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]
www.Pileco.com•3321 E Davis St•Conroe, TX 77301
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.

PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•3321 E Davis St•Conroe, TX 77301
4
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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PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•3321 E Davis St•Conroe, TX 77301
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

PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•3321 E Davis St•Conroe, TX 77301
6
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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PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•3321 E Davis St•Conroe, TX 77301
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

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
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.

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PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•3321 E Davis St•Conroe, TX 77301
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.

PILECO, Inc. office [phone]•1-800-409-0018•fax [phone]
www.Pileco.com•3321 E Davis St•Conroe, TX 77301
10
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.