ORTECO HD 1000 Use And Maintenance Manual Download Page 6

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Summary of Contents for HD 1000

Page 1: ... Bo Italia Tel 39 051 731051 Fax 39 051 731925 mail orteco orteco com www orteco com PILE DRIVER ON CRAWLER USE AND MAINTENANCE MANUAL Manual code 170310 Language english Edition 01 2017 IVth Series Translations of the original instructions in italian language Serial number ...

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Page 3: ...icality system instructions for use 65 B Blade raiser instructions for assembly use and maintenance 59 C Checking and cleaning the supplementary air filter 79 Cleaning and lubrication of hammer lifting chain 83 Controls to run the machine 33 Core borer instructions for assembly use and maintenance 45 D Dashboard controls base version 32 Declaration of conformity 12 Description of the controls 31 D...

Page 4: ...torques chart 84 O Operational stop 75 Operation controls 34 Operator training 6 Overall dimensions 10 P Pile driving procedure 40 Pointed bit instructions for assembly use and maintenance 62 Procedure for getting on and off the transport means 23 Procedure for use of the macro tilt 42 R Re commissioning 74 Refuelling 74 Replacing hosing 88 Replacing supplementary air filter cartridges 87 Replacin...

Page 5: ...the hammer drill frequency instructions for use 67 System for measuring the distance between the piles instructions for assembly use and maintenance 71 T Technical assistance procedure 3 Technical characteristics 9 Track gearmotor oil level check 81 Track tension check 82 Transportation procedure 21 U Unauthorised uses 6 Use and operation safety precautions 18 Use in cold environmental conditions ...

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Page 7: ...serves the right to make changes to the manual without prior notice with the exception of changes concerning the level of safety The manual must be kept for future reference until the machine is scrapped If the machine is sold the seller is required to pass on the manual to the new owner In the case of discordant information between the machine manual and the attached man uals the machine manual m...

Page 8: ...information to identify the machine and the manufacturer Machine identification plate A Manufacturer s details B Machine model C Type of machine D Serial number E Year of manufacture F Maximum pressure G Required oil flow H Engine power L Electric voltage M Overall weight N CE marking R Engine identification plate Punching The following serial numbers are punched on the machine W Undercarriage ser...

Page 9: ...echnical assistance engine malfunction failure etc contact the nearest techni cal assistance service of the engine manufacturer see enclosed manual Disclaimer notice The manufacturer cannot be held responsible for the following use of the machine by untrained and or unauthorised personnel improper use of the machine failure to carry out maintenance unauthorised modifications or repairs use of non ...

Page 10: ... sudden failure to restore the initial operating conditions Operator trained person who has been authorised by the respective manager It is the operator s duty to ensure the operational tasks and daily routine maintenance out lined in this manual are carried out safely Maintenance engineer trained person who has been authorised by the respective man ager It is the maintenance engineer s duty to en...

Page 11: ...the machine to drill holes in conglomerates in the ground and in rocky ground One operator is sufficient to operate the machine said operator must have the necessary requisites to use the machine in total safety Main parts A Pile driver base it contains the slide for the transversal movement of the column B Column to position the hammer in the right position to drive the element into the ground C ...

Page 12: ...ncrete It is prohibited to activate the track movement or correct the position or tilt of the vertical column during pile driving or extraction operations when making holes on elements or drilling the ground Operator training The operator has the task of carrying out all the operations related to the use of the ma chine and ordinary maintenance operations in total safety Personnel authorised by th...

Page 13: ...acturer during testing and must not be altered D Safety guards these protect the operator from accidental contact with moving tracks E Rotating light this signals the start up of the machine and is automatically activated in the ignition phase F Safety lock pin this protects the operator from the accidental and sudden lowering of the percussion hammer G Rotating light optional signals the machine ...

Page 14: ...ible if they are not replace them with new ones maintaining the original location on the machine The illustrations show the position of the safety and information signs on the machine The meaning of each sign is described below 1 Risk of crushing of lower limbs in tracks 2 Risk of limbs being crushed by the machine s moving parts 3 Ear defenders must be worn to protect the user s hearing from loud...

Page 15: ...is shows the connection of the high pressure delivery hose 24 This shows the connection of the low pressure draining hose 25 This shows the maintenance instructions see General maintenance instructions de scribed in the instruction manual provided with the engine 26 This shows the emergency stop button 27 This shows damage to the engine caused by insufficient cooling Always start the engine with a...

Page 16: ...he ground Sound emissions The sound level measured in operating condition when driving metal piles is shown in the table The measurement has been carried out in compliance with the ISO 6395 1988 EN ISO 3744 1997 UNI EN ISO 11201 2010 standards using a ONO SOKKI phonometer model LA 4350 Model A B C D E F G H L1 L2 M N P Q mm HD 800 2370 3355 1930 2570 3570 320 2830 4155 125 45 2800 2125 8 10 HD 100...

Page 17: ... must be programmed to reduce the exposure to noise Gas emissions During operation and or when standing still the machine emits the toxic gases listed be low Carbon monoxide generated by the exhaust of the engine Hydrogen generated by the engine ignition battery Inflammable and explosive fumes produced by the engine fuel Environmental operating limits The machine works correctly at a temperature b...

Page 18: ...O Italia Tel 39 051731051 Fax 39 051731925 of the Machine DESCRIPTION FUNCTION MODEL COMMERCIAL NAME TYPE COMMERCIAL NAME SERIAL NUMBER YEAR OF MANUFACTURE IMPACT ENERGY declares under its own responsibility that the aforesaid machine complies with the provisions of the following directives and subsequent amendments thereto 2 006 42 C E M a c h i n e r y D i r e c t i v e 2 014 30 U E E l e c t r ...

