PILECO HP-60 User manual

OPERATING INSTRUCTIONS HP-60
OPERATING INSTRUCTIONS
Power Unit
HP-60
office [phone]
1-800-409-0018
fax [phone]
www.Pileco.com
3321 E Davis St•Conroe, TX 77301
4/30/2021

PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•3321 E Davis St•Conroe, TX 77301
2
OPERATING INSTRUCTIONS HP-60
TABLE OF CONTENTS
CEO Introduction 3
Features and Benets 3
1.0 Specications and Warnings
1.1 Technical Specications 4
1.2 Fluid Specications and Capacities 5
1.3 Flow Rate / Speed Chart 6
1.4 Warnings and Precautions 7-8
2.0 Operations
2.1 Connecting Hydraulic Lines 8-9
2.2 Explanation of Starting and Control 10
2.3 Prior to Starting the Unit 11
2.4 Starting the Engine Via Remote (preferred) 11-12
2.5 Starting the Engine Via Panel 12
2.6 Starting the Engine Via Panel Then Switching to Remote 13
3.0 Maintenance
3.1 Removing the Roof 13
3.2 Checking Engine Hours 14
3.3 Filling the Hydraulic Fluid 14
3.3.1 Filling Prior to the Filter (preferred) 14
3.3.2 Filling Through Fill Port on the Tank 15
3.4 Draining and Cleaning the Fuel Tank 15
3.5 Priming the Fuel 16
3.6 Adjusting Auto Speeds 17
3.6.1 Steps for setting lower RPM (D6-D70) 17
3.6.2 Steps for setting higher RPM (D80 and Above) 18
3.6.3 Testing 18-19
3.7 Routine Maintenance 20-21
3.8 Fuse and Relay Locations: 22
3.8.1 Fuses 22
3.8.2 Relays 23
3.9 Spare Parts Kit 24
Appendix
Hydraulic Schematic 26
Chassis Electrical Schematic 27
Engine Wiring Schematic 28

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PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
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OPERATING INSTRUCTIONS HP-60
CEO Introduction
Pileco Inc. in our continued search for SMARTER PILE DRIVING PERFORMANCE coupled with its 50-year his-
tory and with today’s technologies are here to provide you with exceptional service, rentals, and technical
support with a superior eet of products. Those products include pile driving equipment, diesel hammers,
hydraulic hammers, vibratory hammers, power units, lead systems and parts. We are always looking to the
future, looking to bring you innovation, continued quality and affordability. We are prepared to assist you in
order to make the best use of your equipment.
So thank you for choosing us as your Diesel Hammer and Foundation Equipment Dealer. Here at Pileco Inc. we appreci-
ate your business and continually strive to provide excellent service and quality products. We are always interested in
hearing from you on how we can make your lives easier. So please contact us with any questions or concerns.
Sincerely,
George Smith, CEO
If you call, please have the following at hand:
Model number:
Equipment serial number:
Features and Benets
The Pileco HP-60 Hydraulic Power Unit is primarily designed to be used to actuate the hydraulic cylinder that initiates
the rst blow of a diesel hammer. However, the Power Unit can be used for any hydraulic application requiring uid power
that falls within its range of specications. These include, but are not limited to: pilegates, spotters, and winches.
The HP-60 features remote functionality for both the engine and the hydraulic bank from up to 1,000 feet away. The
engine may be started and stopped as well as throttling between run and idle speeds. Four of the hydraulic banks can
be operated via remote, and all may be operated locally at the directional control valve.
The HP-60 features and a large, integrated hydraulic tank (over 63 gallons @ 90° ll) to provide an ample supply of
hydraulic uid and easily dissipate heat from the system. Premium Stucchi quick disconnects can be coupled under
pressure and have virtually no spillage upon disconnecting.

