Table of contents - Vibrator HVR 45

Preface............................................................................................................ 3

1 Intended use................................................................................................ 5

2 Description......................................................................................................7

3 Commissioning and control....................................................................... 9

3.1 Commissioning........................................................................................................................ 9
3.2 Control................................................................................................................................... 10
3.2.1 Speed regulation.......................................................................................................... 10
3.2.2 Clamping...................................................................................................................... 10

4 Operation....................................................................................................11
4.1 General safety instructions.................................................................................................... 11
4.2 Safety instructions and restrictions........................................................................................ 12
4.2.1 Dangers and risks........................................................................................................ 12
4.2.2 Danger area................................................................................................................. 13
4.2.3 Operational restrictions................................................................................................ 15
4.2.4Personalprotectionequipment..................................................................................... 15
4.3 Working with the HVR............................................................................................................ 16
4.3.1 Attaching the vibrator.................................................................................................... 16
4.3.2 Attaching and securing of pile elements....................................................................... 19
4.3.3 Pile driving.................................................................................................................... 23
4.3.4 Extracting pile elements .............................................................................................. 25
4.4 Transport................................................................................................................................ 27

5 Maintenance and service.......................................................................... 29

5.1 Regular maintenance work - summary.................................................................................. 30
5.2 Oil change and verification.................................................................................................... 31
5.3 Jaw assembly........................................................................................................................ 33
5.4Elastomer mounts.................................................................................................................. 37

6 Operational failure and trouble shooting................................................ 39

6.1 Hydraulic control system........................................................................................................ 39
6.1.1 Flow regulating valve.................................................................................................... 40
6.1.2 Jaw assembly............................................................................................................... 40
6.2 Table of malfunctions............................................................................................................. 41

7 Technical Data........................................................................................... 43
7.1 Data sheet............................................................................................................................. 43
7.2 Type plate.............................................................................................................................. 45
7.3 Hydraulic control system........................................................................................................ 46

1
Vibrator HVR

Appendix....................................................................................................... 47
1 Tightening moments for screwed connections.......................................................................... 48
2 Lubricants................................................................................................................................. 48
3 Hydraulic oils............................................................................................................................ 49
4 Gear oils for ABI Group attachments........................................................................................ 50
5 Gear greases for ABI Group attachments................................................................................. 50
6 Load securing chart.................................................................................................................. 51

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2
Preface

These operating instructions are designed to familiarize the user with the machine and its designated
use.

The operating manual contains instructions for the safe operation, the maintenance and service as
well as for the transport of the machine. Observing these instructions helps to avoid danger, to reduce
repair costs and downtimes and to increase the reliability and life of the machine.

The instruction manual is to be supplemented by the respective national rules and regulations for
accident prevention and environmental protection. In addition to the operating instructions and to the
mandatory rules and regulations for accident prevention and environmental protection in the country
and place of use of the machine, the generally recognized technical rules for safe and proper working
must be observed. At sale, leasing or resale of machines within the EU, the operators manual has
to be delivered in the official language of the users country according to the 2006/42/EC Machinery
Directive.

These operating instructions must be read and applied by any person in charge of carrying out work
with and on the machine, such as

operation including setting up, troubleshooting in the course of work, care and disposal of fuels
and consumables
maintenance (servicing, inspection, repair)
transport

We particularly draw your attention to the fundamental safety instructions mentioned in chapter 4.
In addition, a comprehensive introduction by an expert designated by ABI Group is required before
starting to operate the equipment.

Please keep the operating manual in the drivers cab of the carrier. It must always be available on
the operation site of the machine.

Due to continuous development and improvement the captions in the operating manual may vary
from the delivered equipment. ABI Group preserves the right to technical modifications. Graphics in
the operating instruction may differ from delivered machine.

ABI Group is at your service at any time if you have questions concerning the operation or the equip-
ment itself.

The reproduction, distribution and utilization of the documents as well as the communication of its
contents to others without express authorization is prohibited. Offenders will be held liable for the
payment of damages. Every substitution beyond the copyright law is prohibited and chargeable. This
especially applies to copying documents as well as saving, processing and distribute them with help
from electronical systems. Preceding manuals expire their validity with the present version.

3
Vibrator HVR

The following designations are used for particularly important indications:

Danger
Disregarding or inaccurate compliance with the instructions results in death or serious injury
or physical damage to the equipment.

Warning
Disregarding or inaccurate compliance with the instructions could result in death or serious
injury or physical damage to the equipment.

Caution
Disregarding or inaccurate compliance with the instructions may result in minor or moderate
injury or physical damage to the equipment and the environment.

Notice
Technical instructions which the user must observe in particular during the operation and
maintenance, as well as information for work simplification or more efficiently working.

If there are any questions concerning the operation of your HVR vibrator, please contact:

ABI GmbH
Am Knckel 4
D-63 843 Niedernberg
Germany

tel: + 49 (0) 6028 123-151 oder -152

fax: + 49 (0) 6028 123-159
e-mail: kd@abi-gmbh.de
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4
1 Intended use

The ABI Vibrator HVR is intended for attachment to the shovel stick of a hydraulic excavator. The
safety requirements, for example the stability and the hydraulic system of the hydraulic excavator is
to check before assembly and commissioning by the distributor of the entire machine and to ensure.

The ABI vibrator HVR is designed for driving and extracting pile elements into driveable soils with
vibration. Solidifying working processes, for example vibro stone column processes, are excluded.
Other working processes are possible, but have to be arranged and permitted in every case by ABI.
In principle ABI vibrators are not designed for working processes under water. At permanent opera-
tion and high duty cycle (20% and more duty cycle) special precautions have to be taken because
of the high thermal loads. System required at this shoring process oscillation energy is fed in the
underground and sound emitted to the environment. Vibrations can cause subsidence of soils and
damages of buildings.

The machine and attachments are intended for use in the commercial sector and may only be ope-
rated by authorized, qualified and instructed personnel. The equipment must always be operated by
two persons. The machine can be operated in a temperature range between - 20 C up to + 40 C.
Consult the manufacturer when working outside of the mentioned temperature range. The operation of
the machine and attachments is not provided within enclosed spaces and areas subject to explosion
hazards.

The machine has been built in accordance with state-of-the-art standards and the recognized safety
rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or
cause damage to the machine and to other material property.

Caution
The machine must only be used in technically perfect condition in accordance with its desi-
gnated use and the instructions set out in the operating manual, and only be safety conscious
persons who are fully aware of the risks involved in operating the machine. Any functional
disorders, especially those affecting the safety of the machine, should therefore be rectified
immediately.

The operating and maintenance personal has to receive a comprehensive introduction by ABI or a
specialist appointed by ABI before starting the equipment. In case of operating mistakes, insufficient
servicing and maintenance, overstressing as well as improper use of the pile driving equipment, no
warranty claims may be asserted.

Spare parts must comply with the technical requirements specified by the manufacturer. Spare parts
from original equipment manufacturers can be relied to do so. Installation and/or use of other spare
parts may affect the safety of the machine.

The machine must be examined at least once a year or after special occurrences by competent per-
sons. The technical condition of the machine must be examined for accident-proofness and thoroughly
on damages. The results of the examination are to be kept at least up to the next examination. The
owner of the machine is responsible for the immediate defect removal.

The national regulations in force in each user's country as well as the environment protection regulati-
ons must be observed. Cranes are usually not suitable for extracting sheet piles with free suspended
vibrators. In case of doubt please contact the crane manufacturer for an approval.

