PILECO V-400 User manual

OPERATING INSTRUCTIONS V-400
office [phone]
1-800-409-0018
fax [phone]
www.Pileco.com
491 Conroe Park W. Dr.•Conroe, TX 77303 9/29/2023
Model: V-400
Serial number: V-400-HPU-018-0921
Year of manufacture: 2022
Revision: -
Op e r a t i n g i n s t r u c t i O n s
Power Unit
V-400

PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•491 Conroe Park W. Dr.•Conroe, TX 77303
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Technical Specications
Diesel Engine: 1x Caterpillar C13 Stage V
RPM: 1800
Drive Pump: Sauer Danfoss
Max. Working pressure: 350 bar
Oil Flow 440 l/min.
Fuel Capacity 1500 litre / 396.26 gal
Length: 4200 mm/ 165.4 inches
Width 1850 mm/ 72.8 inches
Height: 2292 mm/ 90.2 inches
Weight: 7400 kg/ 16,314 lbs

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PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•491 Conroe Park W. Dr.•Conroe, TX 77303
Op e r at i n g i n s t r u c t i O n s V - 4 0 0

PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•491 Conroe Park W. Dr.•Conroe, TX 77303
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Legal Jargon
Pileco Inc. has the right to change parts of the equipment at any time without prior or direct notice to the client. The
contents of this publication are subject to changes without prior notice.
This publication is to be used for the standard version of the equipment only. Pileco Inc. cannot be held responsible for
any damage resulting from the application of this publication to the version actually delivered to you.
For extra information as to adjustments, maintenance and repair, please contact the technical department of
your supplier.
This publication has been written with great care. However, Pileco Inc. cannot be held responsible, either for any errors
occurring in this publication or for their consequences.
Safety Indicators Explained:
The following symbols are used throughout the manual.
CautionCaution indicates a potentially hazardous
situation which, if not avoided may result in minor or
moderate injury. For example,
protect eyes!
WarningWarning indicates a potentially hazardous situation
which, if not avoided could result in death or serious
injury
DangerDanger indicates an imminently hazardous situation,
which if not avoided will result in death or serious
injury
!WARNING!
!DANGER!
CAUTION

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PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•491 Conroe Park W. Dr.•Conroe, TX 77303
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TABLE OF CONTENTS
1. PREFACE 6
2. EXTERIOR 7
3. SAFETY INSTRUCTIONS 8
1. Safety Precautions 8-10
2. Safety Symbols 11
4. DESCRIPTION 12
1. Description of the Hydraulic Power Station 12
2. Hydraulic System 12
3. Electrical System 13
5. ASSEMBLY AND INSTALLATION 14
1. Moving the Equipment 14
2. Connecting the Hydraulic Hoses 14
3. Connecting the Remote Control 15
6. OPERATIONS 16
1. Emergency Stop 16
2. Filling the Hoses 16
3. Control Panel 17-18
4. Display Pages 19-23
5. Starting/Stopping Procedure 23-25
6. Vibro Operation 26
7. Auger Operation 26-27
8. Troubleshooting 27
7. MAINTENANCE 28
1. General 28
2. Service Intervals 28
3. Daily Maintenance 29
4. Inspection and Replacement Intervals 30
5. Remaining Service Intervals 31-32
6. Recommended Fluids 33
7. Welding 33
8. Before Welding 34
8. ORDERING PARTS 35
1. Procedure 35
2. Original Equipment 35
3. Shipment 35
4. Shortages 35
5. Return Of Parts 35
6. Screws and Bolts 35
7. Hoses 35

PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•491 Conroe Park W. Dr.•Conroe, TX 77303
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PREFACE
This owner’s manual has been written for the users of Pileco Inc. Power Units. The owner’s manual explains how to use,
service and inspect the power pack, with the intention to use the power pack safe and efciently.
One copy of the present manual should at any time be at the location where the unit is in operation.
When the instructions of this owner’s manual are not strictly followed, accidents may happen.
Therefore, make sure you understand all the instructions in this manual before you start using the power pack.
For ordering of parts we refer to the parts manual of the relating power pack.
For the operation of the machine which is attached to the power pack, we refer to the owner’s manual of the relating
manufacturer.
If operational or maintenance problems arise which are beyond the scope of this manual, please contact Pileco Inc. at
the telephone number on this page.
We are prepared to assist you in order to make the best use of your equipment.
If you call, please have the following at hand:
Model number:
Equipment serial number:
Model: V-400V
Serial number: V-400-HPU-018-0921
Year of manufacture: 2022
Revision: –
office: [phone]
fax: [phone]
email: [email protected]
www.Pileco.com
491 Conroe Park W. Dr.
Conroe, TX 77303

