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Section 8: TROUBLESHOOTING

Page 5

8

OM-ZR-May15

Clamp Will Not Close (Continued)

Clamp pressure cycles up & down

Turn clamp switch to OPEN for 2 seconds
Shut down engine
Disconnect clamp quick-disconnect
couplers
Restart engine
Turn clamp switch to CLOSE

Clamp pressure is constant

Turn clamp switch to OPEN for
2 seconds
Shut down engine
Replace clamp seals
Reconnect clamp quick-disconnect
couplers
After repairs, resume normal
operation

Clamp pressure cycles up & down

Turn clamp switch to OPEN for
2 seconds
Shut down diesel engine
Reconnect clamp quick-disconnect
couplers

Clean shuttle valve (SV1)
After repairs, resume normal operation

Clamp pressure is constant

Turn clamp switch to OPEN for 2 seconds
Shut down engine
Disconnect and reconnect clamp quick-
disconnect couplers
Restart engine
Turn clamp switch to CLOSE

Clamp does not close

Shut down engine
Disconnect close-clamp hose at clamp
Restart engine
Turn clamp switch to CLOSE

Clamp closes

Resume normal
operation

Point A

Clamp closes

Turn clamp switch to OPEN for 2 seconds
Shut down engine
Recheck clamp quick-disconnect couplers
If problem not solved, call ICE

Clamp does not close

Shut down engine

Clean, repair or replace clamp
holding valve (CV7)
Reconnect open-clamp hose at clamp
Resume operation

Flow from close-clamp hose

Shut down engine
Reconnect close-clamp hose at clamp
Disconnect open-clamp hose at clamp
Restart engine
Clamp switch to CLOSE

No flow from open-clamp hose

Turn clamp switch to OPEN for 2 seconds
Shut down engine
Recheck clamp quick-disconnect couplers
If problem not solved, call ICE

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Summary of Contents for 18ZR

Page 1: ...ONAL CONSTRUCTION EQUIPMENT INC Specializing in Pile Driving and Drilling Equipment Corporate offices 301 Warehouse Drive Matthews NC 28104 USA www iceusa com OPERATION AND MAINTENANCE MANUAL This manual is for ICE Model 18ZR 25ZR 50ZR vibrators used with 350GZ 450GZ 595GZ power units Operation and Maintenance Manual International Construction Equipment Inc All Rights Reserved OM ZR May15 ...

Page 2: ...ue South Seattle WA 98108 USA Phones 704 821 8200 x166 Fax 206 764 4985 Midwest Dealer Location 5025 New Haven Avenue Fort Wayne IN 46803 USA Phones 800 348 1890 Fax 260 426 8717 Eastern Canada Dealer Location 2020 Bantree Street Ottawa Ontario K1B 5A4 Canada Phones 613 737 3963 613 266 5370 Fax 613 737 3908 ICE INTERNATIONAL PARTS SERVICE LOCATIONS 704 821 8200 www iceusa com ICE International Pa...

Page 3: ...driving in excess of 10 blows per inch 25mm set of 0 1 2 5mm per blow is considered practical refusal Driving in excess of 10 blows per inch 25mm for more than 6 inches 150mm or driving in excess of 20 blows per inch 25mm at all is considered improper use and will void the hammer war ranty For vibratory drivers driving extracting when the movement is less than 1 25mm per minute is considered pract...

Page 4: ...Operation and Maintenance Manual Page 2 OM ZR May15 ...

Page 5: ...tifies hazardous and potentially dangerous situations It is imperative that all operators and support staff read and understand the precautions listed before beginning op eration repair or maintenance on the equipment Section 2 Safety These sections are a reference for proper operation Illustrations and proper procedures give guidance for oper ational preparation handling engine starting and equip...

Page 6: ...Section 4 PREPARATION FOR OPERATION General Rigging of Vibrator Installing Proper Remote Control Pendant 17 Connection of Hoses at Power Unit 18 Connection Hoses Models at Vibrator 19 Attach Sheet Clamp Attach Caisson Beam to Vibrator 20 Connection of Hoses for Sheet Clamp Connection of hoses Caisson Clamp 21 Adjusting Position of Caisson Clamps with HydroLocks Bleeding Clamp Hoses 22 Bleeding Hos...