5
Vibrator HVR

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6
2 Description

The vibrator HVR is attached to the shovel stick of

a carrier (hydraulic excavator with shovel or grab) HVR
and is driven by the hydraulic system of the carrier.
6
The vibrator HVR-G needs a free hydraulic
function of the hydraulic excavator to supply the 1 5
clamping cylinders.

On the vibrator HVR-Z, the jaw assembly is di-

rectly connected to the pressure and return line
of the hydraulic motor via an engagement valve.

The HVR consists of a housing 1 which is lodged 2

in an elastic way in the vibrator head 2 with rub-
ber metal elements. A jaw assembly 3 serving to
take-up the pile driving elements is located on the
bottom of the driver unit.
4
The driver unit works according to the principle
of rotating unbalanced masses. A hydraulic motor
3 7
4 drives gear shafts lying one beside the other
on each of which rotate unbalanced flywheels of
the same size with the same speed and with an
opposite sense of rotation. The rotation generates
centrifugal forces whose components neutralize
one another in the horizontal and add up in the
vertical to a sinusoidal oscillation.

Upon vibratory pile driving an important part of the

inner frictional forces of soils as well as the casing
friction of the pile driving elements are reduced
or even totally eliminated through vibration. Thus
the forces required to drive the pile elements into
the soil are very low. The advance heading is
mainly generated by the pile driving and extracting
equipment's own weight and prestressing forces
of the main boom cylinder.

The vibrator HVR stands out for very short starting 1 Driver unit
and stopping times, high speeds and centrifugal 2 Vibrator head
forces at a low total weight. 3 Jaw assembly
4 Hydraulic motor
5 Flow regulating valve
6 Swivel
7 Limit stop

7
Vibrator HVR

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8
3 Commissioning and control
3.1 Commissioning
Caution
Before each commissioning and mounting,
perform a thorough visual and technical in-
spection of the ABI vibrator HVR:
The mounting vibrator HVR Z is controlled
exclusively with the control levers in the
hydraulic excavator. Other control elemets
(e.g. foot pedal) are possible, but have to
be arranged and permitted in every case by
ABI.
Clean ABI vibrator HVR and check complete
condition.
Examine welding seams and mechanical
components for tears and fatigue symp-
toms.
Check perfect condition of the safety devi-
ces (esp. pitching chain).
Check firm seat of screwed connections
(esp. jaw pads and clamping device).
Check oil level in the gear box.
Check hydraulic system and gear box for oil
leakage (esp. hydraulic hoses and fittings),
eliminate if necessary.
Check pilot lamps and control elements.
Check wear and tear parts (esp. jaw pads),
exchange if necessary.
Clean elastomer mounts, check perfect
condition, exchange if necessary.
Secure loose objects.
Observe maintenance intervals.
Before connect attachments at the rapid
changing device the hydraulic system must
be depressurized - Danger of damaging of
the quick-acting couplings. Screw quick-
acting couplings until the rear locking groo-
ve and secure it with clip pin. At incorrect
connecting or loosening quick-acting cou-
pling caused by vibration damaging of the
jaw assembly or vibrator - Danger through
tilting over pile element.
Commission of the ABI Vibrator HVR
Remove the shovel or grab from the hydraulic
excavator (see operating manual of the hy-
draulic excavator).
Mount the HVR to the shovel stick of the hy-
draulic excavator (see chap. Attaching the
vibrator).
Close all unused hydraulic connections with
dust caps to prevent dirt from entering the
hydraulic system.
Check all hydraulic functions without load.
Bring the HVR to operating temperature for
app. 2 ...3 minnutes at low speed without load.
Function Test
Hydraulic hoses
Check connections.
Fix scrubbing hoses if necessary.
Dynamic Test HVR Z
Start hydraulic excavator.
Actuate control lever in direction close excava-
tor bucket / grab - clamp assembly is closing.
Vibrator HVR begins vibrating after clamping
pressure is reached.
Bring control lever close excavator bucket /
grab in neutral position - vibrator stops running.
Actuate control lever in direction open ex-
cavator bucket / grab - clamp assembly is
opening.
Dynamic Test HVR G
Start hydraulic excavator.
Actuate control lever in direction turn grab -
clamp assembly is closing.
Actuate control lever in direction close grab
Vibrator HVR begins vibrating.
Bring control lever close grab in neutral posi-
tion - vibrator stops running.
Actuate control lever in direction turn grab -
clamp assembly is opening.
9
Vibrator HVR

3.2 Control

Caution
The equipment must always be operated by
two persons. One equipment operator who Right control lever
operates the control devices in the driver's
cab, and one slinger or spotter.

3.2.1 Speed regulation

The vibrator HVR is actuated with the control lever

Grab close, the speed increases depending on vibration / open clamp
how far the lever is moved. close clamp assembly
assembly

3.2.2 Clamping

Vibrator HVR G Vibrator HVR Z

The jaw assembly is actuated with the lever switch Close

Grab turn (see manual of excavator).
Warning
Repressurize jaw cylinder in regular inter-
vals - by loss of pressure through leak
oil danger of pile elements falling over or
damage of the machine.
Secure pile elements against falling over
before opening the clamping jaw.
Wait until vibrator stops before opening
the clamping jaw - danger of pile elements
falling over or damage of the machine.
The jaw assembly is actuated with the control
lever Grab close. After having attained the ne-
cessary clamping pressure the vibrator starts
automatically.
Open
Open the jaw assembly by moving the control
lever in opposite direction for a short time.
Warning
Secure pile elements against falling over
before opening the clamping jaw.
Wait until vibrator stops before opening
the clamping jaw - danger of pile elements
falling over or damage of the machine.
To open and close the clamping jaws, move
the control lever slowly and carefully in
order to build up the clamping pressure
completely - danger of pile elements falling
over or damage of the machine.
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10
4 Operation
4.1 General safety instructions
Warning
The operator and the slinger always have to
keep visual contact, if not the operation has
to be stopped immediately. Agree on clear
signals for the communication between
operator and spotter.
Constantly monitor the operations and
interrupt them immediately when danger
occurs.
The machine must not be started if any
person is in the danger area. The operator
has to give warning signals if persons are
in danger.
Wear personal protection equipment upon
operation of and maintenance work on the
machine. The personnel is not allowed to
wear long hair open, loose clothing or je-
welry. There is danger of injury, e.g. through
pulling in or getting caught.
Do not carry out modifications, attach-
ments and alterations at the machine that
affect the safety.
Do not exceed the maximum admissible
ground pressure. An insufficiently bearing
ground may be rendered more bearing, e.g.
by using load distributing boards (excava-
tor mats) or replacement of the soil.
Refrain from any operations that affect the
stability of the device. Pay attention to the
reduced stability when working over the
side.
Remove or secure tools and other objects
before putting the machine into operation.
Caution
The ABI MOBILRAM-System and the ABI at-
tachments may only be operated by autho-
rized, qualified and instructed personnel.
Operating and service personnel has to be
instructed by the contractor to operate or
service the machine.
Working with the equipment always re-
quires to persons, one equipment ope-
rator, and one spotter or slinger. The com-
munication between slinger and operator
must be established in a reliable manner.
Acoustic and optical signalling equipment
serving to monitor or protect the operating
personnel must always be functional.
Observe all safety indications and danger
warnings on the machine and keep them
complete and legible.
Inspect ABI MOBILRAM-System and the ABI
attachments every day for visual defects.
Immediately shut down the machine when
safety relevant changes of the machine or
its operating behavior occur, and inform
the competent office / person.
Properly illuminate the working area. When
operating or displacing the device at night
additional lightning equipment is required.
Regularly check the safety devices and
covers for perfect functioning.
The safety instructions for the particular
carrier have to be observed.
Furthermore, the relevant regulations, stan-
dards and laws in each users country are
valid.
11
Vibrator HVR

4.2 Safety instructions and restrictions

4.2.1 Dangers and risks

Warning
Improper operation of the equipment and
unauthorized modifications may lead to phy-
sical damage and high risks of injuries. The
regulations for prevention of accidents must
be observed in any case.

