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User Manual Hyrax 125-175 Hydraulic Compactors

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DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] User manual Hydraulic Compactor Dehaco Hyrax 125 Dehaco Hyrax 175 Specifications - Safety – Use - Maintenance All people involved in commissioning, operation, maintenance and repair must be given - a copy of - these instructions!! Dehaco Hyrax 125 & 175 Model year 2016 - 1 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] TABLE OF CONTENTS 1. Introduction .......................................................................................................................................................................... 3 2. General description. ............................................................................................................................................................. 4 The ISP System ..................................................................................................................................................................... 5 3. Machine overview. ............................................................................................................................................................... 6 4. Intended use. ........................................................................................................................................................................ 7 5. Technical details. .................................................................................................................................................................. 7 5.1 Sizes and weights: .......................................................................................................................................................... 8 5.2 Wear parts. ..................................................................................................................................................................... 9 5.3 Noise emissions. ............................................................................................................................................................. 9 6. Safety. ................................................................................................................................................................................. 10 6.1 General. ........................................................................................................................................................................ 10 6.2 Specific. ........................................................................................................................................................................ 11 7. Storage. ............................................................................................................................................................................... 13 8. Transport. ........................................................................................................................................................................... 14 8.1 Moving with a excavator .............................................................................................................................................. 15 8.2 Moving with a forklift truck. ......................................................................................................................................... 15 8.3 Moving with a truck or trailer. ..................................................................................................................................... 15 9. Use. ..................................................................................................................................................................................... 16 9.1 Optional Hyrax 175: Mounting the hydraulic rotator.................................................................................................. 16 9.2 Optional Hyrax 175: Mounting the mechanical rotator. ............................................................................................. 17 9.3 Mounting on a excavator. ............................................................................................................................................ 18 9.4 Function test. ................................................................................................................................................................ 19 9.5 Compaction. ................................................................................................................................................................. 20 9.6 Pile driving. ................................................................................................................................................................... 21 9.7 Disconnection ............................................................................................................................................................... 22 10. Maintenance. .................................................................................................................................................................... 23 10.1 Lubricants. .................................................................................................................................................................. 