Ice 18ZR User manual

Sales & Service contacts
Phones: 704 821-8200, 888 ICEUSA1
Fax: [phone]
Email: [email protected]
Parts Contacts
Phones: 704 821-8200, 888 ICEUSA1
Fax: [phone]
Email: [email protected]
INTERNATIONAL CONSTRUCTION EQUIPMENT, INC.
Specializing in Pile Driving and Drilling Equipment
Corporate offices: 301 Warehouse Drive, Matthews NC 28104 USA
www.iceusa.com
OPERATION AND MAINTENANCE MANUAL
This manual is for ICE Model 18ZR, 25ZR, 50ZR vibrators
used with 350GZ, 450GZ, 595GZ power units
Operation and Maintenance Manual © International Construction Equipment, Inc. All Rights Reserved. OM-ZR-May15

ICE® PARTS & SERVICE LOCATIONS
ICE NORTH AMERICA REGIONAL
PARTS & SERVICE LOCATIONS
888-ICE-USA1
www.iceusa.com
ICE Northeast Branch
Service & Parts
259 Jernee Mill Road
Sayreville, NJ 08872 USA
Phone: [phone] x160
Fax: [phone]
ICE Capital Branch
Maryland, Delaware, Northern Virginia
12001 Guilford Rd. Bldg. D
Annapolis Junction, MD 20701 USA
Phones: 704-821-8200 x161
Fax: [phone]
ICE Virginia Branch
Mid-Atlantic and Southeast
1729 West Road
Chesapeake, VA 23323 USA
Phones: 704-821-8200 x169
Fax: [phone]
ICE Lakeland Branch
Florida & Caribbean
310 Winston Creek Parkway
Lakeland, FL 33809 USA
Phones: 704-821-8200 x164
Fax: [phone]
ICE Texas Branch
Texas & West
30095 US Highway 90
Katy, TX 77494 USA
Phone: [phone] x165
Fax [phone]
ICE Louisiana Branch
Gulf Coast Service & Parts
412 Harvey Blvd
Belle Chasse, LA 70037 USA
Phones: 704-821-8200 x163
Fax: [phone]
ICE Seattle Branch
Western US & Western Canada
8101 Occidental Avenue South
Seattle, WA 98108 USA
Phones: 704-821-8200 x166
Fax: [phone]
Midwest Dealer Location
5025 New Haven Avenue
Fort Wayne, IN 46803 USA
Phones: 800-348-1890
Fax: [phone]
Eastern Canada Dealer Location
2020 Bantree Street
Ottawa, Ontario K1B 5A4 Canada
Phones: 613-737-3963, 613-266-5370
Fax: [phone]
ICE INTERNATIONAL
PARTS & SERVICE LOCATIONS
704-821-8200
www.iceusa.com
ICE International Part Sales
301 Warehouse Drive
Matthews NC 28104 USA
Phones: 704-821-8200 x118
Fax: [phone]
Europe
iCON Foundation Equipment BV
Lissenveld 69, 4941 VL Raamsdonksveer
The Netherlands
Phone: [phone]
Email: [e-mail]
www.iceicon.nl
Southeast Asia
ICE Far East Pte Ltd
13 Pioneer Sector 2
Singapore 628374
Phones: 65 6861-3733, 65 9785-1075
Email: [e-mail]
Australia
PILEQUIP Australia Pty Ltd.
P.O. Box 976, Windsor, NSW, 2756
Phones: [phone], [phone]
384
Email: [email protected]om.au
Brazil
CZM Indústria de Equipamentos LTDA
Av. Sócrates Mariani Bitencourt, 364 |
Cinco | Contagem - MG | CEP 32010-010 |
Av. Eliseu de Almeida, 1051 | Butantã |
São Paulo - SP | CEP: 05533-000 |
Phones: [phone], [phone]
Email: [email protected]