Mechanical dangers: Danger from electric effects:

Through crushing: when standing in the Electric contact (direct or indirect).
equipment's danger area (e.g. attaching pile Outside effects on electric devices (power
elements). lines).
Through spraying liquids under high pressure:
upon improper operation and maintenance or
mechanical damage to the hydraulic system.
Risk due to falling snow loads and ice loads.

Danger from thermal effects:

When touching hot machine parts during ope-
ration and maintenance work.
Upon contact with the vibrator body of the
working equipment.

Danger from noise and vibration:

When standing in the danger area without ear
protection.
Upon unauthorized modifications to the equip-
ment and improper operating conditions.

Danger from materials:

Inhalation of harmful liquids or gases.
Through fire and explosion.

Danger from failing machine parts and

other risks:
Unexpected ejection and fall over of machine
and equipment parts.
Upon failure/malfunction of control elements.
Loss of stability. Failure to observe the permis-
sible loads or inadequate ground.
Through human misbehavior and unskilled
operating and maintenance personnel.
Upon careless use of personal protection
equipment.
Danger of slipping at wet and muddy ground.
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4.2.2 Danger area
The danger area is the area around the machine
where persons may come into contact with:
Machine movements while in operation.
Swinging of falling loads.
Falling parts or loads.
Working equipment and its attachments.
Due to the working situation workplaces may be
within the danger area, e.g. operators and spotters
or slingers. Persons that are authorized to be in
such a workplace must be instructed and able to
judge the risk situation on their own.
Danger area:
Safety distance of the maschine to stationary
structures, e.g. buildings or other machines,
min. 0.5 m.
Safety distance = Length of the pile element +
2.0 m.
Safety distance =
Length of the pile element + 2.0 m
Authorized person:
Person who is required to be in the danger area
due to the working process, has an express
authorization from the operating company of
the machine to be in the danger area and was
sufficiently informed, reminded and trained on
the risks involved.
Access to the danger area:
The operating company of the machine has to
restrict the access to the danger area accordingly
as far as possible. If the danger area extends
into public or private area (e.g. working next to
a highway or adjacent property line) the opera-
ting company must take appropriate actions on
the basis of a risk assessment such as blocking
a road, restricting traffic, etc. Determining the
remaining risk and to what extent unauthorized
personnel enter the danger area is entirely on the
responsibility of the operating company and the
authorized personnel, or their supervisors, since
they are aware of the risk due to the conditions
on site.
Danger
When handling the machine improperly
and/or if there are persons in the danger
area there is risk of very severe injuries that
may lead to lifelong handicaps or restric-
tions in daily life or may even be lethal.
Secure the danger area with stable barriers,
if possible.
No unauthorized persons are permitted to
stay in the danger area. The operator may
only work with the machine if there are no
unauthorized persons present in the dan-
ger area. The operator has to give warning
signals if persons are in danger. If unau-
thorized persons do not leave the danger
area despite the warnings stop working
immediately.
Persons are only allowed to be in the dan-
ger area if this is unavoidable for reasons
of the work to be done. On the basis of a
risk assessment the operating company of
the machine has to determine additional
actions, e.g. if space is restricted.
13
Vibrator HVR

To set-up the machine and to sling and

detach or align pile elements or drilling
equipment the help of authorized persons
is required, e.g. slingers or spotters. Do not
stay longer in the danger area as absolute-
ly necessary. Breaking of the sling gears,
dropping of the load, swinging of the load,
pinching of body parts are the essential
risks when slinging loads.
Authorized persons can enter the danger
area after communication with the operator
only. Keep eye contact and coordinate the
working method with each other, e.g. by
hand signals. In the danger area, personal
protective equipment must be worn.
Standing under suspended loads is forbid-
den.
If the operator's view on his driving and
working area is restricted he has to be di-
rected. Spotters must be clearly recogniz-
able. They must be visible to the operator.
Due to the construction of the machine, the
view towards the rear and the right side
of the machine is considerably restricted.
Adjust the existing mirrors for an optimum
view to all sides. Clean window panes and
mirrors regularly. Safety devices that are
available as an option, e.g. cameras for
monitoring the rear of the machine, en-
hance the operator's field of vision in the
restricted area.
Keep a safety distance to stationary struc-
tures, e.g. buildings or other machines, of
min. 0.5 m. This prevents persons from
getting jammed. If this safety distance
cannot be kept, block the area between the
stationary structures and the working area.
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14
4.2.3 Operational restrictions 4.2.4Personalprotectionequipment

Warning
Danger of damaging vibrator and jaw as- All persons occupied with the operation of the
sembly by high dynamic forces. Do not use ABI Vibrator HVR or working near it must wear
ABI vibrators for impact pile driving or with complete protection equipment at all times. Check
open jaw assembly. personal protection equipment to perfect conditi-
Move slow. Do not overlap the movements on before using. Do not use defective protection
and do not break abruptly. equipment for your own health and safety.
Danger of damaging the vibrator, Do not
exceed maximum crowd and extraction
force of the vibrator (see technical data).
Risk of injury. Use jaw assembly to clamp
pile elements only. Do not grap into the jaw
assembly.
Danger of severe injuries by falling or tip- Safety helmet
ping pile elements. Secure pile element with
pitching chain during each pile driving and
extracting operation.
Danger of the machine tipping over. Do not
let the pitching chain fall. By means of the
high dynamic forces the pitching chain can Safety shoes or boots
be damaged or be penetrated.
To avoid danger of accidents do not leave
pile elements in the jaw assembly when the
vibrator is out of service.
In addition, the restrictions for the hydrau-
lic excavator must be observed. Work gloves
It is prohibited to stand in the danger area not the operator!
during the pile driving operation.

Ear protection
at a sound power level
> 85 dB(A)

At heavy formation of dust or when using com-

pressed air as flushing agent:

Breathing mask

Safety glasses

15
Vibrator HVR

4.3 Working with the HVR

Before starting to work commission ABI Vibrator

HVR check perfect condition of the machine.

Warning
Risk of falling objects - Observe pile dri-
ving and extraction process and interrupt
immediately in case of danger.
Do not use vibrator and clamping jaw for
lifting operations.
Always use pitching chain to prevent falling
over of the pile elements.
During extraction the maximum pulling
force of the vibrator should not be ex-
ceeded.

4.3.1 Attaching the vibrator

1 Remove grab or shovel from the hydraulic ex-
cavator (see operating manual of the hydraulic
excavator).
2 Completely retract the shovel cylinder and
secure it.
3 Approach the hydraulic excavator to the vibra-
tor HVR (on the rest).
4 Mount the HVR with an universal coupling
suspension device to the shovel stick of the
hydraulic excavator. Put the connecting bolt
through the shovel stick and the adaptor and
lock it with washer and locking pin.
Notice
The vibrator HVR has to be freely turnable.
The pressure line is marked with red on the
hydraulic hoses.
Keep the hydraulic connections extremely
clean to avoid impurities in the hydraulic
system.
Replace gaskets or screwed connections
upon oil loss.
Collect the remaining oil in a receptacle and
dispose as prescribed.

Warning
Danger of falling over - Always secure con-
necting bolt with awasher and locking pin.

5 Connect the hose assembly of the HVR to the

hydraulic system of the hydraulic excavator.
6 Start the hydraulic excavator, open the jaw
assembly and lift the vibrator HVR from the
rest.
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16
Hydraulic connections HVR Z
Vibrator HVR 30Z
Drain oil line
Lead drain oil line without pressure through the
return line filter into the hydraulic tank.

