Gayk HRE 1000, HRE 4000, HRE 3000 Operating Instructions Manual

Hydraulic Ram Unit

HRE 1000 / HRE 3000 / HRE 4000

Translation of the original operating instructions

Hydraulic Ram Unit HRE

Issue 06.2016

Gayk Baumaschinen GmbH
Dieselstraße 3
D-63762 Großostheim

Telephone: [phone]
Telefax: [phone]
E-mail: [e-mail]
Internet: www.gayk-baumaschinen

 Publisher's copyright:
These operating instructions are intended for installation, operations and maintenance personnel. They may

be duplicated, translated or made available to others only with the expressed approval of the publisher. Also,
the operating instructions contain regulations and drawings of a technical nature which may not be
duplicated, in their entirety or partially, modified or utilised for the purposes of unauthorised competition, or
given to others.

Table of contents

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Table of contents

1 Basic information ................................................................................................................. 5

1.1 Notes on the operating instructions ........................................................................ 5

1.2 Explanations in the operating instructions .............................................................. 5

1.3 Proper use .............................................................................................................. 5

1.4 Usage conditions .................................................................................................... 6

1.5 Guarantee and liability ............................................................................................ 6

2 Safety instructions ............................................................................................................... 7

2.1 Standards and guidelines ....................................................................................... 7

2.2 Explanation of labels in the operating instructions ................................................. 8

2.3 Safety labels on the machine ................................................................................. 8

2.4 Safety labels at the setup location .......................................................................... 9

2.5 Basic safety measures ......................................................................................... 10

2.6 Safety instructions for transport ............................................................................ 10

2.7 Safety instructions for installation ......................................................................... 11

2.8 Safety instructions for operation ........................................................................... 11

2.9 Safety instructions for maintenance and repair .................................................... 12

2.10 Operator responsibility.......................................................................................... 12

2.11 Requirements of personnel .................................................................................. 14

2.12 Personal protective work clothing ......................................................................... 14

2.13 Behaviour in an emergency .................................................................................. 15

2.14 Disposal ................................................................................................................ 16

3 Technical data .................................................................................................................... 19

4 Technical description ........................................................................................................ 21

4.1 Chassis ................................................................................................................. 22

4.2 Drive motor ........................................................................................................... 23

4.3 Hydraulic aggregate ............................................................................................. 28

4.4 Mast (carriage) ..................................................................................................... 31

4.5 Hydraulic hammer ................................................................................................ 32

4.6 Control console..................................................................................................... 33

4.7 Electrical system................................................................................................... 35

4.7.1 Battery .................................................................................................................. 36

4.7.2 Automatic self-regulation ...................................................................................... 37

4.7.3 Electrical switch box ............................................................................................. 38

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5 Transport ............................................................................................................................. 41

5.1 General transport instructions ............................................................................... 41

5.2 Incoming inspections by the operator ................................................................ ... 41

6 Assembly and start-up ....................................................................................................... 43

6.1 General assembly instructions .............................................................................. 43

6.2 Aligning the machine ............................................................................................ 43

7 Operating the machine ....................................................................................................... 45

7.1.1 General instructions .............................................................................................. 45

7.1.2 Operating procedure ............................................................................................. 45

7.1.3 Ramming the profiles ............................................................................................ 46

8 Maintenance and repair ..................................................................................................... 49

8.1 General instructions .............................................................................................. 49

8.2 Maintenance and repair measures ....................................................................... 50

9 Disruptions .......................................................................................................................... 57

Table of figures

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Table of figures

Fig. 1: Nameplate ................................................................................................................... 19

Fig. 2: Main assemblies with optional accessories ................................................................. 21

Fig. 3: Chassis ........................................................................................................................ 22

Fig. 4: Machine in the transport position ................................................................................. 22

Fig. 5: Locking and positioning lever ...................................................................................... 23

Fig. 6: Drive motor .................................................................................................................. 24

Fig. 7: Motor oil fill opening with oil dipstick ............................................................................ 24

Fig. 8: Electric starter and speed adjustment lever ................................................................. 25

Fig. 9: Ignition switch with message lights .............................................................................. 25

Fig. 10: Fuel tank ...................................................................................................................... 26

Fig. 11: Fuel tank shut-off valve ................................................................................................ 26

Fig. 12: Hydraulic tank .............................................................................................................. 28

Fig. 13: Vent filter with contamination display ........................................................................... 29

Fig. 14: Visual fill level display .................................................................................................. 29

Fig. 15: Cooling package .......................................................................................................... 30

Fig. 16: Functioning principle of the cooling package ............................................................... 30

Fig. 17: Mast (carriage) with hydraulic hammer ........................................................................ 31

Fig. 18: Hydraulic hammer ........................................................................................................ 32

Fig. 19: Control console (optional) ............................................................................................ 33

Fig. 20: Gear lever .................................................................................................................... 34

Fig. 21: Control console (standard)........................................................................................... 35

Fig. 22: Tool box for battery and tool kit.................................................................................... 36

Fig. 23: Electrical switch box with automatic self-regulation (option) ........................................ 37

Fig. 24: Exterior of the electrical cabinet (optional) ................................................................... 38

Fig. 25: Interior of the electrical cabinet (optional) .................................................................... 38

Fig. 26: Electrical cabinet (standard) ........................................................................................ 39

Fig. 27: Circular level ................................................................................................................ 44

Fig. 28: Limit switch for shutting off the automatic ramming function ....................................... 46

Table of figures

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Basic information

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NOTE

Hydraulic ram unit HRE 1000/ HRE 3000/ HRE 4000 is only called a machine in the
following chapters of these operating instructions.

1 Basic information

1.1 Notes on the operating instructions

These operating instructions are provided to educate the user concerning the design,
function, operation, setup, maintenance and upkeep of hydraulic ram unit HRE 1000/
HRE 3000/ HRE 4000. The hydraulic ram unit HRE 1000/ HRE 3000/ HRE 4000 was
developed and built by Gayk Baumaschinen GmbH. Before using hydraulic ram unit
HRE 1000/ HRE 3000/ HRE 4000, please carefully read through the operating
instructions. They must be available at the machine at all times for operating personnel.
The operating instructions will allow you to quickly understand the technical details, and
contains necessary information on important technical data and on the expert use of
the machine. Hydraulic ram unit HRE 1000/ HRE 3000/ HRE 4000 is only intended to
be used for the purposes listed in the operating instructions. The manufacturer cannot
be responsible for claims arising from improper use and insufficient maintenance of the
equipment. The component documentation located in the appendix, as well as all other

1.2 Explanations in the operating instructions

documentation provided with the equipment, must be adhered to.

1.3 Proper use

The machine may only be operated in its technically proper state and only for its
intended purpose, in accordance with these operating instructions. The machine is
operated fully-hydraulically and its exclusive purpose is to precisely ram steel or
wooden profiles into earthen soil. The profiles are rammed into the ground through
repeated impacts depending on the ramming depth and the soil characteristics.
No other use of the machine beyond this qualifies as proper use. Any other use can be
dangerous and is not allowed. The manufacturer is not liable for any consequences
arising from improper use of the machine or for any use not in accordance with the
instructions in these operating instructions. If the machine is altered without the
approval of the manufacturer, the manufacturer is not liable for any damages that may
result. Adherence to inspection and maintenance specifications is also part of the
proper use of this equipment. Connection data must be adhered to. If changes are
made to the system by the operator, the CE certificate of compliance will become
invalid.

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1.4 Usage conditions

Before beginning work, check the area to make sure it meets the following criteria:
 Make sure there are no cables, lines, sewer lines, etc., in the area that could

present a hazard.

 Prepare the work area according to how it is found. If necessary, re-route,

disconnect, or secure existing lines.

 The ground must be free of any contaminants and explosive ordinance.
 The ground must be evenly supportive of construction machines being driven on it.
 Establish traffic routes and storage areas and identify them.
 All necessary operating materials such as oils, greases and the like must be made

available in sufficient amounts and qualities prior to start-up corresponding to the
specifications contained in the operating instructions.

The manufacturer must be timely notified of any environmental and operating
conditions that are out of specification at the set-up location of the machine. The
deviating environmental and operating conditions must be listed.

1.5 Guarantee and liability

The “General Conditions of Sale and Delivery” submitted by the manufacturer to the
operator apply fundamentally. Guarantee and liability claims for personal injury and
property damages are not valid if they can be attributed to one or more of the following
causes:

 Use of the machine in a manner that is not intended.
 Improper start-up, operating and maintenance of the machine.
 Alterations to the machine without prior consultation with the manufacturer.
 Operation of the machine with defective safety equipment or improperly attached

safety and protective equipment.

 Non-adherence to the instructions in these operating instructions with regard to

operation and maintenance.

 Insufficient monitoring of machine assemblies that are subject to wear.

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2 Safety instructions

2.1 Standards and guidelines

The machine is designed according to the current state of the art according to
recognised safety rules. The machine was designed according to basic safety
requirements, standards and guidelines. All safety information refers to currently
applicable ordinances of the European Union (EU). In countries outside of the EU, the
applicable laws and ordinances of those countries must be adhered to. In addition to
the safety instructions contained in these operating instructions, the generally
applicable regulations concerning accident prevention and environmental protection
must be followed and adhered to. All information in the operating instructions must be
followed fully. The machine was designed according to the following basic safety
requirements, standards and guidelines.

