International Construction Equipment BV Operating and maintenance manual Power pack INTERNATIONAL CONSTRUCTION EQUIPMENT BV Hefbrugweg 6, 1332 AN Almere The Netherlands Tel. : +31 (036 5492630 E-Mail : [email protected] Fax.: +31 (0)36 532 04 01 Internet: www ice-bv.ni 180-9001 certified companyInternational Construction Equipment BV AA rights reserved. No part of this publication may be copied or published by means of printing, photocopying, microfilm or otherwise without prior written consent of INTERNATIONAL CONSTRUCTION EQUIPMENT BV. This restriction also applies to the corresponding drawings and diagrams. INTERNATIONAL CONSTRUCTION EQUIPMENT BV has the right to change parts of the equipment at any time without prior or direct notice to the client, The contents of this publication are subject to changes without prior notice. This publication is to be used for the standard version of the equipment only. Thus INTERNATIONAL CONSTRUCTION EQUIPMENT BV cannot be held responsible for any damage resulting from the application of this publication to the version actually delivered to you. For extra information as to adjustments, maintenance and repair, please contact the technical department of your supplier. hiss publication has been written with great care. However, INTERNATIONAL CONSTRUCTION EQUIPMENT BV cannot be held responsible, either for any errors ocourring in this publication or for their consequences. IMPORTANT! Important safety instructions are marked as shown below: A CAUTION Indicates a potentially hazardous situation which, if not avoided MAY result in minor or moderate injury. A WARNING Indicates a potentially hazardous situation which, if not avoided COULD result in serious injury or even death. A DANGER Indicates an threatening hazardous situation which, if not avoided WILL result in serious injury or even death. Manual S50RFO40 ‘August 2006 Pago 2 180-9001 ceriffed companyInternational Construction Equipment BV Manual S50RFO40 August TABLE OF CONTENTS INTRODUCTION Dimensions... Specifications, DESCRIPTION AND OPERATION General. Hydraulic system (for the circuitry, refer to the parts manual) . Electrical system (for the circuitry, refer to the parts manual) SAFETY INSTRUCTIONS General. Safety precautions / instructions . Incorporated safety precautions Safety signs on the power pack... ASSEMBLY AND INSTALLATION.. Delivery of equipment... Connecting the hydraulic hoses Connecting the remote control OPERATIONS Emergency stop... a Filling the pressure and return hose. Bleedingffling the clamp hoses Control panel... Pendant remote control, cable Radio remote control (option) Starting / stopping... IQAN PLC System Button description: Main menu... Adjustement / Settings. Adjust pump flow. Troubleshooting CLEANING & MAINTENANCE... General New or stored power packs Service intervals Draining and fi Capac Liquids . Welding ig the hydraulic oil reservoir... 2006 Pages 180-9001 cortiied companyInternational Construction Eq 7 PREFACE This owner's manual has been written for the users of ICE Power packs. The owner's manual explains how to use, service and inspect the power pack, with the intention to use the power pack safe and efficiently. ‘One copy of the present manual should at any time be at the location where the unit is in operation. When the instructions of this owner's manual are not strictly followed, accidents may happen. ‘Therefore, make sure you understand all the instructions in this manual before you start using the power pack. For ordering of parts we refer to the parts manual of the relating power pack. For the operation of the machine which is attached to the power pack, we refer to the ‘owner's manual of the relating manufacturer. If operational or maintenance problems arise which are beyond the scope of this manual, please contact ICE at the telephone number on this page. We are prepared to assist you in order to make the best use of your equipment. Ifyou call, please have the following at hand model Equipment serial number \L CONSTRUCTION Et NT BV Hefbrugweg 6 (De vaart), 1332 AN Almere The Netherlands Tel. #34 (0)36 549 26 30 Fax. #31 (0)36 532.0401 E-Mail [email protected] Intemet www.ice-bv.nl Manual 5602040 ‘August 2006, Page 4 180.9001 cortfed companyInternational Construction Equipment BV 1. INTRODUCTION The power pack can be used for the following purposes: 1. To drive an (ICE) vibratory hammer 2. To drive an auger, impact