Page 19: ...rs four different lengths 3000 mm 3500 mm 3800 mm and 4000 mm D Macro tilt this is used to drive in piles or to use accessories in perfectly vertical manner when the ground is sloping and the standard machine cannot offset the slope with hydraulic manoeuvres Horizontal additional extension skid The machine is equipped with a counter weight A to prevent transverse overtur ning Do not use the machin...

Page 20: ... dimension corresponds to the maximum length of the pile to be driven into the ground Description Weight kg Sliding column 320 Counterweight 142 Oversize fixed vertical column The machine is equipped with a coun terweight E to prevent transverse over turning Do not use the machine without the counterweight On sloping ground do not exceed the maximum longitudinal and transverse slope limits stated ...

Page 21: ...age 15 Use and maintenance TECHNICAL INFORMATION 2 Macro tilt The pile driver is tilted via a manually operated cylinder see Procedure for use of the macro tilt The chart shows the increase in weight Description Weight kg Macro tilt 35 ...

Page 22: ...n action For assembly use and maintenance of the drilling machine see Drilling procedure with the drilling machine D Drill to drill holes in ground containing a small quantity of rock fragments gravel crushed stone etc For assembly use and maintenance of the drill see Drilling procedure with the drill E Electrical power generator this is activated by the machine s hydraulic system and supplies ele...

Page 23: ...of the ground D Compressed air circuit to supply to the boring device the air necessary for the percus sion action and to clean the hole E Lights to illuminate the work area in case of low visibility or at night see Working at night or with low visibility F Tow hook to tow equipment on wheels compressor trolley etc The maximum load that can be towed is shown on the plate on the tow hook G Radio co...

Page 24: ...start or use the machine in poorly ventilated areas If necessary adopt all nec essary precautions to prevent build ups of machine exhaust gas Use and operation safety precautions The operator must know well the performance and weight of the machine in relation to the type of ground flat compact rough sloping in order to always maintain a safe distance when working near open excavations slopes verg...

Page 25: ...ost important safety elements Maintenance schedule operations must be carried out at the set intervals and in the manner foreseen by the manufacturer Formaintenanceoperationsthatrequirespecialequipmentand orspecialisedknowl edge contact the authorised assistance centres Before carrying out any maintenance or adjustment operation lower the hammer to the ground switch off the engine and remove the i...

Page 26: ...e environment and to people s health Fire prevention and first aid measures First aid measures In the event of an accident provide medical assistance as envisaged by legislation and standards in force in the country where the machine is in use In the event of contact with fuel or hydraulic oil refer to the Safety and environmen tal data sheets for hydraulic oil or the Safety and environmental data...

Page 27: ... with the local laws in force If necessary when loading and unloading from the truck use ramps which are in good condition and offer the appropriate load bearing capacity Transportation procedure The machine depending also on the destination can be delivered using different transport means road rail sea and air The machine is delivered completely assembled or divided in two parts tracked truck and...

Page 28: ...outlined below 1 Check the weight of the machine to be lifted in the Technical specifications chapter to make sure the lifting means is suitable 2 Fix the lifting ropes to the eyebolts marked A indicated by a special sign The illustration shows the harnessing points and lifting procedure Lifting the truck Proceed as outlined below 1 Check the weight of the truck to be lifted in the Technical infor...

Page 29: ...ke sure the lifting means is suitable 4 Fix the lifting ropes to the bow shackles A indicated by a special sign The illustration shows the harnessing points and lifting procedure Procedure for getting on and off the transport means WARNING Loading and unloading operations must be carried out on solid and level ground that does not present risks When getting the machine on and off the transport mea...

Page 30: ...ew the wing screw B and remove the rotary lamp to avoid damaging it during transport Use the cap C to prevent the rotary lamp support from getting dirty 2 Start the machine see Starting the engine 3 Position the machine centrally to the ramps and if necessary adjust the width of the ramps so that the machine weight is evenly distributed 4 Move up onto the transport means with minimum forward speed...

Page 31: ...means at minimum forward speed 6 Remove cap C from the rotary lamp support 7 Mount the rotary lamp on the support and tighten the wing screw B to lock it in place Assembly of pile driver on the crawler The machine delivered in different parts crawler and pile driver must be assembled by duly trained personnel in an authorised service centre The authorised service centre has all the information abo...

Page 32: ...oid dangerous situations loosen the valve by maximum one turn and never un screw the lubricator Proceed as outlined below 1 Stop the machine on solid and even ground 2 Switch off the engine and remove the ignition key and keep it in a safe place 3 Lift the machine off the ground the bare minimum needed and block it with external means to prevent it from accidentally coming down 4 Unscrew the screw...

Page 33: ...epth see Pile driving procedure 3 Stop the percussion and rest the hammer on the pile head 4 Loosen the screws A 5 Adjust the device B at the centre line of the proximity sensor C as shown in the fig ure 6 Tighten the screws A 7 Turn the selector D to the PROXIMITY position 1 to activate the device 8 Drive another pile into the ground until the stop device automatically interrupts the pile driving...

Page 34: ...ep the tool in contact with the ground 4 Loosen the screws A 5 Adjust the device B at the centre line of the proximity sensor C as shown in the fig ure 6 Tighten the screws A 7 Turn the selector D to the PROXIMITY position 1 to activate the device 8 Make another hole until the stop device automatically interrupts the progress of the tool 9 Move the lever E to position E0 to stop the tool rotation ...

Page 35: ...and rest the hammer on the pile head 4 Activate the emitter of the laser device 5 Turn the selector A to the laser position 1 to activate the device 6 Position the laser emitter B at a distance of at least 100 150 m from the pile driver 7 Adjust the laser emitter B at a height from the ground similar to that of the receiver and is such a way that there are no obstacles between the emitter and the ...

Page 36: ...ter B at a maximum distance of 100 150 m from the pile driver 7 Adjust the laser emitter B at a height from the ground similar to that of the receiver and is such a way that there are no obstacles between the emitter and the receiver C 8 Loosen the locking levers D 9 Slide the receiver C along the pipe to intercept the laser ray until the green lights E light up 10 Tighten the levers D to lock the...