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OPERATING INSTRUCTIONS HP-60
Engine: CAT 2.2 L Tier 4 Diesel
Max Engine Power: 67 HP @ 2,800 RPM
Hydraulic Pump: Parker 31B Gear Pump
Max Pressure: Produces maximum of 3,000 psi, system is regulated to 2,700 psi through DCV
Displacement: 2.96 in 3 / rev (0.0128 gal / rev or 1.28 GPM / 100 RPM)
Directional Control Valve: 4 or 6 Spool Hydac DX6 with manual and electric spools
Electrical System: 12V system, 31P Battery
Flow Rates: Bank 1 (TRIP): unregulated on ow rate; see section 1.3 for rate / RPM chart
Banks 2-6: Regulated to 10 GPM regardless of RPM
Quick Disconnects: Stucchi VEP15P
Dry Weight: Approx. 2,750 lb
Wet Weight: Approx. 3,350 lbs with 90% ll on hydraulic oil and diesel
Hydraulic Oil Capacity: 70.4 gallon tank, 63.4 gallons @ 90% ll
Fuel Capacity: 24.6 gallon tank, 22.2 gallons @ 90% ll
Dimensions: 68-3/8" L x 50-1/8" W x 61-1/4" L
1.0 Specications and Warnings
1.1 Technical Specications

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OPERATING INSTRUCTIONS HP-60
1.2 Fluid Specications and Capacities
System Type Capacity
Fuel Ultra Low Sulphur Diesel (≤ 15mg/kg) 22.6 gal (90% ll) 84.0 L
Lube Oil
0°F – 105°F: SAE 10W-30 Min 9.4 qt Min 8.9L
15°F – 122°F: SAE 15W-40 Max 11.2 qt Max 10.6 L
Coolant CAT ELC Coolant (1:1 H20:Glycol) 2.2 gal 8.3 L
Hydraulic Oil SAE AW46 63.4 gal (90% ll) 240.0 L

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OPERATING INSTRUCTIONS HP-60
Approximate No-Load Piston Speeds: # of seconds to fully extend/retract on high ow loop
Speed
(RPM)
Flow Rate
(GPM)
D6–D70 D46 & D50
Extension Time (s) Retraction Time (s) Extension Time (s) Retraction Time (s)
1,500 19.2 13 612 5
1,600 20.5 12 511 5
1,700 21.8 12 510 4
1,800 23.1 11 510 4
1,900 24.3 10 5 9 4
2,000 25.6 10 4 9 4
2,100 26.9
Do Not Use at High RPM
2,200 28.2
2,300 29.5
2,400 30.8
2,500 32.0
2,600 33.3
Speed
(RPM)
Flow Rate
(GPM)
D80–D100 D125–D280
Extension Time (s) Retraction Time (s) Extension Time (s) Retraction Time (s)
1,500 19.2 30 24 37 23
1,600 20.5 28 23 35 22
1,700 21.8 26 22 33 21
1,800 23.1 25 20 31 20
1,900 24.3 23 19 29 19
2,000 25.6 22 18 28 18
2,100 26.9 21 17 26 17
2,200 28.2 20 17 25 16
2,300 29.5 19 16 24 15
2,400 30.8 19 15 23 15
2,500 32.0 18 15 22 14
2,600 33.3 17 14 21 14
*Cell highlighted in Green are recommended speeds for the hammer size
1.3 Flow Rates/Speed Chart

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OPERATING INSTRUCTIONS HP-60
1.4 Warnings and Precautions
Failure to Follow Can Cause Severe Injury, Death, and/or Damage
1. Read and understand this manual in its entirety before operating power unit
2. Do not run this unit in an enclosed space, ensure adequate ventilation before starting
3. CA Prop 65 Warning: Some of the components and by-products of this unit are known to the State of California to
cause cancer, i.e. diesel exhaust, battery lead, etc.
4. This unit contains ammable uids such as diesel and hydraulic oil, use caution with ammable uids and follow
all local, state and federal guidelines related to them
5. During maintenance or repair, follow lock out, tag out (LOTO) practices to ensure energy isolation
6. Never attempt repairs to the system while energized or running
7. Ensure there are no open ames or smoking in vicinity of unit
8. This unit features integrated fuel and hydraulic tanks in addition to sensitive electronics, there is to be no
welding on the unit for any reason
9. Do not touch any part of the exhaust system (exhaust pipe, after treatment, etc), it
gets very hot and will cause burns
10. Wear all appropriate PPE during operations, ensure that there is no loose tting
clothing or jewelry worn around rotating components
11. Ensure that all guards are in place at all times
12. Use only proper tools for the task, ensure that all work is performed by competent,
qualied personnel
13. Use caution disconnecting quick disconnects, they can be very hot depending on uid temperature and
may contain pressure
14. Check to ensure that all pressure is relieved from hydraulic lines prior to loosening or tightening ttings
15. Never attempt to crack or disconnect the engine’s steel fuel lines for any reason
16. Ensure prior to lifting that all four pins are in the legs and that each pin’s linch pin and lock ring are installed
and engaged
17. Use only approved lifting devices that are rated for the load
18. Never remove the coolant cap when hot, open carefully when cool
WARNINGS

