Table of contents - Vibrator MRZV-VV

1 Intended use ............................................................................................... 3

2 Description .................................................................................................. 7

3 Commissioning and operation .................................................................. 9

3.1 Commissioning ....................................................................................................................... 9
3.2 Control .................................................................................................................................. 12
3.2.1 Clamping ..................................................................................................................... 13
3.2.2 Display......................................................................................................................... 13

4 Operation................................................................................................... 15
4.1 General safety instructions ................................................................................................... 15
4.2 Safety instructions and restrictions ....................................................................................... 16
4.2.1 Dangers and risks ....................................................................................................... 16
4.2.2 Danger area ................................................................................................................ 17
4.2.3 Operational restrictions ............................................................................................... 21
4.2.4 Emergency stop device ............................................................................................... 21
4.2.5 Personal protection equipment.................................................................................... 23
4.3 Working with the MRZV-VV .................................................................................................. 24
4.3.1 Attaching and Securing Piles....................................................................................... 25
4.3.1.1 Pitching chains / Chain supports - general ..................................................... 25
4.3.1.2 Pitching chains 1,6 t / 3,15 t ............................................................................ 41
4.3.1.3 Pitching chains 2,3 t / 5,0 t .............................................................................. 54
4.3.2 Driving in piles ............................................................................................................. 67
4.3.3 Extracting piles ............................................................................................................ 78
4.3.4 Driving on the construction site ................................................................................... 88
4.3.5 Mounting jaw assembly .............................................................................................. 89
4.4 Transport ............................................................................................................................... 91
4.4.1 Placing and securing the vibrator on the transport frame............................................ 91
4.4.2 Laying down the vibrator ............................................................................................. 93
4.4.3 Raising vibrator ........................................................................................................... 94
4.4.4 Release pitching chains between vibrator and transport frame .................................. 95

5 Maintenance and service ......................................................................... 97

5.1 Regular maintenance work - summary ............................................................................... 100
5.2 Oil change and verification ................................................................................................. 102
5.3 Slide rails and guides .......................................................................................................... 108
5.4 Jaw assembly ..................................................................................................................... 110
5.4.1 Jaw assembly type I .................................................................................................. 110
5.4.2 Jaw assembly type II ................................................................................................. 112
5.5 Filter cartridge control block ...................................................................................................... 115
5.6 Filter cartridges cooling circuit ............................................................................................ 117
5.6.1 Filter cartridge circulation pump (option) ................................................................... 117
5.6.2 Filter cartridge oil cooling .......................................................................................... 117
5.7 Rotating union ..................................................................................................................... 119
5.8 Elastomer mounts ............................................................................................................... 121

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Vibrator MRZV-VV

6 Operational faults and trouble shooting .............................................. 123

6.1 Hydraulic control system ..................................................................................................... 123
6.1.1 Vibrator ...................................................................................................................... 123
6.1.2 Jaw assembly ............................................................................................................ 123
6.2 Electronic control system .................................................................................................... 124
6.3 Table of malfunctions .......................................................................................................... 125

7 Technical Data ........................................................................................ 127

7.1 Data sheet .......................................................................................................................... 127
7.2 Operating and transport dimensions ................................................................................... 128
7.3 Type plate ........................................................................................................................... 129
7.4 Life span ............................................................................................................................. 130
7.4.1 Storage of the vibrator ............................................................................................... 130
7.5 Information card - Pitching chains ...................................................................................... 131

Index ........................................................................................................... 133

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1 Intended use

The ABI pile-driving and extracting vibrator MRZV-VV is an interchangeable piece of equipment to
be used with the ABI MOBILRAM-System and is used exclusively as an attachment to drive-in and
extract suitable piles in displaceable or soft cohesive soil layers using vibration.

The machine and attachments are intended for use in the commercial sector and may only be ope-
rated by authorized, qualified and instructed personnel. The equipment must always be operated by
two persons. The machine can be operated in a temperature range between - 20 °C up to + 40 °C.
Consult the manufacturer when working outside of the mentioned temperature range. The operation of
the machine and attachments is not provided within enclosed spaces and areas subject to explosion
hazards.

In principle ABI vibrators are not designed for working processes under water. In permanent operation
and high duty cycles (50% and more of the normal duty cycle) special precautions have to be taken
because of the higher thermal loads. Due to the system process, oscillation energy is introduced into
the subsurface during the shoring process. Vibrations can lead to subsidence of soil and damage to
structures.

The machine has been built in accordance with state-of-the-art standards and the recognized safety
rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or
cause damage to the machine and to other material property.

Caution
The machine must only be used in technically perfect condition in accordance with its desi-
gnated use and the instructions set out in the operating manual, and only be safety conscious
persons who are fully aware of the risks involved in operating the machine. Any functional
disorders, especially those affecting the safety of the machine, should therefore be rectified
immediately.

The observance of the operating, maintenance and service instructions is also part of the intended
use. Failure to comply with the operating and working instructions may result in severe injuries of
persons or even fatal accidents. The manufacturer may not be held liable for non-intended use. All
risks lie with the user. The interchangeable equipment is designed and constructed for the use indi-
cated and described in the operator's manual only. Any other use of the machine without the written
consent of the manufacturer is considered as non-intended use.

The operating and maintenance personal have to receive a comprehensive introduction by ABI or a
specialist appointed by ABI prior to starting the equipment. In cases of operating errors, insufficient
servicing or maintenance, overstressing as well as improper use of the machine, no warranty claims
may be asserted.

We expressly remind you that original spare parts and accessories that are not provided by us or not
checked and released by us should not be used. The installation and/or use of such products may
affect the safety and any warranty. The manufacturer may not be held liable for the use of non-original
spare parts and accessories.

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Vibrator MRZV-VV

The machine has to be examined by a competent person at least once a year or after special incident.
On any such occasions the technical condition of the machine has to be checked for operational safety
and thoroughly inspected for damage. The results of any inspection have to be documented and re-
corded at least until the next inspection. The competent person inspecting the machine is responsible
for the immediate elimination of any defects prior to any further operational use.

The national regulations in force in each user’s country for drilling/piling units as well as the environ-
mental protection regulations must be observed. For Germany these are, among others, the Occu-
pational Safety Regulation for safety and health in the workplace in special foundation construction
DGUV 101-008.

During the selection and implementation of the shoring method take into account the necessary
information and specifications regarding the building project, e.g. the ground survey, project plans,
conditions on the construction site and the environmental conditions, also the machine parameters e.g.
load capacity, ground pressure, dimensions and forces, as well as the relevant codes and standards.

Essential parameters for the driving of piles are:

• Grain shape, grain shape size and grain size distribution or uniformity coefficient
• Inclusions like stones, foundations or organic materials
• Water content
• Stratification
• Soil displacement

Higher geological demands lead to increased wear or damage to the machine. The pile-driving pro-
gress may vary depending on the soil conditions, pile-driving method, size of the piles, etc.

Loose soils with a round grain shape and slightly cohesive or soft pulpy soils with low plasticity are
particularly appropriate. Mixed soils and cohesive soils are appropriate only if their water content is
sufficient for vibration pile driving. Vibration pile driving is based on displacement processes in the soil.
Soil settlement may occur if the duration of insertion is prolonged. If the subsoil is heavily compacted
the resistance to insertion may increase such that the following adjacent pile sections may not be
driven to the depth of the first section. If working near existing buildings check to what extent these
could be damaged through soil settlement. When a continuous pile-driving progress of app. 10 cm/
min cannot be maintained or when experiencing pulsed loads, e.g. the vibrator is jumping or recoiling
the pile driving must be stopped. Introduce ground release predrilling or jet with pressurized water.

Conditionally suitable are soils that are not displaceable and cannot be rearranged, such as:
• Gravels and sands with angular grain shape
• Dry cohesive soils (such as marl or clay)
• Fine sand
• Soils with closely graded grain distribution
• Frozen soils

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The number of blows in heavy dynamic probing according to DIN EN ISO 22476-2 - Geotechnical
investigation and testing - Field testing.

Number of blows N10 ≤ 20 - pile driving possible without problems.

Number of blows 20 ≤ N10 ≤ 25 - pile driving possible under certain circumstances, supporting mea-
sures for pile driving might be required.
Number of blows 25 ≤ N10 ≤ 35 - predrilling recommended.

Vibro stone column processes significantly impact both the machine and the vibrator compared to
standard applications such as steel sheet piling, for example through continuous operation, more
frequent load changes, unusually a higher centre of gravity and bending of the impact mandrel through
possible evasive movement. Therefore it may be necessary, during such applications, to reduce indi-
vidual parameters (load, pre-stressing and extraction forces) compared with the specifications in the
brochures, as well as taking special measures, e.g. special carriages, pile guides or turning the jaw
assembly 90° if necessary. Even if such applications are coordinated and agreed with ABI, increased
wear and a reduction of the operating life can occur.

Other working processes are possible, but have to be coordinated and agreed in each case with ABI.

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Vibrator MRZV-VV

MRZV-VV

2 10, 11

2
8
10, 11
8
1

13 1

3
12
13
4
8 12 3
8 4

9
5
9
5

6
6

14

1 Hydraulic motor - adjustable 8 Vibrator guide

2 Guiding carriage 9 Gear box
3 Hydraulic motor 10 Valve block
4 Vibrator hood 11 Oil filter
5 Jaw assembly 12 Limit stop
6 Clamping cylinder 13 Rotating union
7 Pitching chain 14 Chain support with fittings

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2 Description

Vibrator MRZV-VV

The ABI vibrator MRZV-VV is equipped with at the same speed but with opposite directions of
adjustable static moment and an adjustable hy- rotation. The opposite rotational direction creates
draulic displacement. This means that work can centrifugal forces that act only in the vertical di-
be carried out very efficiently at lower revolutions rection. Via an adjustable drive 1 the unbalanced
and with increased static moment or at higher re- flywheels can be rotated against each other from
volutions and decreased static moment and with maximum static moment (= maximum oscillation
lower ground vibration. Revolutions above the amplitude) to minimum static moment (minimum
nominal revolution are possible, the static moment oscillation amplitude - vibration-free). When the
is limited according to the permissible centrifugal working speed is attained the static moment or
force. By altering the adjustable hydraulic dis- the critical speed can be adjusted and adapted
placement the machine can be used in a wider to suit the respective soil conditions.
revolution range utilising the maximum available
oil flow. As a result, more power is implemented A circulation pump on the vibrator pumps the
on the pile. MRZV-VV vibrators can also be used vibrator gear oil out of the oil sump over a filter
with larger installed static moment on machines element and through the oil cooler. The cooler is
with low engine output. additionally cooled by a temperature controlled
fan. The cooled gear oil is cleaned via a return
Due to the high-frequency vibration above the filter and returned to the cooling circuit of the ex-
ground resonances, the internal adhesive frictio- citer cell. The oil cooling reduces the transmission
nal forces in the soil and the skin friction of the oil temperatures and thus extends the service
pile elements largely cancel each other out. In intervals of the vibrator.
comparison with other piling methods, conside-
rably lower forces are required for the penetration
of the piling elements into the ground.

The vibration-free start-up and shut-down phases

avoids the transmission of ground resonance to
neighbouring buildings. Even during the piling
process, the static moment and the speed can
be optimally adapted to the ground conditions so
that the MRZV-VV vibrator can also be used on
Minimal static moment
inner-city construction sites

The ABI Vibrator MRZV-VV with adjustable static

moment and adjustable hydraulic displacement
consists of a gear box 9, jaw assembly 5 and
guiding carriage 2. Rubber shock absorbers dam-
pen the transmission of vibrations to the vibrator
guide 8. Limit stops 12 limit the absorber travel
and serve as protection in case of overloading and Maximal static moment
from tearing the shock absorbers. With the clam-
ping cylinder 5 at the bottom of the exciter cell,
the piling elements are lifted and then clamped.
In the exciter cell, hydraulic motors drive 3 gear
shafts lying one below the other. On the trans-
mission shafts unbalance segments are rotary
bearing mounted. The unbalance segments rotate

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Vibrator MRZV-VV

Efficiency Drive-System (option)

Vibrator MRZV-VV
Vibrators often work in a partial load range. This is always the case, when the working pressure
decreases under the permissible value. In a conventional control system the circulating hydraulic
oil flow is mostly independent from the load on the vibrator. The losses which the full volume flow in
the hydraulic system cause, are pressure independent and at partial load are as high as at full load.

Efficiency Drive is a control system which adjusts the volume flow demanded by the vibrator and adjusts
the displacement of the hydraulic motors at the MRZV-VV accordingly. The efficiency of the machine
and attachment combination remains unaffected. A load-depending control system adjusts the diesel
engine revolutions and sets the optimal parameter for hydraulic motor and pumps. Fuel consumption
and noise emission are reduced. The fuel saving are usually in the double digit percentage range.

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3 Commissioning and operation
3.1 Commissioning

Caution
Before each start-up and installation, the ABI
vibrator MRZV-VV must be checked for perfect
technical condition:

• Check and thoroughly clean the ABI vi-

brator MRZV-VV also check for external
damage and completeness.
• Check welds and mechanical components
for cracks and signs of fatigue.
• Check that the safety equipment (especially
the pitching chains, limit stops) are in per-
fect condition and, if necessary, replace
with original spare parts.
• Check that the screwed connections are
secured (especially the jaw assembly and
clamping jaws). Do not retighten bonded
screw connections; otherwise the safety
feature will be lost.
• Check oil level in the gear box.
• Check the gearbox and hydraulic system
and for oil leaks (esp. hydraulic hoses and
fittings), eliminate where necessary.
• Check wear and tear parts (esp. jaw pads
and slide rails), exchange if necessary.
• Clean elastomer mounts and other plastic
parts then check condition and exchange
if necessary.
• Secure loose objects.
• Check the proper functioning of the control
lamps and display devices.
• Observe the maintenance intervals.
• Before attaching working tools at the rapid
changing device the hydraulic system must
be depressurized - Danger of damage to the
quick-release couplings. Screw the quick-
release coupling on until the rear locking
groove locates that it can be secured with
the clip pin. Through incorrect connecting
or loosening of the quick-release coupling
caused by vibration damage can occur to
the jaw assembly or vibrator - danger due
to falling piles.

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Vibrator MRZV-VV

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Commission of ABI vibrator MRZV-VV
• Attach vibrator at docking-system of the ABI
MOBILRAM-System (see Operator's manual /
Telescopic leader mast / attaching and remo-
ving of attachments). Caution
• Start ABI MOBILRAM-System. • Before putting the vibrator into operation,
• Select in ABI MOBILRAM-System vibrator it is imperative to connect the gearbox oil
MRZV-VV. cooling circuit otherwise the hammer will
• Before starting work check all functions without overheat and be damaged.
load - shut down the ABI MOBILRAM-System • Before starting work with the MRZV-VV
should faults or malfunctions appear.. bring the vibrator to its operating tempe-
• Check the emergency stop function of ABI rature, warm up for approximately 5-10
MOBILRAM-System. minutes without any load and at 50% static
• Check the gearbox oil pressure control lamp. moment at a speed of app. 1800 rpm.
• Before starting work with the MRZV- VV bring • For MRZV-VV vibrators that are not inclu-
the vibrator to its operating temperature, warm ded in the original scope of delivery, e.g.
up for approximately 5-10 minutes without any for newly acquired working attachments,
load and at 50% static moment at a speed of rental attachments as well as for a sensor
app. 1800 rpm. exchange, a calibration of the MRZV-VV
sensors must be carried out.

Function test

Hydraulic hoses
• Check connections.
• If necessary tie together rubbing hydraulic
hoses.

Dynamic Test
• Start ABI MOBILRAM-System.
• Actuate the function jaw close - jaw assembly
closes.
• Actuate the control lever in direction piling - the
vibrator begins to run without any vibration.
• Set the function static moment to its maximum
value - the vibrator starts to vibrate.
• Check the maximum speed of vibrator.
• Set the function static moment to its minimum
value - the vibrator runs without vibrating.
• Bring the control lever piling in the neutral
position - the vibrator stops running.
• Activate the function jaw open - jaw assembly
opens.

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Vibrator MRZV-VV

3.2 Control
The ABI MOBILRAM-System is operated and
controlled from the driver's cab of the carrier unit.
Left control lever

Caution Piling /
• The equipment must always be operated
Drilling clockwise
by two people one equipment operator who
operates the control devices in the driver's
cab, and one slinger or spotter.
• Check safety devices of the ABI MOBIL-
RAM- System at regular intervals.
• Controls and control panel see Operator's
manual Control Panel.

Activate the function by moving the excavator

control lever in the desired direction. The speed Drilling counter clockwise
increases in proportion to the deflection of the
control lever. The levers are spring centred back
in the central position.

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3.2.1 Clamping

ABI control panel - jaw pressure

Caution
See Operator's manual - Control Panel.

3.2.2 Display

Clamping pressure
Display in the ABI control panel or on the pres-
sure gauge - Clamping pressure.

Caution
• Monitor the clamping pressure during the
clamping process until the nominal pres-
sure is reached.
• For ABI vibrators VRZ and ZR the clamping
pressure must be reduced - contact ABI
after-sales service. Option: Pressure gauge - jaw pressure

Jaw pressure
nominal jaw pressure 470 ... 500 bar
indicating range 0 ... 600 bar
jaw pressure leader / winch system pressure auger flight casing

Option: Clamping camera

Above the jaw assembly a bracket 1 with integra-
ted clamping camera is attached. As a result the
clamping operation of the pile can be monitored
from the driver's cab. The display for the clamping
camera is mounted above the ABI control panel. 1

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Vibrator MRZV-VV

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4 Operation
4.1 General safety instructions

Warning
• The operator and the slinger always have • The ABI MOBILRAM-System and the ABI at-
to keep visual contact, if not stop the ope- tachments may only be operated by autho-
ration immediately. Agree on clear signals rized, qualified and instructed personnel.
for the communication between operator • Operating and service personnel must be
and slinger. assigned by the contractor to operate or
• Observe all safety instructions and danger service the machine.
warnings on the machine and keep them • Two people are required when working with
complete and legible. the equipment, one equipment operator,
• Constantly monitor the operations and and one spotter or slinger. The communi-
interrupt them immediately when danger cation between slinger and operator must
is apparent. be established in a reliable manner.
• Before turning on commissioning, make • Acoustic and visual signalling equipment
sure that nobody is endangered when the used for monitoring the safety of the opera-
equipment is started. The operator has to ting personnel must always be functional.
give warning signals when people are in • Inspect the ABI MOBILRAM-System and the
danger. ABI attachments every day for obvious de-
• Wear personal protection equipment during fects. In the event of safety-related changes
operation and maintenance work on the to the machine or its operating behaviour,
machine. The personnel are not allowed to stop the machine immediately and report
wear long hair loose, nor may they wear loo- the fault to the responsible body / person.
se clothing or jewellery. There is a danger • Properly illuminate the working area. For
of injury, e.g. loose objects may be pulled operations at night additional lightning
into or get caught in the machine. equipment is required.
• Do not make any changes or attachments, • Regularly check the safety devices and
or any alterations to the machine that would covers for correct function.
affect the safety of the ABI Mobilram sys- • The safety instructions and restrictions for
tem. each particular carrier must be observed.
• Do not exceed the maximum permissible • Furthermore, the relevant regulations,
ground pressure. Insufficient load bearing standards and laws in each user’s country
ground can be improved for example, e.g. apply.
by using load distributing boards (crane • Accidents involving pressurised hydraulic
mats) or by soil replacement. fluids, such as the injection of hydraulic oil
• Refrain from any operations that affect the under the skin, can result in serious injury
stability of the machine. Pay attention to or in the worst case, death. Injured persons
the reduced stability when working over must be taken to the hospital - medical
the side. treatment has to be started immediately
• Remove or secure tools and other objects also at the slightest suspicion of injection
before putting the machine into operation. including minor external injuries.
• Do not exceed the maximum permissible
load capacity of the ABI Mobilram-System
otherwise the stability of the ABI Mobilram-
System will be affected.