Page 37: ...tches filled excavations and ridges rough ground wet or muddy ground On sloping ground move and operate the machine only within the limits foreseen by the manufacturer see Technical characteristics Keep away from the digging area and do not drive near the edges unless they have been tested for stability Before use check the efficiency of the controls braking and parking devices rotary lamp and buz...

Page 38: ... Signal light red this shows there is insufficient engine oil pressure F Signal light red this shows that the engine air filter is clogged G Signal light red this shows the engine is overheating H Signal light orange low fuel warning light L Signal light red this shows that the delivery filter of the hydraulic system is clogged M Area without control device N Buzzer 1 This warns the operator with ...

Page 39: ...ontrols to run the machine A Lever to activate the left track Sx Move the lever to position 1 to move the track in direction I Move the lever to position 2 to move the track in direction II When the lever is released it returns to neutral position 0 When the lever is in neutral position the movements of the left track are disabled B Lever to activate the right track Dx Move the lever to position 1...

Page 40: ...down movements of the percussion hammer NOTICE If equipped with an electric module the proportional distributor has no permanent contact position D3 when actuated manually which means the operator will have to hold the lever in position during work E Lever to shift the column transversally Position 1 this activates column retraction Position 2 this activates column extension When the lever is rele...

Page 41: ...tain accessories such as the corer boring device drill etc see the procedure for the use of the accessory installed on the machine Position L1 to activate the percussion hammer Position L0 to stop the percussion hammer Position L2 if featured it activates the opposite rotation of certain accessories NOTICE The manually operated proportional distributor is equipped with a clutched lever This lever ...

Page 42: ...nd the electrical sys tem 3 Check that the fuel valve T is open 4 Position the accelerator lever R about half way 5 Turn the ignition key B by one click position I 6 The signal lights D and E switch on and the buzzer Q sounds 7 Turn the ignition key B one more click to position B1 to start the engine 8 When the motor is on the signal lights D and E switch off and the buzzer Q stops To start the ma...

Page 43: ... the motor is on the signal lights D and E switch off and the buzzer Q stops Starting the engine with the auxiliary battery NOTICE Do not cause sparks or use naked flames near the batteries Avoid direct contact with the battery liquid Use cables with an adequate section and isolated terminals If the battery is flat the engine can be started with another battery auxiliary with a nomi nal voltage an...

Page 44: ... from the position E foreseen for the operator For transfers at the work site put the pile driver in resting position C and control the ma chine from the position E foreseen for the operator Proceed as outlined below 1 Start the engine see Starting the engine 2 Move levers A and B at the same time towards the position 1 to move the machine forwards in the direction I 3 Move levers A and B at the s...

Page 45: ...peed and visibility When working on sloping ground the operator s experience and good sense prevail over any rule Proceed as outlined below 1 Start the engine see Starting the engine WARNING On sloping ground travel at minimum speed to prevent the risk of the machine over turning 2 Move levers A and B at the same time towards the position 1 to move the machine forwards in the direction I 3 Move le...

Page 46: ...gure When driving the pile into the ground the percussion hammer must be manually placed in a perfectly vertical position see Operation controls or automatically see Using the verticality system To manually place the column in a perfectly vertical position use the level gauge Q Check the need to replace according to the type of pile to be driven the stroke plate H and the matrix T see Replacing th...

Page 47: ...abled before activating the per cussion hammer to avoid damaging the device 16 Move the lever R to activate the percussion hammer NOTICE When working on extremely hard ground it is important not to use a pneumatic drill for more than 30 seconds at a time After this limit stop for at least 15 seconds before resuming drilling If the pile does not go into the ground do not attempt to force it there i...

Page 48: ...e to align the holes corresponding to the neces sary tilt to drive the pile 6 Slide in the pins B and D in the holes and the pegs A and C to lock the base in the required position 7 Insert the lever F in the pin H 8 Turn the lever F to lower the jack shaft 9 Remove the jack E To tilt the base in the opposite direction repeat the same operations on the other side of the base On steeply sloping grou...

Page 49: ...he side of the percussion hammer see figure WARNING Fit the clamp with the machine parked on flat and stable ground the engine off and the percussion hammer at minimum distance from the ground Do not use the grip per if it is damaged or there is a malfunction in the grip lock system Fitting the pile extraction clamp To fit the pile extraction clamp proceed as outlined below 1 Position the bracket ...

Page 50: ... the end of the hammer 6 Lock the grip of the clamp on the pile using the lever P 7 Move the lever N position N2 to slowly lift the percussion hammer until the clamp is tensioned 8 When the clamp is tensioned move the lever Q to position Q1 and then move the lever N to position N2 NOTICE When extracting old piles or files driven into extremely hard ground it is important not to use a pneumatic dri...

Page 51: ...rom the ground Arrange appropriate safety measures and use suitable equipment to avoid accidents that could injure the people in charge of the operation and people nearby Fitting the corer To fit the corer proceed as outlined below 1 Lower the hammer to the limit to make the fitting operations easier 2 Lift the corer and position it against the percussion hammer 3 Lock the corer to the percussion ...

Page 52: ...artz porphyry Medium hardness low abrasion resistance travertine and limestone High abrasion resistance reconstructed stone medium hardness stoneware marble Very high abrasion resistance refractory materials soft stoneware asphalt Tool rotation speed rpm Tool diameter mm Tool diameter mm Tool diameter mm Tool diameter mm Tool diameter mm 1000 16 22 17 45 55 103 112 160 150 200 900 18 25 19 50 60 1...

Page 53: ...using the level gauge S To automatically place the column in vertical position see Using the verticality sys tem 4 Move levers C and D to slightly change the position of the tool 5 Set lever F in position F1 to switch on the hydraulic power to the accessory 6 Open the turn valve Q to cool the tool 7 Move the lever L to activate the tool 8 Use lever N to adjust the tool rotation speed 9 Move the le...