 Machine Guidelines 2006/42/EC dated 17.05.2006
Applied harmonised norms, in particular
 DIN EN-ISO 12100

“Machine Safety - General Structural Guidelines - Risk Assessment and Risk
Minimization” (ISO 12100:2010), German Version EN ISO 12100:2010

 DIN EN 60204-1

“Machine Safety – Electrical Equipment in Machines”

 DIN EN 13849

“Machine Safety – Safety-related Parts in Control Systems”

 DIN EN 13850

“Machine Safety – EMERGENCY STOP Structural Guidelines”

 DIN EN 13857

“Machine Safety – Safe distances to prevent reaching into dangerous areas with
upper and lower extremities”

 DIN EN 1037

“Machine Safety – Preventing unexpected starting of moving elements”

 DIN EN 13478

“Machine Safety – Fire protection”

 DIN EN 414

“Rules for the drafting and presentation of safety standards”

 DIN EN 4844-1

“Graphical Symbols - Safety colours and safety signs Part 1: Structural
fundamentals for safety signs for use in workshops and in public areas”

 DGUV [German Social Accident Insurance] Regulation 3 “Portable and fixed

operating resources
Accident prevention regulation “Electrical systems and resources”

 BGV A8 / DGUV Regulation 9

“Safety and health protection signage at the workplace”

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DANGER

Type and source of danger!
Immediate danger with high risk of death or serious bodily injuries. Measures to avoid
danger.

WARNING

Type and source of danger!
Possible danger with medium risk of death or serious bodily injuries. Measures to
avoid danger.

CAUTION

Type and source of danger!
Dangers with low risk of medium bodily injuries or property damage. Measures to
avoid danger.

NOTE

User tips and useful information.

NOTE

User tips and useful information on environmental protection.

DANGER

Type and source of danger!
Dangers with risk of environmental damages. Measures to avoid danger.

DANGER

Warning of dangerous electrical voltage.

2.2 Explanation of labels in the operating instructions

2.3 Safety labels on the machine

The instructions attached to the machine identify the sources of danger and must be
adhered to absolutely. They must be attached in an easily recognizable area and
maintained in fully legible condition. If these labels are destroyed, new ones must be
attached. The following symbols are attached to the equipment and must be adhered
to:

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DANGER

Warning of crush injuries.

DANGER

Warning of rotating parts.

DANGER

Warning of crushing at chain drives.

DANGER

Warning of hot surfaces.

DANGER

Warning of flammable materials.

DANGER

Warning of explosive materials.

DANGER

Warning of corrosive materials.

DANGER

Risk of accidents!
Unauthorised personnel access to the machine is forbidden.

DANGER

Fire and explosion danger!
The starting of fires and handling of open flames is strictly forbidden. Areas must be
labelled accordingly.

2.4 Safety labels at the setup location

The operator of the machine must make sure that the entire work area in which the
machine is set up is identified appropriately according to operational conditions,
respectively, by means of the following instructions.

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During installation, maintenance and repair work, the entire danger area surrounding
the machine must be blocked off with the following identifying tape:

2.5 Basic safety measures

The following must be adhered to:

 The machine may only be used as intended.
 All safety instructions in these operating instructions and in other documents must

be followed and adhered to.

 The machine may only be set up, installed, operated and maintained by trained

expert personnel. The personnel must have read and understood these operating
instructions. This includes in particular the understanding of how risk of injury can
be averted for the operator and others.

 Unauthorised personnel may not have any direct access to the machine.
 Downtime and environmental impairments due to incorrect handling must be

avoided.

 During transport, installation/removal, operation and care and maintenance, the

pertinent work safety regulations and environmental protection regulations must be
adhered to.

 All work on the machine must be carried out with care and with a perspective on

safety.

2.6 Safety instructions for transport

The following must be adhered to:

 The machine is transported, set up and installed as a complete machine. The

danger area must be blocked off with a wide berth and identified as such.

 Safety regulations as to the transport materials used must be adhered to.
 Unauthorised transport work is not permitted. Significant dangers and property

damages can result.

 Transport activities may only be carried out by trained personnel.
 Only approved lifting equipment and attachment means with sufficient support

capacity may be used.

 Ropes and belts must meet safety requirements. No torn ropes or ropes with

abraded areas may be used. Do not let ropes and belts sit against sharp edges and
corners, do not knot or twist them. When fastening, be aware of the centre of
gravity of the machine.

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2.7 Safety instructions for installation

The following must be adhered to:

 The machine may only be installed by trained, instructed expert personnel.

Unauthorised assembly is not permitted.

 To avoid dangerous situations, and to ensure optimum performance, no

modifications or alterations may be made to the machine.

 The set-up area for the machine must be of such dimensions that sufficient support

is guaranteed.

 Before beginning work, sufficient freedom of installation must be ensured. Maintain

order and cleanliness at the work place. Any components and tools lying around
must be removed.

 Be aware of the dimensions and weight data for the machine. An operational

environment suitable for use of the machine must be guaranteed.

 The machine must be checked each time prior to being turned on for damages and

proper condition. Any modifications to the machine that affect operational safety
must be reported. The causes must be remedied immediately.

 The machine may only be connected to supply lines that are provided and designed

specifically for it.

2.8 Safety instructions for operation

The following must be adhered to:

 The operational safety of the machine must be guaranteed at all times.
 The machine must be immediately shut down if changes are detected during

operation. Listen for any unusual noise.

 Proper attachment and connection of the control console, safety equipment

(EMERGENCY OFF switch, safety switches sensors).

 The machine must be checked each time prior to being turned on for damages and

proper condition. Any modifications to the machine must be reported. The causes
must be remedied immediately.

 Proper connection of all supply media (electrical energy bonding for safe contact,

hydraulics).

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CAUTION

Damage to the machine!
Operational disruptions caused by insufficient or improper maintenance can cause
very high repair costs and long downtimes of the machine. The manufacturer assumes
no liability for damages caused by improper maintenance and care. Maintenance
intervals must be recorded and maintained in a maintenance plan.

2.9 Safety instructions for maintenance and repair

The following must be adhered to:

 All maintenance and repair work on the machine may only be carried out with the

machine turned off.

 The machine may only be maintained and repaired by service personnel from the

manufacturer or personnel specially trained and instructed in the same.

 Unintentional turning of the machine back on must be prevented (shut of the main

switch, attach a warning sign to the main switch, block off the area).

 During maintenance and repair work, sometimes safety equipment needs to be

turned off. This equipment must be properly re-installed immediately after the
maintenance and repair work and checked for proper functioning.

 After the maintenance work, the following checks must be carried out prior to

turning the machine back on, during which time safety regulations are adhered to:

– Check that all bolted connections are tight.
– Ensure that all tools, materials and other equipment used have been removed

from the work area.

– Clean the work area and remove any materials, such as liquids, processing

materials, etc.

2.10 Operator responsibility

The operator of the machine is subject to legal obligations with regard to work safety. In
addition to the safety instructions in these instructions, the applicable safety, accident
prevention and environmental protection regulations must be adhered to.

 The operator must be aware of the applicable work safety specifications. Any

additional dangers that arise from special working conditions at the point of use
must be recorded in an overview. The additional dangers determined to exist must
be recorded by the operator in its operating instructions and incorporated in the
daily handling instructions for the machine.

 During the entire time of use of the machine, the operator must check whether its

operating instructions correspond to the current version of the regulatory policies,
and if not, modify them as needed.

 The operator must use the machine in good, operationally safe condition. The

technical condition must correspond to the legal requirements and regulations.

 The operator must clearly regulate and establish responsibilities for installation

operation, maintenance and cleaning.

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CAUTION

Risk of injury if personnel is insufficiently qualified!
Improper handing can result in serious personal injury and property damage. All
activities must be carried out by qualified personnel only.

Operating personnel

The instruction as to the tasks to be assumed and
possible risks from improper behaviour is done by the
operator.

Maintenance and repair
personnel

Maintenance and repair personnel must be capable, as a
result of expert training, experience and knowledge of the
pertinent specifications, of autonomously carrying out
maintenance and repair work, and of recognising possible
risks and avoiding them. Maintenance personnel are to be
specially trained for this.

Electrician

The electrician must be capable, as a result of expert
training, experience and knowledge of the pertinent
specifications, of autonomously working on electrical
machines and of recognising possible risks and avoiding
them. The electrician is specially trained for this.

 The operator must make sure that all employees handling the machine have read

and understood these instructions. Also, the operator must train its personnel at
regular intervals and make the aware of the risks. Training by the operator must be
recorded.

 The operator must provide its personnel with the required work safety clothing.
 The operator must make sure that the listed maintenance intervals are being

adhered to.

 The operator must check all safety equipment regularly for functionality and

completeness.

As to requirements to be placed on personnel, the operator must adhere to the
following criteria:

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DANGER

Risk of accidents!
Unauthorised persons who do not meed the requirements described must be kept
away from the work area.

PROTECTIVE WORK CLOTHING

Wear snugly-fitting protective work clothing to protect against getting caught by
moving parts. However, the clothing must not restrict the freedom of movement of
personnel.