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OPERATING INSTRUCTIONS HP-60
PRECAUTIONS
Failure to Follow Could Cause Damage and / or Injury
1. Ensure that ball valve to gear pump is open prior to starting unit
2. Ensure that there are no visible uid leaks on the unit prior to operating or shipping
3. Only use Ultra Low Sulfur Diesel in the unit
4. Ensure that re extinguisher is present and charged
5. Ensure that quick disconnects are clean prior to connecting to minimize contaminates in system
6. Check electrical wires often, replace any that are frayed or worn
7. Disconnect the exhaust ange prior to removing lid of the unit, damage to exhaust system will occur if not
8. It is possible that high pressure can stay trapped in hydraulic lines, ensure that they are only disconnected at
Quick Disconnects. It is good practice to cycling the valve handles with the engine stopped prior to connecting
or disconnecting any hoses to relieve pressure
9. Always inspect and clean quick disconnects prior to connecting, debris will damage the hydraulic system
10. Do not tighten quick disconnects with wrenches or other tools, the ats are only for disconnecting if necessary
11. When lling hydraulic uid, ll through the tee prior to the lter to minimize contaminants
12. Ensure that hydraulic uid systems temperatures do not exceed 160°F
2.0. OPERATIONS
This section will feature setup and operating instructions for the HP-60 Power Unit. For information on the setup and
operations of a diesel hammer in conjunction with the Power Unit, refer to Pileco, Inc.’s Operating Manual:
http://www.pileco.com/images/OperatingManual_Pileco.pdf
It can also be reached by going to www.pileco.com, select “Manuals / Documents” and then select “Operations” to
download the pdf.
A Note About Heat Prior to Operating the Unit
As hydraulic uid circulates through the system, heat will begin to build in the uid. This is inuenced by the speed of the
uid, the restrictions it encounters and the time that it is run. Always pay attention to the temperature gauge integrated
into the hydraulic tank level gauge and ensure that the temperature of the uid system does not exceed 160°F. Use cau-
tion when connecting or disconnecting quick disconnects because the heat of the uid gets transferred into them and
they can get very hot.
Note that valves 2-6 (or 2-4 on a 4-bank) are set to 10 GPM regardless of engine RPM. This means that the higher the
engine RPM, the more uid has to bypass through the Directional Control Valve. This causes higher pressure and that in
turn creates more heat in the uid system. If banks 2-6 are to be used for extended periods, it is recommended to run
the unit at a lower RPM to reduce the heat introduced to the system.

9
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OPERATING INSTRUCTIONS HP-60
In the standard application of ac-
tuating the trip cylinder of a diesel
hammer, connect the hydraulic
hose to the bank labeled “TRIP”.
This will provide the highest ow
rate to actuate the cylinder in the
shortest time possible. See section
1.3 for ow rates and trip times.
2.1 Connecting Hydraulic Lines
The HP-60 power unit features Stucchi VEP15P hydraulic quick disconnects. While it should not be necessary to do,
these couplers have the ability to be safely coupled and decoupled under pressure and leak virtually no oil (0.033 ml
per Stucchi). Regardless, it is good practice to relieve pressure by cycling the valve handles at the DCV prior to connect-
ing or disconnecting lines.
Prior to making up connection, remove dust caps and inspect both male and female couplers to ensure that there is no
dirt or debris, either on the threads or on the faces that could enter the hydraulic system. If it is necessary to clean the
face of the female quick disconnect, the connector can be pushed in for access to the face (see below).
Do not tighten with wrenches or other tools. If the coupler is not making up completely by hand, there is an issue with
the connection. Back the connection off, clean and inspect both ends for debris, damage or deformation.
It is also advised to screw the male and female dust caps together while the hose is connected to protect the threads on
them. After disconnecting hoses, always replace the dust caps.