Page 54: ...nd the engine off and the percussion hammer at minimum distance from the ground Arrange appropriate safety measures and use suitable equipment to avoid accidents that could injure the people in charge of the operation and people nearby Fitting the boring device To fit the boring device proceed as outlined below 1 Unlock the guide N from the pin A and rotate it in vertical position 2 Lock the guide...

Page 55: ...lved in the operations 11 Fit the pile guide Z 12 Lift the hammer slightly and unscrew the safety lock pin E 13 Move the lever R to lower the boring device to the ground 14 Stop the machine see Operational stop 15 Fit the half bushings L onto the pile guide and tighten the screws M 16 Connect the hydraulic pipes to the quick couplings N 17 Connect the air supply pipe from the compressor to the cou...

Page 56: ...tion To manually position the column in vertical position use the levers A and B Check the verticality using the level gauge C To automatically place the column in vertical position see Using the verticality sys tem 4 Move levers S and T to slightly change the position of the tool 5 Switch on the supply of compressed air to the boring device 6 Use the knob of the compressed air lubrication device ...

Page 57: ...ed depth see the Adjusting of PROXIM ITY device that stops the hammer s down stroke section If the machine is fitted with the laser device see the Adjusting the laser device that stops the hammer s down stroke section 10 Once the required depth has been reached move the lever V to the disabled position V0 to manually stop tool rotation or activate the automatic stop devices proximity or laser 11 D...

Page 58: ...ng operations described above in reverse order Maintenance for drilling machine hydraulic head The hydraulic head is normally supplied pre greased and complete with the required lubri cant inside the gearbox Upon first use it is compulsory to check that the head is fully greased and filled with lubri cant Carry out scheduled maintenance as stated by the manufacturer see Scheduled mainte nance char...

Page 59: ...lace the column in a perfectly vertical position 3 Unscrew cap A 4 Check that the oil level is at approximately 2 3 of the gear box If topping up is required use PAKELO GEAR OIL EP E GL 5 SAE 80W90 or an equivalent product 5 Screw on the cap A Replacing the gear unit oil RP500 Proceed as outlined below 1 Remove the accessory from the machine 2 Unscrew cap A 3 Unscrew cap B 4 Drain out the oil comp...

Page 60: ... and stable ground the engine off and the percussion hammer at the necessary distance from the ground to fit the tool Arrange appropriate safety measures and use suitable equipment to avoid accidents that could injure the people in charge of the operation and people nearby Rear fitting of the drill For rear fitting proceed as outlined below 1 Remove the peg A and the pin B 2 Fit the head C of the ...

Page 61: ...roceed as outlined below 1 Fit the support A and tighten the screws B to fix it to the percussion hammer 2 Fit the head C of the drill on the support A 3 Insert the pin D and the lock pin E 4 Lift the percussion hammer the bare minimum to fit the tool G 5 Fit the tool G 6 Position the washers L 7 Insert the screw F 8 Tighten the nut M 9 Connect the hydraulic pipes to the quick couplings H ...

Page 62: ...rward 7 Once the required depth has been reached move the lever D to position D0 to man ually stop tool rotation or activate the automatic stop devices proximity or laser 8 Move the lever B to position B1 to remove the tool from the hole Counter rotation of the tool If the counter rotation tool is foreseen move the lever to position D2 to activate the rotation in the opposite direction to the hole...

Page 63: ...ergents authorised by legislation in force and available in the shops Drill lubrication Check the lubricant level in the head visually via the level gauge If topping up is required use PAKELO GEAR OIL EP E GL 5 SAE 80W90 or an equivalent product Replacing the gear unit oil Change the oil when the gearbox is warm When cleaning the internal parts of the gear unit use non flammable non toxic detergen...

Page 64: ...h it off to avoid a drop in the machine s performance To disable the electric generator proceed as outlined below 1 Press the switch A at the same time the signal light B will switch off Electric generator use and maintenance procedures WARNING Do not use the electric generator if it is wet or if it is raining heavily or particularly humid Electrical power generator maintenance WARNING Do not use ...

Page 65: ...te packaging Blade raiser assembly WARNING Use lifting means with a sufficient capacity for the load to be lifted Hooks and ropes in good condition suitable for the load to be lifted must be used for lifting operations Proceed as outlined below 1 Strap up and lift the separate units A F M comprising the accessory properly 2 If necessary fit the shims T supplied with the accessory in order to reduc...

Page 66: ...ccessory is usually supplied in the configuration 1 illustrated in the figure Check that the height of guardrail H is compatible with the height of the guide Should it be necessary to install a lower guardrail perform the procedure de scribed Proceed as outlined below 1 Remove the safety lock pins A 2 Slide out the pins B 3 Remove the rollers C 4 Undo the screws D 5 Remove the bracket E 6 Position...

Page 67: ...the guardrail in the fastening position en visaged in the design 5 Check that the surface of the guard rail is fully in contact with the mount ing surface of the pile If the guardrail is not perfectly in con tact proceed as described below Loosen the nut B Adjust the tie rod C Tighten the nut B 6 Check that the holes in the guard rail are aligned with the holes in the pole If the holes are not ali...

Page 68: ...ven in ground containing some solid materials with small particle sizes such as gravel crushed stone etc The tool makes the hole in the ground into which the pile will be fitted without producing any spoil Fitting the tool WARNING Fit the tool with the machine parked on flat firm ground with the engine stopped and the hammer drill far enough off the ground to facilitate assembly Arrange appropriat...

Page 69: ...tion the component F CAUTION Pay particular attention to the component F which could fall and injure the opera tor 10 Gently move the lever D and carefully lower the percussion hammer 11 Insert the screws B 12 Tighten the nuts A 13 Move the lever D to lift the percussion hammer 14 Position the tool P below the hammer drill 15 Use the lever D to lower the hammer drill and insert the tool into its s...