SAFETY SHOES

To protect from falling parts and slipping on floors that are not non-slip surfaces and
when current-carrying components could possibly be touched.

2.11 Requirements of personnel

The following must be adhered to:

 Smoking, eating and drinking in the area of the machine are not allowed.
 Working on the machine while tired, under the influence of alcohol and medications

is not allowed.

 Personnel may not have any physical limitations that would temporarily or

permanently impair their attentiveness and ability to evaluate a situation.

 Operating personnel must have mastered the national language of the operator

verbally and in written form enough to allow all tasks pertaining to the machine and
the contents of the operating instructions to be understood and internalised.

 Personnel must wear appropriate clothing for the work at hand.
 All safety instructions in these operating instructions and in all other documents

must be followed and adhered to in unlimited extent.

 If danger is recognised which could result in personal injury, the machine must be

shut off immediately.

 Personnel must have thorough understanding of operational procedures,

regulations and processes.

– Operational processes of the machine
– Setting up of perimeters, securing and identifying the area of danger
– Behaviours and actions in case of emergency

 The machine may only be operated and maintained by authorised personnel. If

additional qualifications of personnel are necessary to perform certain work, the
operator must meet all prerequisites for it.

2.12 Personal protective work clothing

The operator will determine which protective work clothing must be worn by personnel.

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SAFETY GLOVES

To protect the skin from friction, scrapes, punctures or deeper injuries of the hands
and to protect against the touching of hot surfaces and substances that are hazardous
to a person's health.

HEARING PROTECTION

Hearing protection offers protection against injury to the auditory system due to excess
and sustained noise.

SAFETY GLASSES

Safety glasses protects the eyes against flying parts (dust particles, liquid and acid
sprays).

FIRST AID AND FIRE-FIGHTING EFFORTS

The locations for first aid equipment and fire-fighting agents must be identified with
information signs. The user must be familiar with these resources. The user must be
able to correctly use and operate them in the event of accidents.

2.13 Behaviour in an emergency

In emergencies or accidents, the machine must be shut off immediately!
Since in the event of an accident quick reaction can save lives, the following actions
must be introduced:

 Immediately initiate the EMERGENCY SHUT-DOWN system.
 Initiate first aid measures. Operating personnel must know where safety equipment,

accident and danger alarms, and first aid and life-saving equipment are located and
must be familiar with how to handle them.

 Remove injured persons from the danger zone.
 Notify responsible parties at the location of use.
 Notify first responders.
 Open access routes to allow access to ambulance vehicles.

The operator is responsible for appropriate training of its operations personnel. All first
aid equipment (first aid kits, stretchers, etc.) and fire-fighting agents (fire extinguishers)
must be maintained in accessible locations and must always be available. All
equipment must be in proper condition and regularly checked.

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DANGER

Environmental hazard!
If environmentally hazardous materials are handled incorrectly, in particular if they are
disposed of incorrectly, serious damages to the environment can occur.
The following must be adhered to:

 The information contained in the operating instructions concerning environmental

protection must be followed at all times.

 If environmentally-hazardous materials accidentally come in contact with the

environment, suitable measures must be taken immediately. The appropriate
authorities must be notified of the damages.

CAUTION

For all auxiliary materials and cleaning agents used, the regulations and EC safety
data sheets of the respective manufacturer with regard to storage, handling, use and
disposal must be adhered to.

CAUTION

Electrical scrap and electronic assemblies require hazardous waste treatment and
may only be disposed of by approved expert operators.

2.14 Disposal

Legal fundamentals on disposal:

 Recycling and Waste Management Act (KrW/AbfG)
 State Waste Act for each of the federal states (LAbfG)
 Ordinance for determining wastes that require monitoring (BestbüAbfV)
 Waste Oil Ordinance (AltölV)
 Packaging Ordinance (VerpackV)
 Battery Ordinance (BattV)
 Commercial Waste Ordinance (GewAbfV)
 Chemicals Act (ChemG)
 Hazardous Materials Ordinance (GefStoffV)
 Industrial Safety Ordinance (BetrSichV)
 Water Management Act (WHG)
 Technical Rules for Hazardous Materials, TRGS 201 Classification and

identification of wastes for disposal while handling

 GUV-SR-2005 Handling hazardous materials in industry

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The following must be adhered to:

 No materials may be used if their physical properties are unknown. A consultation

with the manufacture is required.

 If there is no take-back or disposal agreement in place, the disassembled

components must be sent to a recycling facility after proper disassembly.

– Metallic material residue is scrapped.
– Plastic components are sent to a recycling facility.
– Sort other components according to material properties and dispose of

accordingly.

 Cleaning agents and their containers may not be disposed of as domestic waste or

allowed to flow to sewer systems and to the soil. Applicable disposal regulations
must be adhered to.

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Technical data

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General data

Name

Hydraulic Ram Unit

Type

HRE 1000 / HRE 3000 / HRE 4000

Serial number

9950216

Model

2016

Dimensions (transport dimensions)

Length

4000 mm / 5000 mm

Width

2000 mm

Height

2200 mm / 2500 mm

Weight with hydraulic hammer

3100 kg / 3600 kg (depending on the design of
the hammer IM 150, IM 304, IM 305)

Operating data

Operating conditions

Manual and automatic operation

Post height

3200 m / 4200 mm

Transverse grade

20°

Operating hydraulic fluid pressure

200 bar

Oil amount

180 l

Fuel tank volume

60 l

Motor output

22.5 kW (depending on the motor design;
2-, 3-, 4-cylinder motor

Weight of the hydraulic hammer

76 kg - 136 kg
(depending on the hammer design)

Impact rate

670 min-1 - 1450 min

-1

(depending on the hammer design)

Noise emissions

117 dB

3 Technical data

The nameplate is located below the hydraulic aggregate at the air/hydraulic fluid cooler.

Fig. 1: Nameplate

Technical data

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Technical description

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1 Chassis
2 Control console
3 Hydraulic hammer
4 Mast (carriage)
5 Hydraulic cylinder
6 Fuel tank

7 Electrical cabinet with control elements
8 Drive motor
9 Hydraulic aggregate

regulation

4 Technical description

The hydraulic ram unit is a machine for ramming steel profiles or posts into terrain,
even under severe conditions. Areas of use include guardrail supports along streets,
frames for solar energy facilities, wood profile palisades, supports for earthen slopes
and water bank straighteners. The machine consists of the following main groups:

Fig. 2: Main assemblies with optional accessories

The rugged and stable design of the machine can also facilitate pulling out profiles or
posts, or drilling holes with a drill (optional). At a 1.9 m advancement from the forward
edge of the chain to the middle of the hydraulic hammer and a working height of 4 m,
even large posts can be rammed in effortlessly.

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NOTE

The chassis of the machine is an out-sourced assembly. Construction, function,
maintenance and repair are not described in these operating instructions. Detailed
instructions can be found in the manufacturer's technical documents.

4.1 Chassis

The fully-hydraulic ram unit has a stable crawler chassis with a slewing ring and
rubber-coated chain. A Hatz diesel motor is installed as a drive motor. The chassis
supports all machine assemblies. A drive gear of the chassis moves the chain links
forward in the direction of travel. The rest of the vehicle is pulled along on the runners
and guide wheels. The chain drives on both sides move independently of one another.
In some designs, the chain drives can move in opposite directions and the chassis can
be rotated on the spot.

Fig. 3: Chassis

The machine can be rotated on the chassis by 90°. When it is transported to the work
location, the machine is in its transport position (the hydraulic hammer is parallel to the
direction of travel lengthwise) and during operation it is in its working position (the
hydraulic hammer is perpendicular to the direction of travel).

Fig. 4: Machine in the transport position

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CAUTION

Avoid injuries and machine damage!
When the machine is rotated in a different direction, make sure that the stopping point
has been reached. The lever must be returned back to its proper locking position.

NOTE

When operated over long periods of time without load or very small loads, the running
behaviour of the motor can become worse. A motor load of at least 15%
is required. Under low-load operation, the motor must be operated under a much
higher load for a short period of time before turning it off.

When the locking and positioning lever is moved by 90° (lever position is vertical), the
lock is released and the machine can be manually rotated on the chassis until it rests
against a stop. When it is rotated to another position (such as the working position), the
lever must be moved downward and clamped in this position. Rotation back to the
transport direction is done in the same sequence.

Fig. 5: Locking and positioning lever

4.2 Drive motor

The drive motor is an air-cooled, diesel-operated four-stroke motor with direct injection.
The type and size of the drive motor depends on the type of machine. It is a drive
assembly for the chassis, the slewing ring drive and the hydraulic pump. To dampen
the vibration and noise, the motor is supported on rubber bumpers and fastened to the
chassis.

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1 Drive motor
2 Oil fill nozzle and oil level dipstick
3 Fuel tank

4 Tool box for battery and tool kit
5 Exhaust gas muffler
1 Handle

2 Oil dipstick (MAX/MIN indicator)

Fig. 6: Drive motor

The drive motor must be filled with motor oil before initial start-up. The holding capacity
is 4 l - 8 l, depending on the type. So pay attention to the different types of motors. The
types of motor oils to be used are those with the following specifications:

 ACEA – B2 / E2 and
 API – CD / CE / CF / CF-4 / CG-4

If other motor oils are used, the manufacturer must first be consulted. Unsuitable motor
oil reduces the time between oil change intervals and leads to significant shortening of
the motor lifespan.