Vibrator drive
Connect the hydraulic pressure and return line of
the vibrator HVR directly or through quick-acting
couplings to the hose assembly of the shovel
cylinder (Grab open-close).

Caution
We recommend a ballvalve with locking for
drain oil. Do not use a quick-acting coupling drain oil
- hydraulic motor may be damaged by raised hydr. return line hydr. pressure line
drain oil when loosen by vibrations. Check
drain oil pressure (max. 2 bar).
Vibrator HVR 45Z / 60Z
The jaw assembly is directly connected to the
hydraulic forward and return line of the hydraulic
motor through an engagement valve. After having
reached the required clamping pressure, the vi-
brator starts automatically. Connect the hydraulic
forward and return line directly or through quick-
acting couplings to the shovel cylinder (GRAB
OPEN-CLOSE).

Caution
Don't exchange hydraulic pressure line/hy-
draulic return line with drain oil - danger of
damaging the vibrator. drain oil
hydr. return line hydr. pressure line

Notice Vibrator HVR 75Z / 85Z / 100Z

The hydraulic pressure line is red coloured.

drain oil
hydr. return line hydr. pressure line

17
Vibrator HVR

Option:
Hydraulic connections HVR G

Drain oil line Vibrator HVR G

Lead drain oil line without pressure through the
return line filter into the hydraulic tank. drain oil
clamping cylinder hydr. return line
Vibrator drive
Connect the hydraulic pressure and return line of hydr. pressure line
the vibrator HVR directly or through quick-acting clamping cylinder
couplings to the hose assembly of the shovel
cylinder (Grab open-close).

Caution
We recommend a ballvalve with locking for
drain oil. Do not use a quick-acting coupling
-at incorrect connecting or loosening coupling
caused by vibration the hydraulic motor may
be damaged by raised drain oil. Before com- flow regulating valve
missioning check drain oil pressure (max. 2
bar).

Clamping cylinder
A free hydraulic function of the hydraulic excavator
is needed to supply the clamping cylinder.

Connect the hydraulic forward and return line of

the jaw assembly directly or through quick-acting
coupling to the hose assembly of the shovel cy-
linder (Grab turn).

Caution
For a perfect operation, a clamping pres-
sure (nominal pressure) of at least 240
bar is required. Otherwise retrofit an ABI
engagement valve.
Don't exchange hydraulic pressure line/
hydraulic return line with drain oil - danger
of damaging the vibrator.

Notice
The pressure line is marked red on the hy-
draulic hoses.
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18
4.3.2 Attaching and securing of
pile elements
Lift pile elements with pitching chain to prevent
falling over.

Warning
Only use pitching chain to lift and secure
pile elements. It is prohibited to extract pile
elements with pitching chain.
Do not exceed working load limit of the
pitching chain (see indicated load at badge)
- see for reduced working load limit with
oblique pull.
Always use pitching chain to prevent falling
over of the pile elements.
Risk of pile elements falling over. Only use
pile elements with approved pitching hole
diameter and distance (see chart) and free
of burs - pile elements with other dimensi-
ons can damage the pitching chain.
Do not move pitching chain over sharp
edges, do not crush, bend or clamp with
clamping jaw - danger of unexpected falling
over of pile elements, if pitching chain is
damaged.
Check pitching chain and suspension
points of the chain before every work, at
least once a workday. Replace immediately
at wear or damage (e.g. distortion, chafe
marks).
Do not modify pitching chain or described
lifting method - do not use parts of sup-
pliers. A safe lifting of pile elements is only
guaranteed with original spare parts.
Inspect pitching chain by competent per-
sons once a year and keep test badge.
Danger of machine parts and pile elements
tipping over - do not let pile element fall into
the pitching chain. By means of the high dy-
namic forces the pitching chain and holder
for chain (fittings) is damaged. In this case
replace pitching chain and holder for chain
(fittings) immediately.
Avoid fitful and impact loading of the pit-
ching chain.

19
Vibrator HVR

Warning
Piching chains substitution:
At elongation above 3% of the chain or sin-
gle link or if the link cannot be freely moved
within a link.
At reduction above 10% of the chain link
width.
After contact with energised parts.
At damaging or abrasion of the t-handle.
Replace immediately at wear or damage
(e.g. indentations, deformations, cracks). max. 3%
At deformation of a chain link or the T-
handle.
Chains that have been used in applications
greater than 200C.

Pitching chain
Chain link width: 10 mm max. - 10%
Chain link length: 30 mm
T-handle length: 95 mm

Pitching chain
Chain link width: 13 mm max. - 10%
Chain link length: 39 mm
T-handle length: 120 mm

Pitching chains - indification badge /

test badges
The pitching chains are marked with an indification
badge and test badge on the opposite side of the
Prfplakette
T-handle. On the indification badge the maximum
23 14
capacity and the serial number are indicated. 1S
22 15
BetrSichV
Warning 21
10
16
Do not exceed working load limit of the
1,6 t Nchste
pitching chain (see indicated load at badge) 20 Prfung 17
- see for reduced working load limit with SN xxxxxx
19 18
oblique pull.
Replace pitching chains when the labeling
/ identification on the indification badge is Indification badge test badge
illegible or missing entirely.
Annually examination of the pitching chain
by an expert. Before first use of the pitching
chain mark the next examination date
(year) on the rectangular test badge.
10.2015

20
Attaching pile elements HVR 30, HVR 45, HVR 60

Caution
Two persons are needed for attaching pile ele-
ments. One equipment operator who operates
the control devices in the driver's cab, and one
slinger or spotter.

HVR 30, HVR 45, HVR 60

Only use chain with T-handle, when there
are circular holes (40 mm) in the pile ele-
ment.
Observe the proportions t-handle length/
hole in pile element (e.g. 95/40 mm) given
by the manufacturer when using the chain
with t-handle.
If prementioned boundary conditions are
not observed e.g. by burned holes, use a
washer (punched with 40 mm) additionally.
When picking up stored pile elements take
care, that the t-handle lays correctly, after
threading the t-handle through the hole
at the pile element. When storing the pile
elements observe that a correct picking up
of pile elements is possible.
Make sure, that the t-handle is still hooked
in by a visual inspection before opening the
clamping jaw.

Insert the pitching chain on the clamping jaw

through the boring in the pile element.
Lock the t-handle at the front of the pile element
and observe tight seating.
Pitching hole diameter d - 40 mm
pitching chain max. working load 1600 kg

Distance a from pile edge - 250 mm

HVR30,HVR45,HVR60

Pitching chain - 1600 kg

Chain link width: 10 mm
Chain link length: 30 mm
T-handle length: 95 mm

Notice
Maximum nominal load of the piching chain
see indicated load at badge.

21
Vibrator HVR

Attaching pile elements HVR 75, HVR 85, HVR 100

Caution
Two persons are needed for attaching pile ele-
ments. One equipment operator who operates
the control devices in the driver's cab, and one
slinger or spotter.

HVR 75, HVR 85, HVR 100

Only use chain with T-handle, when there
are circular holes (40/65 mm) in the pile
element.
Observe the proportions t-handle length/
hole in pile element (e.g. 95/40 mm or 120/65
mm) given by the manufacturer when using
the chain with t-handle.
Make sure, that the t-handle is still hooked
in by a visual inspection before opening the
clamping jaw.