Page 70: ...lace the column in a perfectly verti cal position 3 Using the lever B lower the tool un til it is touching the ground 4 Set the lever B in the floating posi tion B3 NOTICE Make sure that the automatic vertical ity system is disabled before activat ing the percussion hammer to avoid damaging the device 5 Move the lever R to activate the percussion hammer NOTICE When working on extremely hard ground...

Page 71: ...the tool carry out the steps in reverse order to the procedure described for the assembly Tool maintenance Carry out scheduled maintenance as stated by the man ufacturer see Scheduled maintenance charts Proceed as outlined below 1 Before carrying out any lubrication work clean the greasing nozzle to prevent pollution of the lubri cant 2 Lubricate via greasing nozzle Grease type use PAKELO BEARING ...

Page 72: ...rtical position of the column in relation to the axis X Signal light on this indicates the incorrect vertical position of the column in relation to the axis X Flashing signal light this indicates that the auto matic verticality system is out of range due to the excessive inclination of the column compared to the axis X C Red signal light Signal light off this indicates the correct vertical positio...

Page 73: ...column is perfectly vertical At the end of each cycle the system goes automatically into stand by 4 Turn the key of the switch A to position 0 to dis able the automatic verticality device NOTICE Do not activate the automatic verticality device while the pile is being driven into the ground to avoid dam aging the device System for adjusting reducing the hammer drill frequency instructions for use T...

Page 74: ...of the switch D to position I 2 Use the lever L to lower the hammer drill onto the pile until the head of the pile is fitted inside the grooved profile of the stop plate and then set it in the floating position L3 3 Use switch A to start the hammer drill working and activate the system The indicator lamp B lights up 4 Use the knob C to reduce the hammer drill stroke frequency When the device H act...

Page 75: ...gnet N Signal light green this shows that the magnet is switched on P Signal light orange this shows that the magnet is about to switch off within 5 seconds Q Audio warning device this audio signal means that the magnet will switch off within 5 seconds Use of the magnet Proceed as outlined below 1 Clean the magnet grip surface and the pile contact surface 2 Position the magnet in the centre of the...

Page 76: ...the switch M to deactivate the magnet At the same time the signal light N switches off the signal light P comes on and the audio signal sounds Q After 5 seconds the signal lights N P switch off the audio signal stops sounding and the magnet is no long er attracted to the pile 9 Release the pile from the safety line R Removing the magnet To remove the magnet carry out the steps in reverse order to ...

Page 77: ...ed 1 Insert the pin A into the bushing B 2 Connect the connector C Use of the system for measuring the distance between the piles Adjust the system according to the distance L between the piles to be driven in The maximum distance L allowed is 4000 mm Carry out the operations described 1 Drive the first pile into the ground see Pile driving procedure 2 Move the machine to the point where the next ...

Page 78: ...spot where the signal light R comes on 9 Tighten the screw D If the movement of the photocell alone is not enough proceed as described below 10 Unscrew the nut P 11 Remove the screws H 12 Remove the washers N 13 Slide out the tubular bar Q until the holes for fastening the tubular bar in the open configuration are aligned 14 Position the washers N 15 Insert the screw H 16 Tighten the nut P 17 Loos...

Page 79: ...ce as stated by the manufacturer see Scheduled mainte nance charts When cleaning the system for measuring the distance between the piles use non flamma ble non toxic detergents authorised by legislation in force and available in the shops Lighting instructions for working at night or in poor visibility conditions Working at night or in low visibility conditions increases the risks that derive from...

Page 80: ... the machine is not going to be used for long periods of time proceed as follows 1 Wash the machine completely 2 Grease the machine see Lubrication diagram 3 Fix any oil leaks hydraulic and engine circuits 4 Repair damaged or worn mechanical parts tracks etc 5 Protect the unpainted parts with antioxidant products 6 Empty the fuel tank completely 7 Turn the battery cut off switch to open the circui...

Page 81: ...ne 6 Remove the ignition key C from the dashboard and keep it in a safe place 7 Close the dashboard guard E and assess the need to padlock it to avoid tampering of the controls and prevent unauthorised use of the machine 8 Turn the battery cut off switch D to open the circuit and isolate the battery 9 Close the valve T 10 If necessary signal the presence of the parked machine Emergency stop Press ...

Page 82: ...ked more often in case of intensive use of the machine Scheduled maintenance chart operator Interval Component Type of work Reference Every 4 hours of work Stroke plate Hammer point Nuts and bolts Accessories and supplements Drilling machine Greasing Greasing Inspection Nut and bolt tightness check Greasing See Lubrication diagram See Lubrication diagram See Nuts and bolts check At the end of the ...

Page 83: ...g Replacing the filter cartridge Replacing the filter cartridge Replacing the gear unit oil Replacing the gear unit oil See Replacing the track reduction gear oil See Replacing the discharge filter cartridge low pressure See Replacing the delivery line filter cartridge high pressure See Drill maintenance See Drilling machine maintenance Scheduled maintenance chart specialist technician Interval Co...

Page 84: ...P2 Oil for chains PAKELO HYDRAULIC EP ISO 46 PAKELO GEAR OIL EP E GL 5 SAE 80W 90 Lubrication diagram Lubricate the parts as shown in the illustration Before lubricating clean the components concerned and the greasing nipples to prevent contamination of the lubricant The lubricants indicated are factory fill lubricants For equivalent lubricants see the Lubricant comparison table ...

Page 85: ...bris suspended in the air from seriously damaging the engine In certain operating conditions dust dirt and debris the air filter may need to be checked and cleaned more frequently Use the valve A to release the dust contained in the fil ter Check the clog signal B every day When the signal is in the red area it means the filter is clogged and must be cleaned or replaced see Replac ing supplementar...