WARRANTY
International Construction Equipment, Inc. Standard Warranty
International Construction Equipment, Inc., hereafter referred to as ICE, warrants new products sold by it to be
free from defects in material and workmanship for a period of one year after date of delivery to the first user
and subject to the following conditions:
ICE’s obligation and liability under this warranty is expressly limited to replacing, at ICE’s option, any parts that
appear to ICE upon inspection to have been defective in material or workmanship. Such parts shall be provided
at no cost to the user at the business establishment of ICE or at the ICE distributor of the product during regular
working hours.
This warranty shall not apply to component parts or accessories not manufactured by ICE and which carry the
warranty of the manufacturer thereof or to normal maintenance parts (such as filters).
Replacements or repair parts installed in the product covered by this warranty are warranted only for the re-
mainder of the warranty as if such parts were original components of said product.
ICE’s obligation under this warranty shall not include any transportation charges, costs of installation, duty, tax-
es or any other charges whatsoever, or any liability for direct, indirect, incidental, or consequential damage or
delay.
If requested by ICE, products or parts for which a warranty claim is made are to be returned, transportation
paid, to ICE.
Any improper use, including operation after discovery of defective or worn parts, operation beyond rated capaci-
ty, substitution of parts not approved by ICE or any alteration or repair by others in such manner as in ICE’s
judgment affects the product materially and adversely shall void the warranty.
For impact pile hammers, driving in excess of 10 blows per inch (25mm) [set of 0.1 (2.5mm) per blow] is
considered practical refusal. Driving in excess of 10 blows per inch (25mm) for more than 6 inches (150mm) or
driving in excess of 20 blows per inch (25mm) at all is considered improper use and will void the hammer war-
ranty.
For vibratory drivers, driving/extracting when the movement is less than 1” (25mm) per minute is considered
practical refusal. Driving/extracting when movement is less than 1” (25mm) per minute for more than 5 minutes
of driving/extracting or driving at all when penetration is less than 1” (25mm) per minute and amplitude is
greater than 1” (25mm) [vibrator and pile are bouncing] is considered improper use and will void the vibrator
warranty. Driving/extracting when bearing covers (paint removed) are above 210°F (100°C) is considered im-
proper use and will void the vibrator warranty. Use of a vibrator on a batter without discussing the operation
with ICE and getting prior written approval is considered improper use and will void the vibrator warranty.
For limited-access drills and top-drive rotary heads, the use of a down-the-hole hammer without discuss-
ing the operation with ICE and getting prior written approval is considered improper use and will void the drill
warranty.
For leads, use in lengths or at batters exceeding the initial set-up without ICE evaluating the new set-up and
providing prior written approval is considered improper use and will void the leads warranty.
For power units, welding on power units or other equipment with electrical or electronic controls must be
done with the battery leads disconnected. Welding with battery leads connected will void the warranty.
ICE MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED, AND MAKES NO WARRANTY OF MERCHANTABIL-
ITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
No employee or representative is authorized to change this warranty unless such change is made
in writing and signed by an officer of ICE.
W10Nov09

Operation and Maintenance Manual Page 2
OM-ZR-May15

INTRODUCTION Page 3 OM-ZR-May15
Literature
Section 1 - General Information
This manual contains parts information for your ICE equipment. This manual should be stored in or near the
power unit in a literature holder or literature storage area. Read, study and keep it with the equipment litera-
ture, ICE Parts Manuals, and CAT engine information. English is the primary language for the ICE publications.
The English used facilities translation and consistency in electronic media deliver. Some photographs or illustra-
tions in this manual show details or attachments that may be different from your equipment. Guards and covers
may have been removed for illustrative purposes. Continuing improvement and advancement of product design
may have caused changes to your equipment which are not included in this manual. Whenever a question aris-
es regarding your equipment or this manual, please consult ICE or your ICE distributor for the latest available
information.
INTRODUCTION
This section provides a description of the equipment and specifications.
Equipment Manual Set
The manuals for your ICE equipment consists of three or four manuals – 1) an Operation and Maintenance
Manual for your power unit and vibrator or rotary head, 2) a Parts Manual for your power unit, 3) a Parts Manu-
al for your vibrator or rotary head, and 4) a Vibrator Clamp and Accessories Parts Manual for your vibrator.
The safety section lists the basic precautions and identifies hazardous and potentially dangerous situations. It is
imperative that all operators and support staff read and understand the precautions listed before beginning op-
eration, repair, or maintenance on the equipment.
Section 2 - Safety
These sections are a reference for proper operation. Illustrations and proper procedures give guidance for oper-
ational preparation, handling, engine starting and equipment warm-up, operation, and stopping the equipment.
Controls and gauges are explained. The operational description is basic. Operators gain knowledge and develop
skills and techniques that enhance efficiency and economical production through experience and time dedicated
to understanding equipment application and operation.
Section 4 & 5 - Preparation for Operation and Operating Instructions
Sections 6 & 7 - Maintenance and Torque Charts
These sections serves as a guide for equipment care. Service intervals, required lubrication, adjustments, and
torque specifications for fasteners are listed. Major repairs are not detailed here or in the troubleshooting sec-
tion. Major repairs should be entrusted only to experienced personnel.
Section 8, 9 & 10 - Troubleshooting, Electrical and Hydraulic Information
These sections aid in resolving difficulties with equipment. The information provided gives indications of possible
causes for difficulties and the repairs required to correct malfunctions. Please contact International Construction
Equipment, Inc. for assistance in diagnosing unresolved issues and corresponding repairs.
Section 3 - Loading, Unloading and Shipping
This section provides information for loading, unloading and shipping the equipment.