Page 7: ...voir Pressure Regulator 595G 700G 800G 47 Section 7 TORQUE SPECIFICATIONS Torque Specifications 48 Torque Value Chart 49 Section 8 TROUBLESHOOTING Electrical Hydraulic Components Schematics Operation Power Unit Monitoring and Protection 50 Engine Problems Indicated on Engine Display 51 Other Engine Screen Displays 52 Hydraulic Problems Indicated on Control Panel Emergency Stop Indicated at Control...

Page 8: ...oring Starting Diesel Engine Changing Engine Speed Stopping Engine Emergency Stop 71 Hydraulic Clamp Vibrator Rotary Head Other 72 Electrical Schematics and Wiring 73 79 Section 10 HYDRAULIC CIRCUITRY Hydraulic Components Vibrator 80 Hydraulic Schematic Vibrator 81 Clamp and Vibrator Operation 82 Vibrator continued ZR Operation 83 ZR Operation Continued Other 84 Table of Contents continued CONTENT...

Page 9: ...ponents the gear case the vibration suppressor and the hydraulic clamp The gear case contains eccentric weights that rotate in a vertical plane to create vibration Hydraulic motors drive the eccentric weights Additionally the ICE ZR series of vibrators have an actuator that can vary the eccentric moment from zero to maximum This controlled variable eccentric moment allows for gentle starts and sto...

Page 10: ... down The ZR vibratory driver extractors are designed to never operate at a frequency range that could cause resonance vibration to the soil structures or crane line Prior to start up the eccentric moment is set to zero During start up vibrator frequency passes through 600 1200 vpm with zero eccentric moment eliminating disturbance in the soil structures or crane line After full operating frequenc...

Page 11: ...1 070 Weight no clamp or hoses lbs kg 7900 3 585 9650 4375 14650 6 645 Non vibrating Weight lbs kg 2960 1 345 4180 1 895 4410 2000 Height without clamp H in mm 80 2 035 78 1 965 82 2 060 Length L in mm 77 1 945 112 2 835 131 3 330 Width W in mm 21 525 26 660 44 1 120 Throat width TW in mm 14 25 362 14 75 375 14 75 375 Hydraulic hose length ft m 150 46 150 46 150 46 Hydraulic hose weight lbs kg 142...

Page 12: ...1556 64 1613 Height in mm 83 2108 91 2312 Hydraulic Reservoir gal lit 275 1040 275 1040 Fuel Capacity gal lit 118 447 118 447 EPA EU Tier Stage 3 IIIA 3 IIIA 595GZ C15 595 444 3 IIIA 1850 5500 380 160 610 4500 310 6 21 16350 7420 160 4040 73 1855 100 2540 430 1630 150 570 700GZ C18 630 475 3 IIIA 1800 5500 380 175 670 4500 310 6 21 26500 12020 218 5540 80 2035 104 2630 550 2080 200 750 800GZ C18 8...

Page 13: ......

Page 14: ...olve a potential hazard The warnings in the manuals and on the equipment are therefore not all inclu sive If a tool procedure work method or operating technique not specifically recommended in writing by au thorized personnel from International Construction Equipment Inc or Caterpillar is used you must satisfy your self that it is safe for you and others You should also ensure that the equipment w...

Page 15: ...protection and other protective equipment as required by job con ditions Do not wear loose clothing or jewelry that can catch on controls or other parts of the equipment Make certain all protective guards and covers are secured in place Use all cleaning solutions with care Never put maintenance fluids into glass containers since glass containers can break Report all needed repairs Maintenance Proc...

Page 16: ...uter covering chafed or cut and wire reinforcing exposed Outer covering ballooning locally Evidence of kinking or crushing of the flexible part of the hose Precautions for Oils Hot oil and components can cause serious personal injury Do not allow hot oil or components to contact the skin Keep all exhaust manifold and turbocharger shields in place to protect hot exhaust from oil spray in the event ...