Page 86: ...ly along the folds of the fil tering material from the inside outwards Be careful not to damage the folds of the filtering ele ment Theprimaryfiltercanbecleaneduptosixtimes ifcleaned and checked correctly then it must be replaced If the filter is damaged torn filtering material damaged seals it must be replaced Secondary filter 10 Unscrew the wing nut M 11 Slide out the secondary filter N Check th...

Page 87: ...he caps as any excess pressure inside the gear unit may force them outwards 3 Unscrew cap A and check that the oil is level with the bottom edge of the hole 4 If necessary unscrew the cap B and top up the oil to the correct level 5 After topping up screw the caps A B back on For oil characteristics see the Lubricant comparison table Hose check Check the seam fastening the fitting to the hose and t...

Page 88: ...f necessary adjust the track to the correct tension see Adjusting track tension Hydraulic oil level check Proceed as outlined below CAUTION Slowly unscrew the cap and discharge the pressure inside the tank to prevent the danger of burning caused by the expulsion of hot liquid 1 Stop the machine on solid and even ground and the pile driver in resting position with all jacks retracted 2 The oil gaug...

Page 89: ...corroded etc it must be replaced immediately see Replac ing the chain Proceed as outlined below 1 Stop the machine on solid and even ground 2 Switch off the engine and remove the ignition key and keep it in a safe place 3 Clean the chain with diesel oil or petrol or a paraffin derived product 4 Lubricate with spray lubricant for chains following the indications During this operation the chain must...

Page 90: ...AGIP MOBIL SHELL Type BEARIN EP2 ATHESIA PGX 2 ENI GREASE MU EP 2 MOBILUX EP 2 ALVANIA GREASE EP Molybdenum disulphide grease specifically for the point and stroke plate Brand PAKELO IP AGIP MOBIL SHELL Type HAMMER GREASE PLUS NLGI 2 BIMOL LTM ENI GREASE SM 2 MOBILGREASE SPECIAL SHELL RETINAX HDX Engine oil standard climates Brand PAKELO IP AGIP MOBIL SHELL Type GOLDEN DIESEL HP A SAE 15W 40 TARUS...

Page 91: ...l system of the emergency button in faulty Repair the fault Contact an authorised service centre Locking machine movements Maximum pressure valves of the distributors clogged with dirt Clean the valves Contact an authorised service centre The accessory does not switch on The hydraulic supply by pass valve lever is in the hammer activation position Turn the valve lever to the correct position The a...

Page 92: ...s or other material near the moving parts or in risk areas Components and waste material must be disposed of in compliance with the law in force concerning waste collection sorting and disposal Replacing the discharge filter cartridge low pressure CAUTION The filter cartridge must be replaced with the hydraulic system depressurised Replace the filter cartridge when the needle of the clog indicator...

Page 93: ...d below 1 Position a container of adequate capacity under the filter to collect the oil 2 Clean the filter s outer surfaces accurately 3 Unscrew the filter unit B 4 Slide out the worn or clogged filter cartridge A 5 Accurately clean the inside of the filter unit B 6 Slide the new filter cartridge into the filter unit 7 Check the state of the seal C and if damaged replace it 8 Tighten the filter un...

Page 94: ...ttings and collect the oil in a suitable container Replace hosing and tighten the fittings Replacing the track reduction gear oil 3 Unscrew the caps A B and allow the oil to run into a sufficiently sized container 4 Wait a few minutes until all the oil has drained out 5 Refill the oil as shown see Oil level check for track gear units 6 Screw on the caps A B For oil characteristics see the Lubrican...

Page 95: ...tely When replacing the chain replace the connection link and the fixing pins that connect the chain to the anchorage blocks The chain must be in any case replaced after 1000 hours of work The chain must be replaced by an authorised service centre Replacing the stroke plate The oversized stroke plate weight over 25 kg must be replaced by two people using suit able lifting and support means 1 Remov...

Page 96: ...ently move the lever D and carefully lower the percussion hammer 9 Fit the screws B and tighten the nuts A 10 Fit the guide plate H 11 Replace the matrix G with the stroke plate Scrapping the machine Scrapping operations must be handled by specialised personnel with suitable skills for the job The components removed must be sorted according to the type of materials they con tain and in compliance ...

Page 97: ...normal personal hygiene and to avoid frequent and prolonged contact Use according to good working practice avoiding to disperse the product in the environment Other hazards This product does not contain any PBT or vPvB substances Composition Information on ingredients 3 Ingredients composition No 1272 2008 CE 93 25 lubricating oils petroleum C24 50 solvent extd dewaxed hydrogenated No EU 309 877 7...

Page 98: ...ent Specific protective equipment for fire fighting personnel Accidental release measures 6 Wear gloves protecting clothes and glasses In case of indoors significant spill avoid to breathe vapours by ventilating the area or by wearing breath protecting equipment Remove possible ignition sources Person related safety precautions The product contains substances harmful to the aquatic environment Avo...

Page 99: ...he product Eyes protection Physical and chemical properties 9 Liquid Physical status Straw yellow Colour Typical Odour Not applicable pH Insoluble Water Solubility 0 880 Density at 15 Ckg l 46 Kinematic Viscosity at 40 CcSt 210 Flash Point C O C C 35 Pour Point C Stability and reactivity 10 Avoid contacts with strong acid strong bases and oxidation agents Avoid extreme heat and high energy sources...

Page 100: ... information 14 Not hazardous for the transport PAKELO HYDRAULIC EP ISO 46 Transport name Regulatory information 15 This Safety Data Sheet complies with the Regulation n 453 2010 Regulation CE n 1907 2006 REACH Regulation CE n 1272 2008 GHS CLP I ATP n 790 2009 II ATP n 86 2011 III ATP n 618 2012 IV ATP n 487 2013 Refer also to local laws Reference Laws Other information 16 Relevant H phrases H315...