23 10.2 Maintenance schedule. .............................................................................................................................................. 24 10.3 Vibration rubber replacement.................................................................................................................................... 25 10.4 Safety belt replacement ............................................................................................................................................. 26 10.5 Table of tightening torques for bolts.......................................................................................................................... 26 11. Malfunctions. .................................................................................................................................................................... 27 12. Guarantee terms and conditions. ..................................................................................................................................... 28 13. Repair. ............................................................................................................................................................................... 28 14. End of life-span. ................................................................................................................................................................ 29 15. Parts. ................................................................................................................................................................................. 29 16. EG conformity declaration. ............................................................................................................................................... 30 Original user instructions in accordance with appendix 1, art.1.7.4. of the Machinery Directive 2006/42/EC. All rights reserved. No part of this publication can be reproduced, placed in an automated database, photocopied, copied or released into the public domain, in any shape or form or in any other manner, be it electronic or mechanical, without prior written consent from DEHACO B.V. This also applies to any accompanying drawings and diagrams. DEHACO B.V. retains the right to change components at any given time, without notifying clients directly or in advance. The contents of this manual can likewise be modified without prior warning. Please contact your supplier's engineering department for configuration, maintenance or repair-related information not addressed in this user manual. Although this user manual has been compiled with great care, DEHACO B.V. cannot accept responsibility for potential errors in this user manual or the accompanying consequences. A.C. Schermers, March 2016 Dehaco Hyrax 125 & 175 Model year 2016 - 2 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 1. Introduction Thank you for purchasing a DEHACO HYRAX hydraulic compactor. You now possess a machine produced using the very latest technology, which you will be able to use for many years without malfunction, as long as you use it in the correct manner. The purpose of this manual is to familiarize you with the operation, to instruct you on safe working practices, and to provide periodic maintenance guidelines. The user manual has been compiled for all people involved in the machine's commissioning, operation and maintenance. These people must:     Hyrax 125 Possess the knowledge and qualifications needed to perform their tasks. Have read and understood this user manual. Comply with all stipulated safety instructions. If necessary, must possess sufficient, appropriate and good quality tools. This user manual, the type plate and the safety stickers placed on the machine feature important safety-related information and are thus an integral part of the delivery. Store this user manual carefully and also supply it if the machine is sold to someone else. If damaged or lost, they must be re-applied or supplied once again. These items can also be re-supplied by Dehaco. Make sure that you are familiar with the contents of this user manual before you start working with the machine, so you can fully and safely use all of the machine's features!! Dehaco Hyrax 125 & 175 Model year 2016 - 3 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] The delivered Dehaco Hyrax hydraulic compactor has already been assembled and tested, and is ready to use. Delivery includes the machine and this user manual. Upon delivery, immediately check whether the machine is complete and undamaged. Immediately contact your supplier if components are missing or if damage has been caused during transport. 