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OPERATING INSTRUCTIONS HP-60
2.2 Explanation of Starting and Control
The HP-60 Power Unit has the ability to be controlled either locally from the unit or from the remote. This includes start-
ing and stopping the unit, throttling from running speed down to idle and back up to running speed, and controlling four
of the valves.
By default, the unit will start in Auto mode. That means that upon pressing the “Start” button on the remote, the engine
will start, then ramp up to the set running speed and stay there. When the “Stop” button is pushed, the unit will ramp
back down to idle speed and then stop.
The unit may be switched from Auto mode to Manual Mode. If started in Auto (the default), upon switching to Manual
Mode, the speed may now be controlled by the RPM Up and RPM Down buttons, either on the Control Panel or with the
remote. The Unit is set to two speeds, a Run and an Idle. Due to differences in piston sizes, running at a high RPM can
be extremely dangerous if used with a small piston. By default, the Units will be programmed to run at an appropriate
speed for the hammers that they will be used with.
Pressing the RPM Up or RPM Down buttons will change between the Run Speed and the Idle Speed. Prior to shutting the
engine down remotely, the Unit will have to be placed back into Auto Mode. If the Unit is at Idle Speed at the time, it will
ramp back up to Running Speed before starting the shutdown process. If the Stop button is pressed locally while run-
ning at high speeds, the engine will immediately stop at the RPM at which it was running, which will damage the engine
over time.
If the application changes for the Unit, it is possible to change the run speed in the eld. See section 3.6 for details on
how to change the setting, but use extreme caution in changing settings and follow the procedures exactly. If there are
questions at any time, stop and call your Pileco representative.
The rst four banks of the Directional Control Valve can be actuated with either the valve handle levers on the valve
bank or with the remote control. The remote has 12 buttons and a power button, the top four are for starting, stopping
and controlling the throttle. The next eight are for controlling the hydraulic banks. With the engine RPM at Running
Speed, either press and hold the remote button for the corresponding valve or use the valve handle at the valve bank to
engage the hydraulic line.
Connect additional lines to the
other quick disconnects. Note
that the VEP quick disconnects
have a yellow O-ring that indi-
cates when the coupler is made
up completely. If the O-ring is
still visible, the coupler is not
made up completely.

11
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OPERATING INSTRUCTIONS HP-60
2.3 Prior to Starting the Unit
1. Ensure that ball valve to supply side of hydraulic pump is open (handle is in line with hose)
a. Note: severe damage or complete destruction will occur to the pump if run dry
2. Ensure that unit is used in well ventilated space with no combustible hazards in the area
3. Check fuel, engine oil and hydraulic oil to ensure they are at the proper level
4. Ensure that there are no visible fuel or hydraulic oil leaks
5. Manually cycle all valve spool handles to ensure there is no residual pressure in the lines
6. Connect the hydraulic hoses that are to be used to the appropriate bank in the manifold and the equipment
2.4 Starting the Engine Via Remote (preferred)
The Power Unit will by default Start in “Auto” mode. When in Auto Mode, the unit will start at a low RPM and ramp up to
the preset RPM to run. Once the “Stop” button is pushed, it will ramp back down to the lower RPM before shutting down.
This will greatly reduce wear on the engine and increase its life. This only works if the unit remains in “Auto” mode and
the operator uses the “Stop” button, if the key switch is turned or the E-Stop is used it will kill the engine immediately.
Note that the Unit is not able to be started via the Remote when in Manual Mode, it will only start or stop the Unit in Auto
Mode.
1. Turn on Battery Disconnect Switch
2. Press and hold the power button on the remote until the green light on the remote turns on
3. Turn on Control Panel key switch
4. Press the “Start / Stop” button on the Remote ONCE
a. The engine will start and ramp up to Running Speed
5. If it is desired to lower the RPMs to Idle speed between operations, press the “Auto / Manual” button on the
remote. The green “Auto” light on the control console will go off

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OPERATING INSTRUCTIONS HP-60
6. Press the RPM ↓ (turtle) button on the remote to lower the RPM to Idle Speed
a. Note that attempting to operate the hydraulics while at Idle Speed may
overburden the engine and cause it to shut down, increase back to Running
Speed prior to operating hydraulics
7. Press the RPM ↑ (rabbit) button to return to Running Speed
8. To shut down the Unit via the remote, press the “Auto / Manual” button again
to return the Unit to Auto Mode
a. Note that if the Unit is at Idle, it may increase RPM back to Running Speed,
then go back to Idle before shutting down. This can be minimized by pressing
the Start / Stop button quickly after returning the Unit to Auto Mode.
9. Press the “Start / Stop” button again to stop Unit
2.5 Starting the Engine Via Panel
Note that Engine will not run if started from the panel initially in Auto mode
1. Turn on Battery Disconnect Switch
2. Turn on Control Panel key switch
3. Press the “Auto” button on the panel once
a. The green light will go off on the panel and the
display will read “Manual”
4. Press the “Start” button on the control panel
a. The engine will start and stay at idle speed
5. Press the RPM ↑ (rabbit) button to increase to
Running Speed
6. Press the RPM ↓ (turtle) button to return to
Idle Speed
7. Press the “Stop” button to stop the Unit
a. Always lower RPM to Idle speed prior to stopping
the Unit