Page 101: ...English language 95 Use and maintenance ENCLOSURES A ...

Page 102: ... 2008 CE 90 00 Lubricating oils petroleum C24 50 solvent extd dewaxed hydrogenated No EU 309 877 7 No CAS 101316 72 7 Asp Tox 1 H304 01 2119489969 06 90 00 Lubricating oils petroleum C 25 No EU 309 874 0 No CAS 101316 69 2 01 2119486987 11 1 50 Zinc alkyl dithiophosphate No EU 272 028 3 No CAS 68649 42 3 Skin Irrit 2 H315 Aquatic Chronic 2 H411 Eye Dam 1 H318 Please refer to section 16 for more in...

Page 103: ...tainers Spillage on ground stem spilled product with soil or sand clean up spilled product and dispose according to local regulations Spillage in water stem immediately the spillage Mechanically remove spilled product from the surface Decontamination procedures Handling and storage 7 Avoid direct contacts with the product Avoid breathing aerosol or product mist guaranteeing a suitable ventilation ...

Page 104: ...d materials to avoid Stable product in normal applications Stability 11 Toxicological information Exposure to oil vapour that exceeds Professional Inhalation Limits can cause respiratory system irritations Chronic toxicity LD50 skin rabbit 2000 mg kg estimated Frequent and continuous contacts could degrease skin and cause dermatitis Skin contact It can cause light irritation Eyes contact LD50 rats...

Page 105: ...ways H315 Causes skin irritation H318 Causes serious eye damage H319 Causes serious eye irritation H411 Toxic to aquatic life with long lasting effects The information presented in this Material Safety Sheet is based on data believed to be accurate as of the date this Material Safety Data Sheet was prepared The purpose of this data sheet is to inform and assume a correct technological use of the p...

Page 106: ...PBT or vPvB substances Other hazards Composition Information on ingredients 3 Ingredients composition No 1272 2008 CE 78 59 lubricating oils petroleum C24 50 solvent extd dewaxed hydrogenated No EU 309 877 7 No CAS 101316 72 7 01 2119489969 06 XXXX 1 19 Phosphorodithioic acid mixed O O bis 1 3 dimethylbutyl and iso Pr esters zinc Eye Dam 1 H318 Aquatic Chronic 2 H411 Skin Irrit 2 H315 No EU 283 39...

Page 107: ...gloves protecting clothes and glasses In case of indoors significant spill avoid to breathe vapours by ventilating the area or by wearing breath protecting equipment Remove possible ignition sources Person related safety precautions Avoid to disperse the product in ground into sewers and into surface waters If necessary inform local authorities Environmental precautions In case of significant spil...

Page 108: ...product Eyes protection Physical and chemical properties 9 Liquid Physical status Amber Colour Typical Odour Not applicable pH Insoluble Water Solubility 0 886 Density at 15 Ckg l 105 8 Kinematic Viscosity at 40 CcSt 215 Flash Point C O C C 34 Pour Point C Stability and reactivity 10 Avoid contacts with strong acid strong bases and oxidation agents Avoid extreme heat and high energy sources of ign...

Page 109: ...6 REACH Regulation CE n 1272 2008 GHS CLP I ATP n 790 2009 II ATP n 86 2011 III ATP n 618 2012 IV ATP n 487 2013 Refer also to local laws Reference Laws Other information 16 Relevant R and H phrases H315 Causes skin irritation H317 May cause an allergic skin reaction H318 Causes serious eye damage H319 Causes serious eye irritation H361f Suspected of damaging fertility Suspected of damaging the un...

Page 110: ...zards The substance is not regarded as hazardous according to the Directive 1272 2008 EEC Label Elements Contain Polysulfides di tert Bu Can Cause allergic reaction Reaction products of bis 4 methylpentan 2 yl dithiophosphoric acid with phosphorus oxide propylene oxide and amines C12 14 alkyl branched Can Cause allergic reaction Main risks to health environment No particular risks in normal workin...

Page 111: ...y refined base stocks blended with additive packages Chemical composition First aid measures 4 In case of exposure to high concentration of oil mist move into fresh air Seek medical attention if necessary If you suspect that there has been inhalation urgently go to hospital with the patient Inhalation Remove contaminated clothing Wash thoroughly with water and then with soap and water If symptoms ...

Page 112: ...rces and direct sun exposition Avoid to accumulate electrostatic charge Keep closed and covered the containers to avoid infiltrations of rain Maintain suitable ventilation of the work place Storage The containers contain product residues Dispose the containers in safe ecological way according to the local regulations Empty containers Exposure controls personal protection 8 Exposure borderline valu...

Page 113: ...posure to the product mist can cause irritation to the respiratory system Inhalation Ecological information 12 The product keeps afloat Mobility Not determined Degradability Not determined Accumulation In compliance with EEC Regulations the product is not regarded as hazardous to the environment Ecotoxicity LC50 acute for freshwater fish 20 200 mg L LC50 acute for freshwater invertebrates 20 200 m...

Page 114: ... Very toxic to aquatic life H411 Toxic to aquatic life with long lasting effects H412 Harmful to aquatic life with long lasting effects H413 May cause long lasting harmful effects to aquatic life The information presented in this Material Safety Sheet is based on data believed to be accurate as of the date this Material Safety Data Sheet was prepared The purpose of this data sheet is to inform and...

Page 115: ... tert butyl 4 hydroxyphenyl propanoate C7 9 alkyl esters mixed Aquatic Chronic 4 H413 No EU 406 040 9 No CAS 125643 61 0 01 0000015551 76 1 07 Reaction products of Benzeneamine N phenyl white nonene Aquatic Chronic 4 H413 No EU 253 249 4 05 2114603735 51 1 07 zinc bis O 6 methylheptyl bis O sec butyl bis dithiophosphate Aquatic Chronic 2 H411 Eye Dam 1 H318 Skin Irrit 2 H315 No EU 298 577 9 01 211...