Fig. 7: Motor oil fill opening with oil dipstick

The oil level is measured using the oil dipstick located in the fill opening. Fill up to the
MAX marking when filling.

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1 Motor “ON” illuminated display
2 Charge Check illuminated display
3 Oil Pressure illuminated display

4 Ignition key
5 Motor temperature illuminated display
6 Air Filter Maintenance illuminated display

The drive motor is started using an electric starter. The speed adjustment lever (gas
lever) is located right next to the ignition switch.

Fig. 8: Electric starter and speed adjustment lever

The ignition switch with key switch for the electric starter has 3 switch positions “0, I, II”.

When the key is rotated to the “I” position, the installed “Check Charge 2” and “Oil
Pressure Display 3” control lamps light up. To start the motor, the key is turned to the

“II” position. When the motor is running, the key is released. The key will turn back to

the “I” position by itself and will remain in this position during operation. The charge

check and oil pressure display go out immediately after the drive motor starts.

Fig. 9: Ignition switch with message lights

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A fuel tank with a holding capacity of 180 l is installed to supply diesel fuel. All diesel
fuels are suitable, provided that they meet the minimum requirements of the following
specifications.

 EN 590
 BS 2869 A1 / A2
 ASTM D 975 - 1D / 2D

Fig. 10: Fuel tank

When work with the machine is finished, the speed adjustment lever must be moved to
the stop position. The motor will run at idle. Close the shut-off valve at the lower end of

the diesel fuel tank. Turn the start key to the “0” position and remove it. The start key

must be protected against unauthorised access.

Fig. 11: Fuel tank shut-off valve

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DANGER

Warning of hot surfaces!
During longer operating durations, various components become very hot, such as the
hydraulic tank, hydraulic hoses (sometimes over 80 °C). Direct contact should be
avoided until the unit cools down completely.

DANGER

Motor damages due to low-quality fuel!
Use of fuel that does not meet the specifications above can lead to motor damage.
Use of fuels with deviating specifications may be used only after prior approval by the
HATZ motor factory.

DANGER

Warning of escaping diesel fuel!
When finished working with the machine and after shutting off the motor, the shut-off
valve at the diesel fuel tank must be closed as well. If this is not done, the diesel fuel
might spill onto the ground.

CAUTION

Machine damage!
Diesel fuel stops flowing at low temperatures. This can cause clogging in the fuel
system. When outside temperatures are below 0 °C, winter fuel should be used or
petroleum should be added.

CAUTION

Danger of poisoning and explosion!
Never run the motor in closed or poorly ventilated rooms. Before starting, make sure
that no other people are in the area of danger around the machine. All safety
equipment should be installed and functional.

NOTE

The drive motor for the chassis is a supplier assembly. Construction, function,
maintenance and repair are not described in these operating instructions. Detailed
instructions can be found in the manufacturer's technical documents. They are part of
the overall documentation.

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1 Hydraulic fluid/air cooler
2 Hydraulic tank
3 Fluid fill level display
4 Visual contamination display

5 Fill and vent opening with replaceable filter insert
6 Warning light

4.3 Hydraulic aggregate

The purpose of the hydraulic aggregate is to provide the necessary fluid pressure for
operating the hydraulic cylinders of the mast (carriage) and the hydraulic hammer. The
hydraulic aggregate consists of a gear pump and a hydraulic tank. The gear pump is
attached to the drive motor. It draws in hydraulic fluid until it has reached the required
operating pressure. The hydraulic tank is a steel container with a holding capacity of
180 l. It may only be filled with hydraulic fluid that meets specification
ISO-VG 46 DIN 51 524 / Part 2. Unsuitable fluid can considerably shorten the lifespan
of the machine. Feet with struts are welded to the hydraulic tank. They are used to
fasten the hydraulic tank to the hydraulic fluid/air cooler. The hydraulic tank consists of
a steel container with a cleaning opening, a drain screw at the bottom of the tank, a
visual fluid level display, a fill and vent opening with a replaceable filter insert and a
visual contamination display.

Fig. 12: Hydraulic tank

The vent filter (tank vent filter) of the hydraulic tank has a corrosion-resistant housing
with an inlet opening on top. A cover with a protective edge prevents splashing water
and allows the filter element to be quickly replaced. The vent filter is used to filter air
when the volume changes in the hydraulic fluid tank and prevents contamination from
ambient air from penetrating into the fluid. The vent filter is equipped with a filling
screen. The filling screen is a support basket that keeps the shape of the filter element
stable. When the fluid tank is filled, coarse contaminants are held back.
A contamination display attached to the vent filter shows the degree of contamination
of the fluid.

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Fig. 13: Vent filter with contamination display

The visual fill level display mounted to the side wall of the tank shows the operator of
the machine the current hydraulic fluid level in the tank. The two markings on the sight
glass indicate the maximum and the minimum fill level.

Fig. 14: Visual fill level display

The air/hydraulic fluid cooler contains a compact cooling package. It consists of
rectangular aluminium profiles in series. Aluminium sheet lamella are inserted between
the individual layers. They enlarge the surface to be cooled. A fan motor with a fan
impeller is located below the air/hydraulic fluid cooler. The fan motor is protected by a
fuse and a protective relay. A thermostat is installed in the air/hydraulic fluid cooler. It
turns on the fan motor with fan impeller at 60 °C. It cools the hydraulic fluid down to 40°
and is then turned off again.

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WARNING

Machine damage!
The hydraulic fluid cooler must always be free of particulates and other contaminants.
Hydraulic assemblies can be damaged by an impaired cooling effect.

Air

Oil

The medium to be cooled (hydraulic fluid) flows through the profiles of the cooling
package. The cooling air flows through the lamella perpendicular to the cooling
package. The medium dissipates heat to the cooler environment and is blown away.

Fig. 15: Cooling package

Fig. 16: Functioning principle of the cooling package

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1 Hydraulic hammer
2 Mast (carriage)

3 Post guide

4.4 Mast (carriage)

The mast (carriage) is a stable steel structure. Pulleys are mounted at both ends. The
drive chains (upper and lower) are guided on the pulleys. At one end, the drive chains
are fastened to the hydraulic hammer sled and at the other end to a chain holder. The
chain attachments at the sled are spring-loaded. The chain tension can be adjusted by
tightening or loosening the nut. Various hydraulic cylinders are attached to the mast.
They are controlled from the control console. With these hydraulic cylinders, the mast
and hydraulic hammer can be moved to the following positions:

 Hydraulic hammer up and down
 Mast upright and store
 Mast set and place
 Mast left and right

Fig. 17: Mast (carriage) with hydraulic hammer

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1 Hydraulic hammer

2 Ram head

NOTE

The hydraulic hammer is a supplier assembly. Construction, function, maintenance
and repair are not described in these operating instructions. Detailed instructions can
be found in the manufacturer's technical documents. They are part of the overall
documentation.

4.5 Hydraulic hammer

The hydraulic hammer has a sled to which it is attached. The rolls of the sled run
frictionlessly in a guide of the mast. The drive chains are fastened at both ends of the
sled. They move the entire hydraulic hammer up and down depending on the motion of
the hydraulic cylinder. The hydraulic hammer converts the work output from the
machine into kinetic energy and transfers it to the upper ram head of the hydraulic
hammer. Hydraulic fluid pressure is built up and is released suddenly to the impact
piston located below it, causing the piston to move. The energy transmitted with each
impact is called impact energy and the number of individual impacts per unit time is
called the impact rate. The impact rate is 670 min-1 - 1450 min-1. It is adjustable. When
the impact piston hits the upper ram head, it conveys the energy to the profile material
to be rammed. The lower ram head guides the rammed material. The shape of the ram
heads depend on the geometry of the rammed material or is specified by the operator
off the machine.

Fig. 18: Hydraulic hammer

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Pos. No.

Process

Figure

1

Turning the hydraulic hammer on
and off

2

Moving the hydraulic hammer up
and down

3
4

Chassis left back and forth
Chassis right back and forth

4.6 Control console

The control console is the workplace for the operator of the machine. All movements of
the entire machine can be controlled from here. By actuating the individual shift levers,
the following functions can be executed:

Fig. 19: Control console (optional)

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Pos. No.

Process

Figure

5

Mast up and down

6

Mast upright and store

7

Mast left and right

8

Advance in and out

9

Not assigned

10

Operating pressure manometer

1 Gear lever
2 Fast rate

3 Slow rate

Fig. 20: Gear lever

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DANGER

If the electrical insulation becomes damaged, immediately shut off the power supply
and have the problem repaired!

 In all work on the electrical system, the system must be de-energised and checked

to make sure of it.

 Do not bypass any fuses or take them out of service. When replacing fuses, make

sure the correct current rating in amperage is used.

 Avoid moisture on live parts. Short-circuiting can occur.

DANGER

Danger of non-functioning safety equipment!
Safety is only ensured when safety equipment is functioning.