7
PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•491 Conroe Park W. Dr.•Conroe, TX 77303
Op e r at i n g i n s t r u c t i O n s V - 4 0 0
2. EXTERIOR
1 Control panel door 5 Door holder
2 Service door fuel /ad-
blue
6 Hydraulics access door
3 Engine access door 7 Hydraulics quick couplers
4 Warning lights 8 Emergency stop button

PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
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3. SAFETY INSTRUCTIONS
1. Safety Precautions
Regular maintenance and skilful operation will not only lengthen the mechanical life but is essential for the safety of the
user and possible bystanders.
It is the responsibility of the user or operator to ensure that the local health and safety regulations are observed
before and during the use of the equipment.
Operators:
• Only trained personnel shall be permitted to operate the machine.
• Temporary employees and trainees shall only be permitted to work with the equipment under the supervision
and instruction of trained personnel.
Owner’s Manual:
• Everyone who works at or with the equipment should be familiar with the contents of this manual and the
manuals of the machines which are driven by the Hydraulic Power Station and should follow the instructions
accurately.
• One copy of the present manual should at any time be at the location where the unit is in operation.
• The management is under obligation to inform the personnel of the contents of this manual and is obliged to
observe all of the regulations and directions.
• Additional manuals are available on request.
Always:
• Lead exhaust fumes outside when operating in a closed area. Continued breathing-in of exhaust fumes
may be fatal.
• Pay attention to irregular or unusual noises and analyze where they come from.
• Remove all tools and electrical cords before starting the Hydraulic Power Station.
• Warn colleagues when you feel uncomfortable with the way the Hydraulic Power Station or the driven
machine is functioning.
Never:
• Make adjustments or repairs while the system is under pressure.
• Make adjustments or repairs while the engine is running.
• Continue operation when service inspection is due, or when a repair is necessary.
• Continue operation when it is known that any of the safety provisions is out of order or not working properly.
• Leave the remote control unattended.
• Attempt to (dis)connect the quick-disconnect couplers when the engine is running.
!WARNING!

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PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•491 Conroe Park W. Dr.•Conroe, TX 77303
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Tools:
• Never use defective (maintenance) tools.
• Only use a tool for the purpose it was designed for.
Clothing and Footwear:
• When working with the equipment, do NOT wear rings, watches, jewellery or any loose clothing/hair which
could be caught in moving or rotating parts.
• Always wear protective goggles, a safety helmet, protective footwear and hearing protection especially
suited for the work.
• Keep hands away from moving or rotating parts.
• Take appropriate measures for the ear protection if the sound level of 85 dB(A) is exceeded; always use ear
protection when working close to a machine in operation.
Water and Moisture:
• Never direct a jet of water at electrical parts.
• Make sure all protective devices of the electric installation have been installed to guarantee adequate
protection from moisture and water. Failure to do so can cause malfunction of safety circuits and cause harm
to personnel and equipment components.
Technical Specications:
• The permissible tolerances as stated in the present manual shall NOT be exceeded.
Safeguards:
• All safeguards must be correctly installed and may only be removed for maintenance and service purposes
by qualied PILECO INC. service engineers.
• The equipment should never be switched ON when the protective covering is incomplete or when
the safeguards are not in place.
• All safeguards must be checked at regular intervals and repaired immediately in case of malfunction.
Safety Directions and Warnings:
• Any safety direction, warning or instruction tted on the equipment shall NOT be removed, rendered illegible
or covered. They shall be present and legible throughout the entire operating life of the equipment.
• Illegible, damaged or covered safety directions, warnings or instructions shall immediately be replaced
or repaired.
Service and Maintenance:
• The service and maintenance activities shall only be carried out by qualied PILECO INC. personnel or one of
PILECO INCs. appointed and certied dealers in full compliance with all safety instructions and service intervals.
• Use original PILECO INC. Parts and liquids.

PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
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Electrical System:
• Work on the electrical system or equipment may only be carried out by skilled electricians or by specially
instructed personnel under the supervision of such electricians and in accordance with the applicable electrical
engineering rules.
Hydraulic System:
• The hydraulic system is a high pressure, high oil ow system. Work on the hydraulic equipment shall only be
carried out by persons having special knowledge and experience in high pressure hydraulic systems.
• When bleeding hoses or looking for leaks, take protective measures. Escaping oil under pressure, even a
pin-hole size leak, can penetrate body tissue, causing serious injury.
Use According to Purpose:
• To guarantee correct operation, the equipment should only be used in accordance with the purpose as
described in this owner’s manual.
Fire or Explosion Prevention:
• Hydraulic oil and diesel fuel are ammable. Therefore:
• Do not weld or ame-cut on pipes or tubes that contain ammable uids. Clean them thoroughly with
non-ammable solvent before welding or ame cutting on them.
• Clean and tighten all electrical connections. Check regularly for loose or frayed electrical wires. Wiring must be
kept in good condition, properly routed and rmly attached. Routinely inspect wiring for wear or deterioration.
Loose, unattached, or unnecessary wiring must be eliminated.
Never smoke when lling the fuel tank or use ames in the vicinity. Never store ammable liquids
near the engine.
Work area:
• Place the Hydraulic Power Station in a safe place.
• Position the Hydraulic Power Station in such a matter that eye contact with the Hydraulic Power Station
is assured.
• Keep the work area clean. Keep the equipment accessible and make sure that the area surrounding of the
equipment is kept clean.
• Always be extremely careful when using a carbon tetrachloride re extinguisher in a closed area, as it may
produce toxic vapors and/or deplete the area from oxygen.
!WARNING!

11
PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•491 Conroe Park W. Dr.•Conroe, TX 77303
Op e r at i n g i n s t r u c t i O n s V - 4 0 0
2. Safety Symbols
HAZARD DESCRIPTION

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www.Pileco.com•491 Conroe Park W. Dr.•Conroe, TX 77303
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4. DESCRIPTION
The V-400V Hydraulic Power Station is designed to drive Fixed moment vibratory hammers and augers.
1. Description of the Hydraulic Power Station
The Hydraulic Power Stations are powered by a diesel engine. The engine is mounted on a tubular sub-base which
serves as a fuel tank. The power unit and the driven machine are operated from the control panel or remote-control
pendant.
Hydraulic oil is stored in the reservoir. Oil cooling is accomplished by an air-to-oil temperature exchanger. All the above
components are contained in a sheet metal enclosure with lockable doors and air vents.
2. Hydraulic system
* (for the circuit, refer to the hydraulic diagram HD-V-400V-1000668-31-05-22)
The hydraulic circuit of the PILECO power station is a so-called open-loop system. This means that the oil is taken from a
reservoir.
The pressure in the return line is low. Each power pack is equipped with several hydraulic pumps.
The main pump(s) are variable displacement pumps and drive the connected equipment.
The Main pump:
When the diesel engine is running and the start button is activated, hydraulic uid is taken from the reservoir by the
drive pump and is pumped to the drive manifold.
The oil is directed through the hoses to the driven machine. It ows back to the power pack through the return line.
The circuit is protected by means of a pressure relief valve and is provided with a return line lter.
The hydraulic hoses can be disconnected at the power pack directly behind the manifold.
The Reservoir:
The hydraulic oil is stored in the hydraulic reservoir. The oil ows into the reservoir via the return lter. The reservoir can
be closed with a buttery valve.

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PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•491 Conroe Park W. Dr.•Conroe, TX 77303
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3. Electrical System
*(for the circuitry, refer to the “Electrical diagram”)
The power pack contains a 24V DC electrical installation. All main functions are electrically controlled either from the
remote control or from the main control panel.
The power pack is equipped with a control module, which will warn the operator in the following cases:
• Hydraulic oil temperature too high, 70°C. The oil ow to the equipment will stop and the engine will run at xed
speed until the oil temperature is 60°C.
• Hydraulic oil level too low.
• All engine faults are shown on the display.
• Emergency stop, this will cut off all power to the diesel engine.
• Limit switch on the main intake valve. If the switch is not activated the engine will not start.
Error Indication
When the error is solved the display warning can be closed by pressing the "X" button on the display warning.
If there appears any fault on the display, lights on the outside of the power pack housing will ash indicating a system
warning.

PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
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5. ASSEMBLY & INSTALLATION
1. Moving the Equipment
The power packs are equipped with four lifting eyes. All four lifts must be used for lifting the power station.
Always lift the power station by its own 4 lifting eyes. Use certied slings and place the power station on a horizontal
and stable surface.
2. Connecting the Hydraulic Hoses
Never connect or disconnect the hoses while the diesel engine is running.
• Make sure the Quick couplers are not pressurized.
• Clean the Quick couplers before connecting.
• Check the (Quick)couplers and hoses for any damage prior to operation.
• Make sure the couplers are FULLY tightened.
1 Vibro Pressure Quick coupler 5 Vibro Clamp Close coupler
2 Vibro Return Quick coupler 6 Pressure coupler Auger CW rotation
3 Vibro Drain Quick coupler 7 Pressure coupler Auger CCW rotation
4 Vibro Clamp Open coupler 8 Auger drain coupler
!WARNING!
CAUTION

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PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
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3. Connecting the Remote Control
Connect the cable plug to the control panel of the Hydraulic Power Station (see picture below, item A).
When the pendant / wireless control cable is:
Connected: The hammer can only be operated by means of the remote control.
Disconnected: The hammer can only be operated by means of the Local operating device at the control panel.
CAUTION
The EMERGENCY STOP on the remote control is only operational when the remote control is connected.

PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
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6. OPERATION
1. Emergency Stop
Always restart the hydraulic power station after the emergency stop is re-set.
Not re-starting can cause damage to the diesel engine.
The Hydraulic Power Station is equipped with several emergency stop buttons, activating the emergency stop will shut
down the diesel engine and cut the main oil-ow.
Do not use the emergency stop buttons for any other use than an emergency stop.
Before operation check that all emergency stop buttons are in operating position, turn the emergency stop button coun-
ter clockwise to release.
Emergency stop indication will show on the control panel main display.
If any of the emergency buttons are energized, make sure to restart the hydraulic power station and shut it down in the
correct way.
2. Filling the Hoses
When the Driven Equipment is delivered the system is usually lled with oil and may be used immediately.
However, if any hoses need to be replaced or connected on site it can be necessary to bleed the hoses
prior to operation.
• Start and warm up the engine (Chapter 6 Starting/Stopping).
• Run the HPU at idle for 5 minutes
• Stop the diesel engine.
• Check the oil level in the hydraulic oil tank. Rell if necessary.
CAUTION

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PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
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3. Control Panel
The control panel contains a control module by which the operator can control the Hydraulic Power Station.
Make sure the operator has a clear view on the connected machine(s) and the working area, when operating via the
control panel.
IMPORTANT:
The operation / maintenance / safety instructions inside the control panel door serve as quick reference. They are not
complete and therefore not intended as a substitute for a thorough understanding of the present manual.
CAUTION
CONTROL PANEL LAYOUT
01 Main Display 04 Remote control connector
16 pin
02 Bluetooth Modem 05 Remote control connector
10 pin
03 Start/Stop button 06 Emergency stop button

PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
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HMI-Display
This Hydraulic Power Station is driven by a Parker IQAN system, all settings and value read-out can be accessed from the
touch screen HMI Display.
Start-up Display
CONTROL PANEL LAYOUT
01 Countdown timer 07 Diesel engine shutdown timer
02 Text shows wait or start 08 Current display page
03 Close Page button 09 Engine status lights
04 Info Button / shows info page 10 Diesel Fuel Level
05 Menu button / show settings menu 11 AdBlue Level
06 Button Panel Light 12 Power station shutdown timer
Engine Status Lights
01 Engine failure 03 Preheat (wait to start) Not installed
02 Stop by engine active 04 Emission system error
05 Exhaust regeneration active
Engine Status Lights

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PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
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4. Display Pages
Display Buttons

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