Page 116: ...pillage stem and transfer product to suitable containers Spillage on ground stem spilled product with soil or sand clean up spilled product and dispose according to local regulations Spillage in water stem immediately the spillage Mechanically remove spilled product from the surface Decontamination procedures Handling and storage 7 Avoid direct contacts with the product Do not breathe aerosol or p...

Page 117: ...le product in normal applications Stability 11 Toxicological information Exposure to oil vapour that exceeds Professional Inhalation Limits can cause respiratory system irritations Chronic toxicity LD50 skin rabbit 2000 mg kg estimated Frequent and continuous contacts could degrease skin and cause dermatitis Skin contact It can cause light irritation Eyes contact LD50 rats 2000 mg kg estimated The...

Page 118: ...tation H318 Causes serious eye damage H319 Causes serious eye irritation H411 Toxic to aquatic life with long lasting effects H413 May cause long lasting harmful effects to aquatic life The information presented in this Material Safety Sheet is based on data believed to be accurate as of the date this Material Safety Data Sheet was prepared The purpose of this data sheet is to inform and assume a ...

Page 119: ...to good working practice avoiding to disperse the product in the environment Other hazards This product does not contain any PBT or vPvB substances Composition Information on ingredients 3 Ingredients composition No 1272 2008 CE 40 00 Residual oil crude oil refine with solvent No EU 265 101 6 No CAS 64742 01 4 01 2119488707 21 30 00 Distillate petroleum hydrotreated heavy naphthenic No EU 265 155 ...

Page 120: ...with self breathing equipment Specific protective equipment for fire fighting personnel Accidental release measures 6 Wear gloves and protective glasses In case of spillage of considerable quantities into bordering place avoid to breathe exhalations air the environment or wear protective breathing apparatus Remove any possible ignition sources Person related safety precautions The product contains...

Page 121: ...le to be in contact with the product Eyes protection Physical and chemical properties 9 Semi solid homogeneous Physical status Coppery Colour Not applicable pH Insoluble Water Solubility 0 950 Density at 15 Ckg l 220 Flash Point C O C C 2 NLGI grade 260 Dropping Point C Stability and reactivity 10 Avoid contacts with strong acid strong bases and oxidation agents Avoid extreme heat and high energy ...

Page 122: ...port name Regulatory information 15 This Safety Data Sheet complies with the Regulation n 453 2010 Regulation CE n 1907 2006 REACH Regulation CE n 1272 2008 GHS CLP I ATP n 790 2009 II ATP n 86 2011 III ATP n 618 2012 IV ATP n 487 2013 Refer also to local laws Reference Laws Other information 16 Relevant H phrases H315 Causes skin irritation H319 Causes serious eye irritation H411 Toxic to aquatic...

Page 123: ...English language 117 Use and maintenance ENCLOSURES A ...

Page 124: ...English language 118 Use and maintenance ENCLOSURES A ...

Page 125: ...English language 119 Use and maintenance ENCLOSURES A ...

Page 126: ...English language 120 Use and maintenance ENCLOSURES A ...

Page 127: ...English language 121 Use and maintenance ENCLOSURES A ...

Page 128: ...English language 122 Use and maintenance ENCLOSURES A ...

Page 129: ...English language 123 Use and maintenance ENCLOSURES A ...

Page 130: ...English language 124 Use and maintenance ENCLOSURES A ...

Page 131: ...English language 125 Use and maintenance ENCLOSURES A ...

Page 132: ...English language 126 Use and maintenance ENCLOSURES A ...

Page 133: ...50 hours of work Date of operation ______ _______ _____ Description of operation Stamp of the authorised service centre Signature of the technician Maintenance register This register is made up of different maintenance operation sheets fill out the sheets after each periodic ordinary and extraordinary maintenance carried out on the machine When the sheets have finished photocopy one or more pages ...

Page 134: ...e of operation ______ _______ _____ Description of operation Stamp of the authorised service centre Signature of the technician Maintenance sheets after 500 hours of work Date of operation ______ _______ _____ Description of operation Stamp of the authorised service centre Signature of the technician Maintenance sheets after 600 hours of work Date of operation ______ _______ _____ Description of o...

Page 135: ...e of operation ______ _______ _____ Description of operation Stamp of the authorised service centre Signature of the technician Maintenance sheets after 800 hours of work Date of operation ______ _______ _____ Description of operation Stamp of the authorised service centre Signature of the technician Maintenance sheets after 900 hours of work Date of operation ______ _______ _____ Description of o...

Page 136: ...e of operation ______ _______ _____ Description of operation Stamp of the authorised service centre Signature of the technician Maintenance sheets after 1200 hours of work Date of operation ______ _______ _____ Description of operation Stamp of the authorised service centre Signature of the technician Maintenance sheets after 1250 hours of work Date of operation ______ _______ _____ Description of...

Page 137: ...e of operation ______ _______ _____ Description of operation Stamp of the authorised service centre Signature of the technician Maintenance sheets after 1500 hours of work Date of operation ______ _______ _____ Description of operation Stamp of the authorised service centre Signature of the technician Maintenance sheets after 1600 hours of work Date of operation ______ _______ _____ Description of...

Page 138: ...e of operation ______ _______ _____ Descrizione intervento Stamp of the authorised service centre Signature of the technician Maintenance sheets after 1800 hours of work Date of operation ______ _______ _____ Description of operation Stamp of the authorised service centre Signature of the technician Maintenance sheets after 1900 hours of work Date of operation ______ _______ _____ Description of o...

Page 139: ...age 133 Use and maintenance ENCLOSURES A Maintenance sheets after 2000 hours of work Date of operation ______ _______ _____ Description of operation Stamp of the authorised service centre Signature of the technician ...

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ORTECO HD 1000, Use And Maintenance Manual, Page: 6 / 142

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Summary of Contents for HD 1000

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