2. General description. Hyrax compactors have been developed as multifunctional hydraulic tools for a variety of purposes. The ISP System (Intelligent Single Power) in the hydraulic circuit is a unique feature: this integrated hydraulic valve has been developed by Dehaco and combines four functions. This makes the Hyrax ideal for multiple applications. The solid design and construction of the compactor, together with the optional mechanical or hydraulic rotator (only Hyrax 175), makes the Hyrax a very versatile tool. Hyrax compactors are used to compact surfaces: sand, clay, silt and organic materials. However, they can also be used to compact stocks of granulates and coal for blast furnaces. The centrifugal force generated by the rotating excenter is transferred to the surface via the highfrequency vibratory base plate. Any air and water is thus effectively pushed out of the material and a compact end product is created. Hyrax 175 A pile sleeve is used to convert centrifugal force into vertical force for driving piles (wood, concrete or metal). The hydraulic rotator (only Hyrax 175!) with internal vent makes it possible to turn the compactor without end stops or limitations due to hydraulic hoses. Dehaco Hyrax 125 & 175 Model year 2016 - 4 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] The ISP System The Hyrax 125 and 175 models feature an integrated DEHACO ISP system, whereby a single hydraulic unit is used to integrate maximum pressure, the power regulator and security features against incorrect connection and peak pressure!! ISP System This allows the Dehaco ISP System to regulate pressure and flow quantity, so the excavator cannot overload the Hyrax. This also helps to prevent damage caused by pressure peaks in the hydraulic system and incorrectly configured excavator hydraulics. ISP (Intelligent Single Power) combines the following in a single unit: 1. 2. 3. 4. Model Flow regulation. Over-pressure regulation. Maximum pressure configuration. Security feature against incorrect connection. The maximum permitted pressure and flow is as follows: Hyrax 125 Hyrax 175 Oil flow min. [l/min] 25 35 Oil pressure max. [bar] 250 250 CAUTION: To make sure that the Hyrax functions effectively, DEHACO recommends using qualified personnel from a DEHACO dealer to configure the excavator's hydraulic system to the above -mentioned specifications. Dehaco Hyrax 125 & 175 Model year 2016 - 5 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 9 3. Machine overview. 8 The Hyrax is connected to the excavator using an adapter plate. Almost all types of adapters can be supplied. 1 2 3 4 5 6 7 Hyrax 175 with hydraulic rotator Dehaco Hyrax 125 & 175 Model year 2016 1. The top plate is part of the compactor's main frame and many components are connected to this plate. This plate also protects the IDP system, motors and excenters. 2. Excenter axles are driven by the hydro-motor. 3. The excenter axle is installed inside the excenter casing. 4. The safety belt protects against personal injury and material damage if vibration rubbers are damaged. 5. The vibration plate transfers power to the material in question. 6. Vibration rubbers connect the excenter casing and the vibration plate to the main frame. The rubbers help to reduce vibration in the excavator. 7. The over-pressure valve in the excenter casing protects against leaks in the hydro-motor's ring seal. 8. The ISP system regulates the volume and pressure of hydraulic oil that flows from the excavator to the hydro-motors. 9. A mechanical as well as a hydraulic rotator can be supplied as an option, but only for the Hyrax 175! The hydraulic rotator can rotate in both directions without restrictions, and without risk of damage to hoses or other components. - 6 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 4. Intended use. The Dehaco Hyrax 125 and Hyrax 175 have been developed for:   compacting soil and raw materials. blasting/driving poles, etc. into the ground using a pile sleeve. as described in this manual. CAUTION Use other than that mentioned above will relieve DEHACO of all its responsibilities!!! When considering specific applications, please contact your DEHACO dealer or DEHACO in advance to discuss whether the Hyrax is actually suitable. All repairs must be carried our by DEHACO or an official DEHACO dealer. Hyrax 125 Dehaco Hyrax 125 & 175 Model year 2016 - 7 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 5. Technical details. 5.1 Sizes and weights: General Dead weight Crane weight Bottom plate (width x length) Height Ideal oil flow Required oil flow Ideal operating pressure Maximum return oil pressure: Frequency Force Volume regulation Hole pattern type Hyrax 125 125 1,2 – 2,5 480 x 340 375 30 25-80 180 15 3000 11 ISP System 4540 Hyrax 175 175 2-7 520 x 455 475 40 35-100 180 15 3000 23 ISP System 4037 Option 1 Mechanical rotator Dead weight incl. MR Total height incl. MR Hole pattern kg mm type ---- 204 499 4038 Option 2 Hydraulic rotator Dead weight incl. HR Total height incl. HR kg mm --- 243 658 Dehaco Hyrax 125 & 175 kg tons mm mm l/min l/min bar bar rpm kN Model year 2016 - 8 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 5.2 Wear parts. Wear parts are components found inside the machine, which do not fall under the guarantee due to increased contact with the product. The wear parts in this machine include: - the Vibration plate. - the Vibration rubbers. 5.3 Noise emissions. When this user manual was being written, noise levels in the immediate surroundings of the water nebuliser during operation had not yet been measured. However, experience with prototypes and past series has been used to determine that noise emissions when the machine is operational amount to > 70 dB(A) at a distance of 1 m. WARNING!! Use hearing protection if you work in the immediate surroundings of the machine. The estimated noise level causes Dehaco to strongly recommend wearing hearing protection, although there are currently no measurements to support this stance. Hyrax 175 side view Dehaco Hyrax 125 & 175 Model year 2016 - 9 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 6. Safety. 