 Before beginning work, check to make sure that the safety equipment is functionally

and correctly installed.

 Never shut down or bypass safety equipment.
 Ensure that safety equipment such as EMERGENCY STOP switches, limit

switches, sensors, etc. are always accessible.

Fig. 21: Control console (standard)

4.7 Electrical system

The electrical system for the machine is a 12 V system. It consists of the following
assemblies:

 12 V battery
 Automatic self-regulation
 Electrical switch box with control elements
 Sensors, safety switches and electrical connection elements

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DANGER

Danger due to uncontrolled turn-on!
Uncontrolled turn-on can lead to serious personal injury. The following must be
adhered to:

 Prior to turning the machine back on, all faults must be remedied, all safety

equipment must be installed and functional.

 An EMERGENCY STOP is initiated by pressing the EMERGENCY STOP button.

After an EMERGENCY STOP button has been pressed, it must be pulled back
again to turn the machine back on.

DANGER

Danger of explosion due to flammable materials!
There is a danger of explosion due to flammable gases. Keep batteries away from
open flames and ignition sparks. Do not smoke when handling batteries.

CAUTION

Danger of corrosion!
When installing and removing batteries for electrical operation, and when filling them
with battery acid, corrosive burning can occur. Protect eyes, skin and clothing from
corrosive battery acid. In the event of acid spray, immediately rinse with clear water
thoroughly and, if necessary, seek medical attention.

4.7.1 Battery

The electrical energy for starting the drive motor is provided by a 12 V, 90 Ah battery.
It is located under a cover in the tool box.

Fig. 22: Tool box for battery and tool kit

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DANGER

Environmental hazard!
If batteries and battery acids are handled incorrectly, serious damages to the
environment can occur. The following must be adhered to:

 Proper disposal of unusable batteries must be done according to the battery

ordinance.

 Prevent battery acid from leaking.
 Store and transport battery acid in containers designed for them.

1 Manual controller
2 Self-regulation On
3 Automatic self-regulation (controller)

4 Automatic self-regulation ON
5 Automatic self-regulation OFF
6 Set zero

4.7.2 Automatic self-regulation

Automatic self-regulation is an option and can be installed at customer request. It
allows the self driving distance to be adjusted. In other words, the machine will travel a
pre-set distance by itself. This distance is input in the associated control system.

Fig. 23: Electrical switch box with automatic self-regulation (option)

The manual controller for automatic self-regulation is equipped with a longer
connection cable. This makes it possible to control the machine from a different
location. If the controller is no longer needed, it can be attached to a flat wall using the
attached magnetic feet.

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1 Hydraulic hammer ON
2 Hydraulic hammer OFF
3 EMERGENCY OFF button
4 Automatic alignment OFF

5 Working headlights ON/OFF
6 Warning light ON/OFF
7 Automatic alignment ON
1 Controls for automatic alignment

2 Fuses, plug connectors, connection elements

4.7.3 Electrical switch box

The machine has an electrical cabinet (optional). It is mounted above the control
console of the hydraulic machine controls. All the control elements, machine
protections and main machine assemblies are installed in the electrical cabinet. All
terminal and connecting elements are also kept there. Every load is separately fused.
Connecting the power and control voltage for the machine is done through terminal
elements directly in the electrical cabinet.

Fig. 24: Exterior of the electrical cabinet (optional)

Fig. 25: Interior of the electrical cabinet (optional)

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Fig. 26: Electrical cabinet (standard)

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DANGER

Risk of accidents!
Before performing transport work, check to see that the machine is stable enough.
To securely load the machine, a loading ramp is always required. It must not be
damaged and must have sufficient support capacity.

DANGER

Risk of accidents!
Falling parts must be removed prior to transport. Standing below a suspended load is
strictly forbidden.

Crush injuries can occur between moving parts. No unauthorised persons are allowed
in the work area of the machine.

5 Transport

5.1 General transport instructions

For transport to the set-up location, VDI 2700 “Process Instructions for Securing Loads

for Road Traffic” must be followed. A vehicle must be prepared. Lashing straps must

also be provided. The loader and the driver of the vehicle are responsible for properly
loading and securing the machine for transport on a vehicle.

5.2 Incoming inspections by the operator

The machine must be checked immediately after transport.

The following must be checked:

 any transport damages
 proper scope of delivery
 loose bolted connections
 other defects

A delivery record is required, with the signature of the driver of the transport vehicle.
Complaints must be submitted to the manufacturer or supplier immediately within
24 hours.
If the machine is not set up and installed immediately after delivery at the customers
location, it must be stored in a protected location. For longer periods of storage
(>3 months), the general condition of the machine and its packing should be checked
regularly. If required, renew or replace preservative.

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DANGER

Unauthorised set-up, assembly and initial start-up is not permitted. Set-up, assembly
and initial start-up of the machine should be done by service personnel or other
authorised personnel of Gayk Baumaschinen GmbH, and all safety regulations must
be observed.

6 Assembly and start-up

6.1 General assembly instructions

The following must be adhered to:

 Before beginning work, sufficient freedom of installation must be ensured.
 Be aware of the dimensions and weight data for the machine.
 Proper assembly procedure. Improperly fastened components can fall off or topple.
 Install assemblies and components properly. Maintain prescribed bolt torques.

In the assembly of the machine, the following protective clothing must be worn:

 Protective work clothing
 Protective safety helmet
 Protective work gloves
 Safety shoes

6.2 Aligning the machine

Before setting up the mast, the machine must always be placed in its work position.
The lock is released and the entire upper structure of the machine is rotated to its
working position and locked. The lock may only move slightly against the stop. The
mast is raised by about 50 cm by actuating the corresponding control lever. When the
vertical position is reached, the mast may not be pressed into the soil. The machine
can be aligned automatically and manually. Automatic operation is turned on by

pressing the “Automatic Alignment ON” button. To check alignment, check the attached

bubble level to see whether the mast of the machine is exactly vertical. Automatic

operation is turned on by pressing the “Automatic Alignment ON” button.

When aligning by hand, the “Mast up and down” shift lever is actuated until the exact

alignment is indicated at the bubble level.

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CAUTION

Aligning the machine!
Improper alignment of the machine and thus all assemblies can lead to damage of the
rammed material and wear of the respective machine parts.

Fig. 27: Circular level

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DANGER

Risk of accidents when turning on the machine!
Any damages found must be reported before turning on the machine. The machine is
only ready to operate after all defects are remedied.

DANGER

Risk of accidents when turning on the machine!
Actuating control devices causes a mechanical movement at the machine. The
following must be adhered to:

 The control device should be actuated slowly. No uncontrolled movements are

allowed.

 No unauthorised personnel are allowed in the work area of the machine.
 Obstructions or other objects near the machine must be removed.

7 Operating the machine

7.1.1 General instructions

7.1.2 Operating procedure

1. The following checks must be done before beginning work:

 check and, if necessary, top up the motor oil level.
 check and, if necessary, top up the fuel.
 check and, if necessary, top up the hydraulic fluid level.
 degree of contamination of the fill and vent filter and, if necessary, change

filter.

 check and, if necessary, replace hydraulic fluid hoses and connectors.
 check chain tension and tighten if necessary.

2. Rotate and lock the upper structure of the machine in the working position.

3. Set ignition key to the “I” position, the check charge and fluid pressure control
lamps will light.

4. Rotate the ignition key to “II”. The motor will start. The charge check and oil
pressure control lamps will go out.

5. Lightly actuate the speed adjustment lever.

6. Bring the machine to the position at which the profile is to be rammed.

7. To move, actuate the two corresponding control levers.

Move straight forward → both control lever are moved in the same direction. To

go around a curve → move the control lever in opposite directions.

When driving the machine, the hydraulic hammer may never be higher than one
meter above the ground.

8. Drive until the correct position is reached.

9. Erect the mast. Move the hydraulic hammer to its centre position.

10. Align the mast automatically or manually (optional).

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1 Limit switch

2 Switch roll

11. Optionally, the corresponding distance can be established in the automatic self­regulation system.

12. Ramming position has been reached.

13. Move the hydraulic hammer upward using the control lever until the profile can be
inserted into the ram head.

14. Place the profile into the post guide and then align it, then move the hydraulic
hammer downward until the profile is pressed into the ground.

15. Before beginning the ramming process, check to see whether the profile is
standing vertically in the machine

7.1.3 Ramming the profiles

1. The ramming process can be done manually with the control levers or using the
automatic ramming function.

2. In the manual ramming process, the “Hammer down” control lever is always
actuated first before the ramming process is begun. The control levers are held
until the desired depth of the profile is reached. To end the ramming process, the

control lever “Hammer in” is released first and then the control lever “Hammer

down”.

3. If the correct depth is not yet reached, the process is repeated until the desired
depth is reached.

4. The hydraulic hammer is lifted far enough that it does not get caught in the
profile.

5. In the ramming process using the automatic ramming function, the height of the
automatic shut-down is adjusted on the mast.

Fig. 28: Limit switch for shutting off the automatic ramming function

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6. The profile is placed under the hydraulic hammer. To start the ramming process,
the green button on the control panel of the electrical cabinet (optional) is
pressed. The machine automatically turns off the ramming process when the
height setting is reached.