hammer, cutter, winch or shear 3. To drive a sand pump 1.1 Dimensions =. g @ @ | 4 4500 740 1.2 Specifications Diesel engine Caterpillar C15 acert Max. theoretical power 403/548 kWIPK (DIN) Max. Frequency 2100 rpm Max. Working pressure 350. bar Hydraulic pump Rexroth A11VLO260/60 Max. oil flow 650. Lmin Diesel oil 650 L Hydraulic oil 1200 L. Weight 7600 kg Manual S50RFO40 Fe ‘August 2006, —— Pege 5 180-9001 certited companyInternational Construction Eq ao a DESCRIPTION AND OPERATION we ‘The 550RF power pack is powered by a CATERPILLAR C15 acert engine. The engine develops 548 horsepower (403 kW) and is mounted on a tubular sub-base which serves as a fuel tank, 2.1 General ‘The power unit and the driven machine are operated from the control panel or remote control pendant. The standard remote control pendant is connected by cable. ICE can provide a wireless pendent as an option. Hydraulic oll is stored in the reservoir. Oil cooling is accomplished by two air-to-oil exchangers. Alll of the above components are contained in a sheet metal enclosure with lockable doors. 2.2 Hydraulic system (for the circuitry, refer to the parts manual) ‘The hydraulic circuitry of the ICE power pack is a so-called open-loop system. This means that the oil is taken from a reservoir. The pressure in the retum line is very low. Each power pack is equipped with several pumps. The main pump drives the vibratory hammer. The secondary pump can be used to open/close a clamp and to adjust the centrifugal force of a RF vibratory hammer. The main pump, When the diesel engine is running and the forward/start button is activated, hydraulic fluid is taken from the reservoir by the drive pump and is pumped to the drive manifold. ‘The oil is directed through the hoses to the driven machine (vibratory hammer). It flows back to the power pack through the return line. The circuit is protected by means of a pressure relief valve and is provided with a return line filter. The hydraulic hoses can be quickly disconnected at the power pack directly behind the manifold, ‘The secondary pump When the diesel engine is running, and the clamp or RF actuator buttons are activated, hydraulic fluid is taken from the reservoir by the secondary pump and pumped directly to the mentioned hydraulic parts. It flows back to the power pack through the return line. ss ‘Menual 550RFO40 Pages ——— = ‘August 2006 180-9004 certified companyInternational Construction Equipment BV haw WZ 2.3 Electrical system (for the circuitry, refer to the parts manual) ‘The power pack contains a 24V DC electrical installation. Ail main hammer functions are electrically controlled either from the remote control or from the main control panel The power pack is equipped with a control module, which will warn the operator in the following cases: Hydraulic oil temperature too high. Hydraulic oil level too low. Engine coolant temperature too high. Engine coolant level too low. Engine Over speed. ‘* Engine lubrication oil pressure too low. If necessary, the Power Pack will stop the main cil flow automatically The power pack is also equipped with the following safety measures: Emergency stop. (Skid, radio remote, cable remote) Safety switch on the butterfly valve. If the oil supply to the main oil pump has been shut off by means of the butterfly valve, the engine can not be started. Optional warning * Warm up active. Manual S50RFO40 it = ‘August 2006 = Page 7 180.9004 certified companyInternational Construction Equipment BV as ha 3. SAFETY INSTRUCTIONS we 3.1 General Power packs contain components which are under high pressure during operation. Some ‘components get very hot, other components have rotating parts which can cause serious injuries. ‘Therefore pay special attention to this chapter and the operation and maintenance section in this manual. REMARK: Regular maintenance and skilful operation will not only lengthen the mechanical life, but is essential for the safety of the user and possible bystanders. ICE accepts no liability for any damage or physical injury caused by non-compliance with the safety instructions in this manual or by carelessness during the installation, use, adjustment ‘or maintenance of the equipment. Safety is basically common sense. There are no standard safety rules, because each situation is different, and can therefore not always be covered by rules. Therefore, your experience and common sense will be your best guide with regard to safety. 