6.1 General. WARNING! Almost all accidents can be attributed to: loss of concentration, carelessness, negligence or errors in judgment! Work calmly and in a concentrated manner: You have been warned!! Please read the user manual carefully before starting the machine! Make sure that the workplace is always well illuminated; possibly install extra temporary (construction) lighting to retain a clear overview. CAUTION! You must, under all circumstances, also comply with safety instructions found in the factory user manual of the hydraulic excavator!! All people who are involved with installation, commissioning, operation, maintenance and repairs must:     have the level of knowledge and qualifications required for their task. have read and understood this user manual. comply with all indicated safety instructions. If necessary, must possess sufficient, appropriate and good quality tools. WARNING!! There is immediate risk of physical injury and/or damage to machines and the environment if the machine is used by inexperienced and/or unqualified persons. Keep observers at a safe distance when work is being carried out!! Dehaco Hyrax 125 & 175 Model year 2016 - 10 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] WARNING!! Use personal protection equipment required nationally, locally and/or at the construction site, which should at least include: safety helmet hearing protection safety goggles gloves safety footwear. CAUTION: Regular lubrication and structural preventive maintenance reduces the risk of malfunctions during operation. 6.2 Specific. CAUTION: Always remove the key from the excavator's ignition when (inspection) activities are being carried out on the compactor!! CAUTION! The compactor must be attached to an appropriately sized excavator in order to avoid dangerous situations!! If the excavator is too small, this could have consequences for the stability of the combination. The compactor could be quickly damaged if the excavator is too big. Look at the specifications or request information from Dehaco or your supplier if you have any doubts!! WARNING! Oil could be released under high pressure during hydraulic leaks. When manually searching for leaks, oi l could penetrate the skin and cause serious damage!! If leaks are encountered, stop all activities and first perform repairs!! Dehaco Hyrax 125 & 175 Model year 2016 - 11 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] Hydraulic oil can cause the compactor to heat up during prolonged use. Always take this into account!! WARNING!! Always use approved hoisting equipment, which is suitable for the weight of the compactor! CAUTION!! Before mounting the compactor on to the boom, make sure that ± a) you have used the right compactor for the excavator in question; b) there is enough hydraulic capacity (pump and pipe diameter) to use the compactor; and c) a 50 micron oil filter has been fitted in the hydraulic circuit. CAUTION: When mounting for the first time, it is strongly advised to have the compactor connected by an experienced hydraulic engineer!! WARNING!! Consider the risk of crushing when attaching the compactor and inserting pins. Once mounted, immediately insert all locking pins so this is not forgotten at a later time!! CAUTION: The vibration function is not determined by the wiring direction in the excenter. However, the connection is important for extra options (hydraulic clamp and rotator). Possibly use color coding on pipes/couplings in case of regular connection and disconnection. Dehaco Hyrax 125 & 175 Model year 2016 - 12 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] CAUTION: The force for compaction or p ile-driving must be generated via the vibration of the hammer while applying light downward pressure with the boom!! The life-span of vibration rubbers will be reduced if the compactor is pressed too heavily for a prolonged period of time!! WARNING!! Before starting activities, always check whether the excavator is stable so it can never topple over! WARNING!! NEVER move the excavator by partly transferring the excavator's weight on to the compactor. This will definitely damage the construction and th e vibration rubbers!! NEVER lift loads using the compactor. This is classed as improper use and will definitely damage the construction and vibration rubbers!! 7. Storage.  The following actions are recommended if the machine has not been used for an extended period of time: TAKE NOTE!! Always be careful with bearings when using a sprayer/blower to clean the machine!     Dehaco Hyrax 125 & 175 Model year 2016 Carefully rinse the machine. Perform maintenance. Possibly apply a preservative. Store the machine in a dry and frost-free location. - 13 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 8. Transport. WARNING! The Hyrax compactor is a heavy machine which can cause major injury and/or damage if it is not transported or moved correctly. Therefore, always be extremely careful and alert during transport. Make sure that no one is located near or under the Hyrax when the compactor is being lifted. During transport, the Hyrax compactor is normally loaded and unloaded by excavator using the adapter plate. The adapter plate almost always features a hoisting eye, so the compactor can also be easily lifted using another piece of lifting equipment. An adapter plate will not be mounted in certain