7. If the automatic ramming process is stopped, the red button on the control panel
of the electrical cabinet is pressed. Only the ramming process is interrupted, but
the machine continues to run. If a dangerous situation arises during ramming, the
emergency stop button must be pressed immediately. The machine is shut down
completely.

8. At the end of the work, the machine must be placed in the transport position. The
lock is opened and the chassis structure is rotated. The lock is re-set.

9. Move the hydraulic hammer all the way downward.

10. The mast must be brought to the transport position. It is folded backward onto its
storage position. Before the mast is fully stored, it must be moved all the way
downward. Otherwise it might damage the hydraulic cylinder.

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DANGER

Risk of accidents!
In all work involving operation, installation and maintenance, the shut-off procedures
described in these operating instructions must be followed, as well as any required
safety measures. After all work on the machine, check whether all safety equipment
has been installed and is functioning properly. Safety equipment may not be bypassed
or shut down.

CAUTION

Maintenance and testing of machine functions may only be performed by qualified
personnel according to the instructions in the operating instructions. The maintenance
intervals established by the manufacturer of the machine must be adhered to. The
operation of the machine must not be affected by a power loss.

CAUTION

Only perform maintenance work with the machine shut off and after it has been
secured against being turned back on. Statutory disposal regulations for waste oil,
lubricants, cleaning agents and filters must be followed. To protect against
unauthorised access, the ignition key must be removed and the negative terminal of
the battery disconnected. At the end of the maintenance work, all tools and
miscellaneous objects must be removed from the machine.

DANGER

Risk of accidents!
After the maintenance work, the following checks must be carried out prior to turning
the machine back on, during which time safety regulations must be adhered to.

 Check that all loose bolted connections are tightened.
 Properly re-install all removed safety equipment. Ensure that all safety equipment

for the machine is properly functioning again.

 Clean the work area and remove any escaped process materials.

CAUTION

Do not use aggressive cleaning agents!
Cleaning agents must not damage the paint and the components of the machine. Use
a lint-free cleaning cloth. Only work with dry, filtered compressed air up to max. 2 bar.
After cleaning work on the machine, perform a visual and functional inspection.

8 Maintenance and repair

8.1 General instructions

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NOTE

The life of the machine depends to a large degree on the quality of the maintenance
measures being performed.

Maintenance and repair measures

Work to be performed

Interval

Figure

Upper mast lubrication
(carriage)
2 to 3 pumps of high­pressure grease

30-50
operating
hours

Mast lubrication (carriage)
2 to 3 pumps of high­pressure grease

1.

Lubricant nipple
at the centre of the mast
(carriage)

2.

Sight holes for
positioning the return
pulleys

30-50
operating
hours

Lower mast lubrication
(carriage) 2 to 3 pumps of
high-pressure grease

30-50
operating
hours

8.2 Maintenance and repair measures

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Maintenance and repair measures

Work to be performed

Interval

Figure

Mast lubrication (carriage) at
hinge 2 to 3 pumps of high­pressure grease

30-50
operating
hours

Lubrication at lower
hydraulic cylinder 2 to 3
pumps of high-pressure
grease

30-50
operating
hours

Lubrication at upper
hydraulic cylinder 2 to 3
pumps of high-pressure
grease

30-50
operating
hours

Lubrication at the hydraulic
hammer
Lay the hydraulic hammer on
a post and push the chisel
completely into the hydraulic
hammer.

2 – 3 times
per day
1 – 2 pumps

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Maintenance and repair measures

Work to be performed

Interval

Figure

Adjusting bolts at sled (4x)
Check the bolted
connections

250 operating
hours

Adjusting bolts at the
advance (8x)
Check the bolted
connections

250 operating
hours

Tensioning bolts at the sled
Check the bolted
connections

250 operating
hours

Slide rails
Adjust play

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Maintenance and repair measures

Work to be performed

Interval

Figure

Check tubing for leaks

Ongoing
checks.
Replace as
necessary.

Chains
Check tension and oil

Gear oil replacement at
vehicle motor

1.

Oil dipstick

2.

Oil fill nozzle

500 operating
hours

Tensioning the vehicle tracks

500 operating
hours

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Maintenance and repair measures

Work to be performed

Interval

Figure

Hydraulic hoses
Visual check for damages,
abrasions, cracks.

Every 6 years
under normal
loads. Under
increased
demands,
after 2 years.

Blow out cooling fins with
compressed air.
Do not set the compressed
air gun onto the cooling fins.

250 operating
hours

Change motor oil
During motor oil change,
place a collection vessel for
the waste oil underneath. It
should not be allowed to
drain to the environment, or
the ground. Danger of
slipping.

The drained waste oil must
be disposed of according to
the waste oil ordinance
(AltölV).

Manufacturer'
s operating
instructions

Replace hydraulic fluid
During a hydraulic fluid
change, place a collection
vessel for the waste fluid
underneath. It should not be
allowed to drain to the
environment, or the ground.
Danger of slipping.

The drained waste oil must
be disposed of according to
the waste oil ordinance
(AltölV).

500 operating
hours

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Maintenance and repair measures

Checking the chain tension

1.

Check on a flat surface.

2.

Rotate the chassis to the working position and lift using the mast until the chain is free.

3.

Lift the opposite side using a suitable forklift below the bracket until the chain is free (make
sure that the machine is secured against slippage).

4.

Never lift both sides at the same time.

5.

Sag of the chain between the pulley and the chain (the distance should be 15-20 mm).

Tensioning the chains

1.

Remove bolts on the cover to the right and left at the drive support and place the manual
grease pump over the lubrication nipple.

2.

Re-tension the chain.

3.

Do not use any chisel paste to tension the chain.

4.

Move the chain and check the chain tension again.

5.

For new rubber tracks, check the sag of the rubber tracks 2-3 times. Tension the rubber
tracks if necessary.

De-tensioning the chains

1.

Slowly loosen the valve with the lubrication nipple and allow grease to flow out until the
correct chain tension is reached.

2.

Re-tighten the valve with the lubrication nipple.

3.

Remove grease and dispose of it properly.

Removing the rubber track

1.

Remove the fenders and raise the chassis.

2.

Loosen the valve until the rubber chain is entirely de-tensioned.

3.

Use a long pry bar to remove the chain.

4.

The lower end at the sagging chain must reach in front of the rear pulley. A lateral force
will be exerted on the chain.

5.

Now slowly move the chain forward using the drive motor and exert more pressure on the
chain. The chain will now move downward from the guide bracket of the guide pulley and
can be pulled backward and removed from the drive pulley.

Installing the rubber track

The rubber track is installed in the same sequence as its removal, but in reverse.

1.

Place the chain completely against the cogging of the drive pulley.

2.

Lay the lower end of the chain onto the guide pulley.

3.

Push on the chain using the pry bar.

4.

Slowly move the chain forward until it is seated on the guide pulley and drive pulley
completely.

5.

Tension the chain according to the description.

Adjusting the slide rails

The slide rails are seated using adjusting bolts at the sled and the base tube.
There are 4 adjusting bolts at the sled with lock nuts, and 8 adjusting bolts at the base tube
with lock nuts.

1. Adjusting the slide rails at the sled

Set the mast in the vertical position. Loosen the lock nut. Tighten the adjusting bolt hand tight
against the lock nut. Check the play in the sled by moving it up and down.
The sled should have a constant speed in each direction. If not, the adjusting bolt must be
readjusted.
Check whether the sled is sitting firmly against the mast by shaking it.

Maintenance and repair

56

Issue 06.2016

Hydraulic Ram Unit HRE

2. Adjusting the slide rails at the base tube

Set the mast in the vertical position. Lock nuts are loose. Tighten the bolts until resistance is
felt. Tighten the lock nuts and check the play by slowly moving the advancement and the left­right cylinder of the mast one after the other. If there is still play in the slide rails, the
adjustment must be repeated at the adjusting bolts.

Disruptions

Hydraulic Ram Unit HRE

Issue 06.2016

57

Type of disruption

Possible causes

Remedy

Motor does not start

Emergency Stop button
activated

Unlock the Emergency Stop
button.

Follow the Hatz operating
instructions.

Hydraulic hammer is not
making impact

Loose quick coupling

Tighten the quick coupling
Follow the Atlas Copco

operating instructions.