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Vibrator MRZV-VV

4.2 Safety instructions and restrictions

4.2.1 Dangers and risks

Warning
Improper operation of the equipment and un-
authorized modifications may lead to physical
damage and high risks of injuries. In all cases,
the applicable national legal regulations and
requirements regarding safety and health
protection must be observed when using
equipment.

Mechanical dangers: Danger from electric effects:

• Through crushing: when standing in the • Electric contact (direct or indirect).
equipment's danger area (e.g. attaching piles). • Outside effects on electric devices (power
• Through spraying liquids under high pressure: lines).
In cases of improper operation during mainte-
nance or mechanical damage to the hydraulic
system.
• Risk due to falling snow loads and ice loads.

Danger from thermal effects:

• When touching hot machine parts during ope-
ration and maintenance work.
• Upon contact with the vibrator body when in
operation.

Danger from noise and vibration:

• When standing in the danger area without ear
protection.
• Upon unauthorized modifications to the equip-
ment and improper operating conditions.
• Strain due to vibration of the body.

Danger from materials:

• Inhalation of harmful liquids or gases.
• Through fire and explosion.

Danger from failing machine parts and

other risks:
• Unexpected ejection and fall over of machine
and equipment parts.
• Upon failure/malfunction of control elements.
• Loss of stability. Failure to observe the permis-
sible loads or inadequate ground.
• Through human misbehavior and unskilled
operating and maintenance personnel.
• Upon careless use of personal protection
equipment.
• Danger of slipping at wet and muddy ground.

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4.2.2 Danger area
The danger area is the area inside and around the
machine where the safety and health of persons
is endangered. Danger
• When handling the machine improperly
Due to the working process workplaces may and/or if there are persons in the danger
be within the danger area, e.g. operators and area there is risk of very severe injuries that
spotters or slingers. Persons that are introduced may lead to lifelong handicaps or restric-
and authorized to be in such a workplace must tions in daily life or may even be lethal.
be instructed and able to judge the risk situation • Secure the danger area with stable barriers,
on their own. if possible.
• No unauthorized persons are permitted to
Authorized person: stay in the danger area. The operator may
Person whose stay in the danger area is unavo- only start the machine if there are no un-
idable due to the working process, who has an authorized persons present in the danger
express authorization from the operating company area. Before starting the machine, the ope-
of the machine to be in the danger area and was rator must make sure that there is nobody
sufficiently reminded and instructed of the risks in the danger area and give warning signals
involved, e.g. operator, spotter or slinger and in case of danger for persons. If unautho-
maintenance staff. rized persons do not leave the danger area
despite the warnings stop working imme-
Access to the danger area: diately.
The operating company of the machine has to re- • Persons are only allowed to be in the dan-
strict the access to the danger area accordingly as ger area if this is unavoidable due to the
far as possible. If the danger area reaches into a working process. It is required that the
public or private area the sphere of influence (e.g. persons are authorized and instructed by
working next to a highway or adjacent property the operating company of the machine and
line) the operating company must take appropriate are able to assess the dangerous situati-
actions on the basis of a risk assessment such as on by themselves. On the basis of a risk
blocking a road, restricting traffic, etc. Determining assessment, the operating company of
the remaining risk and to what extent unauthorized the machine has to determine additional
personnel enter the danger area is entirely on the actions, e.g. when space is restricted.
responsibility of the operating company and the • To operate the machine it is necessary that
authorized personnel, or their supervisors, since the operator stays in the danger area. Make
they are aware of the risk due to the conditions sure that the operator is always inside the
on site. cabin.

17
Vibrator MRZV-VV

• To set-up the machine, for maintenance • The applicable national legal regulations
work and for the working process, e.g. to and requirements regarding safety and
sling and detach or align piles or drilling health protection must be observed when
equipment, the help of authorized persons using equipment. In particular, the workers,
is required, e.g. slingers or spotters. It is e.g. operator, spotter/slinger and mainte-
required that the persons are authorized nance staff, must be informed sufficiently
and instructed by the operating company and appropriately about the existing ha-
of the machine and are able to assess the zards, required protective measures and
dangerous situation by themselves. Do not rules of conduct as well as measures to
stay longer in the danger area as absolute- take in case of accidents and for first aid in
ly necessary. Breaking of the sling gears, case of emergencies. The instructions must
dropping of the load, swinging of the load, be given in regular intervals, however at
pinching of body parts are the essential least once a year. The employer must take
risks when slinging loads. care that the machine is used by personnel
• Authorized persons can enter the danger charged with this task only.
area after communication with the operator
only. Keep eye contact and coordinate the
working method with each other, e.g. by
hand signals. In the danger area, personal Notice
protective equipment must be worn. Warning signs "Danger area" are fixed to the
• Standing under suspended loads is forbid- machine on both sides of the superstructure
den. - keep warning signs in good and legible
• If the operator's view on his driving and condition.
working area is restricted he has to be di-
rected. Spotters must be clearly recogniz-
able. They must be visible to the operator.
Due to the construction of the machine, the
view towards the rear and the right side
of the machine is considerably restricted.
Adjust the existing mirrors for an optimum
view to all sides. Clean window panes and
mirrors regularly. Safety devices that are
available as an option, e.g. cameras for
monitoring the rear of the machine, en-
hance the operator's field of vision in the
restricted area.
• Keep a safety distance to stationary struc-
tures, e.g. buildings or other machines, of
min. 0.5 m. This prevents persons from
getting jammed. If this safety distance
cannot be kept, block the area between the
stationary structures and the working area.

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Danger area for pile-driving operations
The danger area for pile-driving operations is the
area inside and around the machine where the
safety and health of persons is endangered, e.g. Danger
through: • Danger of severe or even deadly personal
• working movements of the machine and the injury through falling piles, or machine
attachments. parts. Before starting the machine, make
• swinging out or tipping over piles. sure that there are no unauthorized per-
• falling machine parts or loads. sons in the danger area. Persons are only
allowed to be in the danger area if this is
Danger area unavoidable due to the working process.
• The danger area 1 is a circular area with a ra- • Risk of crush injuries between the machine
dius around the centre of rotation of the upper and stationary structures, e.g. buildings or
carriage. This includes the area above this area other machines.
as well.
Danger area 1 = maximum distance between
centre of rotation of upper carriage and outer
machine edge, e.g. tail swing radius + min. 0.5 m.
• The danger area 2 is a circular area with a
radius around the centre of the pile-driving
axis.This includes the area above this area as
well. Danger area 2 = Length of the piles + min.
2.0 m.

Danger area 1
Danger area 2

Tail swing radius

+ min. 0.5 m

Danger area 1

Len
+ m gth o
in. f the
2.0
m. piles
0,5 m

Center of pile-driving axis

Danger area 2

Notice
The illustration is an example only and is not true to scale.

19
Vibrator MRZV-VV

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4.2.3 Operational restrictions 4.2.4 Emergency stop device

Warning
• Do not use ABI vibrators for impact pile In cases of emergency the ABI MOBILRAM- Sys-
driving or with the clamping jaws open - the tem is equipped with an emergency stop button.
high dynamic forces can seriously damage The emergency stop device is located in the
the vibrator and clamp assembly. drivers’ cab of the carrier (see operating manual
• Danger through the machine turning over, of the carrier).
do not exceed the maximum admissible
load capacity (see technical data), other- By pressing the emergency stop button, the
wise the stability of the ABI MOBILRAM- functions of the ABI MOBILRAM system are
System is endangered. immediately switched off and the implements
• Carry out movements slowly, do not overlap are disconnected from the power supply. Before
individual movements and do not brake attempting to start again, unlock the emergency
abruptly. stop device. Check the emergency stop device
• Danger of damaging the vibrator - do not daily by activating it to check it functions correctly.
exceed the maximum permissible crowd
or extraction force of the attachments (see Verification of the emergency stop
technical data). • Start the ABI MOBILRAM-System.
• Risk of serious bodily injury - only use the • Verify the functions under no-load condition.
clamp assembly to clamp piles. Do not • Push the emergency stop device until it locks.
reach into the clamp assembly. The functions of the ABI Mobilram-System
• Danger through falling machine elements. must stop immediately.
Always secure the ram element with the • Pull out the emergency stop device, and
pitching chains during the driving and ex- acknowledge the malfunction in the ABI con-
traction process. trol panel to restart the functions of the ABI
• Do not drop the piling elements into the Mobilram-System.
pitching chains - the high dynamic forces
can damage or break through the pitching
chains. There is a risk of falling machine
elements.
• To avoid the risk of accidents, do not let
the pile element hang in the clamp when
the machine is stopped.
• Risk of serious bodily injury with increased
wind pressure there is a risk due to uncon-
trolled swinging of the pile elements.
• Option double clamp assembly: Risk of
turning over - Secure attachment and
trans-port frame with four securing chains.
Attach the securing chains to the suspen-
sion points of the attachment and to the
securing points of the transport frame and
tension them.

21
Vibrator MRZV-VV

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4.2.5 Personal protection
equipment

Anybody who works with the ABI Mobilram-Sys-

tem or are employed in its vicinity must always
wear full protective equipment. Check the Perso-
nal protective equipment before use for proper Safety helmet
condition and check for obvious defects. No defec-
tive personal protective equipment is to be used.

Safety shoes or boots

Work gloves
not the operator

Ear protection
sound pressure level
> 85 db(A)

At heavy formation of dust or when using com-

pressed air as flushing medium:

Breathing mask

Safety glasses

23
Vibrator MRZV-VV

4.3 Working with the MRZV-VV

Set up the ABI MOBILRAM system for pile driving

and check that the machine is in perfect working
condition.

Warning
• Danger from falling objects. Observe the
pile driving and extraction process and
interrupt immediately in case of danger.
• Do not use the vibrator and clamp assembly
for lifting operations.
• Do not exceed the maximum extraction
force during the extraction process.
• Danger of the machine turning over, do not
pull piling elements diagonally.
• Do not move or slew the machine during the
piling process, otherwise there is a danger
of damaging the ABI MOBILRAM-System.
• Before commissioning the vibrator, always
connect the oil cooling circuit, otherwise
overheating and damage must be expected.
• Risk of damage due to increased bearing
wear. Do not operate the Vibrator MRZV-
VV without any load at high speeds and
at maximum static moment or at minimum
static moment, i.e. operate at a minimal
static moment.
• The centre of gravity from the pile must be
centred below the jaw assembly, otherwise
danger of damaging the vibrator or the jaw
assembly must be expected.

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4.3.1 Attaching and Securing Piles
4.3.1.1 Pitching chains / Chain supports - general
The pile must always be secured during every 5
operation with the pitching chains on the vibrator.
At the bottom of the Vibrator are two chain sup-
ports with one or two pitching chains for lifting 2
and securing the piling elements. The piles can
be lifted with the toggle of the pitching chain using
the pitching hole (single-leg arrangement) or in 6
a basket lift (V arrangement) and then secured.
3
Before starting the pile-driving work, determine
the weight of the piles and choose an appropriate
4 4 1 5
method to attach and secure the piles depending
on the weight and the pitching holes of the piles.
When using double profiles secure both piles with
pitching chains. The weight of the combined piles
must not exceed the load capacity of the pitching
chains or the chain supports.
8 8
7
In cases where the piles exceed the load capacity
of the pitching chains or chain supports of the ABI
MOBILRAM system (see chapter Safety proofs,
stability), a suitable third-party device is required
to introduce and secure the piles. During the
entire working process the pile must be secured
by means of a safety rope, or a sling that has at
least the same load capacity as the weight of the
pile. The entire working process encompasses
the attaching and securing of the piles, the lifting
up and installation of the piles, as well as the 10 10
extracting and lowering of the piles. 9

The following piles are appropriate for pile driving

and extracting with the ABI vibrator:
• steel sheet piles, hot and cold rolled steel sheet
pile sections.
• permanently joined double sections (e.g. steel
sheet pile sections with pressed or welded
section interlocks). 1 Chain support
• steel piles and steel beams 2 T-handle holder
• steel plates 3 Adapter plate
• full displacement sections 4 Pitching chain
5 T-handle
6 Chain link
7 Sinlge-leg arrangement with one pitching chain
8 Sinlge-leg arrangement with two pitching chains
9 V-arrangement with one pitching chain
10 V-arrangement with two pitching chains

25
Vibrator MRZV-VV

Danger
Danger of serious or even fatal injury from • Do not run the pitching chains over sharp
falling piles, or machine parts: edges, do not crush them or clamp them in
the clamp assembly.
• The safety instructions of the operating
• Do not twist the pitching chain under load.
manual must be read and applied by each
• Do not modify the pitching chains or chain
person working with or on the machine.
supports. Only use the procedure descri-
• Use piles with proper holes, as described
bed in the operating manual to attach the
in this manual only. In particular, the hole
piles.
diameters and hole distances specified in
• When the machine is shutdown do not let
this operators manual must be taken into
the pile hang freely suspended in the clamp
account. The centre of gravity of the pile
assembly or on the pitching chain.
element must be underneath and in the
• Do not leave the vibrator separated from
centre of the clamp assembly.
the ABI Mobilram system clamped onto a
• Avoid abrupt and sudden movement of the
pile that has already been driven into the
pitching chains. Do not let the piles fall into
ground. If the clamping pressure is lost, e.g.
the pitching chains. The pitching chains
if the clamping cylinder leaks, the vibrator
and the chain supports may be damaged
can overturn.
or even severed abruptly due to the high
• The installation and/or use of unauthou-
dynamic forces. In case of suspected da-
rized accessories that were not tested and
mage, immediately replace pitching chains
approved by ABI may affect the safety - safe
or chain supports and mounting screws.
operation is only ensured when using ori-
• Only use the pitching chains to lift-up and
ginal spare parts.
then secure piles. The vibrator and the
• To avoid accidents, inspect the chains and
clamp assembly are not appropriate for
chain supports according to the inspection
other lifting operations.
intervals, following a special incident have
• Do not pull piles with the pitching chains
them checked by a competent person, or
other than lifting and lowering piles, e.g.
replace them with new chains and chain
dragging piles to required location. The
supports if in doubt. Document the test
pitching chains and the chain supports may
evidence and keep it until the next test. The
be damaged due to high dynamic forces.
operator is responsible for the immediate
• Determine the weight of the piles before
removal of defects.
attaching the load. Do not exceed the load
• Each person working with the ABI MOBIL-
capacity of the pitching chains (as deter-
RAM-System, in particular the driver, the
mined on the chain tags) and the chain
slinger and the spotter, must be instructed
supports - in cases of diagonal forces the
in the safe operation of the ABI MOBILRAM-
load capacity is reduced. Do not exceed
System as described in this operating
the maximum load capacity of the ABI
manual. Any person working in the danger
MOBILRAM-System, otherwise the stability
area, or near the ABI MOBILRAM-System,
will be endangered.
must be reminded of the risk of serious or
• Always secure the pile elements with pit-
even fatal injury.
ching chains for every operation.
• For double sheet piles, use two pitching
chains. Pay attention to an even distance
of the holes from the top of the piles (as
described in this manual). Only use pitching
chains of the same type and length.

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 Caution
• Two persons are required to attach and
secure piles:
- one driver to operate the control devices in
the cabin.
- one slinger or spotter to attach the piles.

• Due to the working situation workplaces

may be within the danger area. Personal
protection equipment must be worn.
• Check the pitching chains and chain sup-
ports for obvious defects and complete-
ness before each operation. Immediately
replace them when they are damaged, or
the wear limits are exceeded (as described
in this manual).
• Before each working process check the
piles for obvious defects e.g. deformation
or cracks. Do not drive or extract damaged
piles. Piles with burr-free holes are requi-
red, with a given hole spacing and diameter,
depending on the pitching chain.
• The ABI MOBILRAM-System and the in-
terchangeable attachments are designed
and constructed for the use mentioned and
described in the operating manual only. Any
other use of the machine without written
consent of the manufacturer is considered
to be an improper use.

27
Vibrator MRZV-VV

Pitching chains in V arrangement

The piles can be lifted or lowered using the pit-

ching chains in basket hitch (V arrangement) (1).
The V arrangement helps guide the pile into the
clamp assembly, as the pile is hanging centered
under the clamp assembly. To attach the pile,
pitching chains with T-handles on both sides are
required. An appropriate length of the pitching
chain and proper configuration of the holes are a
condition for a safe and smooth working process
when picking up and lowering of the pile. 1

Danger
Danger of serious or even fatal injury from
falling piles, or machine parts:
• When using pitching chains without T-
handles on both sides and of unsuitable
length.
• When the load capacity of the pitching
chains is exceeded.
• When using piles without proper pitching
holes.

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Pitching chains in V arrangement

Warning Figure A
• For lifting up and securing the piles in a V
arrangement pitching chains with T-hand-
les on both sides and a length between the
T-handles of at least 1500 mm are necessa-
ry. 1
• Before starting the pile-driving work measu-
re the length of the pitching chain between
the T-handles. If the pitching chain is too
short, the pitching chain may be caught and
damaged when the pile is lifting and laid
down, or even break suddenly due to the
leverage effect on the pile. If the pitching 3
chain is too long it is much more difficult
to thread the pile into the clamp assembly.

• Thread the T-handle 1 at the free end of the

pitching chain through the pitching hole in the
pile 2.
• Thread the T-handle from below through the
hole in the chain support 3 at the opposite side
of the clamp assembly and lock it such that the Figure B
T-handle is aligned vertically (see figure A). 2
Make sure that the T-handle is well secured
in the chain support.
• The pile lies on the chain links of the pitching
chain during the lifting process.The chain must
pass freely through the hole in the pile.
• The pile rests on a chain link horizontally, or
between two chain links, as soon as it hangs
free on the pitching chain (see figure B).

29
Vibrator MRZV-VV

Pitching chains in single-leg arrangement

The piles 1 can be lifted up and secured with the

T-handle 2 of the pitching chain 3 directly via the
pitching hole (single-leg arrangement).

To attach the piles, pitching chain with T-handles

on both sides are required. An appropriate length
pitching chain and proper configuration of the
pitching hole are a prerequisite for a safe and
smooth working process when picking up and
lowering the pile.

Danger 1
3
Danger of serious or even fatal injury from
falling piles, or machine parts:

• When using pitching chains without T-

handles on both sides and of unsuitable
length.
• When the load capacity of the pitching
chains is exceeded.
• When using piles without proper pitching
holes. 3

1
2

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Pitching chains in single-leg arrangement

Warning
• For lifting up and securing the pile in a
single-leg arrangement pitching chains
with T-handles on both sides and a length
between the T-handles of at least 950 mm
are necessary.
• Before starting the pile-driving work measu- 1
re the length of the pitching chain between
the T-handles.If the pitching chain is too
short, the pitching chain may be caught
and damaged when the pile is laid down,
or even break suddenly due to the leverage
effect on the pile. If the pitching chain is too
long it is much more difficult to thread the
pile into the clamp assembly.
• When lifting up the pile in single-leg arran-
gement it is especially important to ensure
the proper configuration of the pitching
holes. If the holes are not true to the di-
mensions, e.g. in case of burned holes with
irregular diameter or edge, the T-handle
may accidentally come out of the pitching
hole.
2
• When picking-up and lifting the piles, make
sure that the T-handle after threading lies
firmly against the pile.