TABLE OF CONTENTS Page 4
OM-ZR-May15
TABLE OF CONTENTS
Parts and Service Locations ....................................................................................................................... Front End Paper
Warranty ........................................................................................................................................................................ 1
Introduction ................................................................................................................................................................... 3
Table of Contents ........................................................................................................................................................... 4
Section 1: GENERAL INFORMATION
Power Unit, Vibrator Driver Extractor .............................................................................................................................. 7
Hydraulic Hoses, Clamps and Accessories, General Description of ZR Operation................................................................. 8
Vibrator Specifications.................................................................................................................................................... 9
Power Unit Specifications ............................................................................................................................................. 10
Section 2: SAFETY
Important Safety Information ....................................................................................................................................... 11
Hazard Info, Maintenance Procedures, Pressurized Air and Water Hazards, Fluid Penetration Risks ................................... 12
Hoses, Lines, Tubes Handling Procedures & Checklist, Precaution for Oil, Fire Extinguisher Requirements ......................... 13
Fire Explosion, Crushing or Cutting Prevention, Mounting and Dismounting ..................................................................... 14
Before Starting the Engine & During Engine Starting, Equipment Operation, Stopping Equipment, Stopping Engine ........... 15
Section 3: LOADING, UNLOADING, AND SHIPPING
Power Unit, Vibrator, Damage During Shipment............................................................................................................. 16
Section 4: PREPARATION FOR OPERATION
General, Rigging of Vibrator, Installing Proper Remote Control Pendant .......................................................................... 17
Connection of Hoses at Power Unit, ............................................................................................................................ 18
Connection Hoses-Models at Vibrator ........................................................................................................................... 19
Attach Sheet Clamp, Attach Caisson Beam to Vibrator ................................................................................................... 20
Connection of Hoses for Sheet Clamp, Connection of hoses Caisson Clamp .................................................................... 21
Adjusting Position of Caisson Clamps with HydroLocks, Bleeding Clamp Hoses................................................................. 22
Bleeding Hoses for ZR Function Hoses........................................................................................................................... 23
Section 5: OPERATION
Control Box & Remote-Control Pendant - Exterior .......................................................................................................... 24
Completion of Set-up & Maintenance, Control Panel Components ................................................................................... 25
Engine Display ............................................................................................................................................................. 26
Power Unit Mode Selection, Changing Mode, Local or Remote Control, Operation Using Remote-control, Control Panel...... 27
Operation with Optional Radio Remote Control .............................................................................................................. 28
Starting & Warming Engine, Changing Engine Speed .................................................................................................... 29
Full Speed, Engine Shutdown, Emergency Stop ............................................................................................................. 30
Resetting Emergency Stop Button ................................................................................................................................. 31
Operation with Vibrator, Limitations, Refusal, Rebound, Bearing Temperatures, Batters, Safety Features .......................... 32
Clamp to Pile, Start Vibrator, Change Eccentric Moment, Stop Vibrator, Unclamp from Pile............................................... 33
CONTENT PAGE