9 Disruptions

Disruptions

58

Issue 06.2016

Hydraulic Ram Unit HRE

Ersatzteilliste HRE / Spare Parts List HRE

A=Aufbau, E=Elektrik, HY=Hydraulik, M= Motor, B=Bohreinheit

A=Assembly, E=Electric, HY=Hydraulic, M=Motor, B=Drilling Unit

Bezeichnung (d) Name (engl) Art-Nr/ArtNo

Große Inspektion Large service 09575274

Kleine Inspektion Minor service 09575174
A Beschriftungstafel zum HRE Identification plate for the HRE 09570499
A Meißelstummel PB 160 chisel stub PB 160 09576374
A Haltebolzen zum PB 160 Retainer pin PB 160 09576474
A Vulkonplattensatz PB 160 Vulcon plate kit PB 160 09570978
A Schlitten z Schlagwerk PB 160 Carriage for pile driver PB 160 09571274
A Spannhalbschale Schlitten PB 160 Clamping half-shell carriage PB 160 09571277
A Hammerkasten/Hammeraufnahme PB 305 Carriage for pile driver PB 305 09571974
A Haltebolzen zum PB 305 Retainer pin PB 305 09570872-1
A Meißelstummel PB 305 chisel stub PB 305 09570881
A Spionrohrhalter Spy pipe clamp 09574479
A Schwingungsdämpfer/Gummi Puffer Vibration damper/rubber buffer 09574475
A Gleitplatte Kst kpl Satz Vorschub Sliding plate plastic cpl. kit feed 09575774
A Gleitplatte Kst Vorschub 150x150x15 Sliding plate plastic feed 150x150x15 09575874
A Gleitplatte Kst Vorschub 150x50x12 Sliding plate plastic feed 150x50x12 09575974
A Gleitplatte z Schlitten (Kunststoff) Sliding plate for carriage (plastic) 09576075
A Halbschale m Schmiertasche z Gelenk Half-shell with lubrication bore relief for joint 09576774
A Axial Nadelkranz Lager Gelenk Axial needle roller bearings joint 09576874
A Kreuzgelenk HRE Stellen/Legen Universal joint HRE erect/lower 09745274-4.3
A Distanzhülse HRE Stellen/Legen Spacer sleeve HRE erect/lower 09745274-4.2
A Geweihmastauflage Mast support 09745474-20
A Mastgrundplatte m Gelenk+Gleitbuchse Mast base plate with joint + slide bush 09752174
A Flyer Kette unten Flyer chain bottom 09752374-10
A Flyer Kette oben Flyer chain top 09752374-9
A Kettenspanner für Flyerkette Chain adjuster for flyer chain 09752378
A Mastgleitplatte m Kstpl+Gewindestift Mast slide plate w pla.plate+grub screw 09752474-1
A Distanzplatte zur Lafette Spacer plate for mount 09752474-2.1
A Gleitleiste Lafette (Metall) Guide rail mount (metal) 09752474.6.8
A Gleitleiste Lafette (Kunststoff) Guide rail mount ( plastic) 09752474.6.9
A Verstärkungsleiste z Kstleiste z Lafette Reinforcment rail for platic rail of mount 09752574-10
A Gleitleiste z Kettenschlitten Guide rail for chain carriage 09752674-7.1
A Gelenklager z HyZyl. Stellen/Legen Swing bearings for hydr.cyl. erect/lower HY1093
A Feder Schlitten Spring carriage 01268174
A Flügelschraube M 12 x 30 Thumbscrew M 12 x 30 93071600
A Spionrohr Länge 1500mm Spy pipe, length 1500mm 09574574
A Schiene für autom.Abschaltung C-Profil Rail for autom. stop C-profile 09574976
A Gewichtsplatte zum HRE 1000x1000x50 Weight plate HRE 1000x1000x50 09500774
A Stoßfeder zum Kettenschlitten Shock spring for chain carriage 012681.74
A Federteller, Federscheibe Hammerschlitten Spring plate, spring disc, hammer carriage 09752674-10
A Zwischenteil Verb.platte Lafette U-Form Connection plate, mount, U-form 09576574
A Zwischenteil Verb.platte Lafette GeradeForm Connection plate, mount, straight form 09576674
A Stehbolzen / Gelenkbolzen M 24x90 Stud bolts / pivot bolts M 24x90 09752174-26
A Gleitplatte zur Mastschwenkplatte groß Sliding plate for mast swivel plate, large 09575374
A Gleitplatte zur Mastschwenkplatte klein Sliding plate for mast swivel plate, small 09575474
A Halteeisen HRE (VR120/150) Holding iron HRE (VR 120/150) 09753574-10
A
A
A

Ersatzteilliste HRE / Spare Parts List HRE

Bezeichnung (d) Name (engl) Art-Nr/ArtNo

E Beleuchtung Arbeitsscheinwerfer LED kpl Light, working light, complete 09500274
E Birne Arbeitsscheinwerfer H1 Bulb, working light H1 000064150
E Birne Arbeitsscheinwerfer H3 Bulb, working light H3 000064151
E Schalter Arbeitsscheinwerfer Switch, working light 09574776.1
E Schalter Not / Aus Emergency stop switch 09570482
E Schalter Rundumleuchte Switch beacon light 09574776
E Rundumleuchte 12 V Beacon light 09574777
E Rundumleuchte 24 V Beacon light 09574780
E Birne zur Rundumleuchte Bulb for beacon light 09577274
E Winkel zum Haltemagnet Angle for holding magnet 09574972
E Haltemagnet 40 mm Holding magnet 40mm 09574973
E Haltemagnet Teller z Bucher Block Holding magnet plate for Bucher block 09574975
E Rollenendschalter z autom.Abschaltung Roller limit switch for automatic cut-off 09574977
E Alurolle für automatische Abschaltung Alu roller for automatic cut-off 09574978
E Sicherung 15 A Fuse 15A 09577174
E Schraubenfeder CB 17, Feder Magnet Coil spring CB17, spring magnet 510.3321
E Schiene für automatische Abschaltung Rail for automatic cut-off 09574976
E
E
HY Öl-Filter Hatz Oil filter Hatz 09574374
HY Öl-Filter kpl. mit Gehäuse Oil filter cpl. with housing 09513176
HY Öl-Filter Oil filter 09513175
HY Öl-Filter kpl. Tank Topper Oil filter cpl. Tank Topper 09513178
HY Lecköl-Rücklaufleitung Oil leakage return line HY0903
HY Runddicht O-Ring z CH 80 (Dichtungssatz) O-Ring to CH 80 (Seal kit) Hy1062
HY Runddicht O-Ring z CH 50 (Dichtungssatz) O-Ring to CH 50 (Seal kit) Hy1063
HY Runddichtring O-Ring 391321936205
HY Führungskette (Lasche) Guide chain (flap) HY0974-1
HY Führungskette (Steg) Guide chain (gutter) HY0974-2
HY Gummi Balg Bucher Block Rubber bellows Bucher Block HY1043
HY Staubkappe Hammerkupplung Gr. 6 Dust cap hammer coupling size 6 HY0978-1
HY Staubkappe Hammerkupplung Gr. 6 Dust cap hammer coupling size 6 HY0979-1
HY Schnellkupplung Staubstecker Gr. 3 Quick connector dust plug size 3 HY0980-1
HY Staubmuffe Gr. 3 Dust bush size 3 HY0981-1
HY Hydraulik Öl, HLP 46 Hydraulic oil, HLP 46 09510174
HY Öl Filter Umbau kpl. Oil filter modification cpl. 09512974
HY Deckel Öl Filter Cap oil filter 09513179
HY Belüfterelement für Tanktopper Aeration element Tanktopper 09513181
HY Runddichtring 15,22x2,62 O-Ring 15.22x2.62 9023485
HY Runddichtring 20,63x2,62 O-Ring 20.63x2.62 903435
HY Runddichtring 4,2x1,9 O-Ring 4.2x1.9 904003
HY Runddichtring 14x2 O-Ring 14x2 904063
HY Runddichtring O-Ring20,22x3,53 z.80ltr Block O-Ring 20.22x3.53 to 80ltr block Hy1060
HY Deckel für 80ltr.Block Cap for 80ltr block Hy09614
HY Kunststoffkappe HRE G 1/2" CH 80 Plastic cap HRE G 1/2" CH 80 HY09616
HY Kunststoffkappe HRE G 3/8" CH 50 Plastic cap HRE G 3/8" CH 50 HY09665
HY Stromregelventil Flow control valve HY0969
HY Gelenklager zum Hydr.Zyl.,stellen-legen Swing bearing for hyd.cyl. erect/lower HY1093
HY Gelenkkopf zum Hydr.Zyl.,stellen-legen Joint head for hyd.cyl. erect/lower HY1095
HY Schlauchschutz Hose protection HYS0001