• Thread the T-handle 1 at the free end of the

pitching chain through the pitching hole in the
pile 2.
1
• Align the shank of the T-handle 1 in the direc-
tion of force. Pay attention to a tight fit of the
T-handle 1 in the pitching hole of the pile 2.
• The pile 2 lies on the T-handle 1 of the pitching
chain during alignment of the pile.

31
Vibrator MRZV-VV

Clamping the piles

The jaw assembly is for the lifting and clamping • The centre of gravity of the pile must be in
of steel piling elements, e.g. Steel sheet piles or the centre of the clamp assembly, otherwise
steel beams with a minimum material thickness the vibrator and the clamp assembly may
of 5 mm to a maximum width of the clamping gap be damaged.
from the applicable jaw assembly being used. • Do not clamp the jaws of the clamp assem-
bly on the interlock connection of the steel
During vibratory insertion and extraction chan- sheet pile sections.
ging system loads are transferred into the pile • Use steel piles and beams of sufficient
elements, resulting in damage to the piles, e.g. width. Do not clamp the jaws on any roun-
sudden shearing or cracking. Before piling starts, ded edges.
if the suitability of the pile elements for the vibra- • Check the clamping jaws and fastening
tory insertion or extraction is in doubt, check or bolts for obvious defects like wear, cracks
determine suitability in an attempt. or damage before each working cycle.
• Improper clamping of the piles, for examp-
For a safe operation and a positive transfer of le partial-incomplete clamping, can cause
clamping forces without damaging the jaw as- damage to the clamping jaws.
semblies’, the pile elements must be clamped
with the entire surface area of the clamping jaws.
The wall thickness of the pile elements must be
uniformly thick in the area of the jaw assembly
and the surface of the pile elements must be free
from any unevenness.

Danger
Danger of serious or even fatal injury from
falling piles, or machine parts:
• The selection and suitability of the piles
for vibratory insertion or extraction must
be checked and ensured by the operating correct wrong
company/operator before commencement
of pile driving.
• The material thickness of the pile element
must be uniform and at least 5 mm in the
clamping area. The material thickness of
the pile element must not exceed the width
of the clamping gap of the jaw assembly.
The strength of the piles must be checked
and ensured by the operator.
• Clamp the pile evenly and with the com-
plete surface of the clamping jaws on both
sides. If the pile is partially clamped, the
clamp assembly, and jaw assembly can be
damaged.

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Pile elements - hole diameter and spacing
The proper pitching hole spacing and hole diame-
ters in the piles is a prerequisite for a safe and
smooth working process when lifting or lowering Danger
Danger of serious or even fatal injury from
the piles.
falling piles, or machine parts. Do not use
piles in cases of safety-relevant defects, e.g.
When using a pitching chain arrange the pitching
when using piles that are damaged or without
holes such that the centre of gravity of the pile is
proper pitching holes.
centred below the pitching chain, thereby allowing
the pile to hang vertically.

When using two pitching chains arrange the pit- Warning

• Check the piles before each working cycle
ching holes in the piles, such that the centre of
for obvious defects and damage eg. defor-
gravity of the entire pile is central between the two
mation or cracks.
pitching chains, so that both chains are loaded
• Check the hole diameters and the positions
evenly and allow the pile to hang vertically.
of the holes in the piles before each wor-
king process. Only use piling elements with
correct perforation. If the hole diameter is
too small, the T-handle of the pitching chain
cannot be threaded through the perforation,
if the hole size is too large or irregular, the
T-handle may slip out of the perforation of
the pile. If the holes are not free of burrs
there is an increased risk of notching the
pitching chain, e.g. when the holes have
been burned out, or are uneven.
• Before each operation, check the piling
element for position of the perforation.
Only use piling elements with correct per-
foration. Measure the distance between
the upper edge of the hole and the upper
edge of the pile element. If the spacing
is smaller than described in the manual,
the pitching chain can be clamped with
the clamp assembly and damaged. If the
distance is smaller than described in the
manual, the pitching chain can be clamped
with the clamp assembly and damaged.
If the distance is greater than described
in this manual, the pitching chain may be
pinched or jammed when the piles are lifted,
or when they are lowered. The chains can
be damaged or even break suddenly, due
to the lever effect of the piles.

33
Vibrator MRZV-VV

Pile elements - hole diameter and spacing

The hole diameter depends on the pitching chain The hole distances from the upper edge of the pile
used. The position of the perforation depends element should be the same, so that the attached
on the pile, jaw assembly type and length of the load is distributed as evenly as possible on the
pitching chain being used. The position is to be pitching chains.
chosen so that the pitching chains when lifting
and lowering the piles are not damaged by the When using a single pitching chain and typical pile
jaw assembly, through a clamped or prying effect, elements, the distance from the top edge of the
for example upon contact of the pile with the jaw pile element to the top edge of the perforation is
assembly. To improve the handling when lifting usually between a range of 300 mm to 450 mm.
and lowering the pile, it may be advantageous
to adjust the position of the hole to the specific When using two pitching chains and typical piles
circumstances with regard to the type of jaw as- and having a horizontal distance between the
sembly and type and size of the pile on site. two perforations of up to 350 mm, the distance
from the top edge of the pile to the top edge of
When attaching loads with two equal chains, the the perforation is usually between a range of 300
centre of gravity is usually centred between the mm to 450 mm.
two pick-up points, i.e. the load is evenly dis-
tributed over both chains (see Figure 1). Small When using two pitching chains and typical piles
irregularities, e.g. differences in the chain lengths and having a horizontal distance between the two
or a difference in the height of the lifting points, perforations of more than 350 mm, the distance
can be compensated for by a shift in the chains from the top edge of the pile element to the top
master link. The load continues to be distributed edge of the perforation is usually 300 mm.
almost evenly over both chains because the cen-
tre of gravity remains approximately in the middle
(see Figure 2). Warning
• The hole diameter depends on the respec-
In contrast to lifting a normal load, the centre of tive pitching chain used.
gravity for piles is far below the pick-up points, • The hole spacing depends on the size of the
which are usually located closer together (see jaw assembly and the length of the pitching
Figure 3).In addition, the chains are fixed in two chain used. The hole spacing should be at
mutually immovable holes on the chain support least large enough to prevent damage to
and not with a master link. In cases of irregulari- the pitching chains by the jaw assembly:
ties, for example different chain lengths or diffe- - If the distance is smaller than described in
rent distances of the perforations from the upper the manual, the pitching chain can be clam-
edge of the pile, the centre of gravity from the pile ped with the clamp assembly and damaged.
moves laterally and leads to a one-sided higher - If the distance is greater than described
load being applied on one pitching chain (see Fi- in this manual, the pitching chain may be
gure 4). When there is a relatively small distance pinched or jammed when the piles are lifted,
between the two perforations the load capacity or when they are lowered. The chains can
from only one pitching chain can be calculated. be damaged or even break suddenly, due
to the lever effect of the piles.
- If the hole spacing is different from the up-
per edge of the piles, the pitching chains
are unevenly loaded or even overloaded.

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Characteristics of lifting pile elements (simplified illustation)

Standard lifting situation Vibrator with pile element

Ideal condition
symmetrical load distribution
Chain 1 Chain 2

Load chain 1 = Load chain 2

Figure 1
Figure 3

Standard lifting situation Vibrator with pile element

Reality / practice
on job sites
additional factors and
inaccuracies Chain 1 Chain 2

significant
change in angle

Centre of mass
remains approx.
in the middle

Centre of mass
Figure 2 moves out fo the
middle
Load chain 1 ~
~ Load chain 2 Figure 4
equal load distribution despite Load chain 1 >> Load chain 2
small inaccuracies
small inaccuracies cause unequal
load distribution

35
Vibrator MRZV-VV

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 (A)
Pitching chain 10
thickness of chain link 10 mm
maximum load capacity 1.6 t or 2.3 t

Hole diameter d = max. 40 mm

Tolerance max. -1 mm (d = 39 mm)

1 Pitching chain: Hole spacing a = 300 - 450 mm

(A)

2 Pitching chains: Hole spacing a = 300 -

450 mm (B) (B) (C)
Tolerance max. +20 mm (a = 340 mm)
Hole spacing b = max. 350 mm

2 Pitching chains: Hole spacing a = 300 mm (C)

Tolerance max. +20 mm (a = 340 mm)
Hole spacing b = min. 350 mm

Inclination angle β - max. 45°

Hole spacing a
Upper edge of hole to upper edge of the pile
element

Hole spacing b
Lateral spacing of the two holes to each other

Hole diameter d
(A)

Pitching chain 13
thickness of chain link 13 mm
maximum load capacity 3.15 t or 5.0 t

Hole diameter d = max. 65 mm

Tolerance max. -4 mm (d = 61 mm)

1 Pitching chain: Hole spacing a = 300 - 450 mm

(A)
(B) (C)
2 Pitching chains: Hole spacing a = 300 -
450 mm (B)
Tolerance max. +20 mm (a = 340 mm)
Hole spacing b = max. 350 mm

2 Pitching chains: Hole spacing a = 300 mm (C)

Tolerance max. +20 mm (a = 340 mm)
Hole spacing b = min. 350 mm

Inclination angle β - max. 45°

37
Vibrator MRZV-VV

Load capacity of the pitching chains

Before starting the pile driving work the weight of

the piles has to be determined to enable select
a suitable method for attaching and securing the Danger
piles dependent on the weight and required pit- Danger of serious or even fatal injury from
ching hole for the piles. falling piles, or machine parts:
• Do not exceed the load capacity of the pit-
The weight of the pile must not exceed the load ching chains.
capacity of the pitching chains, (the maximum • Distribute the load evenly over all the pit-
admissible loads can be found in the following ching chains. When using two pitching
pages). The load capacity indicates the maximum chains, only use chains of the same type
weight that can be lifted with the pitching chains. and length. Pay attention to the same hole
The maximum load capacity of the pitching chain spacing from the top of the piles, so that the
is indicated on the identification tag. load is evenly distributed over both pitching
chains.
Depending on the selected method and on whe- • If you are using other equipment to lift and
re the holes are positioned an inclination angle lower piles, ensure the load cannot slip.
will be formed. The inclination angle is the angle For double sheet pile elements, use two
between the pitching chain and an imaginary pitching chains.
vertical line.

If the load is not evenly distributed over both

chains due to uneven hole measurements from
the top of the pile, or the lateral distance between
holes is too close, the load capacity of one chain
only should be used.

In case of single pile, secure the pile with a

pitching chain in a vertical chain leg (single-leg)
or in a basket hitch with inclination angle (V ar-
rangement).

In case of double piles, secure both piles with

a pitching chain in a vertical chain leg with inc-
lination angle (single-leg) or a basket hitch with
inclination angle (V arrangement). Both pitching
chains must be of the same type and length, so
that the load is distributed evenly over both pit-
ching chains.

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Changing the chain supports

Danger
• Danger of serious or even fatal injury from
falling piles, or machine parts. Pitching
chains with a load capacity of 2,3 t / 5,0 t
must not be used with chain supports wit-
hout load capacity information.
• If pitching chains with a load capacity of
2,3 t / 5,0 t are used and chain supports
without load capacity information are still
attached, the chain supports must be chan-
ged.
• When the chain supports, adapter plates
or T-handle holders are replaced the bolt
must be replaced.

Changing the chain supports

• Secure the chain supports 1 with suitable lifting
equipment.
• Remove all the bolted connections 2 on the
chain supports.
• Remove both chain supports.
• Attach chain supports with increased load 1 2 2 1
capacity for example 3500 kg / 7000 kg. Use
the supplied accessories (bolts, washers, etc).
• Completely attach and tighten all bolted con-
nections of the chain supports.

Changing the adapter plate 3

• Remove old adapter plate.
• Fit new adapter plate. When mounting the
adapter plate, make sure that the chamfer
(chamfered edge) 3 is fitted to the outside of
the chain support.
• Install and fully tighten all bolt connections for
the adapter plate

39
Vibrator MRZV-VV

Changing the pitching chain

Attach the pitching chain 1 on the chain support 2 3
on the side with the clamping cylinder 3 and se-
cure it with the T-handle holder 4.

The end of the pitching chain with the inspection

tags must be attached on the chain support.

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4.3.1.2 Pitching chains 1,6 t / 3,15 t
Pitching chains 10 with maximum load capacity 1,6 t and pitchings chains 13 with
maximum load capacity 3,15 t
Maximum permissible load
V arrangement with one pitching chain

The inclination angle α is the angle between the direction of the chain and an imaginary vertical line
and is determined over the length of the pitching chain. When lifting up or lowering down and securing
the piles in a V arrangement, pitching chains are required with T-handles on both ends and a minimum
length between the T-handles of at least 1500 mm. The maximum permissible load depends on the
pitching chain being used, the chain supports and the pitching situation.

Warning
• The inclination angle α of the pitching chains must not exceed 45°.
• Pitching chains may not be attached crossed (twisted).
• Do not exceed the maximum load capacity of the chain supports.

1 Pitching chain, size 10 1 Pitching chain, size 13

thickness of chain link 10 mm thickness of chain link 13 mm
with maximum load capacity 1,6 t with maximum load capacity 3,15 t
maximum permissible load 1600 kg maximum permissible load 3150 kg
minimum 1500 mm

41
Vibrator MRZV-VV

V arrangement with two pitching chains, size 10

The inclination angle α is the angle between the direction of the chain and an imaginary vertical line
and is determined over the length of the pitching chain. When lifting up or lowering down and securing
the piles in a V arrangement, pitching chains are required with T-handles on both ends and a minimum
length between the T-handles of at least 1500 mm. The maximum permissible load depends on the
pitching chain being used, the chain supports and the pitching situation.

When lifting up and lowering piles with two pitching chains the inclination angle β is generated by the
lateral spacing of the pitching holes in the piles and the length of the pitching chains.

Warning
• The inclination angle α and β of the pitching chains must not exceed 45°.
• Pitching chains may not be attached crossed (twisted).
• Do not exceed the maximum load capacity of the chain supports.
• Only use pitching chains with the same load capacity.

2 Pitching chains, size 10 2 Pitching chains, size 10

thickness of chain link 10 mm thickness of chain link 10 mm
both with maximum load capacity 1,6 t each both with each maximum load capacity 1,6 t each
inclination angle β up to 20° inclination angle β between 20° und 45°
maximum permissible load 1600 kg maximum permissible load 2150 kg
minimum 1500 mm

42 Druckdatum / print date 07/23

Erstelldatum / creation date 03/23 - V 1.0
V arrangement with two pitching chains, size 13

The inclination angle α is the angle between the direction of the chain and an imaginary vertical line
and is determined over the length of the pitching chain. When lifting up or lowering down and securing
the piles in a V arrangement, pitching chains are required with T-handles on both ends and a minimum
length between the T-handles of at least 1500 mm. The maximum permissible load depends on the
pitching chain being used, the chain supports and the pitching situation.

When lifting up and lowering piles with two pitching chains the inclination angle β is generated by the
lateral spacing of the pitching holes in the piles and the length of the pitching chains.

Warning
• The inclination angle α and β of the pitching chains must not exceed 45°.
• Pitching chains may not be attached crossed (twisted).
• Do not exceed the maximum load capacity of the chain supports.
• Only use pitching chains with the same load capacity.

2 Pitching chains, size 13 2 Pitching chains, size 13

thickness of chain link 13 mm thickness of chain link 13 mm
both with maximum load capacity 3,15 t each both with each maximum load capacity 3,15 t each
inclination angle β up to 20° inclination angle β between 20° und 45° maximum
maximum permissible load 3150 kg maximum permissible load 4250 kg
minimum 1500 mm

43
Vibrator MRZV-VV

Single-leg arrangement with one pitching chain

The piles can be lifted up and lowered down in a vertical single-leg. The inclination angle α that is
generated between the pitching chain and an imaginary horizontal line should be equal to 90°. For
lifting up / lowering down and securing the pile in single-leg arrangement pitching chains are required
with T-handles on both ends and a length between the T-handles of at least 950 mm. The maximum
permissible load depends on the pitching chain being used, chain support and the pitching situation.

Warning
Do not exceed the maximum load capacity of the chain supports.

1 Pitching chains, size 10 1 Pitching chains, size 13

thickness of chain link 10 mm thickness of chain link 13 mm
with maximum load capacity 1,6 t with maximum load capacity 3,15 t
maximum permissible load 1600 kg maximum permissible load 3150 kg
minimum 950 mm

44 Druckdatum / print date 07/23

Erstelldatum / creation date 03/23 - V 1.0
Single-leg arrangement with two pitching chains, size 10

The piles can be lifted up and lowered down in a vertical single-leg. The inclination angle α that is
generated between the pitching chain and an imaginary horizontal line should be equal to 90°. For
lifting up / lowering down and securing the pile in single-leg arrangement pitching chains are required
with T-handles on both ends and a length between the T-handles of at least 950 mm. The maximum
permissible load depends on the pitching chain being used, chain support and the pitching situation.

When lifting up and lowering piles with two pitching chains the inclination angle β is generated by the
lateral spacing of the pitching holes in the piles and the length of the pitching chains.

Warning
• The inclination angle β of the pitching chains must not exceed 45°.
• Pitching chains may not be attached crossed (twisted).
• Do not exceed the maximum load capacity of the chain supports.
• Only use pitching chains with the same load capacity.

2 Pitching chains, size 10 2 Pitching chains, size 10

thickness of chain link 10 mm thickness of chain link 10 mm
both with maximum load capacity 1,6 t each both with maximum load capacity 1,6 t each
inclination angle β up to 20° inclination angle β between 20° and 45°
maximum permissible load 1600 kg maximum permissible load 2150 kg
minimum 950 mm

45
Vibrator MRZV-VV

Single-leg arrangement with two pitching chain, size 13

The piles can be lifted up and lowered down in a vertical single-leg. The inclination angle α that is
generated between the pitching chain and an imaginary horizontal line should be equal to 90°. For
lifting up / lowering down and securing the pile in single-leg arrangement pitching chains are required
with T-handles on both ends and a length between the T-handles of at least 950 mm. The maximum
permissible load depends on the pitching chain being used, chain support and the pitching situation.

When lifting up and lowering piles with two pitching chains the inclination angle β is generated by the
lateral spacing of the pitching holes in the piles and the length of the pitching chains.

Warning
• The inclination angle β of the pitching chains must not exceed 45°.
• Pitching chains may not be attached crossed (twisted).
• Do not exceed the maximum load capacity of the chain supports.
• Only use pitching chains with the same load capacity.

2 Pitching chains, size 13 2 Pitching chains, size 13

thickness of chain link 13 mm thickness of chain link 13 mm
both with maximum load capacity 3,15 t each both with maximum load capacity 3,15 t each
inclination angle β up to 20° inclination angle β between 20° and 45°
maximum permissible load 3150 kg maximum permissible load 4250 kg
minimum 950 mm

46 Druckdatum / print date 07/23

Erstelldatum / creation date 03/23 - V 1.0
Identification tag and inspection tag
The pitching chains are identified on one end near
the T-handle with an identification tag 1 and an
Example: Identification tag
inspection tag 2. The identification tag contains
the maximum load capacity and the serial num- Maximum load capacity
ber. The inspection tag contains the date of the in vertical leg
next inspection by a competent person. When
replacing the pitching chains secure one end 1
with the T-handle holder, make sure the tags are
position so they don't have to go through the pile
pitching holes.

Warning
Replace the pitching chains if the identifica-
tion tag, or the inspection tag are missing, or
if the information on the tags are illegible.