Page 17: ...or cut any object or tool that falls into their path Wear protective glasses when striking objects to avoid injury to your eyes Make sure no one can be injured by flying debris before striking any object Chips or other debris can fly off objects when struck Mounting and Dismounting Do not climb on or jump off the equipment or stand on components that cannot support your weight Use an adequate ladd...

Page 18: ...and falling off into traffic Make sure all doors are fully closed and latched Tighten fuel cap and close fuel petcock to prevent loss of diesel fuel Vibrator or Rotary Head The equipment should be shipped laying or sitting flat on the trailer deck Lift the equipment by rigging one line to the lifting pin and one line to the hose bundle as one load Avoid crushing hydraulic lines Damage During Shipm...

Page 19: ...ing Wire rope failure or cable clamp slippage may result in injury or death Check cables and cable clamps daily WARNING Safety Installing Proper Remote control Pendant To use power unit with vibrator install ZR vibrator remote control pendant Emergency Stop Clamp Light Clamp Switch Actuator Switch Main Circuit Engine Throttle Amphenol Connection to Power Unit Control Panel The remote control penda...

Page 20: ... Vibro 350GZ Quick Disconnect Panel The vibrator and hydraulic clamp are connected to the power unit by seven hydraulic hoses The functions are listed above on the corresponding quick disconnect couplers The hoses connect to the power unit with quick disconnect couplers Hose couplers are arranged to insure cor rect connections at the power unit Clean couplers with a lint free cloth before making c...

Page 21: ...quipment and risk to personnel when in operation Motor Pressure Open Clamp Close Clamp Motor Return Case Drain Eccentric Actuator Control 595 GZ Power Pack Quick Disconnect Panel Gear oil from cooler to vibrator 50ZR Hoses at Vibrator Attaching Hydraulic Clamp or Caisson Beam to Vibrator The vibrator is often shipped with the hydraulic clamp or caisson beam already attached If the clamp or beam is...

Page 22: ...ibrator base After caisson beam is attached to vibrator slide the caisson clamps into position on the caisson beam and lock in place The mating surfaces of the caisson beam and clamps must be clean and free of dirt rust or paint See Connection of Caisson Clamp Hoses 1 5 6UNC x 5 Socket Head Cap Screw 1 5 6UNC Socket Head Cap Screw WARNING Safety WARNING Equipment The bottom of the vibrator and the...

Page 23: ...se from fitting marked O on vibrator to fitting marked O on clamp Connection of Caisson Clamp Hoses OPEN CLOSE OPEN CLOSE OPEN The vibrator s clamp connectors are on both sides of base plate Connect hoses from fitting stamped C on vibrator to fittings stamped C on clamps Connect hose from fittings stamped O on the vibrator to fittings stamped O on clamp on either side Clamp Hose Connections Base P...

Page 24: ...aulic cylinder Turn the clamp switch on the remote control pendant to CLOSE Wait until oil flows from the connection at the clamp When oil flows without air tighten the con nection Use a catch basin for escaping oil and discard in an approved manner 3 After the line has been bled alternately turn the clamp switch to CLOSE and OPEN to insure that the clamp is working properly It may be necessary to...

Page 25: ...Section 4 PREPARATION FOR OPERATION Page 23 OM ZR May15 ZR Function Eccentric Moment Actuator Hoses ZR Function Eccentric Moment Rotary Joint Bleeding Hoses for ZR Function Hoses ...

Page 26: ... Box Remote Control Pendants Exterior Section 5 OPERATION 1 2 3 5 6 7 8 9 20 11 10 12 4 16 13 19 18 17 14 15 21 22 23 Inside Panel MAIN CIRCUIT CLOSE CLAMP OPEN CLAMP HYD OIL TEMP RETURN FILTER REMOTE LOCAL DECREASE 24 25 26 27 28 29 INCREASE 30 31 ...

Page 27: ... circuit pressure gauge 3 Hydraulic oil temperature gauge switch 4 Return filter pressure gauge 5 Emergency stop button 6 Hour meter 7 Engine power switch OFF ON START 8 Engine speed switch SLOW FAST 9 Remote Local switch REMOTE LOCAL 10 Main circuit vibro motors switch REV OFF FOR 11 Clamp switch OPEN CLOSE 12 Clamp light CLOSED 13 Moment actuator switch ZR function DEC INC 14 Service engine ligh...