circumstances; in this case, always use approved and appropriatelysized hoisting eyes and make sure that everything is tightly fastened. The basic Hyrax and the rotator version feature fixing holes in the connector plate for this very purpose. You should follow the instructions of the adapter manufacturer if your version features an adapter plate! TAKE NOTE!! When transporting on a trailer or truck, always secure the machine by attaching lashing straps to the lifting eyes !! Dehaco Hyrax 125 & 175 Model year 2016 - 14 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 8.1 Moving with a excavator      Fasten the hoisting eyes to the plate. Always mount diagonally if two hoisting points are used!! Attach the hoisting straps or chains. Make sure they are not twisted. Carefully lift the Hyrax. Keep the Hyrax as close to the ground as possible, and move it carefully and smoothly so swinging is avoided. Place the Hyrax in the desired position. Remove the hoisting straps and hoisting eyes. Warning!! Always use approved hoisting equipment, which is suitable for the weight of the compactor! Hyrax 250 mechanical rotator top view 8.2 Moving with a forklift truck. Never place the Hyrax with the bottom plate directly on the forks. The compactor could slide off the forks and cause serious damage. Place the Hyrax on a good quality wooden pallet, which is large and strong enough. 8.3 Moving with a truck or trailer. It is recommended - and sometimes even mandatory to place the Hyrax on an anti-slip mat. Always use lashing straps (which are strong enough!) to carefully fasten the Hyrax. Make sure that they cannot shift in any direction during transport. Place the lashing strips over the top or across the center. But make sure that they do not damage any hydraulic hoses or motors. Dehaco Hyrax 125 & 175 Model year 2016 - 15 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 9. Use. 9.1 Optional Hyrax 175: Mounting the hydraulic rotator. Hyrax 175 with hydraulic rotator The Hyrax 175 can be fitted with a hydraulic rotator. This is mounted as follows:         Dehaco Hyrax 125 & 175 Model year 2016 Remove the rotor from the packaging and check for damage. If the rotator is damaged, First contact DEHACO or your supplier/dealer. Check whether the delivery is complete and features all hoses and fixing bolts. Remove the Hyrax's adapter plate and check whether the top plate of the compactor is clean, smooth and flat. Place the rotator on the Hyrax, with its hose couplings in the same direction as the hose couplings on the Hyrax's IDP system. Position the holes of the rotator in line with the holes in the head plate, and mount the fixing bolts. Mount the bolts with a flat washer and a curved sealing ring (DIN 128), and tighten to the prescribed torque. Refer to the table (10.5) in this manual! Mount hydraulic nipples in the rotator so the excavator's hydraulic connections will be compatible. Connect the hoses. Make sure that they are not in contact with anything and can move freely when the excavator moves. Carefully check this during operation! Place the adapter plate or head plate on the rotator; correctly position it and firmly fasten it in place. Use sealing rings!! Tighten the bolts to the prescribed toque; see the table in this manual. - 16 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 9.2 Optional Hyrax 175: Mounting the mechanical rotator. The Hyrax 175 can be fitted with a mechanical rotator. This is mounted as follows:      Hyrax 175 with mechanical rotator  Dehaco Hyrax 125 & 175 Model year 2016 Remove the rotor from the packaging and check for damage. If the rotator is damaged, First contact DEHACO or your supplier/dealer. Check whether the delivery is complete and features all fixing bolts and locking pins. Remove the Hyrax's adapter plate and check whether the top plate of the compactor is clean, smooth and flat. Place the rotator on the Hyrax in the indicated position. Position the holes of the rotator in line with the holes in the head plate, and mount the fixing bolts. Mount the bolts with a flat washer and a curved sealing ring (DIN 128), and tighten to the prescribed torque. Refer to the table (10.5) in this manual! Place the adapter plate or head plate on the rotator; correctly position it and firmly fasten it in place. Use sealing rings!! Tighten the bolts to the prescribed toque; see the table (10.5) in this manual. - 17 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 9.3 Mounting on a excavator. The Hyrax compactor must be correctly and effectively attached to a excavator in order to prevent personal injury and/or material damage. The excavator manufacturer's connecting procedure must be followed when connecting the Hyrax to a excavator. CAUTION Before mounting the compactor on the boom, check that: - you have the right Hyrax for the excavator in question; – there is enough hydraulic capacity (pump and pipe diameter) to use this compactor, - a 50 micron oil filter has been fitted in the hydraulic circuit. Hyrax connected Before connecting, always check that:      The Hyrax compactor is stable. The compactor could topple over and cause injuries if the excavator moves unexpectedly during connection. The adapter on the Hyrax is compatible with the adapter on the excavator's boom. Hydraulic hoses are not damaged. Hydraulic couplings are clean. The size and model of hydraulic couplings is compatible with