Serial number Maximum load capacity

in V arrangement

Storing the pitching chains Inspection tag

Clean the pitching chains after use and before
storage and protect them from the effects of the
weather or aggressive substances. If the pitching
2 Prüfplakette
23 14
chains will not be used for a longer period of time,
protect them against corrosion. 22 15
BetrSichV
§10
21 16
Nächste
20 Prüfung 17
19 18

47
Vibrator MRZV-VV

Inspecting the pitching chains Inspection intervals

The pitching chains consist of round steel chain • Before first using the pitching chains have
links grade 8, special links and two T-handles. the condition and the completeness inspected
During use the pitching chains are exposed to by a competent person for lifting accessories.
conditions and wear that may influence the wor- Immediately dispose of and replace the pit-
king safety. Inspect the pitching chains regularly ching chains with new ones in case of safety-
and dispose of and replace them immediately in relevant defects. Mark the next inspection date
case of any safety-relevant defects. When using (month/year) on the rectangular inspection tag.
two pitching chains both pitching chains should
be replaced at the same time. • Before each operation inspect the pitching
chains for obvious defects and completeness.
When inspecting the pitching chains safety related Immediately dispose of and replace with new
defects should be identified and eliminated. The pitching chains in cases of damage, or when
operator is responsible for the immediate remedy the wear limits are exceeded.
of any defects. In cases of extended operational
conditions the test and inspection intervals should • At least every 6 months - have the condition
be re-assessed by the operator and adjusted and completeness of the pitching chains ins-
accordingly. Depending on the operating condi- pected by a competent person for lifting ac-
tions, or in special circumstances, shorter test cessories. Immediately dispose of and replace
intervals may be required. It might be necessary the pitching chains in case of safety-relevant
to clean the pitching chains prior to any visual or defects. Mark the next inspection date (month/
functional testing. year) on the rectangular inspection tag. Docu-
ment the inspection report and keep it until the
next inspection.

• At least every 36 months, or after special

incidents have the pitching chains inspected
for cracks and micro cracks by a competent
person, e.g. via a non-destructive test. Docu-
ment the inspection report and keep it until the
next inspection.

48 Druckdatum / print date 07/23

Erstelldatum / creation date 03/23 - V 1.0
 Danger
Danger of serious or even fatal injury from
falling piles, or machine parts:
• Immediately dispose of and replace pit-
ching chains with new ones in cases of
safety-relevant defects, e.g. wear or over-
stressing.
• When using two pitching chains replace
both pitching chains at the same time and
use pitching chains of the same type only.

max. + 5 %
Warning
• Immediately replace pitching chains in ca-
ses of safety-relevant defects, e.g
- elongation through overstressing, when
the chain or a single link is elongated more A
than 5 % or when there is no free movement max. - 10 %
between the chain links.
- the dimensions of the components are re-
A
duced by more than 10 % in one location.
- mechanical damage caused through crus-
A-A d1+d2 > 0,9 d
hing, notching or surface cracks.
- deformation through bending, twisting or 2
denting.
d = rated thickness
- excessive corrosion.
d1 + d2 = actual dimensions
- contact with electric power.
- heating over 200 °C.
max. - 10 %
• Meet the regular inspection intervals and
keep the test certificates until the next ins-
pection.

49
Vibrator MRZV-VV

Inspecting the pitching chain, size 10

Maximum load capacity 1.6 t

c
e.g. ABI art. No. 76429647
Thickness of chain link a = 10 mm.
Length of chain link b = 30 mm.
Thickness of special chain link c = 10 mm.
Length of special chain link d = 38 mm.
d
Length of T-handle e = 95 mm.
Length of chain between T-handles f = 1510 mm.

Using a caliper determine the chain link diame-

ter at the thinnest spot, each time offset by 90°
a
(d1+d2 on previous page), Replace the pitching
chain at an averaged thickness of a or c = 9 mm
or less. f
Determine the length of the chain links at the lon-
gest internal spot using a slide caliper. Re- place
the pitching chain with an inside measurement of
b = 31.5 mm / d = 39.9 mm or more.
b
Replace the pitching chain upon obvious wear of
the T-handles and special chain links.

Thickness of chain link a

Length of chain link, inside b
Thickness of special chain link c
Length of special chain link, inside d
Length of T-handle e
Length of chain between T-handles f

50 Druckdatum / print date 07/23

Erstelldatum / creation date 03/23 - V 1.0
Inspecting the pitching chain, size 13

Maximum load capacity 3.15 t

c
e.g. ABI art. No. 76429648
Thickness of chain link a = 13 mm.
Length of chain link b = 39 mm.
Thickness of special chain link c = 16 mm.
Length of special chain link d = 70 mm. d
Length of T-handle e = 120 mm.
Length of chain between T-handles f = 1541 mm.

Using a caliper determine the chain link diame-

ter at the thinnest spot, each time offset by 90°
(d1+d2 on previous page), Replace the pitching a
chain at an averaged thickness of a = 11.7 mm /
c = 14.4 mm or less.

Determine the length of the chain links at the lon- f

gest internal spot using a slide caliper. Re- place
the pitching chain with an inside measurement of
b = 41,0 mm / d = 73.5 mm or more.

Replace the pitching chain upon obvious wear of

the T-handles and special chain links. b

Thickness of chain link a

Length of chain link, inside b
Thickness of special chain link c
Length of special chain link, inside d
Length of T-handle e
Length of chain between T-handles f

51
Vibrator MRZV-VV

Inspecting the chain supports

At the lower end of the vibrator there are two pit-

ching chain supports 1 for lifting and securing and
are suitable for one or two pitching chains. The 2
pitching chains are attached and secured to the
chain supports 1 with T-handle holders 2. For pit-
ching chains with a chain link thickness of 10 mm
adapter plates 3 are required to be attached to
the chain supports 1. 3

Danger
Danger of serious or even fatal injury from
falling piles, or machine parts. Immediately
1 Chain support
dispose of and replace chain supports with 1
2 T-handle holder
new ones in cases of safety-relevant defects,
3 Adapter plate
e.g. wear or overstressing.

Warning Chain support without load capacity

• Inspect the chain supports, adapter plates details
and mounting bolts for obvious defects,
Chain support Ø 40 mm - pitching chain 10
e.g. damage, deformation, cracks and
Maximum load capacity: e.g. 1600 kg / 3200 kg
wear. If damaged or if the wear limits are
exceeded, replace immediately. Replace Chain support Ø 65 mm - pitching chain 13
the chain supports and adapter plates if the Maximum load capacity: e.g. 3150 kg / 6300 kg
hole diameters are enlarged by more than
6 % in any one spot.
• Check the attachment of the pitching chains
with the T-handle holders. Make sure that Danger
all mounting bolts are well fastened. • Danger of serious or even fatal injury from
• Check the attachment of the adapter plate falling piles, or machine parts. If pitching
on the chain support. Make sure that all chains with a load capacity of 2300 kg
mounting bolts are well fastened. / 5000 kg are used with chain supports
• When the chain supports, adapter plates without load capacity information are still
or T-handle holders are replaced the bolts fitted, the chain supports must also be
must be replaced as well. changed.
• Only use chain supports with the same load • When the chain supports, adapter plates
capacity. or T-handle holders are replaced the bolts
must be replaced as well.

• Pitching chains with a load capacity of 2,3 t /

5,0 t may only be used if chain supports with
increased load capacity (chain supports
with load capacity details) are attached.

52 Druckdatum / print date 07/23

Erstelldatum / creation date 03/23 - V 1.0
Inspecting the chain supports

Pitching chain 10
Hole diameter d
Adapter plate - hole diameter d = 40.0 mm

Determine the diameter at the largest point using

a caliper. Replace the adapter plate at a diameter
of 42.5 mm or greater.
d d
Pitching chain 13

Chain support - hole diameter d = 65.0 mm

Determine the diameter at the largest point using

a caliper. Replace the chain support at a diameter
of 69,0 mm or greater.

53
Vibrator MRZV-VV

4.3.1.3 Pitching chains 2,3 t / 5,0 t

Pitching chains 10 with maximum load capacity 2,3 t and pitchings chains 13 with
maximum load capacity 5,0 t
Maximum permissible load
V arrangement with one pitching chain
The inclination angle α is the angle between the direction of the chain and an imaginary vertical line
and is determined over the length of the pitching chain. When lifting up or lowering down and securing
the piles in a V arrangement, pitching chains are required with T-handles on both ends and a minimum
length between the T-handles of at least 1500 mm. The maximum permissible load depends on the
pitching chain being used, the chain supports and the pitching situation.

Warning
• The inclination angle α of the pitching chains must not exceed 45°.
• Pitching chains may not be attached crossed (twisted).
• Do not exceed the maximum load capacity of the chain supports.

1 Pitching chain, size 10 1 Pitching chain, size 13

thickness of chain link 10 mm thickness of chain link 13 mm
with maximum load capacity 2,6 t with maximum load capacity 5,6 t
maximum permissible load 2600 kg maximum permissible load 5600 kg

10 13
2.3 t 2.6 t 5t 5.6 t
minimum 1500 mm

54 Druckdatum / print date 07/23

Erstelldatum / creation date 03/23 - V 1.0
V arrangement with two pitching chains, size 10

The inclination angle α is the angle between the direction of the chain and an imaginary vertical line
and is determined over the length of the pitching chain. When lifting up or lowering down and securing
the piles in a V arrangement, pitching chains are required with T-handles on both ends and a minimum
length between the T-handles of at least 1500 mm. The maximum permissible load depends on the
pitching chain being used, the chain supports and the pitching situation.

When lifting up and lowering piles with two pitching chains the inclination angle β is generated by the
lateral spacing of the pitching holes in the piles and the length of the pitching chains.

Warning
• The inclination angle α and β of the pitching chains must not exceed 45°.
• Pitching chains may not be attached crossed (twisted).
• Do not exceed the maximum load capacity of the chain supports.
• Only use pitching chains with the same load capacity.

2 Pitching chains, size 10 2 Pitching chains, size 10

thickness of chain link 10 mm thickness of chain link 10 mm
both with maximum load capacity 2,6 t each both with each maximum load capacity 2,6 t each
inclination angle β up to 20° inclination angle β between 20° und 45°
maximum permissible load 2600 kg maximum permissible load 3500 kg

10
2.3 t 2.6 t
minimum 1500 mm

55
Vibrator MRZV-VV

V arrangement with two pitching chains, size 13

The inclination angle α is the angle between the direction of the chain and an imaginary vertical line
and is determined over the length of the pitching chain. When lifting up or lowering down and securing
the piles in a V arrangement, pitching chains are required with T-handles on both ends and a minimum
length between the T-handles of at least 1500 mm. The maximum permissible load depends on the
pitching chain being used, the chain supports and the pitching situation.

When lifting up and lowering piles with two pitching chains the inclination angle β is generated by the
lateral spacing of the pitching holes in the piles and the length of the pitching chains.

Warning
• The inclination angle α and β of the pitching chains must not exceed 45°.
• Pitching chains may not be attached crossed (twisted).
• Do not exceed the maximum load capacity of the chain supports.
• Only use pitching chains with the same load capacity.

2 Pitching chains, size 13 2 Pitching chains, size 13

thickness of chain link 13 mm thickness of chain link 13 mm
both with maximum load capacity 5,6 t each both with each maximum load capacity 5,6 t each
inclination angle β up to 20° inclination angle β between 20° und 45°
maximum permissible load 5600 kg maximum permissible load 7000 kg

13
5t 5.6 t
minimum 1500 mm

56 Druckdatum / print date 07/23

Erstelldatum / creation date 03/23 - V 1.0
Single-leg arrangement with one pitching chain

The piles can be lifted up and lowered down in a vertical single-leg. The inclination angle α that is
generated between the pitching chain and an imaginary horizontal line should be equal to 90°. For
lifting up / lowering down and securing the pile in single-leg arrangement pitching chains are required
with T-handles on both ends and a length between the T-handles of at least 950 mm. The maximum
permissible load depends on the pitching chain being used, chain support and the pitching situation.

Warning
Do not exceed the maximum load capacity of the chain supports.

1 Pitching chains, size 10 1 Pitching chains, size 13

thickness of chain link 10 mm thickness of chain link 13 mm
with maximum load capacity 2,3 t with maximum load capacity 5,0 t
maximum permissible load 2300 kg maximum permissible load 5000 kg

10 13
2.3 t 2.6 t 5t 5.6 t
minimum 950 mm

57
Vibrator MRZV-VV

Single-leg arrangement with two pitching chains, size 10

The piles can be lifted up and lowered down in a vertical single-leg. The inclination angle α that is
generated between the pitching chain and an imaginary horizontal line should be equal to 90°. For
lifting up / lowering down and securing the pile in single-leg arrangement pitching chains are required
with T-handles on both ends and a length between the T-handles of at least 950 mm. The maximum
permissible load depends on the pitching chain being used, chain support and the pitching situation.

When lifting up and lowering piles with two pitching chains the inclination angle β is generated by the
lateral spacing of the pitching holes in the piles and the length of the pitching chains.

Warning
• The inclination angle β of the pitching chains must not exceed 45°.
• Pitching chains may not be attached crossed (twisted).
• Do not exceed the maximum load capacity of the chain supports.
• Only use pitching chains with the same load capacity.

2 Pitching chains, size 10 2 Pitching chains, size 10

thickness of chain link 10 mm thickness of chain link 10 mm
both with maximum load capacity 2,3 t each both with maximum load capacity 2,3 t each
inclination angle β up to 20° inclination angle β between 20° and 45°
maximum permissible load 2300 kg maximum permissible load 3100 kg

10
2.3 t 2.6 t
minimum 950 mm

58 Druckdatum / print date 07/23

Erstelldatum / creation date 03/23 - V 1.0
Single-leg arrangement with two pitching chains, size 13

The piles can be lifted up and lowered down in a vertical single-leg. The inclination angle α that is
generated between the pitching chain and an imaginary horizontal line should be equal to 90°. For
lifting up / lowering down and securing the pile in single-leg arrangement pitching chains are required
with T-handles on both ends and a length between the T-handles of at least 950 mm. The maximum
permissible load depends on the pitching chain being used, chain support and the pitching situation.

When lifting up and lowering piles with two pitching chains the inclination angle β is generated by the
lateral spacing of the pitching holes in the piles and the length of the pitching chains.

Warning
• The inclination angle β of the pitching chains must not exceed 45°.
• Pitching chains may not be attached crossed (twisted).
• Do not exceed the maximum load capacity of the chain supports.
• Only use pitching chains with the same load capacity.

2 Pitching chains, size 13 2 Pitching chains, size 13

thickness of chain link 13 mm thickness of chain link 13 mm
both with maximum load capacity 5,0 t each both with maximum load capacity 5,0 t each
inclination angle β up to 20° inclination angle β between 20° and 45°
maximum permissible load 5000 kg maximum permissible load 6800 kg

13
5t 5.6 t
minimum 950 mm

59
Vibrator MRZV-VV

Identification tag / inspection tag

The pitching chains are identified on one side near Example: Identification tag
the T-handle with an identification tag 1. The iden-
tification tag contains the maximum load capacity, 1 Serial number
serial number and the date of the next inspection
by a competent person. When replacing the pit-
ching chains secure one end with the T-handle
holder, make sure the tags are position so they
don't have to go through the pile pitching holes.
10
2.3 t 2.6 t

Warning
Replace the pitching chains if the identifica-
tion tag, or the inspection tag are missing, or
if the information on the tags are illegible.

Maximum load capacity

in vertical leg
Maximum load capacity
in V arrangement

13
5t 5.6 t
Notice
For checking the chain links, a wear gauge is
integrated in the inspection tag.

Wear gauge chains Ø

Storing the pitching chains

Wear gauge chain pitch
Clean the pitching chains after use and before
storage and protect them from the effects of the
weather or aggressive substances. If the pitching
chains will not be used for a longer period of time,
protect them against corrosion.

60 Druckdatum / print date 07/23

Erstelldatum / creation date 03/23 - V 1.0
Inspecting the pitching chains Inspection intervals

The pitching chains consist of round steel chain • Before first using the pitching chains have
links grade 8, special links and two T-handles. the condition and the completeness inspected
During use the pitching chains are exposed to by a competent person for lifting accessories.
conditions and wear that may influence the wor- Immediately dispose of and replace the pit-
king safety. Inspect the pitching chains regularly ching chains with new ones in case of safety-
and dispose of and replace them immediately in relevant defects. Mark the next inspection date
case of any safety-relevant defects. When using ((half-year mark) on the rectangular inspection
two pitching chains both pitching chains should tag.
be replaced at the same time.
• Before each operation inspect the pitching
When inspecting the pitching chains safety related chains for obvious defects and completeness.
defects should be identified and eliminated. The Immediately dispose of and replace with new
operator is responsible for the immediate remedy pitching chains in cases of damage, or when
of any defects. In cases of extended operational the wear limits are exceeded.
conditions the test and inspection intervals should
be re-assessed by the operator and adjusted • At least every 6 months - have the condition
accordingly. Depending on the operating condi- and completeness of the pitching chains ins-
tions, or in special circumstances, shorter test pected by a competent person for lifting ac-
intervals may be required. It might be necessary cessories. Immediately dispose of and replace
to clean the pitching chains prior to any visual or the pitching chains in case of safety-relevant
functional testing. defects. Mark the next inspection date (half-
year mark)) on the rectangular inspection tag.
Document the inspection report and keep it
until the next inspection.

• At least every 36 months, or after special

incidents have the pitching chains inspected
for cracks and micro cracks by a competent
person, e.g. via a non-destructive test. Docu-
ment the inspection report and keep it until the
next inspection.

61
Vibrator MRZV-VV

Danger
Danger of serious or even fatal injury from
falling piles, or machine parts:
• Immediately dispose of and replace pit-
ching chains with new ones in cases of
safety-relevant defects, e.g. wear or over-
stressing.
• When using two pitching chains replace
both pitching chains at the same time and
use pitching chains of the same type only.

max. + 5 %
Warning
• Immediately replace pitching chains in ca-
ses of safety-relevant defects, e.g
- elongation through overstressing, when
the chain or a single link is elongated more A
than 5 % or when there is no free movement max. - 10 %
between the chain links.
- the dimensions of the components are re-
A
duced by more than 10 % in one location.
- mechanical damage caused through crus-
A-A d1+d2 > 0,9 d
hing, notching or surface cracks.
- deformation through bending, twisting or 2
denting.
d = rated thickness
- excessive corrosion.
d1 + d2 = actual dimensions
- contact with electric power.
- heating over 200 °C.
max. - 10 %
• Meet the regular inspection intervals and
keep the test certificates until the next ins-
pection.

62 Druckdatum / print date 07/23

Erstelldatum / creation date 03/23 - V 1.0
Inspecting the pitching chain 10 c
Maximum load capacity 2.3 t

e.g. ABI art. No. 76429633

Thickness of chain link a = 10 mm.
Length of chain link b = 30 mm. d
Thickness of special chain link c = 10 mm.
Length of special chain link d = 37 mm.
Length of special chain link g = 39 mm. g
Length of T-handle e = 95 mm.
Length of chain between T-handles f = 1534 mm.

Checking the round steel chain by means of

wear gauge. The wear gauge is integrated in a
the inspection tag: f h
Check the diameter a of the chain link at the thin-
nest spot, each time offset by 90°, with the wear
gauge chain Ø. If the chain link can be pu- shed
in all the way to the stop of the gauge, the chain
must be replaced.
b
Check the chain pitch h of the chain link with the
wear gauge of the chain pitch. If the wear gauge
can be pushed between the two chain links, the
d
chain must be replaced.