TABLE OF CONTENTS Page 5
OM-ZR-May15
Unclamp Pile, Changing Frequency, Underwater Operation............................................................................................ 34
Section 6: MAINTENANCE
General, Maintenance Safety, Caterpillar Maintenance.................................................................................................... 37
Daily Maintenance-Power Unit, Vibrator......................................................................................................................... 38
Clamp Jaws, Service Intervals, 100 Hours, 500 Hours, Power Unit Maintenance, Severe Conditions .................................. 39
Lubrication, Crankcase-Diesel Engine, Grease Clamp Plungers ........................................................................................ 40
Hydraulic System, Draining & Filling Hydraulic Oil Reservoir, Changing Return Filters ....................................................... 41
Recommended Hydraulic Oil, Operating in Sub-freezing Conditions ................................................................................. 42
Setting Clamp Relief Valve............................................................................................................................................ 43
Setting ZR Function Relief Valve (Eccentric Moment Control Actuator Relief) .................................................................. 44
Setting Clamp Restore Pressure, Setting Clamp Temperature Relief ................................................................................ 45
Setting Main Circuit Relief Valve.................................................................................................................................... 46
Setting Pilot Relief Valve & Setting Reservoir Pressure Regulator (595G, 700G, 800G)...................................................... 47
Section 7: TORQUE SPECIFICATIONS
Torque Specifications ................................................................................................................................................... 48
Torque Value Chart...................................................................................................................................................... 49
Section 8: TROUBLESHOOTING
Electrical & Hydraulic Components, Schematics & Operation, Power Unit Monitoring and Protection.................................. 50
Engine Problems Indicated on Engine Display ................................................................................................................ 51
Other Engine Screen Displays ....................................................................................................................................... 52
Hydraulic Problems Indicated on Control Panel, Emergency Stop Indicated at Control Panel ............................................. 53
Diesel Engine Does Not Start ........................................................................................................................................ 54
Diesel Engine Does Not Run at Full Speed ..................................................................................................................... 55
Clamp Closes but CLOSE Light Does Not Come On......................................................................................................... 56
Clamp Will Not Close .................................................................................................................................................... 57
Clamp Does Not Open ................................................................................................................................................. 59
Vibrator Does Not Start ............................................................................................................................................... 61
Vibrator Does Not Come Up to Speed............................................................................................................................ 63
Vibrator Does Not Stop ............................................................................................................................................... 64
Case Drain Relief Valve Leaks ....................................................................................................................................... 65
Vibrator Gear Case Runs Hot, Vibrator Gear Case Fills With Oil ...................................................................................... 66
Eccentric Moment Actuator Control (DECR - INCR) Is Not Operational............................................................................. 67
Section 9: ELECTRICAL COMPONENTS & CIRCUITRY
Electrical Components .................................................................................................................................................. 68
Electrical Schematic ..................................................................................................................................................... 69
Table of Contents (continued)
CONTENT PAGE

TABLE OF CONTENTS Page 6
OM-ZR-May15
Section 9: ELECTRICAL COMPONENTS & CIRCUITRY (continued)
Electrical Components & Operation, Optional Control, Control Panel Display, Engine Monitoring ....................................... 70
Hydraulic System Monitoring, Starting Diesel Engine, Changing Engine Speed, Stopping Engine, Emergency Stop ............. 71
Hydraulic Clamp, Vibrator, Rotary Head, Other .............................................................................................................. 72
Electrical Schematics and Wiring ...............................................................................................................................73-79
Section 10: HYDRAULIC CIRCUITRY
Hydraulic Components Vibrator..................................................................................................................................... 80
Hydraulic Schematic Vibrator ........................................................................................................................................ 81
Clamp and Vibrator Operation....................................................................................................................................... 82
Vibrator (continued), ZR Operation ............................................................................................................................... 83
ZR Operation Continued, Other..................................................................................................................................... 84
Table of Contents (continued)
CONTENT PAGE

Section 1: GENERAL INFORMATION Page 7 OM-ZR-May15
Section 1: GENERAL INFORMATION
Power Unit
The ICE power unit is powered by a Caterpillar Tier 3 diesel engine and is mounted on a tubular sub-base that
serves as a fuel tank. The power unit and vibrator are operated from the control panel or remote control pen-
dant. Hydraulic oil is stored in the reservoir. A heat exchanger is mounted in front of the engine for engine
cooling, hydraulic oil cooling, and turbocharger after-cooling. All components are contained in a sheet metal en-
closure with lockable doors and a central lifting point.
Vibrator Driver/Extractor
The Vibratory Driver/Extractor consists of three major components - the gear case, the vibration suppressor, and
the hydraulic clamp. The gear case contains eccentric weights that rotate in a vertical plane to create vibration.
Hydraulic motors drive the eccentric weights. Additionally, the ICE ZR series of vibrators have an actuator that
can vary the eccentric moment from zero to maximum. This controlled variable eccentric moment allows for
gentle starts and stops. The vibration suppressor contains rubber elastomers to isolate the vibration from the
crane line. The hydraulic clamp attaches the vibrator to the pile.
N
E
CLOSE
OPEN
BRAKEREVERSE
DRIVEFORWARD
C
N
T
R
L
P
Heat Exchanger
Fuel Tank
Control Panel
Hydraulic Reservoir
Clamp Manifold
Main Manifold
Remote Control
Elastomer
Eccentric Assembly Hydraulic Motor
Universal Clamp Hydraulic Clamp Cylinder
Gear Case
Actuator Manifold
Suppressor
Actuator