13
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OPERATING INSTRUCTIONS HP-60
2.6 Starting the Engine Via Panel Then Switching to Remote
1. Turn on Battery Disconnect Switch
2. Turn on Control Panel key switch
3. Press the “Auto” button on the panel once
a. The green light will go off on the panel and the display will read “Manual”
4. Press the “Start” button on the control panel
a. The engine will start and stay at idle speed
5. PRIOR to switching to “Auto” mode, press the power button on the remote to turn on
6. On the remote, press and release the “Start / Stop” button ONCE
7. On the remote, press and release the “Auto / Manual” button ONCE
8. The remote may now be used to control the Unit per Section 2.3
3.0 Maintenance
3.1 Removing the Roof
1. Removethe2X1/2-13Bolts,Nuts,WashersandLockWashersthatareconnectingtheexhaustangejustbelow
theexhaustexconnection
2. Removethereusablegasketbetweentheanges
3. Remove the four linch pins, one from each clevis pin in the legs of the unit
4. Remove the clevis pins from each leg
5. Change the main lifting shackle from the front to
the rear lifting hole (labelled “Roof Removal”
in following image, lift eye opposite from hydraulic
tank, closest to the grating)
6. Lift the roof off of the Unit and set aside
7. Reinstallation is the reverse of removal
8. Ensure that all clevis and linch pins are in place
prior to lifting the unit

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OPERATING INSTRUCTIONS HP-60
3.2 Checking Engine Hours
1. Turn on Battery Disconnect Switch
2. Turn on Control Panel Key Switch
3. Use the Down Arrow on the Control Panel to cycle though
the menu screens until “System Information” is reached
4. Engine hours, date / time, and other data are displayed
on this screen
3.3 Filling the Hydraulic Fluid
There are two methods for lling the hydraulic uid on the
HP-60. The preferred method is through the ller point on the
return line to the hydraulic tank. This will send the hydraulic
uid through the main lter prior to entering the hydraulic tank to minimize contaminates from entering the system. This
method will require a pump and the ability to connect to a 1” male quick disconnect. Pileco offers a complete manual
transfer pump package, part # 8100400.
Note: For estimating required volume, each inch (1”) on the Sight Glass is approximately 1.4 gallons of hydraulic uid, or
about one gallon for every ¾”.
3.3.1 Filling Prior to the Filter (preferred)
1. Remove the dust cap on the male quick disconnect prior to the lter
2. Connect the ller hose with a female quick disconnect
3. Place suction side into oil barrel
4. Turn on pump or rotate hand crank until up to full
line on sight glass
5. Disconnect and replace dust cap when
nished lling

15
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OPERATING INSTRUCTIONS HP-60
The second method will require the roof to be removed from the unit which will require a hoist or crane to lift. Ensure
that the exhaust is disconnected at the ange before attempting to remove the roof or damage will occur. If lling with
these two methods, it is highly recommended that a transfer pump with integral lters is used to minimize contaminants
from entering system.
3.3.2 Filling Through Fill Port on the Tank
Do not attempt to unbolt the top of the hydraulic tank to ll with hydraulic uid. The lid is sealed to the tank body and
removing will require it to be resealed as well as greatly
increase the chances for contamination of the system.
1. Remove the Roof per Section 3.1
2. Remove the ll cap
3. Fill though ller neck until top of sight glass
4. Replace the ll cap
5. Replace the roof (reverse of removal)
3.4 Draining and Cleaning the Fuel Tank
The HP-60 features a cleanout port on one end of the fuel tank for periodic maintenance or inspection of the fuel tank.
The fuel must be drained or run out prior to removing the cover plate.
1. Drain all fuel from unit
2. Remove the 4X ¼-20 x 5/8” Button head screws (5/32” hex wrench required)
3. Thread two of the screws into the threaded holes on the cover (45° from the original holes)
4. Screw in the two ¼-20’s one turn at a time alternating between the two until O-ring is unseated
5. Remove cover and clean fuel tank, ensuring that tank is completely clean and dry prior to relling
6. Inspect the O-ring before reinstallation, if damaged replace (8100064 – 351 Buna N)
7. Grease O-ring and reinstall cover and screws
8. Check Secondary Fuel lter and prime if necessary (see section 3.5)