Checking the special chain links with vernier

calipers:
Using a caliper determine the chain link diame- e
ter at the thinnest spot, each time offset by 90°
(d1+d2 on previous page), Replace the pitching Thickness of chain link a
chain at an averaged thickness of c = 9,0 mm or Length of chain link, inside b
less. Thickness of special chain link c
Length of special chain link, inside d / g
Determine the length of the chain links at the lon- Length of T-handle e
gest internal spot using a slide caliper. Re- place Length of chain between T-handles f
the pitching chain with an inside measurement of Chain pitch h
d = 38.9 mm / g = 41,0 mm or more.

Replace the pitching chain upon obvious wear of

the T-handles and special chain links..
10
2.3 t 2.6 t

Wear gauge
chains Ø

Wear gauge chain pitch h

63
Vibrator MRZV-VV

Inspecting the pitching chain 13 c

Maximum load capacity 5.0 t

e.g. ABI art. No. 76429634

Thickness of chain link a = 13 mm.
Length of chain link b = 39 mm. d
Thickness of special chain link c = 16 mm.
Length of special chain link d = 68 mm.
Length of T-handle e = 120 mm.
Length of chain between T-handles f = 1566 mm.

Checking the round steel chain by means of a

wear gauge. The wear gauge is integrated in
the inspection tag:
h
Check the diameter a of the chain link at the thin- f
nest spot, each time offset by 90°, with the wear
gauge chain Ø. If the chain link can be pu- shed
in all the way to the stop of the gauge, the chain
must be replaced.
b
Check the chain pitch h of the chain link with the
wear gauge of the chain pitch. If the wear gauge
can be pushed between the two chain links, the
chain must be replaced.

Checking the special chain links with vernier

calipers:
Using a caliper determine the chain link diame-
ter at the thinnest spot, each time offset by 90° e
(d1+d2 on previous page), Replace the pitching
chain at an averaged thickness of c =14.4 mm Thickness of chain link a
or less. Length of chain link, inside b
Thickness of special chain link c
Determine the length of the chain links at the lon- Length of special chain link, inside d
gest internal spot using a slide caliper. Re- place Length of T-handle e
the pitching chain with an inside measurement of Length of chain between T-handles f
d = 71.4 mm or more Chain pitch h

Replace the pitching chain upon obvious wear of

the T-handles and special chain links..

13
5t 5.6 t

Wear gauge
chains Ø

Wear gauge chain pitch h

64 Druckdatum / print date 07/23

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Inspecting the chain supports

At the lower end of the vibrator there are two pit-

ching chain supports 1 for lifting and securing and
are suitable for one or two pitching chains. The 2
pitching chains are attached and secured to the
chain supports 1 with T-handle holders 2. For pit-
ching chains with a chain link thickness of 10 mm
adapter plates 3 are required to be attached to
the chain supports 1. 3

Danger
Danger of serious or even fatal injury from
falling piles, or machine parts. Immediately
1 Chain support
dispose of and replace chain supports with 1
2 T-handle holder
new ones in cases of safety-relevant defects,
3 Adapter plate
e.g. wear or overstressing.

Warning Chain support with load capacity details

• Inspect the chain supports, adapter plates
and mounting bolts for obvious defects, Chain support Ø 40 mm - pitching chain 10
e.g. damage, deformation, cracks and Maximum load capacity: e.g. 3500 kg
wear. If damaged or if the wear limits are
exceeded, replace immediately. Replace Chain support Ø 65 mm - pitching chain 13
the chain supports and adapter plates if the Maximum load capacity: e.g. 7000 kg
hole diameters are enlarged by more than
6 % in any one spot.
• Check the attachment of the pitching chains
with the T-handle holders. Make sure that
all mounting bolts are well fastened. Maximum load capacity
• Check the attachment of the adapter plate in vertical leg
on the chain support. Make sure that all
mounting bolts are well fastened.
• When the chain supports, adapter plates
or T-handle holders are replaced the bolts
must be replaced as well.
• Only use chain supports with the same load WLL 7 t
WLL 3,5 t 0°-45°
capacity. R006201

Maximum load capacity

in V arrangement
Production number

65
Vibrator MRZV-VV

Inspecting the chain supports

Pitching chain 10
Hole diameter d
Adapter plate - hole diameter d = 40.0 mm

Determine the diameter at the largest point using

a caliper. Replace the adapter plate at a diameter
of 42.5 mm or greater.
d d
Pitching chain 13

Chain support - hole diameter d = 65.0 mm

Determine the diameter at the largest point using

a caliper. Replace the chain support at a diameter
of 69,0 mm or greater.

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4.3.2 Driving in piles

Caution
• Two people are required to drive and
extract piles:
- one driver to operate the control devices in
the cabin.
- one slinger or spotter to attach and align
the piles, as well as to monitor the driving
and working area.

• The safety instructions in the operating

manual must be read and applied by each
person who is responsible for working with
or at the machine.
• Due to the working situation workplaces
may be within the danger area. Personal
protection equipment must be worn.
• Check the pitching chains and chain sup-
ports for obvious defects and complete-
ness before each operation. Immediately
replace them when they are damaged, or
the wear limits are exceeded (as described
in this manual).
• Before each working process check the
piles for obvious defects e.g. deformation
or cracks. Do not drive or extract damaged
piles. Piles with burr-free holes are requi-
red, with a given hole spacing and diameter,
depending on the pitching chain.
• Do not use any other equipment to raise
and lower the pile in conjunction with the
pitching chains.
• The ABI MOBILRAM-System and the in-
terchangeable attachments are designed
and constructed for the use mentioned and
described in the operating manual only. Any
other use of the machine without written
consent of the manufacturer is considered
to be an improper use.

67
Vibrator MRZV-VV

1 Preparing the work

• Examine the soil report and establish if the • Take further organizational measures. Pre-
soil is appropriate for pile driving. Determine pare storage areas for the piling elements as
driving procedure, work sequence, machines, close as possible so that the piling elements
auxiliary equipment and consider pile-driving can be picked up and laid down without endan-
aids if applicable. Examine the subsoil for un- gering the slinger or other construction site
exploded ordnance, cavities and hazardous personnel. Check the condition and design
substances. of the piling elements clean the profile locks
• Prepare sufficiently large and adequate load and if necessary, lubricate. For the driving and
bearing working areas. Take the required soil extraction of double profiles, sheet pile profiles
bearing capacity (kN/m²) for the operation of the must be permanently joined (e.g. profiles with
machine from the stability and ground pressure pressed profile locks) are required.
calculation. An insufficient load bearing ground
can be made more load bearing by using load
distributing boards (crane mats or steelplates)
and through replacement of the soil or stabili-
zation of the soil.
• Determine the danger area, travel routes
and work processes together with the site
supervisor and the people responsible for oc-
cupational safety and health, mark off the work
areas if necessary (see chapter Safety instruc-
tions and restrictions, danger area). Determine
the safety distances to possible danger points,
e.g. overhead lines, buried lines, buildings,
embankments or other hazards. In addition,
the applicable national regulations for piling
and piling equipment must be checked and
observed.
• Check environmental protection regulations
and take the necessary measures to prevent
and reduce harmful environmental effects, in
particular from exhaust, noise and vibration
emissions as well as water protection measu-
res.
• Check the weather conditions for the sche-
duled construction period. The maximum
permissible wind pressure is 250 N/m², this
corresponds to a wind velocity of 20 m/s or 72
km/h. The wind velocity must be measured at
the machine (see chapter Safety Proofs, Wind
velocity). Wind speeds below the maximum
permissible wind speed or wind surges can
also cause an uncontrolled oscillation of the
pile element, depending on the cross-sectional
area being pitched. Increased rainfall may
affect the load bearing capacity of the soil.

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2 Attaching the pile

Danger
• Danger of serious or even fatal injury from
falling piles, or machine parts:
- Always secure the piles with pitching
chains before each work process.
- Check the piles for obvious defects before
each work process.
- Only use piles with correct pitching holes. If
the spacing is smaller than described in the
manual, the pitching chain can be clamped
with the clamp assembly and damaged. If
the spacing is larger than decribed in this
manual, the pitching chain may be pinched
or jammed, when the piles are lifted, or es-
pecially when they are lowered. The chains
can be damaged, or even break suddenly,
due to the lever effect of the piles, which
can result in severe injury, or even death.
- Do not use additional equipment other than
the pitching chains to raise or lower the
piles.
- The installation and/or use of accessories
not tested and approved by ABI may affect
the safety - a safe work process is only
ensured when using original spare parts.
- Store the piles in such a manner that they
can be raised and lowered without any
danger.
- Do not pull the piles along the ground using
the auxiliary winch; avoid diagonal pulling
of the winch rope.

• Danger of severe or even fatal injury

through crushing:
- When staying in the danger area, e.g. when
making corrective movements with the
machine.
- Whilst attaching and detaching the pitching
chains. Do not operate any function whilst
the slinger attaches or detaches the pit-
ching chain.

• Danger of burns from hot machine parts.

The vibrator can get very hot during opera-
tion.

69
Vibrator MRZV-VV

Attaching the pile

Caution
• Check the pitching chains and chain sup-
ports, before each work process for obvi-
ous defects, e.g. completeness, damage
and wear.
• The pitching hole must be freely accessible
when attaching the piles.

• Move the machine as close as possible to the

pile.
• Align the vibrator and the pitching chain in the
pile direction.
• Lower the vibrator until the pitching chain is
vertically above the pitching hole in the pile.
• Securely attach the pile. Do not exceed the
maximum safe working load of the pitching
chains and the maximum load capacity of the
ABI Mobilram-System (see chapter Safety
Proofs, Stability). Make sure that the T-handle
is well fastened.
• In addition, the national regulations in force for
pile drivers and pile driving equipment must be
checked and observed. If necessary or requi-
red additionally secure the piles using safety
hooks or shackles. If in doubt please contact
your safety officer.

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3 Lifting the pile

Warning
• Danger of serious or even fatal injury from
falling pile elements, or machine parts:
- Make sure that the pile and the pitching
chain does not get caught during lifting.
The pitching chain may be damaged
or break suddenly through jamming or
pinching.
- Always align the vibrator and the pitching
chain towards the pile, avoid diagonal
pulling on the pitching chain by tracking the
machine. When lifting the pile the machine
should travel forwards as the pile is being Example - figure A
raised (figure A). The speed of travel should
be synchronized with the lifting rate.
- Make sure that the T-handle is secured in
the chain support and the pile element.
- Only raise or lower the pile so long as there
is nobody in the danger area. The slinger
must leave the danger area before lifting the
pile and must be within the driver's visual
range. The lifting process must be cons-
tantly monitored by the driver and slinger
in order to stop the lifting process, e. g. if
the pitching chain is jamming or pinching
or if there are persons in the danger area.
The slinger must assist in the lifting of the
pile using signals, e.g. hand signals, agreed
upon previously.
- Ensure clear vision in the driving and work
area, also the machine and surrounding
areas. When vision is restricted, e. g. when
reversing, a signaller is required. The
slinger / instructor must always be in the
drivers’ vision. The lifting process must
be constantly monitored by the driver and
slinger in order to stop the lifting process,
e. g. if the pitching chain is jammed or
pinched or if there are people in the danger
area. The slinger must assist in the lifting
process using signals previously agreed
upon, e.g. hand signals.
- Only activate the vibrator or move the ma-
chine if the pile is completely and correctly
clamped in the clamp assembly.
- Do not stand under suspended loads.

71
Vibrator MRZV-VV

Example - figure A
• Danger of serious or even fatal injury
through crushing:
- The pile may swing as soon as it hangs
freely in the pitching chain. Raise the pile
slowly at the end of the lifting process to
avoid the pile swinging.
- Do not make sudden movements with the
machine when lifting pile.

Warning
• Stop the lifting process and switch off the
machine or place the machine in the trans-
port position if the maximum permissible
wind velocity is exceeded. Wind speeds
below the maximum permissible wind
speed or wind surges can also cause an
uncontrolled oscillation of the pile element,
depending on the cross-sectional area
being pitched.

Lifting the pile

• Make sure that there is nobody in the danger
area.
• Slowly raise the vibrator and track forward and
follow the pile simultaneously, until the pile
hangs freely in the pitching chain just above
the ground. Avoid diagonal pulling by tracking
the machine (figure A).
• Whilst lifting the pile ensure that the pitching
chain runs freely and does not get jammed or
trapped. Ensure good visibility..

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4 Clamping and aligning the pile

Danger
• Danger of serious or even fatal injury from
falling piles, or machine parts:
- Clamp the pile element evenly and with the
complete surface of the clamping jaws on
both sides. If the pile is partially clamped,
the clamp assembly, and jaw assembly can
be damaged.
- Do not let the pile fall into the pitching
chains, the pitching chains and the chain
supports may be damaged or even severed
abruptly through the high dynamic forces.
- Only move the machine so long as there is
nobody in the danger area.
- The slinger must be within the visual ran-
ge of the operator. Assist in the alignment
using previously arranged signals, e.g.
hand signals. Only enter the danger area if
it is absolutely necessary.

• Danger of serious or even fatal injury

through crushing:
- When inserting the pile into the clamp as-
sembly or a profile interlock.
- Do not reach into the clamp assembly when
it is being closed.
- Do not make sudden movements with the
machine when clamping and aligning the
pile.

Caution
• Immediately stop the operation if the requi-
red clamping pressure is not attained.
Eli- minate the cause of the malfunction or
contact your service partner.
• Only activate the vibrator if the pile is clam-
ped in the clamp assembly.
• Pay attention to the parallel orientation of
the leader mast to the pile element. Incor-
rect orientation of the piling element may
damage the machine.

73
Vibrator MRZV-VV

Clamping and aligning the pile

• Lower the vibrator until the pile stands on the
ground.
• Insert the pile into the clamp assembly by
lowering the vibrator. Completely insert the
piling element into the clamping gap to prevent
it from falling sideways or slipping out of the
clamping jaws. The view of the upper end of
the pile and the clamp can be facilitated by a
clamp-on camera (option).
• Close the jaw assembly. Clamp the pile evenly
on both sides with the complete surface of the
clamping jaws. The function Clamp on the ABI
control panel must remain in the CLOSED
position.
• If necessary, raise the vibrator approx. 0.5 m
with the pile clamped and move the machine
carefully to the required position.
• Vibrate the pile element to the required posi-
tion, e.g. for sheet pile introduce the bottom
edge of the pile into a previously driven sheet
interlock.
• Build up the pre-stressing pressure and slightly
press the pile into the ground and align it par-
allel with the leader mast.
• Manually align the leader mast or switch on
the automatic alignment system on the ABI
control panel.

Notice
The insertion of the pile and the pile alignment
may be assisted by the slinger/spotter.

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5 Driving in the pile

Danger
• Danger of serious or even fatal injury from
falling piles, or machine parts:
- Only move the machine as long as nobody
is in the danger area.
- The slinger must be within the visual ran-
ge of the operator. Assist in the operation
using previously arranged signals, e.g.
hand signals. Only enter the danger area if
it is absolutely necessary.
- Do not stand in the danger area during the
pile driving operation.

Caution
• Immediately stop the operation if the requi-
red clamping pressure is not attained.
Eli- minate the cause of the malfunction or
contact your service partner.
• Do not track the machine during the piling
operation especially avoid movements with
the main boom or chassis.The machine may
be damaged through jamming or tilting the
pile.
• If the pile-driving progress is less than 10
cm/min, or if the vibrator is recoiling or
shaking violently, the pile driving operati-
on must be stopped immediately, or pile-
driving aids must be used, e.g. predrilling
or jetting. If the pile driving lasts longer
than 10 cm/min, the soil may settle through
compaction of the ground material and
cause damage to the machine, or to adja-
cent buildings. If no pile-driving aids are
used on hard to install piles this may lead
to material failure and premature wear.
Hydraulic hoses and attached parts may
become loose. The vibrator may over- heat
and be damaged or the pile may shear or
tear off.

75
Vibrator MRZV-VV

Driving in the pile

• Build up the pre-stressing pressure and slightly
press the pile into the ground.
• Check the alignment of the pile again. If ne-
cessary, open the clamp assembly again to
release the pile, but do not back the clamp
assembly out of the pile. Realign the pile and
mast so they are parallel. Close the jaw as-
sembly again.
• Switch off the automatic alignment system.
• Bring the vibrator to operating speed.
• Adjust the speed, static momentum and
the pre-stressing pressure to the respective
ground conditions of and construction site.
• Check the alignment of the pile during the pile
driving operation and correct if necessary.
• Drive the pile into the ground.

Notice
• If the piles cannot be driven in or at an ad-
vancement of less than 10 cm/min loosen
the ground material by predrilling or water
jetting. The pile driving times as well as
noise and vibration will be reduced signi-
ficantly.
• If the soil material is compacted too much,
the ground resistance may increase to such
an extent that subsequent pile elements
cannot be driven to the depth of the previ-
ous profile.

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6 Detaching the pile

Danger
• Danger of serious or even fatal injury
through crushing:
- When detaching the pitching chain.
- Do not reach into the clamp assembly du-
ring opening.
- Do not make sudden movements while
detaching piles.
- The slinger must be within the visual range
of the operator. Only enter the danger area
if it is absolutely necessary.

• Danger of burns from hot machine parts.

The vibrator can get very hot during opera-
tion.

Caution
• Do not move the machine until the clamp
assembly is open and the pitching chain is
detached.

• Check the alignment of the pile before the

following steps:
- Remove the pre-stressing pressure. Raise the
vibrator a little to release the tension on the
elastomers.
- Set the static moment to minimum.
- As soon as the vibrator runs vibration-free, shut
off the speed and wait until it stops.
- Open the jaw assembly completely.
- Detach the pitching chain.

77
Vibrator MRZV-VV

4.3.3 Extracting piles

Caution
• Two people are required to drive and
extract piles:
- one driver to operate the control devices in
the cabin.
- one slinger or spotter to attach and align
the piles, as well as to monitor the driving
and working area.

• The safety instructions in the operating

manual must be read and applied by each
person who is responsible for working with
or at the machine.
• Due to the working situation workplaces
may be within the danger area. Personal
protection equipment must be worn.
• Check the pitching chains and chain sup-
ports for obvious defects and complete-
ness before each operation. Immediately
replace them when they are damaged, or
the wear limits are exceeded (as described
in this manual).
• Before each working process check the
piles for obvious defects e.g. deformation
or cracks. Do not drive or extract damaged
piles. Piles with burr-free holes are requi-
red, with a given hole spacing and diameter,
depending on the pitching chain.
• Do not use any other equipment to raise
and lower the pile in conjunction with the
pitching chains.
• The ABI MOBILRAM-System and the in-
terchangeable attachments are designed
and constructed for the use mentioned and
described in the operating manual only. Any
other use of the machine without written
consent of the manufacturer is considered
to be an improper use.

