from a connection Slow connection Gasket wear-out Tighten the tube Substitute the gasket Hammer: The nitrogen accumulator is empty or Check the nitrogen cartridge in lost pressure the accumulator or re-establish The tubes of the hammer vibrate IMPORTANT: It is advisable to excessively.
APPENDIX A OPERATING PROCEDURE FOR DOWN THE HOLE HAMMER ROCK DRILL The down the hole hammer rock drill was designed to drill through ground that is too hard for the hammer to drive a post i.e. soft to hard rock Before operating your rock drill please follow this procedure;...
OPERATING PROCEDURE FOR SCREW PILES Your model pile driver is with a hydraulic motor. figure 1 1. To use the Quantum to screw in piles you need to connect a factory screw pile plate to the bottom of the drill. figure 1 2.
APPENDIX C QUANTUM QUICK HITCH - INSTRUCTIONS If a quick hitch is fitted to your machine please follow these instruction to change from the hammer to the second attachment (Rotary drill) Disconnect all hydraulic hoses. Keep them clean. Remove all 8 bolts down both sides of the main frame – store for later use Look under the drill, you will see one bolt in the centre of the frame –...
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Lift the hammer to position using suitable and certified lifting equipment. The hammer is placed on to the location pins on the top and bottom Once it is in place – insert the bottom bolt, which is located between the location points, this bolt will pull the hammer down so the bolt holes are aligned.
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(see JH-APP-RCC-003-02 for a full description of Risk Consequence, Opportunity Consequence and Likelihood Ratings) Action and Approval Scheme These suggested timings and tolerance levels in the Action Table will be overridden by specific policies of the company that either dictate shorter timeframes for corrective action or zero tolerance.
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1. Are there specific warnings conditions (Manufacturers or other) relating potential hazards from the operation of the item of plant? ■ Refer to technical or operating manuals, SOPs, safe use instructions ■ List any relevant safety warning hazards & controls 2.
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4. Can anyone CRUSHED TRAPPED? (e.g. through unexpected movement, lack capability for plant or equipment slowed, stopped immobilized, plant tipping or rolling, being thrown from plant) ■ Emergency stop (E Stop) ■ Service or parking brake ■ Battery isolator ■ ROPs/FOPs ■...
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5. Can anyone be CUT, STABBED or PUNCTURED? ■ Flying objects ■ Moving parts ■ Pinch points ■ Sharp edges ■ Isolation devices ■ Warning decals ■ Guarding 6. Can SHEARING occur? ■ Between two moving and rotating parts ■ Between fixed and moving parts ■...
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Controls New or Additional Action Verified Hazard New or Additional Currently Controls Action Controls Required Potential Hazards Describe Hazard Current Risk Level Final Risk Place Complete: on Plant Level Plant (Name and Date) (Name and Date) 9. Can a hazardous PRESSURE be produced? ■...
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■ Slippery surfaces Controls New or Additional Action Verified Hazard New or Additional Currently Controls Action Controls Required Potential Hazards Describe Hazard Current Risk Level Final Risk Place Complete: on Plant Level Plant (Name and Date) (Name and Date) 13. Are there ERGONOMIC - MANUAL HANDLING hazards associated...
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■ Operation by two or more persons Controls New or Additional Action Verified Hazard New or Additional Currently Controls Action Controls Required Potential Hazards Describe Hazard Current Risk Level Final Risk Place Complete: on Plant Level Plant (Name and Date) (Name and Date) 15.
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■ Ability to lower suspended loads 17. Can anyone be SUFFOCATED? ■ Lack of oxygen ■ Contaminated atmosphere ■ Confined spaces ■ Spaces where air flow is inadequate Controls Action Verified Hazard New or Additional New or Additional Currently Controls Required Controls Action By: Potential Hazards Describe Hazard...
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20. Can certain WEATHER conditions create a hazard? ■ Hypothermia / extreme cold ■ Heat stroke / extreme hot ■ Wet conditions ■ Electrical storms ■ Dirt & mud on roads at egress points 21. Does VIBRATION of the plant create a hazard? ■...
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23. Carry out NOISE survey on page 14. Is the plant noisy? ■ Emit >85 dBA at the operator ■ Effects operator communication ■ Noise impacts on community during out-of-hours work (including reversing beepers) 24. Carry out the LIGHT survey on page 14. Is there poor visibility ■...
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26. Can operation of the plant create DUST? ■ Explosive atmosphere ■ Breathing hazard ■ Reduced visibility ■ Nuisance dust at nearby community ■ Impact on local flora and fauna ■ Loss of topsoil and spread of weeds and pathogens 27.
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29. Is there anything in the SURROUNDING ENVIRONMENT that may produce a hazard? ■ Power lines ■ Low ceiling ■ Other plant ■ Storage areas ■ Co-located equipment ■ Isolation requirements ■ Potential for flash flooding if operating adjacent to waterways ■...
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Potential Hazards Describe Hazard Currently Current Risk Level Controls Required Final Risk Controls Action Action Verified Place on Plant Level Plant (Name and Date) Complete: (Name and Date) 32. Are there ANY OTHER potential hazards generated during the use of this item of plant and/or any attachments? ALL OPERATORS OF THE PLANT OR EQUIPMENT MUST BE BRIEFED ON THE PLANT HAZARD ASSESSMENT (PHA) PRIOR TO FIRST TIME USE.
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Noise Report /Lighting Report NOISE REPORT LIGHTING REPORT Equipment Type: Serial/Asset No. Test by (print): Date: Make: Model: Signature: Test by (print): Date: Lux Meter used: Signature: Results – Operator’s station Sound Level Meter Unit Used: At controls Manufacturers specified noise level: At emergency control Background level: In front/over task...
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Completed Check the following Okay Needs Repair Repaired Initials Check all Oils, Engine, Hydraulic, and Water levels Check for Body Damage Check for Wiring damage Check that all Guards, Covers are in place Latches and Handles are all working Clean Tracks of rocks, stones and spoils Controls for fully functional and Operation correctly Fire Extinguisher and First Aid Kit Check Lights if fitted are working...
If the vehicle is unsafe and needs to be dead lined/red tagged: 1. Remove keys 2. Fill out repair order 3. Submit repair order to office Appendix F - Warranty Claim Form Company Address Contact Person Contact Email Contact Phone Fault Date Machine Model Machine Serial...
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I declare that all information on this document is correct. I am responsible for any problems arising from incorrect or incomplete information. Please give a full description of the fault with supporting photos:...
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