3.2 Safety precautions / instructions Itis the responsibilty of the user or operator to ensure that the local health and safety regulations are observed before and during the use of the equipment. Operators * Only trained employees should be permitted to operate the machine. ‘+ Temporary employees and trainees should only be permitted to work with the ‘equipment under the supervision and instruction of trained personnel. Owner's manual «Everyone who works at or with the equipment should be familiar with the contents of this manual and the manuals of the machines which are driven by the power pack and should follow the instructions accurately. * One copy of the present manual should at any time be at the location where the unit is in operation. ‘+The management is under obligation to inform the personnel of the contents of this manual and is obliged to observe all of the regulations and directions. + Additional manuals are available on request. Clothing and footwear + When working with the equipment, DO NOT wear watches, jewellery or any loose clothing which could be caught in moving or rotating pars. * Always wear protective goggles, a safety helmet, protective footwear and hearing protection specially suited for the work. + Keep hands away from moving or rotating parts. Wear working gloves. + Take appropriate measures for the protection of hearing if the sound level of 85 dB(A) is exceeded; always use ear protection when working close to a ‘machine in operation. Manual S50RFO40 ‘August 2006 Pages 180.9004 cetied companyInternational Construction Equipment BV 7 Water and moisture + Make sure all protective devices of the electric installation have been installed to guarantee adequate protection from moisture and water. Failure to do so can result in malfunction of safety circuits and cause harm to personnel and ‘equipment components, + NEVER direct a jet of water at electrical parts. Fire or explosion prevention Hydraulic oil and diesel fuel are flammable. Therefore: Do not weld or flame-cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with non-flammable solvent before welding or flame cutting on them. * Clean and tighten all electrical connections. Check regularly for loose or frayed electrical wires. Wiring must be kept in good condition, properly routed and firmly attached. Routinely inspect wiring for wear or deterioration. Loose, unattached, or unnecessary wiring must be eliminated. A WARNING Never smoke when filling the fuel tank or use flames in the vicinity. Never store flammable liquids near the engine. Work area * Place the power pack in a safe and “watch-friendly” place. * Keep the work area clean. Keep the equipment accessible and make sure that the area surrounding of the equipment is kept clean * Always be extremely careful when using a carbon tetrachloride fire extinguisher in a closed area, as it produces toxic vapour. ALWAYS ‘* lead exhaust fumes outside when operating in a closed area. Continued breathing-in of exhaust fumes may be fatal = pay attention to irregular or unusual noises and analyse where they come from. * remove all tools and electrical cords before starting the power pack. * warn colleagues when you feel uncomfortable with the way the power pack or the driven machine is functioning. NEVER * make adjustments or repairs while the engine is working. * continue operation when service inspection is due, or when a repair is necessary, * continue operation when it is known that one of the safety provisions is out of order or not working properly. + Leave the remote control pendant unattended + Attempt to connect the quick-disconnect couplers when the engine is running, Tools * Never use defective (maintenance) tools. * Only use a tool for the purpose it was designed for. Manual S50RFO4O ‘August 2006 180-9001 cortited company PegeoInternational Construction Eq we Technical specifications The permissible tolerances as mentioned in the present manual should NOT be exceeded. Safeguards * All safeguards must be correctly installed and may only be removed for maintenance and service purposes by qualified ICE service engineers. * The equipment should never be switched ON when the protective covering is incomplete or when the safeguards have been rendered inoperative, * All safeguards must be checked at regular intervals and repaired immediately in case of malfunction Safety directions