78 Druckdatum / print date 07/23

Erstelldatum / creation date 03/23 - V 1.0
1 Preparing the work
• Examine the soil report and establish if the • Take further organizational measures. Pre-
soil is appropriate for pile driving. Determine pare storage areas for the piling elements as
driving procedure, work sequence, machines, close as possible so that the piling elements
auxiliary equipment and consider pile-driving can be picked up and laid down without endan-
aids if applicable. Examine the subsoil for un- gering the slinger or other construction site
exploded ordnance, cavities and hazardous personnel. Check the condition and design
substances. of the piling elements clean the profile locks
• Prepare sufficiently large and adequate load and if necessary, lubricate. For the driving and
bearing working areas. Take the required soil extraction of double profiles, sheet pile profiles
bearing capacity (kN/m²) for the operation of the must be permanently joined (e.g. profiles with
machine from the stability and ground pressure pressed profile locks) are required.
calculation. An insufficient load bearing ground
can be made more load bearing by using load
distributing boards (crane mats or steelplates)
and through replacement of the soil or stabili-
zation of the soil.
• Determine the danger area, travel routes
and work processes together with the site
supervisor and the people responsible for oc-
cupational safety and health, mark off the work
areas if necessary (see chapter Safety instruc-
tions and restrictions, danger area). Determine
the safety distances to possible danger points,
e.g. overhead lines, buried lines, buildings,
embankments or other hazards. In addition,
the applicable national regulations for piling
and piling equipment must be checked and
observed.
• Check environmental protection regulations
and take the necessary measures to prevent
and reduce harmful environmental effects, in
particular from exhaust, noise and vibration
emissions as well as water protection measu-
res.
• Check the weather conditions for the sche-
duled construction period. The maximum
permissible wind pressure is 250 N/m², this
corresponds to a wind velocity of 20 m/s or 72
km/h. The wind velocity must be measured at
the machine (see chapter Safety Proofs, Wind
velocity). Wind speeds below the maximum
permissible wind speed or wind surges can
also cause an uncontrolled oscillation of the
pile element, depending on the cross-sectional
area being pitched. Increased rainfall may
affect the load bearing capacity of the soil.

79
Vibrator MRZV-VV

2 Attaching the pile

Danger
• Danger of serious or even fatal injury from
falling piles, or machine parts:
- Always secure the piles with pitching
chains before each work process.
- Check the piles for obvious defects before
each work process.
- Only use piles with correct pitching holes. If
the spacing is smaller than described in the
manual, the pitching chain can be clamped
with the clamp assembly and damaged. If
the spacing is larger than decribed in this
manual, the pitching chain may be pinched
or jammed, when the piles are lifted, or es-
pecially when they are lowered. The chains
can be damaged, or even break suddenly,
due to the lever effect of the piles, which
can result in severe injury, or even death.
- Do not use additional equipment other than
the pitching chains to raise or lower the
piles.
- The installation and/or use of accessories
not tested and approved by ABI may affect
the safety - a safe work process is only
ensured when using original spare parts.
- Store the piles in such a manner that they
can be raised and lowered without any
danger.
- Do not pull the piles along the ground using
the auxiliary winch; avoid diagonal pulling
of the winch rope.

• Danger of severe or even fatal injury

through crushing:
- When staying in the danger area, e.g. when
making corrective movements with the
machine.
- Whilst attaching and detaching the pitching
chains. Do not operate any function whilst
the slinger attaches or detaches the pit-
ching chain.

• Danger of burns from hot machine parts.

The vibrator can get very hot during opera-
tion.

80 Druckdatum / print date 07/23

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Attaching the pile

Caution
• Check the pitching chains and chain sup-
ports, before each work process for obvi-
ous defects, e.g. completeness, damage
and wear.

• Move the machine as close as possible to the

pile.
• Align the vibrator and the pitching chain in the
pile direction.
• Lower the vibrator until the pitching chain is
vertically above the pitching hole in the pile.
• Securely attach the pile. Do not exceed the
maximum safe working load of the pitching
chains and the maximum load capacity of the
ABI Mobilram-System (see chapter Safety
Proofs, Stability). Make sure that the T-handle
is well fastened.
• In addition, the national regulations in force for
pile drivers and pile driving equipment must be
checked and observed. If necessary or requi-
red additionally secure the piles using safety
hooks or shackles. If in doubt please contact
your safety officer.

81
Vibrator MRZV-VV

3 Clamping the pile

Danger
• Danger of serious or even fatal injury from
falling piles, or machine parts:
- Clamp the pile element evenly and with the
complete surface of the clamping jaws on
both sides. If the pile is partially clamped,
the clamp assembly, and jaw assembly can
be damaged.
- Do not let the pile fall into the pitching
chains, the pitching chains and the chain
supports may be damaged or even severed
abruptly through the high dynamic forces.
- Only move the machine so long as there is
nobody in the danger area.
- The slinger must be within the visual ran-
ge of the operator. Assist in the alignment
using previously arranged signals, e.g.
hand signals. Only enter the danger area if
it is absolutely necessary.

• Danger of serious or even fatal injury

through crushing:
- When inserting the pile into the clamp as-
sembly or a profile interlock.
- Do not reach into the clamp assembly when
it is being closed.
- Do not make sudden movements with the
machine when clamping and aligning the
pile.

Caution
• Immediately stop the operation if the requi-
red clamping pressure is not attained.
Eli- minate the cause of the malfunction or
contact your service partner.
• Only activate the vibrator if the pile is clam-
ped in the clamp assembly.
• Pay attention to the parallel orientation of
the leader mast to the pile element. Incor-
rect orientation of the piling element may
damage the machine.

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Clamping the pile

• Lower the vibrator and insert the pile into the

clamp assembly. A clamp assembly camera
(option) can facilitate the view on the top end
of the pile and the clamp assembly.
• Close the jaw assembly. Clamp the pile evenly
on both sides with the complete surface of the
clamping jaws. The function Clamp on the ABI
control panel must remain in the CLOSED
position.
• Manually align the leader mast or switch on
the automatic alignment system on the ABI
control panel.

Notice
The insertion of the pile and the pile alignment
may be assisted by the slinger/spotter.

83
Vibrator MRZV-VV

4 Extracting the pile

Danger
• Danger of serious or even fatal injury from
falling piles, or machine parts:
- Only move the machine as long as nobody
is in the danger area.
- The slinger must be within the visual ran-
ge of the operator. Assist in the operation
using previously arranged signals, e.g.
hand signals. Only enter the danger area if
it is absolutely necessary.
- Do not stand in the danger area during the
pile extracting operation.
- Do not stand under suspended loads.

Caution
• Immediately stop the operation if the requi-
red clamping pressure is not attained.
Eli- minate the cause of the malfunction or
contact your service partner.
• Do not track the machine during the piling
operation especially avoid movements with
the main boom or chassis.The machine may
be damaged through jamming or tilting the
pile.
• If the pile-extracting progress is less than
10 cm/min, or if the vibrator is recoiling or
shaking violently, the pile-extracting opera-
tion must be stopped immediately, or pile-
extracting aids must be used, e.g. predril-
ling or jetting. If the pile-extracting lasts
longer than 10 cm/min, the soil may settle
through compaction of the ground mate-
rial and cause damage to the machine, or
to adjacent buildings. If no pile-extracting
aids are used on hard to install piles this
may lead to material failure and premature
wear. Hydraulic hoses and attached parts
may become loose. The vibrator may over-
heat and be damaged or the pile may shear
or tear off.

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Extracting the pile

• Switch off the automatic alignment system.

• Bring the vibrator up to operating speed.
• Adjust the speed, static momentum and
the pre-stressing pressure to the respective
ground conditions of and construction site.
• Build up the pre-stressing pressure and extract
the pile until the pile is just above the ground.
• Remove the pre-stressing pressure.
• Set the static moment to minimum.
• As soon as the vibrator runs vibration-free, shut
off the speed and wait until it stops.

Notice
• If the pile cannot be loosened or an ex-
traction rate greater than 10 cm/min is
unachievable loosen the ground material
by predrilling or water jetting. The pile ext-
raction times as well as noise and vibration
will be reduced significantly.
• Established piles can be loosened from the
ground using maximum static momentum,
briefly drive the piles down if necessary. If
the speed drops after the piles loosen redu-
ce the static momentum until the operating
speed is reached again.

85
Vibrator MRZV-VV

5 Lowering the pile

Danger
• Danger of serious or even fatal injury from - Only activate the vibrator or move the ma-
falling piles, or machine parts: chine if the pile is completely and correctly
- Make sure that the pile and the pitching clamped in the clamp assembly.
chain does not get caught during setting - Do not stand under suspended loads.
down. The pitching chain may be damaged
or break suddenly through jamming or • Danger of serious or even fatal injury
pinching. through crushing:
- Do not let the pile fall into the pitching - The pile may swing during lifting as soon
chains, the pitching chains and the chain as it hangs freely in the pitching chain.
supports may be damaged or even severed - When detaching the pitching chain.
abruptly through the high dynamic forces. - Do not reach into the clamp assembly when
- Always align the vibrator and the pitching it is being opened.
chain towards the pile, avoid diagonal - Do not make sudden movements with the
pulling on the pitching chain by tracking machine when lowering pile.
the machine. When lowering the pile the
machine should travel backwards as the
• Danger of burns from hot machine parts.
pile is being raised (figure A). The speed
The vibrator can get very hot during opera-
of travel should be synchronized with the
tion.
lowering rate.
- Make sure that the T-handle is secured in
the chain support and the pile element.
- Only raise or lower the pile so long as there
is nobody in the danger area (other than the
operator). The slinger must leave the dan-
ger area (see chapter before lowering the
pile) and must be within the driver's visual Example - figure A
range. The lowering process must be con-
stantly monitored by the driver and slinger
in order to stop the lowering process, e. g.
if the pitching chain is jamming or pinching
or if there are persons in the danger area.
The slinger must assist in the lowering of
the pile using signals, e.g. hand signals,
agreed upon previously.
- Ensure clear vision in the driving and work
area, also the machine and surrounding
areas. When vision is restricted, e. g. when
reversing, a signaller is required. The
slinger / instructor must always be in the
drivers’ vision. The lowering process must
be constantly monitored by the driver and
slinger in order to stop the lifting process,
e. g. if the pitching chain is jammed or
pinched or if there are people in the danger
area. The slinger must assist in the lifting
process using signals previously agreed
upon, e.g. hand signals.

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 Warning
• Before opening the clamp assembly make
sure that the pile is set down on solid
ground and secured against falling over. Do
not let the pile fall into the pitching chains.
The pitching chains and the chain supports
may be damaged or even severed abruptly.
• First let the vibrator stop completely, then
open the jaw assembly.
• Whilst lowering the pile ensure that the
pitching chain runs freely and does not get
caught or trapped.
• Only use the procedures described to drive
in and extract piles. Do not use any other
auxiliary equipment.
• The pitching hole must be freely accessible
when detaching the piles.

Lowering the pile

• Make sure that there are no persons in the

danger area, other than the operator.
• Move the machine in position to lay down the
piles. Align the vibrator and the pile in the di-
rection of the required storage position.
• Lower the vibrator until the bottom end of the
pile rests on solid ground in the required posi-
tion.
• Open the jaw assembly.
• Slowly raise the vibrator until the pile hangs
freely in the pitching chain. Example - figure A
• Slowly lower the vibrator and track backwards
and follow the pile down simultaneously (figure
A). Avoid diagonally pulling the pitching chain
by following-up with the machine.
• Lower the vibrator until the pile is set down at
the required storage position.
• Detach the pitching chains.

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Vibrator MRZV-VV

4.3.4 Driving on the construction site

Warning
The following points must be observed when
corrective movements are made with the at-
tachments mounted:

• Load bearing, horizontal ground.

• Lock the upper carriage of the carrier in the
direction of travel.
• Do not exceed the maximum admissible
load capacity of the attachment.
• Bring the leader mast in a upright position
and retract leader cylinders I and II as far
as possible.
• Switch off the automatic alignment.
• Switch on the acoustic or visual travel
alarm of the carrier.
• When moving the equipment the distance
between leader mast base and ground must
not exceed 0.5 m.

When moving the equipment on the construction

site or driving up slopes observe chapter: Telesco-
pic leader mast, driving on the construction site.

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4.3.5 Mounting jaw assembly

Warning Caution
• Danger from falling piles or damage to the Before using bolts clean the screw threads
machine. Use grease and silicone cleaning agents.
When changing a clamp assembly the fol-
• for set screws with metric regular thread ac-
lowing conditions must be fulfilled:
cording to DIN ISO 262.
The clamping force of the jaw assembly
• condition new, with thread grease - Flor Plus
must be 1.2 - times of the centrifugal force
Super Grease 1300.
of the vibrator.
• M30 - 8.8 for attaching the clamp assembly.
Example: centrifugal force 600 kN - clam-
ping force minimum 720 kN.
Tightening moment with locking
• Completely attach all screwed connections
washer DIN 25201 M30
of the jaw assembly and check connections
at tensile strength 8.8 Nm 1740
daily.

Caution
The jaw assembly must be attached to the
vibrator as follows - incorrect installation can
cause damage to the gear box.

Notice
Set the centrifugal force in the MRZV-VV mode
- see Operator's manual - control panel.

Example
Hole pattern: Bottom side - gear box
for MRZV 30VV, 36VV
front front

rear rear

rear Connections for jaw assembly

front

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Vibrator MRZV-VV

Fitting the adapter plate – assembling the jaw assembly turned through 90°

Caution
The jaw assembly can be assembled turned
through 90°. For this an adapter plate must be
fitted - through incorrect assembly there is a
danger of damaging the gear box.
Hole pattern: Adapter plate - gear box
Warning
Completely assemble all the bolted connec-
tions for the adapter plate and check bolted
connections daily.

Connections for adapter plate on the gear box

Adapter plate

Warning Hole pattern: Jaw assembly - adapter plate

Completely assemble all the bolted connec-
tions for the jaw assembly and check bolted
connections daily.

Connections for jaw assembly on adapter plate

Jaw assembly

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4.4 Transport
4.4.1 Placing and securing the vibrator on the transport frame

Danger Notice
• Only transport the attachment on the ap- • For transport place the vibrator together
propriate transport frame. with the transport frame in a horizontal
• Position and secure the attachment in the position.
appropriate transport frame – check the • Use anti sliding mats between the vibrator
stability of the transport frame. Close the and the loading platform.
jaw assembly. • Transporting on the side can cause bearing
• Only load the attachment using suitable damage.
lifting equipment at the provided lifting • Plug the hydraulic connections with sealing
points – the lifting points are coloured. plugs (dust cover).
• Never work or stand under suspended
loads.
• Whilst attaching and removing or loading
an attachment there is a risk of being crus-
hed.
• Only position attachments on load bearing
and horizontal ground.
• Option - Double clamp assembly: Risk of
tipping over - Secure the attachment and
transport frame together with four lashing 1
chains. Attach and tension the lashing
chains on the attaching points of the at-
4a
tachment and to the attaching points on 4a
the transport frame. 3a
3a
• Position vibrator in the transport frame. 4
4
• Close jaw assembly. 3
• Release hydraulic hoses and electric cable 3
from rapid changing device or from the
docking-system (see Operator's manual for
Telescopic leader mast, attaching and remo-
ving attachments). A check valve prevents any
unintended opening of the jaw assembly.
• Additionally secure the transport frame by 2
threading the pitching chains 1 through the
openings on the chain support 2 and insert the
T-handle holder into the openings 3 or 4 on the
transport frame.
- openings 3: for short pitching chain 10 2
- openings 3a: for long pitching chain 10
- openings 4: for short pitching chain 13
- openings 4a: for long pitching chain 13
• Remove the vibrator from the rapid changing
device or from the docking-system.
• Place the vibrator together with transport frame
in the horizontal position (see chapter4.4.3).
• Lash the vibrator on the transport support or on
the transport trailer. Secure attachments and
accessories against moving during transport.
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Vibrator MRZV-VV

Vibrator with Docking-System Vibrator with double clamp assembly

= Lifting points Danger

Double clamp assembly: Risk of tipping over
- Secure attachment and transport frame
with four lashing chains 1. Attach the lashing
= Lashing points chains to the connecting points of the attach-
ment and to the connecting points of the
transport frame and tension them.
Centre of gravity

Example Example

1 1

1 1

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4.4.2 Laying down the vibrator Example

1
Warning
• Whilst attaching and removing or loading
an attachment there is a risk of being crus-
hed.
• Never work or stand under suspended
loads. 90°
• Position the attachment in the appropriate
transport frame and then secure – check
the stability of transport frame. Close jaw
assembly.
• Use suitable lifting equipment with suffici-
ent load capacity and pay attention to the
total weight of the vibrator and the storage
frame.
• Do not exceed the load capacity of the au-
xiliary winch. Otherwise use a additional,
suitable lifting device.
2
• Slew upper carriage and auxiliary winch in
direction of travel.
• Incline the leader mast as far as possible to the
front and retract the telescopic leader mast.
• Position the vibrator at a 90° angle in front of
the leader mast (see figure 1).
• Attach suitable lifting equipment to the front
liftingpoints 4 of the vibrator.
• Carefully lay down the vibrator backwards, by
slowly unwinding the auxiliary winch rope and
at the same time slowly slewing the upper car-
riage. Avoid sudden movements (see figures
2 and 3).

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Vibrator MRZV-VV

4.4.3 Raising vibrator Example

1
Warning
• Whilst attaching and removing or loading
an attachment there is a risk of being crus-
hed. 90°
• Never work or stand under suspended
loads.
• Only raise the attachment together with the
transport frame.
• Use suitable lifting equipment with suffici-
ent load capacity and pay attention to the
total weight of the vibrator and the storage
frame.
• Do not exceed the load capacity of the au-
xiliary winch. Otherwise use a additional,
suitable lifting device.

• Slew upper carriage and auxiliary winch in 2

direction of travel.
• Incline the leader mast as far as possible to the
front and retract the telescopic leader mast.
• Position the vibrator at a 90° angle in front of
the leader mast (see figure 1).
• Attach suitable lifting equipment to the upper
liftingpoints 4 of the vibrator.
• Carefully raise the vibrator, by slowly winding
up the auxiliary winch rope and at the same
time slowly slewing the upper carriage. Avoid
sudden movements (see figures 2 and 3).

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4.4.4 Release pitching chains between vibrator and transport frame

Warning
• Whilst attaching and removing or loading
an attachment there is a risk of being crus- 1
hed.
• Risk of serious injury from falling transport
frame. Before attaching the vibrator, remo-
4a
ve the pitching chains 1 from the transport 4a
frame 3 or 4. Then pull out the pitching 3a
3a
chains through the openings on the trans-
4 4
port frame 2.
3
3
Notice
Attach the vibrator at the docking-system
or at the rapid changing device on the ABI
MOBILRAM-System (see Operator's manual
of Telescopic leader mast / attaching and re-
moving attachments). 2

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Vibrator MRZV-VV

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5 Maintenance and service

Warning
• All service and maintenance work must • Before carrying out welding work on the
be carried out by a qualified person using machine or on parts attached to the ma-
original ABI spare parts. chine that might conduct electrical cur-
• Before beginning any maintenance work let rent, cut the power supply of the carrier by
hot machine parts cool down. means of the battery section switch and
• When working over 2 m above ground use protect the electronic components (see
a fall arrestor or provide an assembly plat- Operator's manual of carrier).
form. • Fire risk - No welding work or open flames
• Keep tools in operationally safe and reliable near flammable operating liquids or hyd-
condition. raulic components.
• For lifting and loading operations use lifting • Do not carry out welding work on sup-
equipment with sufficient load capacity. porting parts.
• Only attach components on the designated • Accidents involving pressurised hydraulic
points provided. fluids, such as the injection of hydraulic oil
• Before starting work, lower the equipment under the skin, can result in serious injury
components and ensure that the hydraulic or, in the worst case, death. Injured persons
system has been depressurised. must be taken to the hospital - medical
• Do not start the machine during mainte- treatment has to be started immediately
nance work. Secure the machine against also at the slightest suspicion of injection
unexpected starting and put up warning including minor external injuries.
signs.
• Only carry out maintenance work when the If it is necessary that an operator or the auxiliary
machine is placed on load bearing ground staff repairs or services the pile driving equipment
and secured against moving. in the working area (danger area) and that one
• Only authorised personnel with special or several functions have to be activated for that
knowledge in hydraulics are allowed to purpose, then this work may only be carried out
work on the hydraulic installations. under the following conditions:
• Do not carry out alterations on the machine
that could affect the safety. This applies • at least two persons who are both instructed
especially to the installation and adjust- in safety issues must always be present.
ment of safety devices and valves (e.g. limit • one of them has to survey the safety of the
switches, pressure relief valves). other person(s) from the main operating stand.
• Work on the electric installations have to be • the surveying person must have immediate
carried out by an electrician in accordance access to an emergency stop device in all
with any electrical standards. situations.
• Before working on the electrical installation • the working area has to be sufficiently illumi-
the power supply to the carrier has to be nated.
switched off. • visual contact between the operator and the
• Do not change the programs of program- person carrying out the maintenance work
mable controls. Unintended changes to the must be established at all times.
controls affect the safety concept of the
Only when the equipment is completely shut down
machine.
and all means of starting have been disconnected
• Do not blast electric and electronic compo-
may a person carry out maintenance and service
nents with the high-pressure cleaners.
work on the equipment.