Section 1: GENERAL INFORMATION Page 8 OM-ZR-May15
Hydraulic Hoses
There are seven hoses, that connect vibrator to the power unit. Two hydraulic hoses, 150 feet (45 m) in length,
connect the main circuit to the motors on the vibrator. Two additional smaller hoses connect the eccentric -
moment shift actuator, two more connect the clamp circuit. A hose is also provided for motor case drainage
return to the hydraulic reservoir.
Clamps and Accessories
A variety of clamps and accessories are available for ICE vibrators. Please consult the individual Vibrator Parts
Manual or the Vibrator Clamps & Accessories Parts Manual.
Zero Resonance vibratory driver/extractors eliminate vibration in the damaging range by adjusting eccentric
moment to zero during start-up and shut-down. The ZR vibratory driver/ extractors are designed to never
operate at a frequency range that could cause resonance vibration to the soil, structures or crane line.
 Prior to start-up, the eccentric moment is set to zero.
 During start-up, vibrator frequency passes through 600-1200 vpm with zero eccentric moment’eliminating
disturbance in the soil, structures or crane line.
 After full operating frequency is reached, eccentric moment is set to maximum for driving and extracting.
 Before shut-down, the eccentric moment is again set to zero.
 During shut-down, vibrator frequency again passes through 600-1200 vpm with zero eccentric moment and
no disturbance in the soil, structures or crane line.
Eccentric moment is controlled from the vibrator remote-control pendant. Shifting between zero and maximum
eccentric moment occurs simply and quickly.
General Description of ZR Operation
Eccentrics 180° out of phase (top to bottom row)
Zero eccentric moment
180°out of phase

Section 1: GENERAL INFORMATION Page 9
OM-ZR-May15
Description Unit 18ZR 25ZR 50ZR
Eccentric moment in-lbs, kg-m 1500, 18 2200, 25 4400, 51
Maximum frequency vpm 1650 2050 1600
Driving Force tons, kN 93, 825 136, 1 210 168, 1 495
Centrifugal force tons, kN 85, 755 130, 1 170 160, 1 425
Amplitude (free w/o clamp) In, mm 0.9, 24 0.8, 20 0.86, 22
Standard line pull for extracting tons, kN 30, 270 100, 890 120, 1 070
Maximum line pull for extracting tons, kN 40, 355 100, 890 120, 1 070
Weight (no clamp or hoses) lbs, kg 7900, 3 585 9650, 4375 14650, 6 645
Non-vibrating Weight lbs, kg 2960, 1 345 4180, 1 895 4410, 2000
Height without clamp (H) in, mm 80, 2 035 78, 1 965 82, 2 060
Length (L) in, mm 77, 1 945 112, 2 835 131, 3 330
Width (W) in, mm 21, 525 26, 660 44, 1 120
Throat width (TW) in, mm 14.25, 362 14.75, 375 14.75, 375
Hydraulic hose length ft, m 150, 46 150, 46 150, 46
Hydraulic hose weight lbs, kg 1425, 646 1425, 646 1555, 705
Power Unit Model 350GZ / 450GZ 450GZ / 595GZ 700GZ / 800GZ
Height with clamp (HH) in, mm 118, 3 661 116, 2 924 120, 3 019
Universal clamp weight lbs, kg 2200, 1 000 2200, 1 000 2900, 1 315
Universal clamp Model 140 140 196
Vibrator Specifications

Section 1: GENERAL INFORMATION Page 10
OM-ZR-May15
Power Units Specifications
Constant improvement and engineering progress make it necessary that we reserve the right to make
specification changes without notice. Please consult ICE for the latest available information.
Description Unit 350GZ 450GZ
Engine - Caterpillar C9 C13
Power HP, kW 350, 261 440, 328
Operating Speed rpm 1950 2000
Drive Pressure (max.) psi, bar 5500, 380 5500, 380
Drive Flow (no load) gpm, lpm 97, 367 126, 477
Clamp Pressure psi, bar 4800, 331 4800, 331
Clamp Flow gpm, lpm 6, 21 6, 21
Weight (W) lbs, kg 11000, 4990 14675, 6657
Length (L) in, mm 130, 3302 147, 3728
Width (W) in, mm 62, 1556 64, 1613
Height in, mm 83, 2108 91, 2312
Hydraulic Reservoir gal, lit 275, 1040 275, 1040
Fuel Capacity gal, lit 118, 447 118, 447
EPA, EU Tier, Stage 3, IIIA 3, IIIA
595GZ
C15
595, 444
3, IIIA
1850
5500, 380
160, 610
4500, 310
6, 21
16350, 7420
160, 4040
73, 1855
100, 2540
430, 1630
150, 570
700GZ
C18
630, 475
3, IIIA
1800
5500, 380
175, 670
4500, 310
6, 21
26500, 12020
218, 5540
80, 2035
104, 2630
550, 2080
200, 750
800GZ
C18
800, 597
3, IIIA
1800
228, 880
228, 880
4500, 310
6, 21
26500, 12020
218, 5540
80, 2035
104, 2630
550, 2080
200, 750
Clamp & Accessory Specifications
Please consult the Clamps & Accessories Parts Manual for specification information on those items.
Constant improvement and engineering progress make it necessary that we reserve the right to make
specification changes without notice. Please consult ICE for the latest available information.
L W
H