Page 28: ...mal 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 If a screen similar to that below appears go to Section 8 TROUBLESHOOTING ...

Page 29: ... control panel the switch must be in the LOCAL position Operation From the Control Panel LOCAL if Pendant is Damaged or Missing If the remote control pendant is damaged if the pendant line is cut or if the radio remote is malfunctioning the equipment may be operated from the control panel If the remote control pendant is damaged disconnect the remote control pendant from the control panel Open the...

Page 30: ...ng buttons is activated or damaged Correct situation 3 Blinks three times at power on battery is discharged Charge battery 4 On for 2 seconds unit does not work correctly Repair or replace radio remote control 5 Blinks slowly About 4 hours battery time remaining 6 Blinks fast About 10 minutes battery time remaining Checking battery available run time 1 Turn ENGINE POWER switch on control panel to ...

Page 31: ... the ENGINE POWER switch to START There is one second delay before the engine will crank If engine fails to start after thirty seconds of cranking allow starter to cool for two minutes before attempting to start again 6 As the engine starts release the ENGINE POWER switch It will return to the ON position providing power to the controls WARNING Equipment Vibrator or the rotary head could start or ...

Page 32: ...bove 175 F 80 C may result in damage to hydraulic components Full Speed Operation 1 Stop the vibrator by turning the MAIN REV OFF FOR switch to OFF 2 If the engine has not been warmed up the engine may be shut down without a cool down period Turn the ENGINE POWER switch to OFF 3 If the engine has been warmed up running at above 185o F 85o C for 15 minutes or more the engine should be cooled down b...

Page 33: ...ing 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: ...arranty Maximum Bearing Temperatures Maximum bearing cover temperatures paint removed should not exceed 210 F 100 C Driving extracting when bearing covers paint removed are above 210 F 100 C is considered improper use and will void the vibrator warranty Operation on Batters Call ICE to review the planned operation before using an ICE vibrator on a batter Use of a vibrator on a batter without discu...

Page 35: ...V OFF FOR switch to FOR position To Change Eccentric Moment 1 To increase eccentric moment turn the Moment DEC INC to INC The eccentric moment will increase Full eccentric Moment should be achieved in about 3 seconds 2 To decrease eccentric moment turn the MOMENT DEC INC switch to DEC The eccentric moment will decrease Zero eccentric moment shall be achieved in about 3 seconds 1 Turn the MOMENT DE...

Page 36: ... psi 1 bar relief valve into a gear case fill hole On vibrators with only one fill hole remove the centrifugal breather and attach relief valve there 2 Air pressure is applied at the other gear case fill hole The preferred method of pressure control is to use a diving regulator mounted on the suppressor housing to automatically regulate pressure 3 Connect an air hose to other the gear case fill ho...

Page 37: ...on fittings caps filler and level plugs and their surrounding surfaces to prevent dirt from entering with lubricants and coolants The intervals given in the schedule are based on normal operating conditions For operation under abnormal or severe conditions such as heavy dust or severe cold perform these services lubrications and inspections more often and as needed WARNING Equipment Batteries must...

Page 38: ...rator Before Start up Checklist 1 Check the entire set up prior to starting the power unit 2 Visibly inspect and check tightness of all bolts nuts and screws including the bolts fastening the hydraulic clamp to the vibrator gear case 3 Grease the plunger in the hydraulic clamp with any good multi purpose grease 4 Check wire ropes connecting vibrator to crane or piling rig 5 Check the oil level in ...

Page 39: ... of those specified Operating in salt or high moisture have hydraulic oil tested quarterly and use normal service intervals Extended Work Hours 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 SEHS90...

Page 40: ...red for standard vibrator gear cases and power unit pump drive adapters It is our experience that Schaeffer oil allows for reduced maintenance time and cost In addition extensive tests have indicated that the use of SCHAEFFER 740 741 ISO 220 ISO 150 results in better performance with less fluid resistance to drive gears cooler operation and extended bearing life for the ZR Vibrators Schaeffer 740 ...