Insert the pitching chain on the clamping jaw

through the boring in the pile element.
Insert the pitching chain with the t-handle
through the boring in the clamping jaw and lock
the t-handle at the chain holder and observe Pitching hole diameter d
tight seating. pitching chain max. working load 1600 kg 40 mm
pitching chain max. working load 3150 kg 65 mm

Distance a from pile edge - 320 mm

HVR 75. HVR 85, HVR 100

Pitching chain - 1600 kg

Chain link width: 10 mm
Chain link length: 30 mm
T-handle length: 95 mm

Pitching chain - 3150 kg

Chain link width: 13 mm
Chain link length: 39 mm
T-handle length: 120 mm

Notice
Maximum nominal load of the piching chain
see indicated load at badge.
10.2015

22
4.3.3 Pile driving

1 Check situation on job site before starting to

work:
Spacious and bearing working area. For
operating a ABI Mobilram-System a bearing
capacity of minimum 250...400 kN/m is re-
quired. Use load distributing boards (excavator
mats) or exchange soil in case of unsufficient
bearing ground.
Safety distance to power lines and cables,
buildings and other machines.
Environment protection (noise, vibration,
water protection area).
Job planning. Attach and lay down pile ele-
ments as near as possible to ABI Mobilram-
System - avoid diagonal lifting operations.
Store pile elements in a way, that they can be
attached and laid down without danger for
the slinger. Clean sheet locks and grease if
necessary.

2 Attach pile element

Dont actuate any functions while slinger is
inserting / pulling out pitching chain.

Warning
Risk of severe or even deadly injuries by
falling pile elements. Only use pile elements
with approved pitching hole diameter and
distance.
Always secure pile elements with the pit-
ching chain.
Risk of crushing - Do not stand in the dan-
ger area when corrective movements of the
leader mast are executed.

3 Raise pile element

Slowly lift the vibrator until the pile element
hangs free in the pitching chain.

Warning
Risk of tipping over - check tight seat of
t-handle.
Risk of tipping over - Avoid diagonal lifting
operations.
Execute the erecting operation very slowly
at the end to keep the pile element from
swinging.

23
Vibrator HVR

4 Clamp and align pile element

Descend vibrator until the pile element touches
the ground. Rest clamping jaw on the pile ele-
ment.
Close jaw assembly. Align pile element.
Warning
To close the clamping jaws move the con-
trol lever slowly and carefully in order to
build up the clamping pressure complete-
ly - danger of pile elements falling over or
damage of the machine.
Risk of crushing - Do not grab into the clam-
ping jaw.
Damage of piles and clamping jaw. Always
grip pile elements with complete surface of
jaw pads.
Stop pile driving immediately if nominal
clamping pressure is not attained.
Do not move piling equipment before pile
elements are gripped with the clamping jaw.
Notice
If the speed decreases because of difficult
soil conditions:
reduce the prestressing until the vibrator
reaches his operating speed,
then slowly start increasing the pre
stressing pressure.
When the pile driving progress is smaller than
10 cm/min release the ground by augering
or flush with water under pressure. By using
pile driving aids the pile driving time as well
as noise emissions and vibrations are consi-
derably reduced.
6 At desired penetration depth
Remove prestressing pressure.
Shut off speed and wait until it stops.
Entirely open clamping jaw.
Detach pitching chain.

5 Drive pile
Press pile element slightly in the ground. Bring
vibrator to operating speed.
Raise the prestressing pressure with the shovel
stick. If necessary align the pile element with
the shovel stick.

Warning
Immediately interrupt the pile driving opera-
tion if the pile element is not tightly clamped
in the jaw assembly.
HVR G: Reactuate the clamping cylinder
during the pile driving operation in regular
intervals.
10.2015

24
4.3.4 Extracting pile elements

1 Attach pile element

Don't actuate any function as long as slinger
secures pile elements with pitching chain

Warning
Always secure pile elements with pitching
chain.
Only use pile elements with approved pit-
ching hole diameter and distance.
Risk of bruise - do not stay in danger zone
during correction movements.

2 Clamp pile element

Set the jaw assembly on the pile element.
Close jaw assembly.

Warning
Risk of crushing - do not reach into the jaw
assembly.
Always grip pile elements with complete
surface of jaw pads. Otherwise piles and
jaw assembly will be damaged.
It is prohibited to extract pile elements with
pitching chain only while the jaw assembly
is open.

3 Extract pile element

Bring vibrator to operating speed.
Release pile element with pile driving.
Extract pile element.

By using pile driving aids the pile extracting time

as well as noise emissions and vibrations are
considerably reduced. When the pile extracting
progress is smaller than 10 cm/min release pile
elements by augering.

Caution
If no pile driving progress can be discerned
immediately stop the pile driving operation
because otherwise the soil may be compacted
and the attachment will be damaged.

25
Vibrator HVR

4 As soon as the pile element is totally ex-

tracted off the soil:
Shut off speed and wait until it stops.
Reduce speed as soon as pile element hangs
free. This avoids unnecessary vibrations and
wear on the hydraulic excavator.

5 Deposit pile element

Warning
Wait until vibrator stops before opening
the clamping jaw - danger of pile elements
falling over or damage of the machine.
Place pile elements on bearing ground and
secure pile elements against falling over
before opening the clamping jaw.
Use only suitable pitching chains.
Danger of damaging the pitching chains
and risk of falling pile element when pile
is lowered improperly. Slew uppercarriage
and main booe in the required position so
you can see the chains from the cab, if
possible. Orientate vibrator respectively
to the pitching chains and the pile element
in one line. Avoid diagonal lowering opera-
tions. Other personnel should also assist
in observing chains during lowering of pile
element, especially if operator can not see
the pitching chains.
Lower vibrator with pile element slowly to
avoid damage to the pitching chains.
Drive crawler chassis slowly backwards to
deposit the pile element. When lowering
pile elements, observe that the pitching
chains are not pinched between pile ele-
ment and mast and are hanging freely.

Place pile element on solid ground.

10.2015

26
4.4 Transport

Warning
Transport attachment only on appropriate
transport frame.
Use only suitable and technically perfect
lifting gear and suspension systems with
adequate lifting capacity.
Never work or stand under suspended load.
While mounting, demounting and loading of TIE DOWN TIE DOWN
attachments - risk of crushing.
Deposit attachments only on bearing and
horizontal ground.
Deposit vibrator on the transport frame - see
to bearing and horizontal ground.
Close jaw assembly. A non-return valve pre-
vents an unintended opening of the jaw as-
sembly.
Remove hydraulic hoses from the hydraulic
excavator.
Remove the connecting bolt between the sho-
vel stick and the adaptor of the vibrator HVR.
Lash vibrator on transport support or on the
low-bed trailer. Secure attachments and ac-
cessories against moving while transporting.

Notice
Close the hydraulic connections with plugs
(dust caps).