the excavator. Connections: P = supply, T = return WARNING!! Risk of crushing when manually mounting the compactor and inserting pins. CAUTION: Always close the return hose as the first step, and disconnect it as the last step. This will prevent the Hyrax being damaged due to potential peaks in pressure. NEVER use the Hyrax if the return hose is not connected!! This will severely damage the hydro-motors and diverter valve inside the compactor. Dehaco Hyrax 125 & 175 Model year 2016 Once mounted, immediately insert all locking pins so this is not forgotten at a later time!! Always visually inspect whether (quick) couplings are nice and tight before starting activities. All pressure must be removed from hydraulic hoses before they are connected. This will simplify connection, prevent fiddling around with oil and stop the compactor being damaged due to peaks in pressure. - 18 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 9.4 Function test. Start the excavator and check:   TAKE NOTE!! If you see leakage from the over -pressure valve in the excenter casing: STOP THE HYRAX!  If there is a leak in the hydro -motor, pressure from the hydraulic system will enter the excenter casing. The machine will be seriously damaged if activities are continued!! FIRST HAVE REPAIRS CARRIED OUT!!   the connections for leakage. the boom does not touch any part of the compactor when moving to the most extreme cylinder positions. that hydraulic hoses are long enough and do not tear when the fork cylinder moves to the furthest setting. Any other additional functions. The machinist will be responsible for making sure the machine is used correctly so personal injury or damage to equipment is prevented! CAUTION: The Hyrax, hoses and other – optional components must have been correctly mounted, tightened and fastened. Before starting activities, but also regularly during activitie s (!), check whether everything is still nice and tight so accidents and damage can be prevented. CAUTION: Wear appropriate hearing protection! This applies to the machinist as well as persons in the immediate surroundings of the activities. Comply with local safety requirements!! A safety helmet, safety goggles and gloves are often mandatory. Dehaco Hyrax 125 & 175 Model year 2016 - 19 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 9.5 Compaction. In principle, compaction activities are carried out in the same way for all materials. The extent to which the material can be compacted will be determined by the following factors:    Water and air content in the product. The Hyrax will push water and air out of the product: moist material is easier to compact than dry product. Shape, size and density of the product. Material of different shapes and sizes is easier to compress than product with uniform dimensions. Layer thickness. The vibration plate has a bigger impact on thinner layers. WARNING!! Before starting activities, always check whether the excavator is stable so it can never topple over! Performing compaction activities: 1. Bring the vibration plate to a few centimeters above the product. 2. Place the vibration plate flat on the surface. 3. Start the Hyrax. 4. Lightly press the vibration plate on to the material. 5. Slowly slide the Hyrax over the product; in lines back and forth. 6. Lift the Hyrax and switch off the motor once the accessible section has been treated. 7. Move the excavator to the next location and repeat the process above from point 1. CAUTION: Force used for compacting purposes must be generated via the high frequency vibration of the Hyrax, In case of a new location or product, it is advised to first perform a test to determine the optimum compaction depth and speed of movement. It may be necessary to repeat compaction several times to achieve the desired results! AND NOT BY APPLYING DOWNWARD PRESSURE WITH THE BOOM!! Dehaco Hyrax 125 & 175 Model year 2016 - 20 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 9.6 Pile driving. When driving piles, the following external factors have an impact on work speed and the overall result:    The soil type. The length and diameter of the pile. The material of the pile (metal, wood or concrete). CAUTION: When driving metal piles/pipes, you MUST place a pile sleeve on the Hyrax to prevent slipping. WARNING!! The Hyrax is not a hoisting tool and should not be used for this purpose. This will cause damage to vibration rubbers. Only use approved hoisting equipment so work can be carried out safely for all involved persons. Performing activities: CAUTION: The pile must be driven via high frequency vibration and not via downward pressure applied by the excavator. If a lot of pressure is placed on the Hyrax, rubbers will be damaged/tear and need to be replaced prematurely! Dehaco Hyrax 125 & 175 Model year 2016 1. Place and keep the pile in place so it does not fall over. Use approved hoisting equipment to position the pile, and not the Hyrax clamp! The approved hoisting eye on the connector plate, or the hoisting hook in the boom, is ideal for this! 2. Carefully place the Hyrax - with pile sleeve – flat on the top of the pile and apply light pressure on the Hyrax. 3. Carefully start the Hyrax. 4. Continue to use the Hyrax to apply LIGHT pressure on the pile, and drive the pile into the earth. 5. Lift the Hyrax and switch it off once the pile reaches the required depth. 