and warnings © Any safety direction, warning or instruction fitted on the equipment should NOT be removed, rendered illegible or covered. They should be present and legible throughout the entire operating life of the equipment. * llegible, damaged or covered safety directions, warnings or instructions should immediately be replaced or repaired, Service and maintenance The service and maintenance activities should only be carried out by qualified ICE personnel or one of ICE’s appointed and certified dealers or its endorses in full compliance with all safety measures and service intervals. © Use original ICE Parts and liquids. Electrical system ‘* Work on the electrical system or equipment may only be carried out by skilled electricians or by specially instructed personnel under the supervision of such electricians and in accordance with the applicable electrical engineering rules. Hydraulic system * Work on the hydraulic equipment may only be carried out by persons having special knowledge and experience in hydraulic systems. ‘+ When bleeding hoses or looking for leaks, take protective measures. Escaping oil under pressure, even a pin-hole size leak, can penetrate body tissue, causing serious injury or possible death Use according to purpose In order to guarantee correct operation, the equipment should only be used in accordance with the purpose as described in this owner's manual. Manual 550040 “August 2008 Page 10 —S== 180.9004 certified companyInternational Construction Equipment BV 3.3 Incorporated safety precautions In case a vibratory hammer is used in combination with the power pack, a number of safety provisions are built-in. These safety provisions ensure that the risk for failures, human injuries and environmental pollution is reduced to a minimum: + Dual operating functions, either by hand-held pendant or on the control box in the power pack + Return line, although virtually not under pressure, is in pressure mode, preventing hose bursts when the quick disconnect coupling is not tightened properly or out of order. ‘+ Emergency stop on hand-held pendant. ‘+ Emergency stop on radio remote control .(with a 5 second delay) Emergency stop on outer side of the power pack. Z\ warNine Never change the electrical wiring or hydraulic safety setting, which changes the above safety provisions. In most countries the hammer and power pack are not allowed to operate in explosion-risk areas without modifications. Always contact ICE when special Tequirements are compulsory. Manus! S50RFO40 per os papal 2006 = Page 180-9001 certfled companyInternational Construction Equipment BV @ CS 3.4 Safety signs on the power pack HAZARD DESCRIPTION HOW TO PREVENT ‘THE SURFACE CAN BE HOT DO NOT TOUGH. ALLOW THE SURFACE TO COOL DOWN EXPLOSION RISK | KEEP AWAY FROM FIRE COMPONENT IS PRESSURIZED DEPRESSURIZE BEFORE MAINTENANCE RISK FOR IMBALANCE ‘SLIPPERY SURFACE USE ADEQUATE CLIMBING DEVICE RISK FOR SHORT CIRCUIT DISCONNECT POWER SOURCE BEFORE OPENING DASHBOARD HIGH NOISE LEVEL USE EAR PROTECTION RISK OF BURNS TO FINGERS OR HANDS RESULTING FROM DANGEROUS LIQUIDS OR CHEMICALS WEAR PROTECTIVE GLOVES FIRE RISK KEEP MACHINE CLEAR OF OIL RESTS BE CAREFUL WHEN HANDLING FUEL AND HYDRAULIC OIL Page 12 180.9001 cot ZS Manuel S50RFO40 ‘August 2006 ied companyInternational Construction Equipment BV 4, ASSEMBLY AND INSTALLATION 4.1 Delivery of equipment ‘Make a thorough inspection of the unit immediately after delivery. In case of any damage or shortage notify the transit agent at once and have the delivery carrier make a remark on the freight bill A WARNING Always lft the power pack by its own lifting lugs. Use certified slings and place the power pack on a horizontal and stable ground (surface). 4.2 Connecting the hydraulic hoses A CAUTION Never connect or disconnect the hoses while the engine is still running, Make sure the connectors are not under pressure. Clean the couplers with a lint-free cloth. Check the couplers and hoses for any damage. Connect the hoses with the help of quick-disconnect couplers. Avoid kinking and chafing. The couplers are sized to ensure correct connection. ‘+ Make sure the couplers are FULLY tightened, The drive pressure coupler (1) and drive return coupler (2) can be tightened with a chain-wrench, the others should be tightened by hand. 1. Drive pressure hose 6. Drain hose 9. Cooler in 2. Drive return hose 6 Drain hose 10. Cooler out 3. Clamp