27
Vibrator HVR

10.2015

28
5 Maintenance and service
Warning
All service and maintenance work must be
carried out by qualified personnel using
original ABI spare parts.
Let hot machine parts cool down before
beginning with the maintenance work.
For service and maintenance work on the
telescopic leader you will need a lifting plat-
form as well as additional lifting equipment.
When working over 2 m above ground use
safety gear or provide a movable platform.
Keep tools in operationally reliable condi-
tion.
Use hoisting gear of sufficient load capacity
for lifting and loading operations.
Only fix components on the slinging points
provided for that purpose.
Lower and relieve the equipment before
starting to work. The hydraulic system must
be depressurized.
Do not start the machine during the main-
tenance work. Secure the machine against
unexpected starting and put up warning
signs.
Only carry out maintenance work when the
machine was placed on bearing ground and
secured against rolling.
Only authorized personnel with special
knowledge in hydraulics is allowed to work
on the hydraulic installations.
Do not carry out alterations on the machine
that could affect the safety. This applies
especially to the installation and adjust-
ment of safety devices and valves (e.g. limit
switches, pressure relief valves).
Work on the electric installations has to be
carried out by an electrician in accordance
with the electrotechnical rules.
Before working on the electric installation
the power supply to the carrier has to be
switched off.
Do not change the programs of program-
mable controls. Unintended changes to the
controls affect the safety concept of the
machine.
Do not blast electric and electronic compo-
nents with the high-pressure jet.
Before carrying out welding work on the
machine or on parts attached to the ma-
chine in a conducting way, cut the power
supply of the carrier by means of the bat-
terie section switch and protect electronic
components (see operating manual of the
carrier).
Fire risk - No welding work or open flames
near inflammable operating liquids and
hydraulic components.
Do not carry out welding work on support-
ing members.
If it is necessary that an operator or the auxiliary
staff repairs or services the pile driving equipment
in the working area (danger area) and that one
or several functions have to be activated for that
purpose, then this work may only be carried out
under the following conditions:
at least two persons who are both instructed
in safety issues must always be present.
one of them has to survey the safety of the
other person(s) from the main operating stand.
the surveying person must have immediate
access to an emergency stop device in all
situations.
the working area has to be sufficiently illumi-
nated.
visual contact between the operator and the
person carrying out the maintenance work
must be established at all times.
Only if the equipment is completely shut down and
all means serving to set it to operation are cut out,
a single person may carry out maintenance and
service work on the equipment.
29
30
before every 10 every 50 every 250 every 1000 see
starting oh oh oh oh chapter
operation or daily or weekly or 4 weeks or yearly
Vibrator HVR

Entire machine Visual and functional inspection, completeness

Screwed connections: Check condition
Appendix
and tight seating
Check elastomer mounts for cracks
and damages
Change elastomer mounts every 2000 oh 5.4

Check weld seams for cracks and damages

Gear box Check oil level 5.2

Change oil 5.2

Jaw assembly Visual and functional inspection of jaws 5.3

Visual and functional inspection of
pitching chain
5.1 Regular maintenance work - summary

Check screwed connections at jaw pads

Jaw assembly: check for cracks

Grease lubricating nipples

Visual inspection, replace damaged
Hydraulic system hoses and tubes
Check quick-locking couplings for tightness

Safety devices Check function, condition and completeness

Pile driving equipment Expert inspection

oh operating hours regularly

at first use

10.2015
5.2 Oil change and verification
In all cases, use the operating liquids and lu- Check oil level in gear box
bricants specified by ABI. Check miscibility of
lubricants when changing the sort. Check compa- every 10 operating hours or once a day
tibility of sealings when using scavengers. Remo-
ve all scavengers before filling with lubricants. HVR 30 / HVR 45 / HVR 60
Bleed valve - Oil inlet screw
Checking the oil level

Set down the vibrator vertically.

Check oil level in the oil level sight glass - the
oil should be in the middle of the sight glass.

Caution
Check oil level at standstill and in cold
condition.
Damage of vibrator body - Check oil level
daily. Keep normal oil level in all cases. No
lube, if oil level is too low, overheating, if
oil level ist too high.
Turbidity of oil indicates water or conden-
sed water. Change oil immediately and rinse
vibrator body with fresh oil!
Oil sight glass
If the oil level is too low:
Screw out the bleed valve. HVR 85 / HVR 100
Fill in gear oil. Bleed valve - Oil inlet screw
Recommended gear oils see Appendix
Check the oil level in the oil sight glass.
Replace the copper gasket of the bleed valve
Screw in bleed valve and tighten.
Start vibrator for a period of appr. 5 minutes.
Check again oil level in oil sight glass at
standstill. Fill in gear oil of same quality when
needed.

Warning
The gear box can get extremely hot during
operation. Do not touch the gear box wit-
hout appropriate protective clothes.
Check oil level in cold condition otherwise
gear oil is burning hot.
Casing is under pressure.
Oil sight glass

Normal oil level

31
Vibrator HVR

Oil change
Oil change intervals
Warm up gear oil to operating temperature. at normal operation every 40 op. hours
Bring vibrator to standstill. for operating times over 50 % every 12 op. hours
Set down vibrator vertically. upon pile driving with normal
Carefully unscrew the bleed valve, let escape wal beams or grouting lances every 4 op. hours
the pressure.
HVR 30 / HVR 45 / HVR 60
Warning Bleed valve - Oil inlet screw
The gear oil is burning hot.
The gear box can get extremely hot during
the operation. Do not touch the gear box
without appropriate protective clothes.
Casing is under pressure.

Screw out oil drain plug. Collect outflowing oil

and dispose as prescribed.

Caution
Dispose used oil as prescribed. Use drain
can with sufficient volume.
Gear oils must not enter the soil or waters.
Never run vibrator without gear oil, other-
wise gearbox is damaged.
Oil sight glass
Check and clean magnetic oil drain plug for
particles. Oil outlet screw
Replace gasket of oil drain plug. HVR 85 / HVR 100
Screw in oil drain plug again and tighten.
Fill in gear oil with a funnel. Bleed valve - Oil inlet screw

Recommended gear oil see Appendix.

Filling quantity gear box see Technical Data.

Check oil level in the oil sight glass.

Check the gasket of the bleed valve, replace
as required.
Screw in bleed valve and tighten.
Start vibrator for a period of appr. 5 minutes
Check again oil level in oil sight glass at
standstill. Fill in gear oil of same quality when
needed.

Oil outlet screw

Oil sight glass
Normal oil level
10.2015

32
5.3 Jaw assembly type I
The jaw assembly consists of jaw assembly ca- 1
sing 1, clamping cylinder 2 and two round jaws 3
and a pitching chain 4 at the bottom.

Notice
Increasing wear of pile section and jaw pads
at:
improper use
too low clamping pressure
worn out guide bushing

The section may burn out in the area of con- 2

tact with the jaw and the jaw wears out at the
corrugated surface or is even cold-welded
to the casing. In this case the complete jaw 3
assembly must be replaced.
4

Caution
Examinate the pitching chain yearly by an
expert.

Warning old new

Immediately replace the jaw pads if the
corrugated surface is worn out or pieces type II
have broken away. 1
Regularly inspect the jaw block for crack
formation with a colour diffusion test proce-
dure.
Check the pitching chains and the t-hand-
les daily for damage and wear - if damaged,
the chain must be replaced immediately.
Check screwed connections at clamping
device and jaw pads daily.

3
4

old new
33
Vibrator HVR

Changing the jaw pads - type I

7 6
Caution 3 1
Tighten screws with prescribed torque - Tigh-
tening moments for screwed connections see
appendix.
5
Loosen the screws 3 on the clamping cylinder.
By actuating the control lever in the hydraulic 4
excavator, extend the clamping cylinder so far
that the clamping cylinder 2 can be withdrawn
from the jaw assembly 1, place a wedge in the
clamping gap if necessary.
Withdraw the clamping cylinder 2.
2 8
Notice
Check the lubricating grooves in the front
area of the guide bushing 7. Replace the guide
bushing if the grooves are worn out.

Unscrew jaw 6 by turning it counterclockwise.