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OPERATING INSTRUCTIONS HP-60
3.5 Priming the Fuel
Occasionally it may be necessary to prime the fuel on the engine, such as if the tank is run dry, after changing the fuel
lter, or servicing the fuel tank. An indication of needing to be primed will be an unlled secondary fuel lter (attached to
engine). This will require a 6mm hex key, which will be available in the spare parts box (housed in gray enclosure along
with remote).
Never attempt to prime the engine by loosening the high pressure fuel lines on the engine, severe injury or damage can
occur due to high pressure in the fuel lines. It is recommended to have two personnel available during this operation
since the keyswitch is on the opposite side of the engine from the fuel lters. For more detailed information see CAT
Operation and Maintenance Manual M0064264-02.
1. Ensure that the fuel tank is full
2. Turn on Battery Disconnect Switch
3. Turn the keyswitch on the Control Panel to the “On” position but do not start the engine
a. With the keyswitch in the “On” position the low pressure fuel pump will pump fuel until the required
pressure is met or the switch is turned off, use caution as this can spill large amounts of fuel of
left unattended
4. Loosen the bleeder screw on the secondary fuel lter
5. When the level lls and is about to exit the vent screw, tighten the screw to 212 in-lb (~18 ft-lb)
6. Allow fuel pump to operate for an additional 2 minutes
7. Turn the keyswitch to the “Off” position
8. Clean up any spilled fuel prior to starting engine
9. Start engine in Manual Mode and
allow to idle at 1,000 RPM for
ve minutes
10. Inspect fuel system for leaks

17
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OPERATING INSTRUCTIONS HP-60
3.6 Adjusting Auto Speeds
The HP-60 features a xed displacement pump, so ow rate is directly related to engine RPM. Due to different piston
sizes on hammers, HP-60 power units should be set to run at different speeds depending on the size of hammer being
used. Using high RPM on a smaller hammer (with smaller piston) can cause the piston to extend and retract dangerously
fast, potentially causing physical harm or equipment damage.
The recommended speeds are as follows:
D6–D70: 1,600 RPM
D80 and Above: 2,600 RPM
Follow these steps exactly, failure to do so may cause engine damage or inability to run
1. Do not modify settings other than the ones listed in the following steps
2. Familiarize yourself with the Tec-10 Control Panel prior to modifying engine settings
3. If there is any doubt at any point, stop and call your Pileco Representative
4. Do not attempt to start engine without checking ball valve and uid levels
5. Never exceed 2,600 RPM on maximum engine speed
3.6.1 Steps for setting lower RPM (D6–D70)
1. Turn on Main Disconnect
2. Turn on Tec-10 Control Panel key switch
3. Press the “Menu” button
4. Enter the passcode “1111”
5. Press down arrow to highlight “Engine Settings” and press “Enter”
6. With “Maximum Engine Speed” highlighted, press “Enter”
7. Enter the speed “1600” RPM and press “Enter”
8. Press “Back” button once
9. Press down arrow until “Cooldown Delay” is highlighted and press “Enter”
10. Enter “5” and press “Enter” three times to set cooldown to ve seconds
a. The display should read “00:00:05 HH:MM:SS”
11. Press “Back” button once to get to main menu
12. Scroll down until “Application Conguration” is highlighted and press “Enter”
13. With “Auto Running Loaded Speed” highlighted press “Enter”
14. Enter Auto Running Loaded Speed “1600” RPM and press “Enter”
15. Press “Menu” button to exit menu
16. Turn off power to key switch and Main Disconnect
17. Turn power and key switch back on and test function per “Testing” section
WARNINGS