hose (close) 7. Eccentric mom. + 11. Pendant remote control connector 4, Clamp hose (open) 8._Eccentric mom. - Manual S50RFO40 ‘August 2006 —— = Page 13 180-9001 certified companyInternational Construction Equipment BV 4.3 Connecting the remote control Connect the cable plug to the control panel of the power pack (see illustration, item A). When the pendant control cable is: connected The hammer can only be activated by means of the pendant control. disconnected: The hammer can only be activated by means of the control module at the control panel, or radio remote control. REMARK ‘The EMERGENCY STOP on the power pack housing is always operational ‘The EMERGENCY STOP on the pendant remote control and radio remote control are operational only when they are connected eae cee ee Manual S50RFO40 Page 14 55 “August 2006 180.9001 certified companyInternational Construction Equipment BV 5, OPERATIONS A WARNING Make sure you are familiar with the SAFETY INSTRUCTIONS as described in chapter 3 before you operate the power pack. Make sure the operator has a clear view on the working area and the machine which is driven by the power pack Make sure that communication with other involved persons (crane driver) is always possible. 5.1 Emergency stop Check if the emergency stop buttons on the remote control pendant / radio remote control and the outside of the power pack are released. If not, turn the button clockwise. IMPORTANT! Always reset the emergency stop button immediately after the hammer and power pack have been shut down completely. 5.2 Filling the pressure and return hose When the driven machine is shipped with all hoses attached, the hoses are usually full of oil and may be used immediately. However, if any of the hoses are connected at the jobsite or if air is present in hoses, they must be bled prior to operation ‘* Start and warm up the engine (read chapter "Starting the engine” on page 21). Keep the engine running at 1500 rpm. Press the forward button for appr. 2 seconds and than stop, to build up some pressure without running the machine(vibratory hammer). Do this 2 or 3 times and the hoses are filled. * Check the oil level in the hydraulic oil tank. Refill if necessary. 5.3 Bleeding/filling the clamp hoses ‘When the vibrator and hydraulic clamp are shipped with all hoses attached, the hoses are usually full of oil and may be used immediately. However, if the clamp hoses are connected at the jobsite or if air is present in hoses, they must be bled prior to operation. + Start and warm up the engine (read chapter “Starting the engine” on page 21,). ‘+ Tum the clamp switch (OPEN/CLOSE) on the remote control to the position ‘OPEN. The pressure in the clamp hoses will go down to almost zero. ‘+ Shut down the engine (read chapter “Stopping the engine” on page 23.). Manual S50RFO40 a ‘August 2006 [SS - 180-9004 certified comoany Page 15International Construction Equipment BV A CAUTION When bleeding hoses or looking for leaks, take protective measures. Escaping oil under pressure, even a pin-hole size leak, can penetrate body tissue, causing serious injury or possible death. * Loosen the clamp-close-connector a little bit at the clamp (with a tray under the connector). + Start and warm up the engine (read chapter “Starting the engine" on page 21) * Tum the clamp switch (OPEN/CLOSE) on the remote control to the position CLOSE. Wait until fluid flows without any traces of air, then tighten the connector. Repeat the above instruction for the clamp-open-connector. ‘Tum the clamp switch to CLOSE and OPEN several times to ensure the clamp cylinder is working properly. 7 ee - Manual S50RFO4O Paste ———— "Nagel 2008 180.9001 corttied companyInternational Construction Equipment BV vibratory hammer, the clamp and the power pack. 5.4 Control panel The control panel contains a control module from which the operator can control the A CAUTION Make sure the operator has a clear view on the connected machine(s) and the working area, IMPORTANT: The operation / maintenance / safety instructions on the inside of the control panel door merely serve as reminders. They are not complete and therefore not intended as a substitute for a thorough understanding of the present manual. IQAN PLC control IQAN PLC module Remote control battery charger (option) Remote control battery charging adapter (option) Start switch Remote control connector omeens Manual SSORFO4O August 2006 