Section 2: SAFETY Page 12 OM-ZR-May15
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safe-
ty rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before
an accident occurs. A person must be alert to potential hazards. This person should also have the necessary
training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this equipment can be dangerous and could result in
serious injury or death to you or other persons.
Do not operate or perform any lubrication, maintenance or repair on this equipment, until you have read and
understood the operation, lubrication, and maintenance and repair information in both the International Con-
struction Equipment, Inc. and Caterpillar Operation & Maintenance Manuals.
Safety precautions and warnings are provided in the manuals. If these hazard warnings are not heeded, serious
bodily injury or death could occur to you or other persons.
Important Safety Information is marked as shown below.
Section 2: SAFETY
Important Safety Information
International Construction Equipment, Inc. and Caterpillar cannot anticipate every possible circumstance that
might involve a potential hazard. The warnings in the manuals and on the equipment are therefore not all inclu-
sive. If a tool, procedure, work method or operating technique not specifically recommended in writing by au-
thorized personnel from International Construction Equipment, Inc. or Caterpillar is used, you must satisfy your-
self that it is safe for you and others. You should also ensure that the equipment would not be damaged or
made unsafe by the operation, lubrication, maintenance and/or repair procedures you choose.
The information, specifications, and illustrations in the manuals are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete
and most current information before starting any job. International Construction Equipment, Inc and Caterpillar
dealers have the most current information available.
!WARNING – Equipment!
The meaning of this safety warning is as follows:
Attention! Become Alert! Equipment could be damaged.
The message that appears under the warning, explaining the hazard, can be either written
or pictorially presented.
The meaning of this safety warning is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning, explaining the hazard, can be either written
or pictorially presented.
!WARNING – Safety!

Section 2: SAFETY Page 13 OM-ZR-May15
Hazard Information
Stop the equipment. Stop the engine.
Ensure the protective locks or controls are in the applied position.
Disconnect the batteries whenever performing any maintenance or before servicing the electrical system. If the
engine has an electric starter, disconnect and tape the battery ground leads to prevent accidental starting.
Disconnect the batteries before performing any welding. Failure to do so will cause serious damage to the power
unit's operating system.
Do not attempt any repairs or adjustments to the engine or equipment while it is running.
Do not attempt any repairs that you do not understand or for which you are not qualified. Use proper tools; re-
place or repair broken or damaged equipment.
Block or restrain the equipment, if applicable before operating or performing maintenance.
Do not adjust, or set, hydraulic pressures higher or lower than those specified in the parts manual.
Use caution when removing filler caps, grease fittings, pressure taps, breathers or drain plugs. Hold a rag over
the cap or plug to help prevent being sprayed or splashed by liquids under pressure.
Wear a hard hat, protective glasses, hearing protection and other protective equipment as required by job con-
ditions.
Do not wear loose clothing or jewelry that can catch on controls or other parts of the equipment.
Make certain all protective guards and covers are secured in place.
Use all cleaning solutions with care.
Never put maintenance fluids into glass containers since glass containers can break.
Report all needed repairs.
Maintenance Procedures
Pressurized Air and Water Hazards
Pressurized air can cause personal injury. When using pressurized air for cleaning, wear a protective face shield,
protective clothing and protective shoes.
The maximum air pressure must be below 30 psi (205 kPa) and maximum water pressure must be below 40 psi
(275 kPa) for cleaning purposes.
Wear eye protection at all times when cleaning the cooling system. Pressurized water could cause debris and/or
hot water to be blown and result in serious personal injury.
Do not spray pressurized water at the control box. Pressurized water could result in damage to the onboard
computer module, which could cause the operating system to malfunction.
Fluid Penetration Risk
Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pinhole size
leak, can penetrate body tissue, causing serious injury or possible death.
If fluid is injected into your skin, a doctor familiar with this type of injury must treat it immediately.