6. Move the excavator to the next pile and repeat the process from point 1. - 21 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 9.7 Disconnection CAUTION: For the safety of people who help to disconnect the Hyrax or who work close to the activities!! CAUTION: Hoses and oil can still be hot if you disconnect immediately after activities are completed!! Either wait a while or take precautionary measures!! Always wear gloves to avoid direct cont act with the oil!!    Make sure that the ground where the compactor is disconnected is firm, flat and clean. If the - optional - clamp has been mounted, the Hyrax must be placed so the largest surface is in contact with the ground. Make sure that the motors do not touch the ground or any other obstacles. Now depressurize the hydraulic system. First disconnect the supply hose and then the return hose. Take precautionary measures to collect potential oil leaks. Now disconnect the compactor and adapter based on instructions provided by the excavator manufacturer. If the adapter has been coupled manually, be very careful and certainly do not operate the excavator if someone else is releasing the locking pin!! Dehaco Hyrax 125 & 175 Model year 2016 - 22 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 10. Maintenance. CAUTION: Regular lubrication and structural preventive maintenance reduces the risk of malfunctions during operation. Regular inspection and maintenance is necessary to keep the Hyrax compactor in good condition. Clean the Hyrax on a regular basis! This is more practical and allows potential defects to be found a lot sooner. Due to the high frequency vibration, components are placed under severe pressure and there is genuine risk of loose bolts and torn pipes!! All inspection and maintenance activities must be carried out once the Hyrax has been disconnected. The Hyrax must only be connected when checking for proper connection to the excavator. Never perform inspections or maintenance when the Hyrax is operational!! Various components will be warm or hot after the Hyrax has been used - this is normal. After use, and prior to inspection, allow the Hyrax to cool down to avoid injury due to hot components. 10.1 Lubricants. Dehaco recommends the following lubricants: Dehaco Hyrax 125 & 175 Model year 2016 Crank chamber oil: Q8 EL-Greco 150. Greasing: Q8 Rembrandt EP2 grease. - 23 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] Yearly Weekly Daily 10.2 Maintenance schedule. ● Maintenance Continuous check for potential hydraulic leaks. FIRST REPAIR any leaks! ● Check the vibration rubbers for damage/tears. REPLACE if damaged! ● Check and lubricate the options (rotator, electricity cables, etc.) ● Check the fastening bolts on the adapter plate ● Check the safety belt for damage/wear. REPLACE if damaged! ● Check hydraulic hoses for wear. REPLACE if damaged! ● Check the connection between the Hyrax and the crane. ● Check hydraulic connections. REPLACE damaged couplings ● Check the excenter casing for oil leaks. ● Check all bolt connections (also see tightening torques table) ● Lubricate the mechanical rotor (option) with EP2 grease. ● Thoroughly clean the machine ● Replace the oil in the excenter casing. 2 plugs at the side of the excenter casing: The bottom one is the tapping plug; the top one (the over-pressure valve) is the fill opening and fill level. ● Carefully check/inspect the Hyrax. Replace damaged components. Also check welds for tears! Dehaco Hyrax 125 & 175 Model year 2016 - 24 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 10.3 Vibration rubber replacement Disconnect the Hyrax from the excavator. 3, 13 2, 14 7,9 5 1. Thoroughly clean the Hyrax (particularly the hose couplings and the bolts of vibration rubbers). 2. Disconnect the hoses between the ISP system and the motors. Carefully plug the connections to prevent pollution. 3. Remove the locking bolts and locking pins on the safety belt in order to loosen the belt. 4. Attach a hoisting strap to the top plate and lift until the rubbers are free of pressure. (fixing points opposite each other!) 5. Remove bolts from vibration rubbers on the top plate. 6. Lift the top plate and place it in a safe place. 7. Loosen and remove the other bolts on the defect vibration rubber. 8. Use new nuts and bolts when mounting! 9. First mount the vibration rubber on the excenter casing. 10. Tighten these bolts to the prescribed torque; see the table. 11. Place the top plate at the right height above the vibration rubbers. 12. Attach the vibration rubbers to the top plate and tighten the bolts to the prescribed torque (table 10.5). 13. Use the locking pin and locking bolt to reassemble the safety belt. CAUTION - Insert the pin through both loops ! - Make sure that the belt is not twisted! 14. Re-attach the hydraulic hoses. 15. Thoroughly test the compactor before using it again. Dehaco Hyrax 125 & 175 Model year 2016 - 25 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 10.4 Safety belt replacement The safety belt is a safety feature that has been incorporated into the design of the Hyrax to protect the immediate surroundings if one of the vibration rubbers fails. 1 2 3 This safety belt is certified for 1 year and must be replaced thereafter. The belt must be replaced immediately if it is found to be damaged when inspected during this period. Proceed as follows: 1. Remove locking bolts. 2. Remove the locking pin from the top plate. 