Page 41: ...ining Oil Remove pipe plug at either end of the gear case base plate Tilt the case for complete drainage Power Unit Pump Drive Adapter 350G 350GZ only Checking Oil Level Check oil level using the dipstick mounted on the pump drive adapter Adding Oil Add oil by removing the vent fitting from the top of the pump drive adapter of the pump drive adapter Draining Oil Remove the drain plug on the bottom...

Page 42: ...he alternates in the table More frequent service is recommended if these alternate lubricants are used Engine oil CAT CH 4 10W 30 Vibratory gear case Schaeffer 740 741 ISO 220 150 Pump drive adapter Schaeffer 268 ISO 320 Gear Case Oil Lube Pump The hoses on the gear case lube pump hoses should be bled when first placed in operation to ascertain proper function and to purge air from system The filt...

Page 43: ...ugh the return filters F1 to insure no dirt enters Draining oil Drain by removing the plug on the bottom of the reservoir Changing Hydraulic Return Filter Elements filter on back of reservoir Removing return filter elements 1 Loosen the bolts on the cover and rotate cover clockwise 2 Bypass check valve and spring will come off with cover 3 Remove the filter elements from the filter housing Replaci...

Page 44: ... same base and additive It is necessary to contact an oil supplier to determine if oils can be mixed Do not add any other oil to CHEVRON Clarity AW46 hydraulic oil If an alternate oil is used the following list contains recommendations that may be used to replace CHEVRON oil in the hydraulic system CHEVRON CLARITY AW46 EXXON MOBIL DTE 15M TEXACO RANDO ASHLESS CHEVRON HYDRAULIC OIL AW ISO 32 EXXON ...

Page 45: ...lamp OPEN CLOSE switch to OPEN 5 The pressure should read 4800 psi 330 bar 6 If the pressure does not read 4800 psi 330 bar a Release the clamp OPEN CLOSE switch b While holding the clamp relief valve adjusting screw with a hex key loosen the adjusting screw jam nut with an open end wrench c Adjust the clamp relief valve by turning the adjusting screw approximately 1 8th turn in the desired direct...

Page 46: ...sure on the CLAMP pressure gauge GA4 turn the control switch INCR DECR to DECR 5 The pressure should read 1500 psi 103 bar 6 If the pressure does not read 1500 psi 103 bar a Turn the torque switch DECR INCR to INCR b While holding the clamp relief valve adjusting screw with a hex key loosen the adjusting screw jam nut with an open end wrench c Adjust the clamp relief valve by turning the adjusting...

Page 47: ...p gauge Adjust the adjusting screw of the pressure switch with a flat blade screw driver to 4500 310 bar Clockwise increases the pressure setting and counterclockwise reduces the pressure setting 8 It may be necessary to momentarily turn the Clamp switch to OPEN and release some of the pressure before bringing the pressure adjustment down Make adjustments to the switch and then turn the Close Clam...

Page 48: ...2 Disconnect main pressure hose coupler at power unit left coupler 3 Start and warm up the diesel engine 4 With the engine warmed up increase engine speed to 1800 rpm 5 For vibrators turn CLAMP switch on pendant to CLOSE and wait until clamp CLOSED light comes on 6 Turn the MAIN REV OFF FOR switch to FORWARD Pressure should read 150 200 psi 10 14 bar 7 Turn the adjusting screw on the relief valve ...

Page 49: ...gulator The Reservoir Pressure Regulator RR on the hydraulic schematic must be set at 1 5 psi 0 1 bar Check the air pressure on Gauge GA4 which is installed on the front of Regulator RR The Reservoir Pressure Regulator is located inside the power unit enclosure on the back of the control panel Mounted on the side of the Regulator RR is the Reservoir Pressure Solenoid Valve V4 on the hydraulic sche...

Page 50: ...rque wrench Do not use adapters that change the length of the torque wrench For the correct use of the torque wrench refer to the instructions that were packaged with the torque wrench Prior to installation of any hardware ensure that components are in near new condition Bolts and threads must not be worn or damaged Threads must not have burrs or nicks Hardware must be free of rust and cor rosion ...