Section 2: SAFETY Page 14 OM-ZR-May15
Hoses, Lines and Tubes Handling Procedures
Do not pull on, or attempt to move equipment, by force or pressure to the hydraulic hoses. The power unit will
need to be moved closer to the work if hoses do not reach.
Do not operate this equipment with hydraulic hoses that are damaged or kinked. Replace damaged hoses imme-
diately.
Do not lift or support hydraulic hoses with wire rope slings.
Do not pull kinks in the hoses. Kinks will reduce the hose safety factor by 50 percent.
Do not bend or strike high-pressure lines. Do not install bent or damaged lines, tubes or hoses.
Leaks can cause fires. Repair any loose or damaged fuel and oil lines, tubes and hoses.
Inspect all lines, tubes and hoses carefully. Do not use your bare hands to check for leaks. Tighten all connec-
tions to the recommended torque.
Make sure that all clamps, guards and heat shields are installed correctly to prevent rubbing against other parts
and excessive heat during operation.
Hoses, Lines and Tubes Check List
 End fittings damaged, leaking or displaced.
 Outer covering chafed or cut and wire reinforcing exposed.
 Outer covering ballooning locally.
 Evidence of kinking or crushing of the flexible part of the hose.
Precautions for Oils
Hot oil and components can cause serious personal injury. Do not allow hot oil or components to contact the
skin.
Keep all exhaust manifold and turbocharger shields in place to protect hot exhaust from oil spray in the event of
a hose, tube or seal failure.
Fire Extinguisher Requirements
Have a fire extinguisher of the appropriate type and size available and know how to use it. Inspect and have it
serviced as recommended on its instruction plate.
Fire or Explosion Prevention
All fuels, most lubricants, hydraulic oil, and some coolant mixtures are flammable.
Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel and gasoline fumes is extremely explosive.
Do not weld or flame cut on pipes or tubes that contain flammable fluid(s). Clean them thoroughly with non-
flammable solvent before welding or flame cutting on them.
Shields must be installed correctly. These shields are for the purposes of protecting against some hot exhaust
components produced by oil or fuel and can assist in lessening the range of a spray in the event of a line, hose,
and tube or seal failure.

Section 2: SAFETY Page 15 OM-ZR-May15
Fire or Explosion Prevention (continued)
Clean and tighten all electrical connections. Check regularly for loose or frayed electrical wires. Refer to mainte-
nance schedules for inspection interval. Have all loose or frayed electrical wires tightened, repaired or replaced
before operating the equipment.
Wiring must be kept in good condition, properly routed and firmly attached. Routinely inspect wiring for wear or
deterioration. Loose, unattached, or unnecessary wiring must be eliminated. All wires and cables must be of the
recommended gauge and properly fused. Never bypass fuses. Maintaining tight connections, and replacing
worn, frayed or damaged wire and cable will prevent arcing that could cause a fire.
Crushing or Cutting Prevention
Support equipment and attachments properly at all times and especially when working beneath them.
Never attempt adjustments while the engine is running unless otherwise specified in this manual.
Stay clear of all rotating and moving parts. Guards should be in place whenever maintenance is not being per-
formed.
Keep objects away from moving fan blades. They will throw or cut any object or tool that falls into their path.
Wear protective glasses when striking objects to avoid injury to your eyes.
Make sure no one can be injured by flying debris before striking any object. Chips or other debris can fly off
objects when struck.
Mounting and Dismounting
Do not climb on, or jump off the equipment or stand on components that cannot support your weight. Use an
adequate ladder. Always use steps and handholds when mounting and dismounting.
Clean steps, handholds and areas of the equipment you will be working on or around.
Before Starting the Engine
Read "Before Starting the Engine" in the Caterpillar Operation & Maintenance Manual.
Make sure the remote-control pendant (or radio control) is in a safe place. Do not leave the pendant (or radio
control) unattended.
On the control panel, make sure the main circuit (REV-OFF-FOR) and auxiliary circuit (REV-OFF-FOR) switches
are set to OFF.
On the remote-control pendant, make sure the main circuit (REV-OFF-FOR) and auxiliary circuit (REV-OFF-FOR)
switches are set to OFF.
On the control panel and pendant, make sure the clamp OPEN-CLOSE switch is in the center (neutral) position.
Make sure power unit is on level, stable ground.
Make sure equipment areas are clear for operation.
Do not smoke or use open flame in the vicinity when filling fuel tanks or when flammable vapors are present.