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OPERATING INSTRUCTIONS HP-60
3.6.2 Steps for setting higher RPM (D80 and Above)
1. Turn on Main Disconnect
2. Turn on Tec-10 Control Panel key switch
3. Press the “Menu” button
4. Enter the passcode “1111”
5. Press down arrow to highlight “Engine Settings” and press “Enter”
6. With “Maximum Engine Speed” highlighted, press “Enter”
7. Enter the speed “2600” RPM and press “Enter”
8. Press “Back” button once
9. Press down arrow until “Cooldown Delay” is highlighted and press “Enter”
10. Enter “10” and press “Enter” three times to set cooldown to thirteen seconds
a. The display should read “00:00:10 HH:MM:SS”
11. Press “Back” button once to get to main menu
12. Scroll down until “Application Conguration” is highlighted and press “Enter”
13. With “Auto Running Loaded Speed” highlighted press “Enter”
14. Enter Auto Running Loaded Speed “2600” RPM and press “Enter”
15. Press “Menu” button to exit menu
16. Turn off power to key switch and Main Disconnect
17. Turn power and key switch back on and test function per “Testing” section
3.6.3 Testing
1. Ensure that ball valve between hydraulic tank and pump is open
2. Check fuel, engine oil and hydraulic oil levels and add if needed
3. Turn on Main Disconnect
4. Ensure that ball valve between hydraulic tank and pump is open
5. Press power button on Remote to turn on Remote
6. Turn on Tec-10 Control Panel key switch
7. Ensure that “Auto” is displayed on the control panel upon turning key switch
8. Press “Start” button on the remote
a. The engine should start, delay for a few seconds then ramp up to the set RPM (1,600 RPM for D6-D70 or
2,600 RPM for D80 and above)
b. If the RPM is incorrect, revisit steps 6-7 & 13-14 of the above instructions, ensure that both speeds from steps
7 and 14 match
9. Press the “Stop” button on the remote
a. The engine should slowly ramp down the speed until it reaches 1,000 RPM then stop
b. If the engine stops before reaching 1,000 RPM or delays for several seconds after reaching 1,000 RPM, revisit
steps 9 & 10 of the above instructions

19
PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•3321 E Davis St•Conroe, TX 77301
OPERATING INSTRUCTIONS HP-60
10. Press “Start” button on the remote again and allow to ramp to set Running Loaded Speed
11. Press “Auto” button on the remote to change from “Auto” to “Manual” mode
12. Press “RPM Down” button the remote
a. The RPM should ramp down to 1,000 RPM and stay
13. Press “RPM UP” button on remote once
a. RPM should ramp back up to set point, if not, check steps 6 & 7 and ensure that “Maximum Engine Speed” is
set to the same RPM as “Auto Running Loaded Speed”
14. Press “RPM Up” button again
a. Nothing should happen, if speed increases again check “Maximum Engine Speed” from steps 6-7
15. Press “RPM Down” to get to 1,000 RPM, then press “Stop” button
16. Turn off Key switch and Main Disconnect Switch

PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•3321 E Davis St•Conroe, TX 77301
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OPERATING INSTRUCTIONS HP-60
As Required
Replace Battery
Replace Battery Cables / Disconnect
Clean Engine
Prime Fuel System
Daily
Check Engine Coolant Level
Inspect Air Cleaner Service Indicator
Check / Clean Engine Air Pre-cleaner
Check Engine Oil Level
Drain Primary Fuel / Water Separator
Drain Secondary Fuel / Water Separator
Walk-Around Inspection
Every 250 Hours Obtain Level 1 Coolant Sample
Obtain Engine Oil Sample
Every 500 hours
Inspect / Adjust Belts
Replace Engine Air Cleaner Element
Check Fan Clearance
Every 500 hours or 1 year
Change Engine Oil and Oil Filter
Replace Fuel System Primary Filter Element
Replace Fuel System Secondary Filter Element
Inspect / Replace Hoses and Clamps
Every Year Obtain Level 2 Coolant Sample
Every 1,000 hours
Replace Alternator and Fan Belts
Check Engine and Valve Lash
Inspect Turbocharger
Change Hydraulic Oil and Filter*
Every 1,500 hours Replace Engine Crankcase Breather Element
Every 2,000 hours
Inspect Alternator
Inspect Engine Mounts
Inspect Starting Motor
Every 3,000 Hours
Replace Cooling System Water Temperature Regulator
Clean Exhaust Gas Recirculation Valve
Inspect Water Pump
Every 4,000 Hours Inspect Aftercooler Core
Every 6,000 Hours or 3 Years Add Cooling System Coolant Extender
Every 12,000 Hours or 6 Years Change Cooling System Coolant (ELC)**
3.7 Routine Maintenance
Below is a compiled list of recommended routine maintenance for the power unit. All engine maintenance is per CAT
maintenance guidelines. For detailed instructions on each maintenance step of the CAT 2.2 L engine and other proce-
dures for the engine not covered in this manual, see CAT Operation and Maintenance Manual M0064264-02.