180.9004 certified company Page 17International Construction Equipment BV 5.5 Pendant remote control, cable Connect the cable plug (A) to the control panel of the power pack. Release the emergency stop. When the pendant control cable is: connected: The hammer can only be activated by means of the pendant control. disconnected : The hammer can only be activated by means of the switches/buttons at the control panel, or the radio remote control. ‘The remote contro! pendant contains the following functions: Emergeney stop Clamp open / close Warning lamp: clamp closed Start operation Stop operation Eccentric moment switch RPM switch NoOwpens Manual S50RFO40 ‘August 2008 Page 18 180.9001 cortiod companyInternational Construction Equipment BV 5.6 Radio remote control (option) Connect the cable plug (A) of the receiver (B) to the control panel of the power pack. To turn on the radio remote contr: Make sure the emergency stop is pulled out, The following steps must_be taken in a few seconds. Step 1. Press the no. 1) button, Red led starts flickering Step 2. 2 Press the no.’ ‘button. Green led up once, + Sie03. Press the no. button. Green led starts flickering. Remote control is ready for use. Manual SSORFO40 oe ‘August 2006 = 180.9001 certified company Page 18The remote control pendant contains the following functions: Emergency stop International Construction Equipment BV Clamp open Clamp close Start operation ‘Stop operation Eccentric moment - Eccentric moment + Remote start Remote stop switch switch RPM - RPM + Manual S50R040 Page 20 ‘August 2008 180-9001 certified companyInternational Construction Equipment BV 5.7 Starting / stopping @) arth switch ©) IQAN PLC control @) start switch ©) Remote control 4. Tum earth switch ((A)) to “ON” position. (clockwise) 2. Turn on remote control Make sure the emergency stop is not switched on. The following steps must_be taken in a few seconds. step 1. Press the no.\*) button, Red led starts flickering #Step2. Press the no. 2) button. Green led up once. + ste03. Press the no. \37 button, Green led starts flickering. Remote control is ready for use. Manus S50RFO40 ‘August 2006 Page 21 180-9001 certified companynal Construction Equipment BV 3. Tum start switch ((B)) to “I ‘position The “WAIT" screen Will popup. 4. After a few seconds the “: * sign will popup. Sey Page 22 === 180-9004 certified company ‘Manual 5508040 ‘August 2006Stopping ‘© Stop operation * Allow the engine to run at idle speed for at least § min. + Tum start switch ((@)) to “O" (OFF) «Tum earth switch (1) to “OFF”. nal Construction Equipment BV * Tum off the radio remote control (stop button). 2 AN 2 CAUTION a Vibrator may fall off pile. If the diesel engine is shut down while the vibrator is clamped to apile, the clamp check valve will keep the vibrator clamped to the pile. However, system leakage could result in a loss of clamp pressure over time. Therefore, it is not recommended to leave the vibrator clamped to a pile when the diesel engine is not ore 5.8 IQAN PLC System This power pack is provided with an IQAN PLC system. All controls, settings, parameters, etc. are set and can be read out of the display. The advantage with respect to the EMS system, it requires much less electronics, no more pressure gauges, hydraulic settings can be changed easily, it’s all in one. ta Remote Control Active ‘Manual S50RFO40 ‘August 2006 = - 180.9004 certified company Page 23nal Construction Equipment BV 5.8.1 Button descriptions Remote Control Active Press (a) ICE info. Press @) for engine parameters. Press © for hydraulic parameters. Press (D) for internal light. Press (=) for main menu Press &) to enter. Tum @) to scroll Press &) for previous screen. Page 24 130-9001 certified company Manual S50RFO40 ‘August 2006International Construction Equipment BV @ TF, 5.8.2 Main menu Press (=) to enter the main menu, ¢ Adjust Measure Preferences Press(rt) for adjust menu Press @) for measure. Press(F3) to adjust preferences. Press(ra) for machine information. Press (34) t0 enter. Turn (9) to scroll. Press) for previous screen. ‘Manual S50RFO40 ‘August 2006 ———— Page 25 180-9001 cotified companyInternational Construction Equipment BV 5.8.3 Go to main menu |=) and select adjust @ low selection |control Settings lengine Setting lPump Settings lecc Settings [clamp Settings The following settings are adjustable: Pump flow ‘Accessible. Control setting ICE qualified personnel