Page 51: ...80 150 M36 2800 350 2100 260 Torque Specifications continued UNC Screw Size Allen Wrench Size Standard Torque Ft lbs N m UNF Screw Size Allen Wrench Size Standard Torque Ft lbs N m 1 4 20 3 16 10 14 1 4 28 3 16 12 16 5 16 18 1 4 22 30 5 16 24 1 4 24 32 3 8 16 5 16 38 52 3 8 24 5 16 43 58 7 16 14 3 8 61 83 7 16 20 3 8 68 92 1 2 13 3 8 93 126 1 2 20 3 8 105 142 5 8 11 1 2 179 243 5 8 18 1 2 202 274 ...

Page 52: ...n of these systems is useful in locating and resolving operating difficulties Power Unit Monitoring and Protection Both ICE and Caterpillar monitor critical operating parameters and can display a warning derate slow down the engine and in some cases shut down the diesel engine Read Engine Problems Indicated on Display and Hydraulic Problems Indicated on Control Panel on the next few pages Electric...

Page 53: ...2o F 111o C the engine will derate slow down If the vibrator was running when the coolant temperature became high the engine derate will usually cause the engine to stall If the vibrator was not running the engine will just run at reduced speed To reduce engine coolant temperature turn vibrator MAIN switches pendant and control panel to OFF and follow normal engine start procedure Allow engine coo...

Page 54: ... 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 The screen on the right shows certain engine information for ICE engineering This screen may be assessed by pressing the upper arrow key twice To return to the normal operating ...

Page 55: ...LIC OVERRIDE The red light at the button will come on 3 Close the control panel 4 Follow the normal engine start procedure 5 The engine will run until it is shut down manually normally or another fault occurs If the condition causing a shutdown has not been fixed and the engine has been manually normally shut down the above override sequence must be repeated for engine restart Hydraulic Problems I...

Page 56: ...own light is on Correct problem or bypass hydraulic shutdown After correcting situation resume operation No Shutdown lights are on Check if engine fault message appears on engine display Fault message Correct engine problem After correcting situation resume operation No fault message Check the following Battery Electrical connections and components Starter relay Fuel filter If problem is not solve...

Page 57: ...y 50 of normal engine speed If the condition is severe the engine may be shutdown If the ECM derates or shuts down the engine a fault indicator will appear on the engine display on the control panel see page 51 When the condition causes derate or shutdown is corrected the engine may be started If the problem cannot be resolved consult the Caterpillar Operation Maintenance Manual or call your local...

Page 58: ...0 seconds and observe open clamp pressure One CLOSED light out Replace bulb or fix wiring Resume normal operation Pressure below 4500 psi Set clamp relief valve RV2 to 4800 psi see Section 6 MAINTENANCE Set pressure switch to 4500 psi After setting resume normal operation Pressure at 4500 psi Change pressure switch PS1 or check wiring from pressure switch to lights After repairs resume normal oper...

Page 59: ...mote to Local or vice versa see Section 5 OPERATION Works in Local Replace pendant Works in Remote Replace clamp switch Clamp pressure is zero Turn hold clamp switch on OPEN Clamp pressure is zero Shut down diesel engine Cycle clamp relief valve RV2 by moving adjusting screw in and out Reset relief valve to 4800 psi see Section 6 MAINTENANCE Turn hold Clamp switch on OPEN Clamp pressure builds but...

Page 60: ...EN for 2 seconds Shut down engine Disconnect and reconnect clamp quick disconnect couplers Restart engine Turn clamp switch to CLOSE Clamp does not close Shut down engine Disconnect close clamp hose at clamp Restart engine Turn clamp switch to CLOSE Clamp closes Resume normal operation Point A Clamp closes Turn clamp switch to OPEN for 2 seconds Shut down engine Recheck clamp quick disconnect coup...

Page 61: ...4800 psi see Section 6 MAINTENANCE Restart engine Turn hold clamp switch on OPEN Clamp pressure is zero Repair or replace clamp pump P2 After repairs resume operation Clamp opens Resume normal operation Works in Local Replace or repair pendant After repairs resume operation Clamp pressure builds but clamp does not open Check voltage to clamp close solenoid No voltage to solenoid Switch from Remote...