97
Vibrator MRZV-VV

Warning
For safe operation of the machine, careful
handling is required. This also includes the
timely detection and replacement of worn
or no longer functional safety-relevant com-
ponents. The operator‘s manual contain all
the necessary information, e.g. information
on wear limits, maintenance, as well as a de-
scription of the individual work or steps for a
safe exchange.

Follow is an overview of the most important com-

ponents:
• Pitching chains
• Chain support / t-handle
• Jaw pads
• Slide rails and slide guides

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Examination by a competent person
(Explanation)

Competent persons must meet the prerequisites

in the respective user's country and must have
been charged by the employer with the examinati-
on of equipment. The requirements of the national
regulations on operational safety must be com-
plied with. The required technical knowledge is
acquired through vocational training, professional
experience and a professional occupation within
a short period after the training. The competent
person must have knowledge about the state of
the art equipment and the known hazards. He/she
must be familiar with the national industrial safety
regulations and other rules such that he/she can
judge the safe condition of the equipment.

• A completed vocational training allows him/her

to establish the professional knowledge about
this equipment.
• Professional experience implies that the com-
petent person has been handling the equip-
ment to inspect it in the field. By participating
in inspections of equipment he/she has gained
adequate experience to qualify as an inspector.
• A professional occupation is comprised of
a current experience along with contionus
training and education. To gain practical ex-
perience, it is necessary to carry out several
inspections per year.

Additional requirements (additional professional

experience) must be complied with for the inspec-
tion of specific equipment or hazards, e.g. hazards
through pressure or electrical hazards.

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Vibrator MRZV-VV

5.1 Regular maintenance work - summary

Maintenance and Operations to perform see
inspection intervals chapter

oh operating hours
every 500 oh or six-monthly
every 250 oh or monthly

regularly
every 1000 oh or yearly
before commissioning

every 50 oh or weekly

during first use

every 10 oh or daily

Entire machine
Visual and functional inspection, completeness
Screwed connections: Check condition and tight seating Appendix
Check weld seams and cast pieces for cracks and damages
Gear box
Check oil level 5.2
Change oil 5.2
Rotating union: Replace transfer tubes and flange 5.7
Jaw assembly
Visual and functional inspection of jaws 5.4
Visual and functional inspection of pitching chain
Check screwed connections at jaw pads
Jaw assembly: check for cracks
Grease lubricating nipples 5.4
Pitching chain
Inspected by a qualified person for lifting accessoires 4.3.1
Slide rails and guides
Clean, check and grease as required 5.3
Check wear, replace at 3 mm abrasion

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Maintenance and Operations to perform see
inspection intervals chapter

oh operating hours
every 500 oh or six-monthly
every 250 oh or monthly

regularly
every 1000 oh or yearly
before commissioning

every 50 oh or weekly

during first use

every 10 oh or daily

Hydraulic system
Visual inspection hydraulic hoses and tubes,
replace damaged parts
Check quick-acting couplings and fittings for tightness
Change filter cartridge control-block 5.5
Change filter cartridge circulation pump 5.6
Change filter cartridge oil cooler 5.6
Check accumulator - only for docking-system (see spare parts
Appendix
list MRZV-VV)
Electric system
Visual and functional inspection
Check cable connection
Safety devices
Check function, condition and completeness
Pile driving equipement
Examination by a competent person

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Vibrator MRZV-VV

5.2 Oil change and verification

Analyse the oil at regular intervals. The analysis
should cover viscosity, oxidation water content,
additives and contamination. The gear oil oxidizes
over time and faster at higher temperatures. This
is indicated by changes in colour and smell, and
the formation of sludge in the gear box. High con-
tamination causes increased wear of the hydraulic
components. The cause of contamination must be
immediately investigated and remedied.

With synthetic gear oils higher oil change

intervals are achieved - have the gear oil ana-
lysed at regular intervals and changed when
necessary.

Only use lubricants recommended by ABI. When

changing grades, pay attention to the miscibility of
the lubricants. When using detergents, pay atten-
tion to the compatibility with any seals. Remove
all detergent before filling.

Warning
• During operation the hydraulic system is
under high pressure. In the event of a leak,
escaping oil can injure unprotected parts
of the body.
• Before starting any maintenance work the
hydraulic system must be depressurised.
• Allow all components to cool before star-
ting any maintenance work.
• Oils must not enter the soil or any water-
courses.

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Checking the oil level

On the front of the vibrator gearbox there are two

Checking the oil level
oil sight glasses for checking the oil level.
Check the oil level daily whilst cold.

Caution
• Check the oil level daily whilst cold. Depen-
ding on the temperature, air inclusion etc.
the volume of the gear oil changes during
the vibrator operation.
• After a longer standstill period of the vibra-
tor, the gearbox oil level is higher because
the hydraulic lines running over the leader
mast from the carrier are draining into the
gearbox.

• Only check the oil level when cold.

• Align the vibrator vertically.
• Charge the hydraulic lines, to do so run the
oil sight glasses
vibrator at 0% static moment and a slow
speed between 500-1000 rpm and for approx.
3 minutes. Then stop the vibrator and wait for
3 minutes (5 minutes for the MRZV 17 VV).
Then check the oil level - the oil level should
be approximately in the middle of the lower oil
sight glass.

Caution
• Damage to the vibrator gearbox - main-
tain the oil level. Insufficient lubrication is
caused by a low oil level. Overheating of
the gearbox is caused if the oil level is too
high.
• A cloudy oil appearance indicates ingress
of water or condensation in the gearbox
cell. Change the oil immediately and flush
the vibrator gearbox with fresh oil.
• Metallic abrasion and dirt in the gearbox
oil increases wear. Metal particles indicate
gearbox damage - immediately remedy the
lower oil sight glass
cause.

normal oil level

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Vibrator MRZV-VV

1
If the oil level is too low:
• Carefully unscrew the oil filler plug 1, let the
pressure escape.

Danger
Gearbox is under pressure.

• Using a funnel, top up the gear oil through the

opening of the oil filler plug 1.

Notice oil filler plug

Recommended gear oil see Appendix.

• Check the oil level in the lower oil sight glass.

• Replace sealing ring of the oil filler plug.
• Screw in the oil filler plug and tighten.
• Charge the hydraulic lines, to do so run the
vibrator at 0% static moment and a low speed
between 500-1000 rpm and for appox. 3
minutes. Then stop the vibrator and wait for
3 minutes (5 minutes for the MRZV 17 VV).
Then check the oil level - the oil level should
be approximately in the middle of the lower oil
sight glass.
• At standstill check again the oil level in the lo-
wer oil sight glass. When needed drain off the
gear oil until the required oil level is reached.
Use gear oil of the same quality.

lower oil sight glass

normal oil level

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Oil change
- vibrator with gear oil cooling circuit-

Change the gear oil for the first time after 50 ope-
Oil change with gear oil cooling
rating hours. Then change in regular intervals
every 4 weeks or at least after 250 operating Oil change with gear oil cooling every 250 oh
hours. During heavy working conditions (e.g. Heavy working conditions:
grouting lances) reduce the oil change intervals.
with grouting lances (vibroflot),
With oil analysis longer intervals are possible. every 60 oh
stone column or for cut-off wall

Danger
• Risk of being burnt from hot gearbox oil.
• The gearbox can get extremely hot during
operation. Avoid contact with the gearbox
when without protective clothing.
• Gearbox is under pressure.

• Bring the vibrator up to operating tempera-

ture.
• Switch-off the vibrator.
• Align the vibrator vertically.
• Carefully unscrew oil filler plug, carefully let the
pressure escape.
• Unscrew the oil drain plug. Collect the draining
oil in an oil drain container.
• Collect the draining oil in an appropriate oil
drain container.

Caution
• Use an oil drain container with sufficient
oil filler plug
volume.
• Dispose of used oil in an environmentally
friendly manner - gear oils must not enter
the soil or any watercourses.
• Never run the vibrator without appropriate
gearbox oil, otherwise damage to the gear-
box must be expected.
• Damage to the vibrator gearbox - main-
tain the oil level. Insufficient lubrication is
caused by a low oil level. Overheating of
the gearbox oil is caused if the oil level is
too high. oil drain plug
• A cloudy oil appearance indicates ingress
of water or condensation in the gearbox
cell. Change the oil immediately and flush
the vibrator gearbox with fresh oil.
• Metallic abrasion and dirt in the gearbox
oil increases wear. Metal particles indicate
gearbox damage - immediately remedy
cause.
105
Vibrator MRZV-VV

• Check and clean the magnetic oil drain plug Docking-System

for particles.
• Replace sealing washer of the oil drain plug. C1
• Replace the oil drain plug and retighten.
• Using a funnel pour in the complete oil quantity
(vibrator plus cooling circuit) through the oil
filler plug.

Notice
Recommended gear oil see Appendix, filling
quantity incl. cooling circuit see Technical
Data.

• Replace sealing washer of the oil filler plug.

• Screw in the oil filler plug and tighten.
• Remove the hose return line - gear oil cooling
C1.

Only for docking-system

• Attach the provided hose for the oil change to
the quick release coupling return line-gearbox
oil cooling C1 on the vibrator.

Caution
• Use an oil drain container with sufficient
volume.
• Dispose of used oil in an environmentally
friendly manner – gear oils must not enter
the soil or any watercourses.
• Never run the vibrator without appropriate
gearbox oil, otherwise damage to the gear-
box must be expected.
lower oil sight glass
• Place the free end of the provided oil drain
hose in an appropriate oil drain container.
• Collect the draining oil in the oil drain container.
normal oil level

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• Charge the hydraulic lines, to do so run the vi- Docking-System
brator at 0% static moment and at a low speed
between 500-1000 rpm until the new gear oil C1
comes out the oil drain hose and the oil level
in the vibrator gearbox is approximately in the
lower third of the bottom oil sight glass.
• Then stop the vibrator and wait for 5 minutes.
Then check the oil level - the oil level should
be approximately in the middle of the lower
oil sight glass.

• At standstill check again the oil level in the

lower oil sight glass. Use gear oil of same
quality, add when needed or drain off the gear
oil until the required oil level is reached.

Only docking-system
• Reconnect the return line gearbox oil cooling
circuit with quick release coupling C1 on the
vibrator.

lower oil sight glass

normal oil level

107
Vibrator MRZV-VV

5.3 Slide rails and guides

Clean and grease the guide rails and guides each
Slide rails and guides
time prior to attaching of the attachment and in
clean and grease every 250 oh
cases of excessive contamination, at least every
4 weeks. al least every 4 weeks

Grease slide rails

• Grease the contact surfaces of the slide rails
and guides.
• Grease the gearbox housing via the greasing
points use multipurpose grease MPG-A.

Recommended lubricants see Appendix

When cleaning the slide rails look for evidence

of wear, e.g. excessive scoring. Maximum wear
dimension compared with new condition should
not exceed Δs = 3 mm.

Notice
Regular cleaning reduces the appearance of
wear and increases the service life.

Converting guide rails on the attach-

ment carriage (option)

Caution
Completely attach the bolted cnnections 1 of
the guide rails and check the bolted connec-
tions daily.

1
• Clean the bolt threads before use using
grease
and silicone-dissolving cleaning agents
only.
• For setscrews with metric standard thread
according to DIN ISO 262.
• Condition new, with thread lubrication - Flor
Plus Super Grease 1300.
• M24 - 8.8 for attaching the guiding rails on 1
the attachment carriage.

Tightening moment with locking

washer DIN 25201 M24
at tensile strength 8.8 Nm 876

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Changing the slide rails on the guide 1
carriage
• Remove the attachment and place in the trans-
port frame.
• Clean the guide carriage.
• Remove the Allen bolts.
• Using a punch, remove the slide rails 1 from
the outside of the guide block.
• Insert new slide rails.
• Screw in and tighten the Allen bolts.
• Grease the running surfaces of the slide rails
with multipurpose grease MPG-A.

Version A - Changing the slide rails 2 1

on the guide cover
• Loosen the hex bolts on the limit stop angles
1 (3 per angle).
• Remove the limit stop angles.
• Remove slide rails, e.g. with punch.
• Insert new slide rails 2.
• Screw in and tighten the hex bolts of the stop
angles.
• Lubricate grease nipples of the slide rails with
multipurpose grease MPG-A

Version B - Changing the slide rails on

1
the guide cover 2

Caution
The slide rails 3 are equipped with wear indica-
tors 1. Check the wear indications on the slide 3
rails. If the slide rails are at the same height
as the wear indicators, the slide rails must be 2
replaced. 2
1
• Loosen the countersunk bolts 2 from the slide
rails 3.
• Clean the guide rails.
• Insert new slide rails 3.
• Screw in the countersunk bolts 2 for the slide
rails 3 and tighten.
• Lubricate grease nipples of the slide rails with
multipurpose grease MPG-A.
1

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Vibrator MRZV-VV

5.4 Jaw assembly

5.4.1 Jaw assembly type I
The jaw assembly consists of a clamp housing 1
1, clamping cylinder 2 and two round jaw pads 3
and a pitching chain 4 at the bottom. The clam-
ping pressure is generated by a pressure multi-
plier on the ABI carrier. The clamping pressure is
displayed on the control panel or on a pressure
gauge.

Notice
Increased wear of pile section and jaw pads
from:
• Improper use
2
• Clamping pressure too low
• Too much play in the guide bushing

The profile may be subject to heat stressing 3

in the contact area with the jaw pads and the
jaw wears out the serrated surfaces or is even
fusion-welded to the casing. In this case the
complete jaw assembly must be replaced. 4

Warning
• Immediately replace the jaw pads if the
serrated surface is worn out or pieces have
broken away.
• Regularly inspect the clamp assembly
block for crack formation using a Non-
destructive weld testing method.
• Check the pitching chains and the T-hand-
les daily for damage and wear - if damaged,
the chain must be replaced immediately.
• Check bolted connections at the clamping old new
device and jaw pads daily.

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Changing the jaw pads - type I

• Open jaw assembly completely.

Caution
• Swap the hydraulic connections on the
clamp cylinder to avoid damage to the
jaw assembly - the functions of the switch 9 6
clamp Open-Close are now reversed. Da-
mage of the jaw assembly - do not activate 3 1
the function clamp close after swapping the
hydraulic hoses.

• Loosen the bolts 3 on the clamping cylinder. 5

• By operating the switch clamp Open-Close on
the ABI control panel to clamp Open extend
the clamping cylinder so far that the clamping 4
cylinder 2 can be withdrawn from the jaw as-
sembly 1 place a wedge in the clamping gap
if necessary.
• Withdraw the clamping cylinder 2.

Notice 2 7 8
Check the lubricating grooves in the front
area of the guide bushing 9. Replace the guide
bushing if the grooves are worn out.

Caution
Tighten bolts with prescribed torque - Tigh- 1 Jaw assembly
tening moments for bolted connections see 2 Clamping cylinder
appendix. 3 Bolts Clamping cylinder
4 Bolts Jaw
• Drive out roll pin 7. 5 Jaw pad - Jaw block
• Remove jaw pad 6. 6 Jaw pad - Clamping cylinder
• Check adapter 8, replace if required. 7 Spring sleeve
• Insert new jaw pad 6. 8 Adapter
• Drive in new roll pin 7. 9 Guide bushing
• Loosen attaching bolt 4.
• Remove jaw pad 5 and insert new one.
• Tighten screw 4.
• Replace clamping cylinder and lock with
bolts 3.

Caution
• Swap back the hydraulic connections on
the clamping cylinder.
• Check function under zero-load condition.

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Vibrator MRZV-VV

5.4.2 Jaw assembly type II

The jaw assembly consists of a clamp housing 1
1, clamping cylinder 2 and two rectangular jaw
pads 3 and two pitching chain 4 at the bottom.
By exchanging the jaw pads the jaw assembly
can be fitted with either standard or Interlock jaw
pads. The clamping pressure is generated by a
pressure multiplier on the ABI carrier. The clam-
ping pressure is displayed on the control panel
or on a pressure gauge.

Notice
Increased wear of pile section and jaw pads 2
from:
• Improper use
• Clamping pressure too low 3
• Too much play in the guide bushing

The profile may be subject to heat stressing 4

in the contact area with the jaw pads and the
jaw wears out the serrated surfaces or is even
fusion-welded to the casing. In this case the
complete jaw assembly must be replaced.

Warning
• Immediately replace the jaw pads if the
serrated surface is worn out or pieces have
broken away.
• Regularly inspect the clamp assembly
block for crack formation using a Non-
destructive weld testing method. old - worn out
• Check the pitching chains and the T-hand-
les daily for damage and wear - if damaged,
the chain must be replaced immediately.
• Check bolted connections at the clamping
device and jaw pads daily.

new

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Changing the jaw pads - type II 7 6
1
9b
• Open jaw assembly completely.
• Loosen bolt 4 in jaw pad 9a. 3 9a
• Remove jaw pad 9a laterally from the jaw as-
sembly, loosen with punch if necessary.
• Loosen Allen key bolts 8, use shortened Allen
key if necessary.
• Remove jaw pad 9b laterally from the jaw as- 4
sembly.

Notice 2
Check the lubricating grooves in the front
5 8
area of the guide bushing 7. Replace the guide
bushing if the grooves are worn out.

• Mount the new jaw pads in reverse order.

• Check function under zero-load condition.
1 Jaw assembly
2 Clamping cylinder
Caution 3 Bolts Clamping cylinder
• Tighten bolts with prescribed torque - Tigh-
4 Bolts Jaw
tening moments for bolted connections see
5 Spring sleeve
appendix.
6 Adapter
7 Guide bushing
8 Allen key bolt - Jaw
9a, 9b Jaw pads (2x)

113
Vibrator MRZV-VV

Replacing the guide bushing

• Open jaw assembly completely.

• Loosen bolt 4 in jaw pad 9a. 7 6
1 9b
• Remove jaw pad 9a laterally from the jaw as-
sembly, loosen with punch if necessary. 3 9a
• Loosen Allen key bolts 8, use shortened Allen
key if necessary.
• Remove jaw pad 9b laterally from the jaw as-
sembly.
4
Caution
• Swap the hydraulic connections on the
clamp cylinder to avoid damage to the
jaw assembly - the functions of the switch 2
clamp Open-Close are now reversed. Da- 5
mage of the jaw assembly - do not activate 8
the function clamp close after swapping the
hydraulic hoses.