only. | Pump setting ICE qualified personnel only. Sensor setting ICE qualified personnel only. Engine setting ICE qualified personnel ont Maintenance reset ICE qualified personnel only. Lube oil cooler Option Warm - up system Option Flow sélection (key switch) Option. Pump flow is accessible, for the rest of the settings you need to contact ICE, or your nearest, ICE dealer. Page 26 180.9004 certied company Adjustement / Settingswe 5.8.4 Adjust pump flow With this setting you can choose to drive your machine at normal operation or full power operation. For example: 36RFs at normal operation 2000 rpm 36RFts at full power operation 2300 rpm Other speed settings are possible on request. nal Construction Equipment BV Go to main menu | =) and select adjust (*) Scroll trough the menu by turning the &) button. Enter pump flow by pressing () Value power operation| flow setting Manual S50RFO40 E ‘August 2006 = a 180-9004 certified company Page 27& wi c i. 3 & a g 3 ° 3 & 3 3 & 2 = @ e Enter flow setting by pressing the() button Choose NORMAL OPERATION or FULL POWER OPERATION by turning the (q0)button Enter the setting by pressing the ) button, Manual S50RFO40 ‘August 2006 Page 28 180-9004 certified companyInternational Construction Equipment BV 5.9 Troubleshooting It can not be emphasized enough that most difficulties can be prevented by good periodic inspection, lubrication and maintenance. The time and energy consumed in proper care is only a fraction of that incurred when trouble stops operation. If the difficulty cannot be corrected, contact your local ICE service location. For difficulties which involve the hammer or the clamp, we refer to the relating owner's manuals. Engine does not start * Check if the IQAN PLC display shows a message. Remedy the cause if necessary. + Ifthe engine does not tum over, check the battery and check if the connectors of the battery are fully tightened. If the engine tums over, check the fuel supply and the fuel filter. Consult the Caterpillar Operation & Maintenance Manual. * Call your local Caterpillar dealer. Engine does not stop If there is an emergency, push the emergency stop button. Check the electrical components and connections. Menusl S50RFO40 a — as ‘August 2006 ——$—————SSSS———————— Page 28 180-9001 cortfied company= ao 6. CLEANING & MAINTENANCE QS? 6.1 General Preventive maintenance includes normal servicing that will keep the power pack in good operating condition and will prevent unnecessary trouble. Lubrication is an essential part of the protective maintenance, therefore it is important to follow-up the instructions carefully. A CAUTION Regularly maintenance will not only increase the life span and the output of the power pack, but is essential for the safety of the user and possible bystanders, Before starting the maintenance, make sure the machine has cooled down and the working area is safe and clean. Install a DO NOT OPERATE or similar warning label to the ignition switch, ‘Tum off the mass switch prior to maintenance work on the electrical system. IMPORTANT! ‘© Thoroughly clean all fittings, caps, filler plugs and level plugs and their ‘surrounding surfaces before servicing. Prevent dirt from entering lubricants and coolants. Except for the visual inspections, all maintenance work shall be carried out with the diesel engine stopped. Take care that the earth switch is in the “OFF” position. 6.2 New or stored power packs For new or stored power packs, refer to the diesel engine Operation’s Manual (section “Preparation for Starting Engine, First Time"). Manual S50RFO40 ‘August 2006 Page 20 180.9001 certified companye Every 250 Service hours, the MAINTENANCE WARNING SIGN will appear on the display. 6.3 Service intervals Contact ICE or your nearest ICE dealer for a service appointment or more information| For more detailed information regarding the engine, refer to the “Operation and maintenance manual” of the Caterpillar C15 engine. Daily maintenance Before start up: Engine: * Check the coolant level in the radiator (engine should be cooled down). * Check the air filter service indicator. * Check the engine oil level. Inspect the water separator of the Fuel filter. Drain if necessary. * Check for leaks and loose connections. * Check the fuel level. Other components: Clean the bottom plate of the power pack Inspect hydraulic system for leaks. Visually check all couplers and hoses for signs of damage or