Page 62: ...from open clamp hose Shut down engine Reconnect open clamp hose at clamp Disconnect close clamp hose at clamp Restart engine Turn hold clamp switch to OPEN No flow from open clamp hose Shut down engine Reconnect open clamp hose at clamp Recheck clamp quick disconnect couplers If problem not solved call ICE Clamp opens Shut down engine Reconnect close clamp hose at clamp Recheck clamp quick disconn...

Page 63: ...ero Go to Point B on next page Pressure is above zero Check wiring to main control valve solenoid or replace solenoid Pressure is zero Turn main switch to OFF Shutdown engine Remove clean reinstall orifice OR1 Restart engine Turn main switch to FOR Check main pressure gauge reading Pressure is less than 1500 psi Call ICE to discuss checking vibrator anti cavitation check valve CV6 Pressure is abov...

Page 64: ...ator motors or gear case Pressure is zero Turn main switch to OFF Shutdown engine Remove clean reinstall orifice OR1 Restart engine Turn main switch to FOR Check main pressure gauge reading Pressure is 5500 psi Turn main switch to OFF Shutdown engine Reconnect main quick disconnect couplers Restart engine Turn main switch to FOR Pressure is zero Call ICE to discuss main pump Pressure is 5500 psi T...

Page 65: ...ed Engine is running at proper speed Vibrator appears slow Engine is not running at proper speed Increase speed to proper speed Check engine for derate condition After achieving speed resume operation ZR Eccentric moment control is set at or near zero resonance Move control to INC until full speed is reached Check controls ...

Page 66: ...OTE to LOCAL or vice versa Restart engine CAUTION Vibrator may start Check operation and connections of REV OFF FOR switch REV OFF FOR switch works in LOCAL Replace or repair pendant After repairs resume normal operation REV OFF FOR switch works in REMOTE Repair control panel After repairs resume normal operation Vibrator still does not stop Stop diesel engine to stop vibrator Call ICE to discuss ...

Page 67: ...nect reconnect case drain quick disconnect coupler at power unit Check that case drain hose is not pinched QD Coupler and hose OK Replace case drain relief valve RV3 Coupler loose or hose pinched After correcting problem resume operation Leak stopped Resume normal operation Case drain relief valve still leaks Call ICE Case Drain Relief RV3 ...

Page 68: ... little oil will cause overheating Temperature of Bearing Covers paint removed should be below 210 F 100 C Oil level OK Check if oil is milky or dirty Oil high or low Correct oil level Milky or dirty Change oil Oil Clean Call ICE to discuss operating or bearing problem Oil Level Sight Gauge Vibrator Gear Case Fills With Hydraulic Oil Call ICE Proper oil level ...

Page 69: ... Point A on next page Pressure is zero Go to Point B on next page Pressure is above zero Check wiring to main control valve solenoid or replace solenoid Pressure is zero Turn main switch to OFF Shutdown engine Remove clean valve reinstall Restart engine Turn main switch to DECR INC Check pressure gauges reading Pressure is low Call ICE to discuss checking Moment actuator control system Pressure is...

Page 70: ...anel Assembly EP 110615 1 Engine Power ET 100566 1 Engine Throttle Switch FS 750513 1 Forward Solenoid FI 840872 1 Fault Indicator Light FLR 731201 1 Filter Lamp Relay FT1 840097 1 Fuel Level Transducer Assembly HOL 100314 1 Hydraulic Fluid Level Switch MPR 731202 1 Main Power Relay MR 731179 1 Maintenance Reset Switch OC 130155 1 Clamp Switch OS 730807 1 Open Clamp Solenoid P 840090 1 Pendant Con...

Page 71: ...Section 9 ELECTRICAL COMPONENTS AND CICUITRY Page 69 OM ZR May15 Electrical Components 350GZ 450GZ 595GZ 700GZ 800GZ Eccentric Moment Actuator Control ZR DECREASE INCREASE ZR Controller ...