Ersatzteilliste HRE / Spare Parts List HRE

Bezeichnung (d) Name (engl) Art-Nr/ArtNo

HY Schlauchbefestigungschelle Hose fixing clamp 09577574
HY Schlauchhalter Hose bracket HY 1090
HY Quadring für Flansch 3/4" Quad-ring for flange 3/4" HY90Q34V
HY Quadring für Flansch 1" Quad-ring for flange 1" HY 90Q1V
HY Quadring für Flansch 1 1/4" Quad-ring for flange 1 1/4" HY90Q114V
HY Manometer 1/4" 0-250bar Manometer 1/4" 0-250 bar HY 1025
HY Verschmutzungsanzeiger Fouling detector Hy1025.1
HY Schwenkverschraubung Swivel fitting Hy 1010
HY Drossel Schwenverschraubung Throttle swivel fitting Hy 1011
HY Hammer Schnellkupplungssatz Stecker 18 L Hammer quick coupler kit plug 18L HY0977
HY Hammer Schnellkupplungssatz Muffe 18 L Hammer quick coupler kit socket 18L HY0976
HY Hammer Schnellkupplungssatz Stecker 22 L Hammer quick coupler kit plug 22L HY0979
HY Hammer Schnellkupplungssatz Muffe 22 L Hammer quick coupler kit socket 22L HY0978
HY Hy Schlauch Hammer/Tank Hy hose hammer/tank Pos95 /Pos30
HY HY Schlauch Hammer P Hy hose hammer P Pos92 /Pos27
HY HY Schlauch Hammer T Hy hose hammer T Pos96 /Pos31
HY HY Schlauch Tank/Winkelschott Hy hose tank/elbow bulkhead Pos99 /Pos34
HY HY Schlauch Pumpe/Mengenteiler Hy hose pump/flow divider Pos98/Pos33
HY HY Schlauch Kühler / Tank Hy hose cooler / tank Pos102/Pos37
HY HY Schlauch Saugleitung / Tank Hy hose suction line / tank Pos101/Pos36
HY HY Schlauch Hammer / Steuerblock Hy hose hammer / control panel Pos91/Pos26
HY Hy Zylinder Mast stellen - legen Hy cylinder erect / lower mast HY0951-1
HY Dichtsatz Hy Zyl. Mast stellen-legen Seal kit hy cyl erect / lower mast HY0951.1
HY Hy Zylinder Mast re - li Hy cylinder mast right/left HY0939
HY Dichtsatz Hy Zyl re - li Seal kit hy cyl right/left HY0952.1
HY Schalldämpfer Sinterbronze G 1/4" Sound absorber sintered bronze G1/4" 93280074
HY Schalldämpfer Sinterbronze G 1/2" Sound absorber sintered bronze G1/2" 93100110
HY Schalldämpfer Sinterbronze R 1/4" Sound absorber sintered bronze R1/4" 93100140
HY Schmiernippel R 1/4" Grease nipple R 1/4" 93280074
HY Dichtsatz PB 160 Seal kit PB 160 3361120011
HY Dichtsatz PB 305 / PB 310 Seal kit PB 305 / PB 310 3361140011
HY Dichtsatz PB 405 / PB 420 Seal kit PB 405 / PB 420 3361150011
HY Handhebelgeh. Danfoss Handleveling Danfoss HY157B3171
HY Handhebelgeh. Bucher Handleveling Bucher HY200707020410
HY
HY
HY
HY
HY
HY
HY
HY
HY
HY
HY
HY

Ersatzteilliste HRE / Spare Parts List HRE

Bezeichnung (d) Name (engl) Art-Nr/ArtNo

M Kraftstoff-Vorfilter Fuel prefilter 09574174
M Tankdeckel Tank cap/filler cap 09574377
M Starter Anlasser Starter starting motor 09574378
M Gas Verstellhebel Gas adjusting lever 09574379
M Startfüllung Start filling 09574472
M Spannrolle PolyVRiemen (Abstellvorrichtung) Tension roller Poly V belt (cut-off device) 09574473
M Poly-V-Riemen 9PJ920, Keilriemen Poly-V-belt 9PJ920, V-belt 09574474
M Poly-V-Riemen 9PJ910, Keilriemen Poly-V-belt 9PJ910,V-belt 09574474-1
M Gaszug Accelerator cable HY1069
M Regulierhebel Control lever HY1073
M Dichtstoff Silikon Sealant Silicone 50282501
M Zündschlüssel Ignition key 50404900
M Dämpfer Gasgestänge Damper carburettor linkage 02018611
M Dichtung Startfüllung zum 2L41C seal start-up filling for 2L41C 03614002
M Dichtung zum Tragbock seal for support block 03754400
M Dichtung zum Abstellmagnet seal for stopping magnet 03934400
M Abgas Dämpfer Auspuff Hatz kpl. Exhaust gas damper, exhaust pipe Hatz cpl. 03829901
M Dichtung zum Nebenantrieb vorne seal for front auxiliary drive 03568000
M Dichtsatz Nebenantrieb seal kit cpl. to power take-off 0992201
M Luftfilter Hatz C 25 124 Air filter Hatz C 25 124 09574074
M Tank Sieb Tank sieve 50387300
M Dichtungssatz K.L/M31/41 Hatz seal kit K.L/M31/41 Hatz 0992202
M Regler + Bürste zum Hatz Motor Regulator + brush for Hatz motor 049084900
M Generator Hatz Generator Hatz 050504200
M Ventildichtring zum Hatz Motor Valve seal ring for Hatz 050579500
M Kupferdichtring zum Hatz Motor Copper seal ring for Hatz 050579501
M Dichtungspaket Abgasdämpfer (Auspuff) Seal package gas exhaust damper (exhaust) 01603700
M Absperrmagnet / Motorabschaltung shutoff solenoid/engine shutdown 01660910
M Batterie Battery 09513574
M Kraftstoffleitung Fuel line 09574173
M Kraftstoff-Rücklaufleitung Fuel return-line 01799300
M Kraftstoffleitung mit Rückschlagventil Fuel line with check/return valve 01191101
M Kraftstoff-Filter Fuel filter 09574274

Ersatzteilliste HRE / Spare Parts List HRE

Bezeichnung (d) Name (engl) Art-Nr/ArtNo

B Rolle zur Bohrhammerführung Roller for drill hammer guide 09570278
B Gummiplatte zum Staubsauger Rubber plate for vacuum cleaner 09056274
B Gummistaubsauger Manschette Rubber vacuum cleaner sleeve 09056174
B Schalldämpfer aus Sinterbronze R 1/4" Sound absorber sintered bronze R1/4" 93100140
B Schalldämpfer G 1/2", Auspuff Schaltpult Sound absorber G1/2", tailpipe control desk 93100110
B Wellendichtring Bohr Dreh Simmerring Rotary shaft seal Drill Rotate 09058274-6.1
B Sechskantschraube M 16 x 140 Hexagon bolt M 16 x 140 9301148
B Mutter M 16 selbstsichernd Nut M 16 self locking 93120175
B U-Scheibe 17er U-disc 17mm 93130140
B Rohrabdeckung 80x40x4 Pipe cover 80x40x4 00000125
B T-Stück zur Bohreinheit T-piece for drill unit 09570284
B Oeler Halter Bohreinheit oel holder Drilling unit 09570299
B Stoßdämpfer kpl. Bohreinheit shock absorder cpl. For drilling unit 09058274-0
B Dämpfer Unterteil mit API Gewinde Damper bottom section with API thread 09058274-13
B Hubzylinderstütze Staubabsaugung support stroke cylinder Dust extraction 09753074-10

Hammerkasten neu PB 305 / PB 405 for new hammer case PB 305 / PB 405
B

Repair order: HRE Series No.

Customer: Service hours

Spare parts list Repair order

Designation Item No. Quantity: New Quantity

Hours of mechanic:

Short text:

Date: Mechanic:

Spare part list with pictures and numbers

3363491004 09029274
Service box / Nitrogen bag PB 160/310/420 box level
with 2l bottle

09570878
Nitrogen bottle
1329518

Manometer for testing
the nitrogen pressure in
the hydraulic hammer

1329516
Filling valve to fill nitrogen
in the hydraulic hammer
incl. manometer

09513074 09512074

09574977
roller limit for automatic shutdown

Grease nipple R ¼“

09574977.2
Pivoting lever for roller limit

3363087286
Filling valve tot he PB 160 – 420

PB 160 - 09576374
PB 310 - 09570881
PB 420 - 09903774-40

09511074
Grease press for chisel paste

grease hammer/chisel paste

93280074

chisel

Spare part list with pictures and numbers

09513179 09513183 937894Q
black plastic cover Oil filter supporting cage Hydraulic filter

HY 10125

dust indication Hydraulic filter
HY 1025

09513181 Glycerin - Manometer
Breather item Tank topper

09500274
Working lights LED working lights H3

Hydraulic pipe bar block
HY 0955 HY 0805
Hydraulic cylinder mast up-down

HY 0986
S traight screw-in fitting

09500474

HY 0972

Spare part list with pictures and numbers

09574977.2

Hydraulic pipe hammer up-down Hydraulic cylinder left-rights
HY 0803 for 3,7m erector HY 0939
HY 0804 for 4,7m erector

HY 0951-2 HY0987.1 locking block sagging compensate
Cylinder put-lay

09574977
Revolving limit switch

Lever to the revolving limit switch

HY 0973 09752474-2.2
three-way shift ball valve guide rail-Set - erector

09575774 09752674-7.2guide plate - Set feed
guide rail-Set - Slide

Spare part list with pictures and numbers

09753574-10

rubber chain
Holding iron PB 160-420 Let us know the serial number)
8x hexagon Screws M20x50 - 93011890
8x NL-disc 20 - 93149591

09570880 - PB 310
09576474 - PB 160
09570887 - PB 420 HY 0976 HY 0977
retaining bolt Hydraulic hammer Coupling muff coupling plug

HY09585.1 HY09585.2
Gear pump 2 cylinder gear pump 3 cylinder

01663600 01413801
Flange to the elastic-coupler clutch hub

Spare part list with pictures and numbers

2013

09574475 Poly-V-belt/ V-belt
Vibration damper Hatz-engine 09574474 - 2-Cyl-engine
09574474-1 - 3 Cyl-engine

50404900
50600800
Key until year of manufac. 08/2013 key from 08/

09574973 09570482
holding magnet locking block emergency stopp with case

Half-shell brass
09576774