• Unscrew the Allen key bolts 3 in the clamping

cylinder. 1 Jaw assembly
• By operating the switch clamp Open-Close on 2 Clamping cylinder
the ABI control panel to clamp Open extend 3 Bolts clamping cylinder
the clamping cylinder so far that the clamping 4 Bolts Jaw
cylinder 2 can be withdrawn from the jaw as- 5 Spring sleeve
sembly 1 place a wedge in the clamping gap. 6 Adapter
• Using a puller, remove the old guide bushing 7 7 Guide bushing
from the jaw assembly, insert the new bushing. 8 Allen key bolt - Jaw
9a, 9b Jaw pads (2x)

Caution
Tighten bolts with prescribed torque - Tigh-
tening moments for bolted connections see
appendix.

• Assemble the clamping cylinder and jaw pad

in reverse order.

Caution
Swap back the hydraulic connections on the
clamping cylinder.

• Check function under zero-load condition.

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5.5 Filter cartridge control block

The Filter cartridge must be changed after the

Change interval filter cartridge - control block
first 50 operating hours and the second change
should to be carried out after 4 weeks or at 250 at normal operation every 500 oh
operating hours whichever comes first. They 6 month
must then be changed at regular intervals of 6
month or 500 operating hours. Halve changing
intervals during heavy duty operations.

Warning
• Only change the filter cartridge when the
engine of the carrier is switched off.
• During operation the hydraulic system is
under high pressure. In the event of a leak,
escaping oil can injure unprotected parts
of the body.

115
Vibrator MRZV-VV

Changing filter cartridge

1
• Switch off the carrier.
• Depressurize the hydraulic sys-
tem.
2
3 • Unscrew the filter housing 2.

Caution
Dispose of used oil in an envi-
ronmentally sound manner. Gear
oils must not enter the soil or any
waters. Use an oil drain container 5

with sufficient volume.

• Remove the filter element 3 from

the retainer 5 by turning it slightly
and dispose of as prescribed.
Check the surface for dirt and
particles.
• Clean the filter housing 2.
• Check new filter 3 for mechanical
damages, especially check seal
face 6 and thread 7.
• Lubricate seal face 6 and th-
read 7.
• Insert new filter element 3 in the
retainer 5.
• Screw in completely the filter ca-
sing 2 in the filter body.
• Check again the oil level in the
gearbox lower oil sight glass at
standstill. Add in gear oil of same
quality if needed.

Notice
Watch out for extreme cleanness
6 during the whole process.
6
7

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5.6 Filter cartridges cooling circuit
5.6.1 Filter cartridge circulation pump (option)

The filter cartridge at circulation pump must be

changed after the first 50 operating hours and Vibrator
the second change should to be carried out after
4 weeks or at 250 operating hours whichever
comes first. They must then be changed at
regular intervals of 6 month or 500 operating
hours. Halve changing intervals during heavy
duty operations.

Change interval filter cartridge -

circulation pump
at normal operation every 500 oh
6 mouth

Filter cartridge
circulation pump

5.6.2 Filter cartridge oil cooling

The filter cartridge at oil cooler must be changed SR20-F

after the first 50 operating hours and the second SR25-F
change should to be carried out after 4 weeks or
at 250 operating hours whichever comes first.
They must then be changed at regular intervals of
6 month or 500 operating hours. Halve changing
intervals during heavy duty operations.
SR30-F

Change interval filter cartridge -

oil cooler
at normal operation every 500 oh
6 mouth

Warning SR35-F
• Only change the filter cartridges with the Filter cartridge
engine of the carrier stopped. oil cooler
• Risk of being burnt from hot gearbox oil.
• The gearbox can get extremely hot during
operation. Avoid contact with the gearbox
SR45-F
without protective clothes.
• Gearbox is under pressure.

117
Vibrator MRZV-VV

Changing of filter cartridge

1
• Switch off the carrier.
• Carefully unscrew the oil filler
plug 1, slowly let the pressure
2
3 escape.
• Unscrew the filter housing 2.
4

Caution
Dispose of used oil in an envi-
ronmentally sound manner. Gear
oils must not enter the soil or any
5
waters. Use an oil drain container
with sufficient volume.

• Remove the filter element 3 from

the retainer 5 by turning it slightly
and dispose of as prescribed.
Check the surface for dirt and
particles.
• Clean the filter housing 2.
• Check new filter 3 for mechanical
damages, especially check seal
face 6 and thread 7.
• Lubricate seal face 6 and th-
read 7.
• Insert new filter element 3 in the
retainer 5.
• Screw in completely the filter ca-
sing 2 in the filter body.
• Check again the oil level in the
gearbox lower oil sight glass at
standstill. Add in gear oil of same
quality if needed.

Notice
Watch out for extreme cleanness
6
during the whole process.
6
7

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5.7 Rotating union

The adjustable drive inside the gear box is sup-

plied with hydraulic oil via a rotating union. Repla- Rotating union
ce transfer tubes complete with O-rings and flange
Replace transfer tubes and flange 250 oh
every 250 operating hours. Before starting work
thorough clean the vibrator

Warning
• Only replace wear parts with the engine Rotating union
of the carrier switched off and the vibrator
cooled down.
• Depressurize the hydraulic system before
starting to work.
• Dispose of used oil in an environmentally
sound mannee. Gear oils must not enter
the soil or any waters.

Replace of transfer tubes and flange

• Loosen the hydraulic hoses on the rotating
union.
• Loosen the bolts 1 on the rotating union 2 and
carefully remove the rotating union to the front.
• Remove the transfer tubes 3.
• Loosen bolts 4 from the connection flange 5.
• Remove the flange from the shaft.

Caution
• Do not use any hard or sharp edged objects,
otherwise the gearbox housing or shaft will
be damaged.
• Make sure no objects fall into vibrator ge-
arbox cover the area around the shaft.

5 6 3 1 2

119
Vibrator MRZV-VV

• Fit the new flange 5 with new O-rings on the

shaft.
• Insert bolted connections 4 with bonding ad-
hesive (Loctite 243) and retighten (12 Nm). 6 3 1 2
5
• Put new transfer tubes 3 in rotating union.

Caution
• Firstly insert the transfer tubes into the
rotating union see (if existing, observe any
alignment marks). Swapping the sides of
the transfer tubes may damage the gear- 4
box).

• Insert the springs 6 in flange 5. Alignment marks "Feder - Spring"

• Fit the rotating union 2 with a new O-ring on (if existing)
the flange face.
• Insert bolted connections 1 with bonding ad- 1 Bolts-rotating union
hesive (Loctite 243) and retighten (31 Nm). 2 Rotating union
• Connect hydraulic hoses. 3 Transfer tubes
• Check tightness of rotating union and hydraulic 4 Bolts-flange
hoses, and then check the function without any 5 Flange
load. 6 Compression springs

Caution
• Pay attention to the cleanliness during the
entire process. Do not allow impurities or Rotating union mounted
particles into the hydraulic system or into
the gearbox cell.
• Secure bolted connections with bonding
adhesive. Apply on grease and silicone free
threads only.
• Only have the work completed by a trained
specialist or inform ABI after sales service.

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5.8 Elastomer mounts

The gear box is attached to the vibrator guide

using elastomer mounts. Clean and check elas-
tomer mounts every 50 operating hours or at
least once a week. Replace the elastomer mounts
every 2000 operating hours or at least every 2
years.

Elastomer mounts
Check elastomer mounts 50 oh
Replace elastomer mounts 2000 oh

Elastomer mounts age due to overloading, ozone

and temperature effects. Replace immediately
when tears, splits, or cracks appear. Elastomer mounts

Caution
Do not clean elastomer mounts with corrosive
liquids.

121
Vibrator MRZV-VV

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6 Operational faults and trouble shooting

Notice
If faults cannot be remedied immediately in-
form the ABI after-sales service.
Pressure oil filter
6.1 Hydraulic control system
Suction valve
Caution
• Before starting to work on the hydraulic sy-
stem switch of the carrier and depressurize
the system.

6.1.1 Vibrator

Suction valve
The suction valve on the upper hydraulic motor
forms during the shutdown process of the ham-
mers eccentric weights, a hydraulic short-circuit
between the pressure and return lines, thus re-
ducing cavitation and wear.

Special tools are required to remove the check

valve in the anti-cavitation block, replace the entire
valve block if necessary.
Check valve
Pressure oil filter
See chap. 5, Pressure filter element.

6.1.2 Jaw assembly

For faults with the pressure multiplier, pressure

switch or pressure reducing valve see chapter
Telescopic leader mast, Operational faults and
trouble shooting.

Check valve
The check valve on the back side of the clam- ping
cylinder maintains the clamping pressure in an
inactivated state and prevents pressure losses
via the hydraulic system.

Upon a loss of pressure clean the check valve,

replace if necessary. Loosen the valve with a
socket wrench and unscrew counter clockwise.

123
Vibrator MRZV-VV

6.2 Electronic control system

Via the control panel the operating modes and

parameters for the vibrator can be modified. The
control board evaluates the sensors signals and
activates the solenoid valves which control the
static moment and the vibrator speed.

Inductive sensor

Located on the top of the gearbox of the MRZV-VV

are two inductive sensors, these register the vib-
rator speed and relative positions of the eccentric
weights. When a fault occurs an error is displayed
in the control panel.

Cable and plug-in connections

Check cable connections for chafe marks, kinks

or other damages. Check electrical connections,
terminals and plug-in connections for perfect
contact and condition.

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 Malfunction Cause Check Trouble shooting
Attachment does not start No operating pressure at the Check quick-acting couplings at the
running attachment hydr. shut off device
Hydraulic system of carrier See Operating manual of carrier
Feed valve Clean or replace valve
Hydraulic motor Inform ABI after-sales service
Hydraulic oil enters into the Check rotary shaft seals of the drive
Loss of power Gear oil level
driver unit motors
6.3 Table of malfunctions

Adjusting drive leaking - Inform

or
ABI after-sales service
Vibrator gets too hot Increased friction Change gear oil and add additive
Pressure oil filter obstructed Filter cartridge Change oil filter
Clamping pressure is not Check valve connector and cable
Solenoid valve CLAMP Valve and in switch box
attained connection
or Clean check valve
Pilot lamp Jaw assembly Replace valve
CLOSE blinks Pressure multiplier: clamping Indicating device Clamping
pressure Replace pressure multiplier
pressure
is not attained
Indicating device Clamping
Clamping pressure switch Inform ABI after-sales service
pressure
Check valve connector and cable
Pressure relief valve Valve and in switch box
connection
Replace valve
Clamping cylinder Replace clamping cylinder

125
 126
Malfunction Cause Check Trouble shooting
Check electric plug-in connections at
Adjustment of static moment
Solenoid valves are not activated hydr. shut off device and at solenoid
not working
Vibrator MRZV-VV

valves
Message on display E01 - sensor 1 Check adjustment sensor 1
Message on display E02 - sensor 2 Check adjustment sensor 2
Max. speed of attachment is Hydraulic oil volume flow too high Adjust proportional valve
higher than nominal speed Check position of attachment
selection switch
Quick-acting couplings O-ring of coupling leaking Replace O-ring
leaking
Seat of coupling insufficient Further unscrew sleeve and lock in
(only for rapid chaging device) 2nd groove with clip pin

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7 Technical Data
7.1 Data sheet

Vibrator MRZV 30VV Q2-D6

Static moment -adjustable- .................................................................. kgm 30
Dynamic weight ................................................................................... kg 3925
Amplitude x 2 ....................................................................................... mm 15,2
Nominal revolutions ............................................................................. min-1 2140
Max. revolutions per minute ................................................................ -1 2600
min
Frequency ........................................................................................... Hz 43
Centrifugal force with jaw assembly SKZ 1800 ................................... kN 1500
Recommended installed power of carrier ............................................ kW 470-570
Nominal oil pressure ............................................................................ MPa 35
Min./max. ambient temperature ........................................................... °C -20...+40
Max. extraction force / pre-stressing force ........................................... kN 300
Max. load capacity* ............................................................................. kg 10000
Gear oil - see ABI appendix - gear oils ................................................
Gear oil quantity gear box ................................................................... l 12
Gear oil quantity cooling system TM 17 (approx.) ................................ l 31
Gear oil quantity total (approx.) ............................................................ 43

Dimension and weight

Height .................................................................................................. mm 3373
Width ................................................................................................... mm 832
Depth ................................................................................................... mm 1464
Guide to driving axle ............................................................................ mm 358
Locking to bottom jaw assembly ......................................................... mm 2678
Locking to bottom vibrator body........................................................... mm 3190
Total weight ........................................................................................ kg 5380

Transport dimensions and transport weight

Length ................................................................................................ mm 3630
Width ................................................................................................... mm 1480
Height .................................................................................................. mm 1770
Transport weight ................................................................................. kg 5900

Jaw assembly SKZ 1800

Clamping force .................................................................................... kN 1800
Clamping pressure .............................................................................. MPa 48
Max. clamp gap ................................................................................... mm 40
Max. load per pitching chain (option) .................................................. kg 1600 / 3150
2300 / 5000
Total weight ......................................................................................... kg 1360

* Do not exceed max. load per pitching chain. Observe the maximum load capacity and the
stability and ground pressure calculation of the ABI Mobilram-System.
Design subject to modifications.

127
Vibrator MRZV-VV

7.2 Operating and transport dimensions

Centre of gravity

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7.3 Type plate

There are information of the type and serial num-

ber on the type plate. The type plate is fixed on
on the front of the vibrator cover.

Notice
The type plate also carries the test badge
indicating the next date of inspection by com-
petent persons.

Example: Vibrator-type code

MRZV20VV Q2-S4-F-C SKZ1120 ABI Maschinenfabrik und

Foundation E quipment
Vertriebsgesellschaft mbH Typ Type MRZV20VV Q2-S4-F-C SKZ1120
Am Knückel 4
D-63843 Niedernberg Fabr.Nr. Machine G0007888 / 11125
01 02 03 04 05 06 07 08 Germany
Tel.: +49(0)6028/123-0
No.
Year of
Fax: +49(0)6028/123-199
Baujahr construction 2015
Drehmoment Torque kNm
max. Zugkraft Pulling
force max. 200 kN
Operating
01 - Type Betriebsdruck pressure MPa

Schmierstoff Lubricant Omala S4 GX 150

Schmierstoff- Lubricant
02 - Design size menge fill quantity
Operating
10 l/kg

Einsatzgewicht weight 4100 kg

03 - Series Transportgewicht Transport

weight 4320 kg

04 - Motorisation - hydraulic motor

05 - Cut surface - leader mast
06 - Guide width - leader mast carraige
07 - Extraction- and pre-stressing force
08 - Clamp assembly type

129
Vibrator MRZV-VV

7.4 Life span 7.4.1 Storage of the vibrator

The ABI vibrator generates vibration in a vertical

direction within a compact and high performance
Caution
gear box. The high dynamic forces generate
• Store the vibrator horizontally (see drawing
effective pile driving but can also leads to stress
when it is not in use for a longer period
and to natural wear of the components. Damage
than (3-4 weeks). Remove the gearbox oil
of the vibrator by faulty operation or non-intended
completely and then refill the gearbox com-
use causes increased wear and corresponding
pletely with clean oil (maximum capacity).
higher repair costs.
• Only fill the hammer with oil when it is in
vertical position. Add new gear oil until the
For a longer service life of the vibrator we re-
gearbox cell is completely filled - maximum
commend that the gearbox and hydraulic oil are
capacity. This ensures that all bearings are
bought up to operating temperature before star-
well covered with oil and that no air cavities
ting work and to adapt static moment and vibrator
are created.
speed to specific load requirements and soil con-
• Store the vibrator laid down (hydraulic mo-
ditions. Ensure regular maintenance and service
tor facing upwards).
of the vibrator. Adjust the service intervals to the
respective operating conditions and change the
oil more frequently if necessary. Avoid prolonged
overloading as well as prolonged idling of the vib-
rator. This reduces operating costs and emissions
and increases the service life of the vibrator

Caution
• Before starting work bring the vibrator
MRZV-VV up to operating temperature for
approximately 5-10 minutes under zero load
and with 50% static moment and at a speed
of approximately 1800 rpm.
• Reducing the static moment or speed of
vibrator during easy pile driving conditions
or with small working mass does not lead
to a decrease in the pile driving process.
• Do not exceed the maximum rated speed
of the vibrator - an over speed, e. g. via a
higher adjusted oil flow, causes rapid wear
of the bearings.
Caution
Before commissioning the vibrator remove the
gearbox oil until a normal oil level (working
level) is achieved.

• Set down the vibrator vertically.

• Check the oil level in a cold condition.
• Check the oil level in the oil level sight glass -
during normal operating conditions the oil level
is between upper and lower oil sight glasses.

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7.5 Information card - Pitching chains

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Vibrator MRZV-VV

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 Index
A H
Adapter plate 90 Hole diameter 53, 66
changing 39 Hole diameter and spacing 33, 34
fitting 90 Hole pattern
adapter plate 90
C jaw assembly 90
Hydraulic control system 123
Cable connections 124
Centre of gravity 92 I
Chain supports 25
changing 39 Identification tag 47
inspecting 52, 53, 65, 66 Inductive sensor 124
Check valve 123 Information card 131
Clamping 13 Inspection intervals 48, 61
Clamping camera 13 Inspection tag 47
Clamping pressure 13 Intended use 3
Commissioning 9 J
Control 12
Jaw assembly
D failures 123
Danger area 17 mount 89
Dangers and risks 16 type I 110
Data sheet 127 type II 112
Description 7 Jaw pads changing
Driving on the construction site 88 type I 111
type II 113
E
L
Efficiency Drive-System 8
Elastomer mounts 121 Left control 12
Electronic control system 124 Life span 130
Emergency stop device 21 M
F Maintenance and service 97
Filter cartridge Maintenance work - summary 100
change 116, 118 Mounting
circulation pump 117 jaw assembly 89
control block 115 O
oil cooling 117
Flange 119 Oil change 102, 105
Function test 11 Oil level 103
Oil verification 102
G Operating dimensions 128
General safety instructions 15 Operation 15
Guide bushing Operational faults 123
replace 114 Operational restrictions 21
Guide rails
converting on the attachment carriage 108
Guides 108

133
Vibrator MRZV-VV

P V
Pile elements Vibrator 123
hole diameter and spacing 33, 34 laying down 93
Piles placing and securing on the transport frame 91
attaching 25, 69, 70, 80, 81 raising 94
clamping 32, 82, 83 with Docking-system 92
clamping and aligning 73, 74 with double clamp assembly 92
detaching 77
driving in 67, 75, 76 W
extracting 78, 84, 85 Working with the MRZV-VV 24
lifting 71, 72
lowering 86, 87
securing 25
Pitching chains 25, 41, 54
changing 40
inj single-leg-arrangement 31
in single-leg-arrangement 30
inspecting 48, 61
in V-arrangement 28, 29
load capacity 38
maximum permissible load 41, 54
release between vibrator and transport frame 95
storing 47
Plug-in connections 124
Pressure gauge - jaw pressure 13
Pressure oil filter 123

R
Recommended gear oil 104
Recommended lubricants 108
Restrictions 16
Rotating union 119
S
Safety and protective devices
Personal protection equipment 23
Safety instructions 16
Service 97
Slide rails 108
changing on the guide carriage 109
grease 108
Static moment 7
Storage 130
Suction valve 123
T
Table of malfunctions 125
Technical Data 127
Transfer tubes 119
Transport 91, 93, 95
Transport dimensions 128
Trouble shooting 123
Type plate 129

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