cuts. Make sure all connections are tightened fully, especially the quick-disconnect couplers. * Check the oil level of the hydraulic tank on the level gauge. (should be in between min. and max. indication). After start up: * Check hoses for leaks. Make sure they hang freely with no kinks. * Check the pump, hydraulic manifolds and fittings for leaks. © Check the return filter service indicator. Every 250 Service hours / 6 months Engin * Check on the hour counter (IQAN) if the engine is due for a service interval (besides the 250 hours service interval). ‘* For detailed information about inspection and maintenance, refer to the diese! engine “Operation & maintenance manual’. Other components * Visually check the condition (dirt) of the oil cooler and the radiator. Clean when necessary. + Grease the door hinges Manual S50RFO40 ‘August 2006 Page 31 180-9001 certified companyInternational Construction Equipment BV @ VIF Engine: * Refer to the diesel engine “Operation & maintenance manual’, Other components: © Have the hydraulic fluid analysed by a local hydraulic service centre. Replace fluid if required. + Have the hydraulic system inspected by IGE (authorized) service personnel The intervals are based on normal operation. Perform these services more often as needed for operation under abnormal or severe circumstances. Severe conditions The intervals specified are based on normal operating conditions. Operating under severe or unusual conditions will require some adjustments in service intervals. In the following circumstances, the service time intervals should be reduced by one-half of those specified. ‘when the average temperature is above 35°C (80°F) or below -23°C (-10°F) © when operating in the presence of dust or sand © when operating in excess of twelve hours per day When operating in air with high salt or moisture, the service intervals do not need to be changed. However, the unit should be inspected weekly to determine if additional servicing is required. Also, have the hydraulic oil tested quarterly, For extended inactive periods, the engine should be started at least once a week and run until thoroughly warm. Service intervals may be extended from those specified. For stored power packs, refer to the diesel engine Operation's Manual (section "Preparation for Starting Engine, First Time’). 6.4 Draining and filling the hydraulic oil reservoir ‘The Hydraulic reservoir is drained by removing a plug on the bottom of the of the reservoir. ‘The hydraulic reservoir is filled by the manual pump mounted on the back (engine side) of the reservoir. All oil is pumped to the reservoir through the return filter to insure no dirt enters the hydraulic system. 6.5 Capacities | Refill Capacity engine oil +32L| Capacity hydraulic oil tank | 1200 L| s Manuel SSORFOe0 Page 32 >> “August 2008 180.9001 cerified companyInternational Construction Equipment BV we 6.6 Liquids NORMAL CIRCUMSTANCES (-23°C to 35°C) (-10°F to 80°F): Diesel engine oil | Mobil Delvac MX 15W-40 Hydraulic fluid _| Mobil DTE15M_ eee Coolant Mono Ethylene Glycol (1:1 mixture with water) Cat inhibitor 3% ‘SEVERE CIRCUMSTANCES: ‘* Engine: refer to the ‘Operation and maintenance manual” of the Caterpillar C15 engine, + Hydraulic system: contact your local specialist 6.7 Welding Do not weld or flame-cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with non-flammable solvent before welding or flame cutting on them. Proper welding procedures are necessary in order to avoid damage to the engine’s computer, sensors and associated components. When possible, remove the component from the unit and then weld the component. If this is not possible, follow the instructions below: * Stop the engine. Tum the ignition switch to the “OFF” position. * Disconnect the negative battery cable from the battery. * Disconnect the connectors from the Engine Control Module. Move the harness to a position that will not allow the harness to accidentally move back and make contact with any of the ECM pins. Disconnect the connectors from the IAN PLC in the control panel. Connect the welding ground cable directly to the part that will be welded Place the ground cable as close as possible to the weld Protect the wiring hamess from welding debris and spatter. Use standard welding practices to weld the materials. DISCONNECT Manual S50RFO4O ‘August 2006 Page 93 180-9001 certified company‘Ag quewidinby uoRonysuog jeuo}eUIe}uI