To do so, place a metal pin in the bore of the 1 Jaw assembly
jaw and loosen it by slightly tapping with a 2 Clamping cylinder
hammer. 3 Screws Clamping cylinder
Replace the O-ring. 4 Screw jaw
Screw on the new jaw. 5 Jaw pad - Jaw assembly
Loosen mounting screw 4. 6 Jaw pad - Clamping cylinder
Remove jaw 5 and place new one. 7 Guide bushing
Tighten screw 4. 8 O-ring
Replace clamping cylinder and lock with
screws 3.
Check faultless functioning in no-load conditi-
on. 7 6 5
3 1

2 8
10.2015

34
Changing the jaw pads - type II 7 6
1 9b
Open jaw assembly completely.
Loosen screw 4 at jaw pad 9a. 3 9a
Remove jaw pad 9a laterally from the jaw as-
sembly, loosen with punch if necessary.
Loosen Allen key bolts 8, use shortened Allen
key if necessary.
Remove jaw pad 9b laterally from the jaw as- 4
sembly,

Notice
Check the lubricating grooves in the front 2
area of the guide bushing 7. Replace the guide 5 8
bushing if the grooves are worn out.

Mount the new jaw pads in reverse order.

Check faultless functioning in no-load conditi-
on.
1 Jaw assembly
2 Clamping cylinder
Caution
Tighten screws with prescribed torque - Tigh- 3 Screws Clamping cylinder
tening moments for screwed connections see 4 Screws Jaw
appendix. 5 Spring sleeve
6 Adapter
7 Guide bushing
8 Allen key bolt - Jaw
9 Jaw pads (2x)

35
Vibrator HVR

Replacing the guide bushing

7 6
1 9b
Caution 9a
Tighten screws with prescribed torque - Tigh- 3
tening moments for screwed connections see
appendix.

Loosen the Allen key bolts 8 at jaw pad 9.

Unscrew the Allen key bolts 3 at the clamping 4
cylinder.
By actuating the control lever in the hydraulic
excavator, extend the clamping cylinder so far
that the clamping cylinder 2 can be withdrawn 2
from the jaw assembly 1, place a wedge in the
5 8
clamping gap if necessary.
Remove the jaw pad 9 laterally from the jaw
assembly.
Using a puller, remove the guide bushing from
the jaw assembly, insert new bushing.
Assemble clamping cylinder and jaw pad in 1 Jaw assembly
reverse order. 2 Clamping cylinder
Check faultless functioning in no-load condi- 3 Screws Clamping cylinder
tion. 4 Screws Jaw
5 Spring sleeve
6 Adapter
7 Guide bushing
8 Allen key bolt - Jaw
9 Jaw pads (2x)

10.2015

36
5.4Elastomer mounts

The gear box is lodged in the vibrator guide with

elastomer mounts. Clean and check elastomer
mounts every 50 operating hours or at least once
a week. Replace elastomer mounts every 2000
operating hours or at least every 2 years.

Elastomer mounts ages by overload, ozone and

temperature effects. Replace immediately when
cuts and splits occurs.

Caution
Do not clean elastomer mounts with acid
liquids.

Elastomer mounts

Elastomer mounts
check elastomer every 50 oh
replace elastomer mounts every 2000 oh

37
Vibrator HVR

10.2015

38
6 Operational failure and trouble shooting

Notice HVR 85
If failures cannot be remedied inform the ABI Drain oil pressure
after-sales service immediately. protection

6.1 Hydraulic control system Measuring point:

Drain oil pressue
max. 2 bar
Warning
Before starting to work on the hydraulic
system switch of the hydraulic excavator
and depressurize the system.
Adjustments of hydraulic components
affect the safety concept of the machine
and must only be performed by trained
specialist staff.
HVR 85 / HVR 100
Drain oil pressure protection Drain oil pressure
Check drain oil pressure (max. 2 bar). protection

HVR 30
Measuring point:
Drain oil pressure Drain oil pressue
protection max. 2 bar

Measuring point:
Drain oil pressue HVR 100
max. 2 bar

Measuring point:
HVR 45/60
Drain oil pressue
Drain oil pressure
max. 2 bar
protection

Measuring point:
Drain oil pressue Drain oil pressure
max. 2 bar protection

39
Vibrator HVR

6.1.1 Flow regulating valve

Vibrator HVR Z: no free function available
The flow regulating valve limits the oil volume flow
to the maximum admissible oil quantity of the hy-
draulic motor. The engagement valve (secondary
valve) is set to 150 bars.

Vibrator HVR G: Grab turn available HVR 45/60

The flow regulating valve limits the oil volume
flow of the hydraulic excavator to the maximum
admissible oil quantity of the hydraulic motor.

Caution Flow regulating valve

A wrong setting of the flow regulating valve
may lead to loss of performance or damage
of the attachment. Please inform the ABI after
sales service.

HVR 85/100

6.1.2 Jaw assembly

Non-return valve
The non-return valve on the back side of the clam-
ping cylinder maintains the clamping pressure in
unactuated state and prevents pressure losses
through the hydraulic system.

Upon loss of pressure clean the non-return val-

ve, replace if necessary. Loosen the valve with a
socket wrench and screw it out counterclockwise.
10.2015

Non-return valve

40
 Malfunction
Attachment does not
start running
loss of power or
Vibrator gets to hot
Clamping pressure is
not attained
Max. speed of attachment is
higher than nominal speed
41
Cause
no operating pressure at
the attachment
drain oil line closed or damaged
hydraulic motor
hydraulic oil enters into
the drive unit
increased friction
no pressure at clamping cylinder
additional valve misadjusted
jaw assembly
hydr. oil volume flow too high
Check
hydraulic system of carrier
suction pressure in drain oil
line max. 2 bar
gear oil level
flow regulating valve and
additional valve
flow regulating valve
Trouble shooting
check hydraulic connection, fittings or quick-
acting couplings at the hydr. shut off device
see Operating manual of carrier
leed drain oil line in hydraulic tank without
pressure
inform ABI after-sales service
check rotary shaft seal of drive motor, check
drain oil pressure
6.2 Table of malfunctions
change gear oil and add additive
check hydraulic connection, fittings or quick-
acting couplings at the hydr. shut off device
clean check valve
inform ABI after-sales service
replace jaw assembly
inform ABI after-sales service
Vibrator HVR

10.2015

42
7 Technical Data
7.1 Data sheet

Vibrator HVR 45
Static moment .......................................... kgm 4,5
Dynamic weight ....................................... kg 740
Amplitude ................................................ mm 12,2
Max. revolutions per minute .................... min-1
2.460
Centrifugal force ...................................... kN 300
Max. extraction force ............................... kN 40
Nominal pressure .................................... MPa 32
Hydraulic flow rate ................................... l/min 130
Required hydraulic input .......................... kW 70
Total weight .............................................. kg 1.100
Transport weight ...................................... kg 1.185
Max. load capacity** ................................ kg 800
Min./max. ambient temperature ............... C -20...+40
Clamping force ........................................ kN 480
Gear oil .................................................... Shell Omala S4 GX 150
or optionally
SAE 75W-90
Gear oil quantity ....................................... l 3,5

Dimension and weight

Length ...................................................... mm 1.595
Width ........................................................ mm 1.050
Depth ....................................................... mm 614
Max. centre width ..................................... mm 352
Locking to bottom clamp assembly*......... mm 1.325
Locking to vibrator body ........................... mm 778

Transport dimensions
Length ...................................................... mm 1.670
Width ........................................................ mm 1.135
Depth ....................................................... mm 660

* With standard clamp assembly.

** Do not exceed max. load per pitching chain.
Design subject to modifications.

43
Vibrator HVR

HVR 45

1050
440,5 402

60-90
352
1325
1240
1595
1670

778
988
1233

497,5
1000 614
1132 660

10.2015

44
7.2 Type plate

The type plate of the vibrator HVR is fixed on the

side of the drive unit.

Notice
The type plate also carries the test badge in
compliance with TBG indicating the next date
of inspection by competent persons.