Page 72: ...peration Optional Control Control Panel Display The control panel DISPLAY D shows engine speed coolant temperature charging voltage oil pressure and fuel pressure Engine fault codes are shown on the DISPLAY These codes go out if the condition is corrected Engine Monitoring The ENGINE CONTROL MODULE ECM monitors the engine for any of the following conditions 1 Low oil pressure 2 High fuel temperatu...

Page 73: ...switch HOL turns on the HYD OIL LEVEL LOW light on the control panel If the hydraulic oil pressure at the return filters is too high and the hydraulic oil temperature is warm the RETURN FILTERS PRESSURE SWITCH PS2 and RETURN FILTERS TEMPERATURE SWITCH TS1 turn on the RETURN FILTER CLOG light on the control panel If the hydraulic oil temperature in the reservoir is too high the HYDRAULIC OIL TEMPER...

Page 74: ...l to the vibrator hydraulic motors and the vibrator starts With the diesel engine running turning the MAIN REV OFF FOR switch on the PENDANT to OFF de energizes the FORWARD SOLENOID on the MAIN CONTROL VALVE The vibrator stops 1 To increase eccentric moment turn the Moment DEC INC to INC The eccentric moment will increase Full eccentric Moment should be achieved in about 3 seconds 2 To decrease ec...

Page 75: ...Section 9 ELECTRICAL COMPONENTS AND CICUITRY Page 73 OM ZR May15 Electrical Schematic and Wiring A ...

Page 76: ...Section 9 ELECTRICAL COMPONENTS AND CICUITRY Page 74 OM ZR May15 Electrical Schematic and Wiring B Vibrator ZR Function Eccentric Moment Actuator DECR INCR ...

Page 77: ...Section 9 ELECTRICAL COMPONENTS AND CICUITRY Page 75 OM ZR May15 Electrical Schematic and Wiring B Rotary Head ...

Page 78: ...Section 9 ELECTRICAL COMPONENTS AND CICUITRY Page 76 OM ZR May15 Electrical Schematic and Wiring C ...

Page 79: ...Section 9 ELECTRICAL COMPONENTS AND CICUITRY Page 77 OM ZR May15 Electrical Schematic and Wiring D ...

Page 80: ...Section 9 ELECTRICAL COMPONENTS AND CICUITRY Page 78 OM ZR May15 Electrical Schematic and Wiring E ECCENTRIC MOMENT DECR ECCENTRIC MOMENT INCR ...

Page 81: ...Section 9 ELECTRICAL COMPONENTS AND CICUITRY Page 79 OM ZR May15 Electrical Schematic and Wiring F ...

Page 82: ...Section 10 HYDRAULIC CIRCUITRY Page 80 OM ZR May15 Hydraulic Components Vibrator Section 10 HYDRAULIC CIRCUITRY ...

Page 83: ...Section 10 HYDRAULIC CIRCUITRY Page 81 OM ZR May15 Hydraulic Schematic Vibrator ...

Page 84: ...CK VALVEs CV5 CV7 The clamp opens Pressure in the clamping circuit is limited to 4800 psi 330 bar by the CLAMP RELIEF VALVE RV2 A TEMPERATURE RELIEF VALVE RV4 limits pressure in the close clamp circuit caused by high ambient temperatures to 5800 psi 400 bar 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 ...

Page 85: ... F 38 C the COOLER VALVE directs flow through the HEAT EXCHANGER HE and then through the RETURN FILTERS Over pressurization of the HEAT EXCHANGER is prevented by CHECK VALVE CV3 which limits pressure to 65 psi 4 5 bar Returning oil is filtered by the RETURN FILTER F1 The return FILTER CHECK VALVE CV1 prevent oil loss from the RESERVOIR when the filter elements are removed RETURN FILTERS pressure i...

Page 86: ...turning to the RESERVOIR exceeds 175 F 80 C the HYDRAULIC OIL TEMPERATURE SWITCH TS2 shuts down the diesel engine and turns on the HYD OIL TEMP HIGH light on the control panel If the hydraulic oil temperature returning to the RESERVOIR is below 75 F 24 C the HYDRAULIC OIL TEMPERATURE SWITCH TS3 turns on the HYD OIL TEMP LOW light on the control panel A manual PUMP MP is provided to fill the hydrau...

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