Section 3: LOADING, UNLOADING & SHIPPING Page 16
OM-ZR-May15
Section 3: LOADING, UNLOADING & SHIPPING
Power Unit
The power unit should be loaded with the heat exchangers facing to the rear of the truck to prevent damage to
the heat exchangers from flying objects. The power unit is usually held to the truck by wrapping a chain around
both ends of the fuel tank sub-base. Before shipping the power unit, tape the exhaust rain cap shut to prevent
rainwater from entering. If quick-couplers do not have safety cables for the caps and plugs, store caps and
plugs under the panel in the storage box rather than risk the possibility of them coming loose and falling off into
traffic. Make sure all doors are fully closed and latched. Tighten fuel cap and close fuel petcock to prevent loss
of diesel fuel.
Vibrator or Rotary Head
The equipment should be shipped laying or sitting flat on the trailer deck. Lift the equipment by rigging one line
to the lifting pin and one line to the hose bundle as one load. Avoid crushing hydraulic lines.
Damage During Shipment
Before the truck leaves, carefully inspect the equipment and hoses for any missing components or signs of
damage that may have occurred during shipment or unloading. In the event of damage during shipment,
notify the trucking agent at once. Note all damage on the bill of lading. Fax or email the information to
International Construction Equipment, Inc. as soon as possible. Any delay may make it difficult to identify the
responsible party.

Section 4: PREPARATION FOR OPERATION Page 17 OM-ZR-May15
Section 4: PREPARATION FOR OPERATION
General
When unloading and unpacking the power unit and equipment, use extreme care.
For your protection, make a thorough inspection of the unit immediately upon delivery. In case of any damage
or shortage, notify the transit agent at once and have the delivering carrier make a notation on the freight bill.
Rigging of Vibrator
A steel wire rope sling must be connected to the lifting pin of the vibration suppressor. The required strength
of this sling depends on the capacity of the crane and the work to be carried out. A safety factor of five is
recommended. Several turns of a smaller diameter cable will usually last longer than one turn of a larger
diameter cable. Consult a rigging expert or rigging handbook for guidance. Be aware of protocols, regulations,
and guidelines for rigging.
Wire rope failure or cable clamp slippage may result in injury or death.
Check cables and cable clamps daily.
!WARNING – Safety!
Installing Proper Remote-control Pendant
To use power unit with vibrator, install ZR vibrator remote control pendant
Emergency
Stop
Clamp
Light
Clamp
Switch
Actuator
Switch
Main
Circuit
Engine
Throttle
Amphenol™ Connection to Power Unit Control Panel
The remote-control pendant is connected to the power unit at the control panel with a multi-pin modular plug
and hand nut connection. The pendant control has switches for the clamp, vibrator, engine throttle,
emergency stop, clamp indicator light. The cable allows 50 feet of distance from the power unit. If pendant
cable needs to be connected to power unit, align modular plug and push together before tightening metal nut
on Amphenol™ connection.
!WARNING – Equipment!
Remote Pendant should not be left unattended while power unit engine is running. Be
cautious of damaging pendant cable or allowing controls to be submerged in water or
mud. Avoid stretching cable or shutting control panel door on cord.
Cable

Section 4: PREPARATION FOR OPERATION Page 18 OM-ZR-May15
Connecting Vibrator Hoses to Power Unit
The vibrator’s interconnecting hoses (in the bundle) terminate with quick disconnect couplers specific to each
function and mating quick disconnect at the power unit. Use care to connect couplers straight and screw
together completely. Should quick disconnects or hoses require replacement, use care not to mix up the
connectors and hose routing.
Eccentric Moment Actuator
Open Clamp
Motor Return
Motor Pressure
Motor Case Drain
Close Clamp
Gear Oil to Vibro
350GZ Quick Disconnect Panel
The vibrator and hydraulic clamp are connected to the power unit by seven hydraulic hoses. The functions are
listed above on the corresponding quick disconnect couplers.
The hoses connect to the power unit with quick-disconnect couplers. Hose couplers are arranged to insure cor-
rect connections at the power unit .
Clean couplers with a lint-free cloth before making connections.
Make sure that the couplers are fully run up and hand tightened prior to using an appropriate chain type
wrench.
Power unit must be shut down during connection of hydraulic hoses.
Improper hose connections can cause ruptured hoses or damaged components and poor
equipment performance.
!WARNING – Safety! !WARNING – Equipment!
Gear Oil to Cooler