ABI Maschinenfabrik und

Foundation E quipment
Vertriebsgesellschaft mbH Typ Type
Am Knckel 4
D-63843 Niedernberg Fabr.Nr. Machine
Germany No.
Tel.: +49(0)6028/123-0 Baujahr Year of
Fax: +49(0)6028/123-199 construction
Drehmoment Torque kNm
max. Zugkraft Pulling
force max. kN
Operating
Betriebsdruck pressure MPa

Schmierstoff Lubricant
Schmierstoff- Lubricant
menge fill quantity l/kg

Einsatzgewicht Operating
weight kg

Transportgewicht Transport
weight kg

ABI Maschinenfabrik und

Foundation E quipment
Vertriebsgesellschaft mbH Typ Type
Am Knckel 4
D-63843 Niedernberg Fabr.Nr. Machine
Germany No.
Tel.: +49(0)6028/123-0 Baujahr Year of
Fax: +49(0)6028/123-199 construction
Drehmoment Torque kNm
max. Zugkraft Pulling
force max. kN
Operating
Betriebsdruck pressure MPa

Schmierstoff Lubricant
Schmierstoff- Lubricant
menge fill quantity l/kg

Einsatzgewicht Operating
weight kg

Transportgewicht Transport
weight kg

45
Vibrator HVR

7.3 Hydraulic control system

HVR-Z

10.2015

46
Appendix

1 Tightening moments for screwed connections

2 Lubricants
3 Hydraulic oils
4 Gear oils for ABI Group attachments
5 Gear greases for ABI Group attachments
6 Load securing chart

47
Vibrator HVR

1 Tightening moments for screwed connections

The tightening moments are guilty for following screwed connections: For screwed connections wi-
thout adhesive and screwed connections with Loctite 222 low strength, Loctite 243 middle strength
and Loctite 270 high strength.
for set screws with metric regular thread according to DIN ISO 262.
condition new, try and degreased.

Caution
Before using screws clean thread of screws. Apply on fat and silicone free threads only.
When using adhesive a complete tightness is reached after 24 hours.
Admissible temperature range < 100C.

Tightening moment without locking washer M10 M12 M16 M20 M24 M30
at tensile strength 8.8 Nm 49 85 210 425 730 1450
at tensile strength 10.9 Nm 72 125 310 610 1050 2100
Tightening moment with locking washer DIN 25201 M10 M12 M16 M20 M24 M30
at tensile strength 8.8 Nm 60 102 252 510 876 1740
at tensile strength 10.9 Nm 86 150 372 730 1260 2500

The tightening moments are for fastening of the clamp assembly.

for set screws with metric regular thread according to DIN ISO 262.
condition new, with thread grease - Flor Plus Super Grease 1300.
M30 - 8.8 / M30 - 10.9 for fastening of the clamp assembly.

Tightening moment with locking washer DIN 25201 M30

at tensile strength 8.8 Nm 1740
at tensile strength 10.9 Nm 2500

2 Lubricants
Multi-purpose grease Li based
Short term Consistence class
MPG-A NLGI 2 KP2K-20
Temperature range: whole year in moderate zones

FUCHS Lubritech Lagermeister BF2

SHELL Gadus S2 V220 2

Multi-purpose grease Li based

Short term Consistence class
MPG-A NLGI 00/000
Temperature range: subpolar zones

SHELL Gadus S4 V45AC 00/000

Notice
The use of lubricants with enlarged temperature range, for example KP2N-30, is allowed.
10.2015

Lithium-soap based lubricants (Li) are mixable in any ratio.

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3 Hydraulic oils

Mineral hydraulic oil

Short term Quality class Viscosity class
HYD 10 HLP ISO VG 46
Temperature range: whole year in moderate zones

SHELL Tellus S2 M 46
CHEVRON Rando HD
CATERPILLAR HYDO SAE 10W

Mineral hydraulic oil

Short term Quality class Viscosity class
HYD 0530 HVLP ISO VG 46
Temperature range: whole year in moderate zones

Mineral hydraulic oil

Short term Quality class Viscosity class
HYD 1030 HVLP ISO VG 68
Temperature range: whole year in moderate tropical zones

Biodegradable hydraulic oil Synthetic ester based

Short term Quality class Viscosity class
BIO-E-HYD 0530 HEES ISO VG 46
Temperature range: whole year in moderate zones

CHEVRON Clarity
PANOLIN HLP Synth

Caution
Do not mix hydraulic oils with different specifications or manufacturers, especially ash
free and hydraulic oils with zinc additives. A mixing leads to degradation of quality or to
incompatibility - filled hydraulic oil ex work see information on hydraulic tank.
Do not use or add seed oil or unsaturated synthetic oils.
Do not mix biodegradable and mineral hydraulic oils.
Attend the VDBM adjustment directive 24569 when changing the mineral hydraulic oil to
biodegradable hydraulic oil.
The hydraulic oil can be operated in a temperature range between -20 C up to +40 C. Con-
sult the manufacturer if working outside of the mentioned temperature range - inform ABI
after sales service.

49
Vibrator HVR

4 Gear oils for ABI Group attachments

ABI Vibrator HVR, ABI Auger drive BA
Synthetic based gear oil
Short term Quality class Viscosity class
GO 7590 API GL-5 SAE 75W-90
Temperature range: whole year in moderate zones

ABI Vibrator MRZV, MRZV-VS, MRZV-V, MRZV-VV, MRZV-S, ABI Auger drive BA,
ABI Vibrator HVR, DELMAG Rotary Head BT (single stage planetary gears).
Fully synthetic gear oil PAO based

Temperature range: whole year in moderate zones

SHELL Omala S4 GX 150

EXXON MOBIL Mobilube SHC 629

DELMAG Rotary Head BT-2 (two-stage planetary gears)

Automatic transmission gear oil
Short term
ATF
Temperature range: whole year in moderate zones

SHELL Spirax S4 ATF HDX

5 Gear greases for ABI Group attachments

DELMAG Rotary Head BT (main gear case)
Synthetic gear grease PG based
Quality class
NLGI 00
Temperature range: whole year in moderate zones

SHELL Gadus S5 V142W 00

Caution
A mixing of different gear oils leads to degradation of quality or to incompatibility - use only
recommended by the factory gear oils. The use of gear oils based on Polyalkylglycol (PG)
in ABI Group attachments is not approved.
Gear oils based on Polyalkylglycol (PG) are not mixable with PAO based gear oils.
Consider incompatibility of gear oils based on Polyalkylglycol (PG) with lacquers and seal
materials.
The gear oil can be operated in a temperature range between -20 C up to +40 C. Consult
the manufacturer if working outside of the mentioned temperature range - inform ABI after
sales service.
10.2015

50
6 Load securing chart

Machinery:
Weight of machine Permitted tension force of loading chain Quantity - loading chain
15000 - 35000 kg 10500 kg 4
35000 - 50000 kg 10500 kg 4-6
50000 - 65000 kg 10500 kg 6
65000 - 80000 kg 10500 kg 8
80000 - 100000 kg 10500 kg 8 - 10

Notice
Anti sliding mats are not included on the specifications of the load securing chart.

Attachment - Equipment:
Weight of machine Permitted tension force of loading belt Quantity - loading belt
50 - 500 kg 2500 kg 1
500 - 1500 kg 2500 kg 2
1500 - 2500 kg 2500 kg 2-4
2500 - 4000 kg 2500 kg 4
4000 - 5000 kg 2500 kg 4-6
5000 - 6500 kg 2500 kg 6
6500 - 8000 kg 2500 kg 6-8
8000 - 9500 kg 2500 kg 8
9500 - 11000 kg 2500 kg 10

Notice
Anti sliding mats are not included on the specifications of the load securing chart.

51
Vibrator HVR

10.2015

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