3. Now remove the belt from the excenter casing. 4. Place the new belt around the excenter casing. CAUTION: make sure the belt is not twisted! 5. Insert the locking pins once again through BOTH ENDS OF THE BELT!! 6. Place the ring and a NEW split pin in the locking pin. CAUTION: Check the safety belt for damage on a DAILY basis. In case of DOUBT: REPLACE the belt! 10.5 Table of tightening torques for bolts. Model Part Draw no Torque Nm / kgf-m / lbf-ft 250/400 Bolt for vibration rubber 8 85 / 8.5 / 63 250/400 Bolt for the motor 22 25 / 2.5 / 18 250/400 Bolt for the ISP system 9 85 / 8.5 / 63 250/400 Bolt for the hydr. Rotator 435 / 44 / 321 250 Bolt Excenter flange 19 10 / 1 / 7.5 250 Bolt excenter flange, motor side 23 10 / 1 / 7.5 400 Bolt Excenter flange 19 50 / 5 / 37 400 Bolt excenter flange, motor side 23 50 / 5 / 37 Dehaco Hyrax 125 & 175 Model year 2016 - 26 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 11. Malfunctions. Follow the instructions in the table below. Phone your supplier or DEHACO if this does not result an appropriate solution. Problem Possible cause Solution Compactor does not start Hydr. hoses mixed up Connect properly Hydr. pressure too low Check the crane Oil yield too low Check the excavator Oil filter blocked Check filter and pipes Hydr. pressure too low Check excavator Pressure in return pipe too high Check and modify. Extra valve in return pipe Remove or create direct return Vibration frequency too low Force too low See also: vibration frequency too low Hydr. oil leak Coupling not tight enough Tighten Hoses torn Replace Hydro engine leaking Seal or replace Loose lids Tighten bolts Defect seal Replace O-ring Crank chamber oil leak Oil temperature too high Oil is continuously pushed through Reduce flow to the Hyrax the ISP over-pressure valve Excavator problem Dehaco Hyrax 125 & 175 Model year 2016 Refer to excavator handbook - 27 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 12. Guarantee terms and conditions. The machine is subject to a guarantee period of 1 year after delivery, in accordance with BMWT* conditions. These conditions stipulate that, within this period, only equipment and manufacturing errors will be repaired free of charge, AFTER BEING EVALUATED BY DEHACO. Transport and or travel costs must be paid by the customer. GUARANTEE CANNOT be provided for defects caused if:        the machine has demonstrably been overburdened. the machine has been used for purposes for which it was not constructed. the maintenance has been performed demonstrably badly. the information from this manual has not been properly complied with. the machine has been used by unauthorized persons. the machine has been repaired using parts which are not original. the machine has been modified without written consent from DEHACO. GARANTEE CANNOT be provided for wear parts, as mentioned in chapter 5. * BMWT is the sector organization for importers and/or manufacturers of construction machines, warehouse fixtures and fittings, road building machines and transport equipment. 13. Repair. DEHACO explicitly recommends that repairs are only carried out by qualified and experienced personnel. Comprehensive repair instructions have not been included in this user manual, but you can always contact DEHACO if you have any questions. Dehaco Hyrax 125 & 175 Model year 2016 - 28 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 14. End of life-span. You must always comply with the current and local requirements in force and the guidelines of safe work and responsible disposal! If the machine has reached the end of its technical lifespan after long-term use, then follow the procedure below so it can be processed in a responsible manner:     Clean the machine. Disassemble electrical components. They can be disposed of separately. Disassemble plastic components; they can be disposed of separately. The remaining components are made of steel and can be scrapped. 15. Parts. The parts list has been supplied as a separate document. This machine has been developed and constructed using tailor-made parts as well as standard components. These standard components can be supplied very quickly, often within 24 hours. Please contact DEHACO to place orders and to check delivery times!! Dehaco Hyrax 125 & 175 Model year 2016 - 29 of 30 - File:Hyrax 125-175 v1.2 (EN) DEHACO B.V. Kruisbaak 25, 2165 AJ Lisserbroek (NL) Postbus 189, 2160 AD Lisse (NL) Tel.:+31(0)252 417 95 www.dehaco.nl [email protected] 16. EG conformity declaration. IN ACCORDANCE WITH APPENDIX IIA OF THE MACHINERY DIRECTIVE 2006/42/EC We, DEHACO B.V., Kruisbaak 25, NL-2165 AJ LISSERBROEK. declare entirely under our own responsibility that the product: Fire: DEHACO, Machine: Hyrax Compactor, Type: Hyrax 125, Hyrax 175. to which this declaration applies, meet all stipulations in the following directives: Machine directive 2006/42/EG, Noise Directive 2000/14/EG. and in conformity with the following standards and/or other normative documents: NEN-EN-ISO 12100:2010 Risk reduction, NEN-EN-ISO 4413:2010 Safety hydraulic systems, NEN-EN-ISO 11161:2007 Integrated systems, NEN-EN-500-1: 2006 Road construction machinery, common requirements NEN-EN 500-4: 2011 road construction machinery, compaction machines. Drawn up in: Town: Lisserbroek, Date: 16-03-2016, DEHACO B.V. F. Berbée, director Dehaco Hyrax 125 & 175 Model year 2016 - 30 of 30 - File:Hyrax 125-175 v1.2 (EN)