Ceteau Manual

VERTICAL DRAIN INSTALLATION RIG
MODEL CTW-25G2-H140
CeTeau B.V.
It Gruthof 6
8754GZ, Makkum
The Netherlands
________________________________________________________________________
Contents
FOREWORD...................................................................................................................3
SAFETY FIRST...............................................................................................................4
SAFE OPERATIONS.......................................................................................................5
1. BEFORE OPERATION........................................................................................... 5
2. START USING THE RIG........................................................................................ 6
3. AFTER OPERATION..............................................................................................6
4. MAINTENANCE.....................................................................................................6
TECHNICAL DATA........................................................................................................ 8
DESCRIPTION OF MACHINE PARTS........................................................................... 9
ASSEMBLING THE RIG...............................................................................................10
Wire Installation:....................................................................................................11
Sensor Positioning:................................................................................................ 13
Mandrel Welding:...................................................................................................13
Drain Installation:.................................................................................................. 14
OPERATING INSTRUCTIONS.....................................................................................15
TRANSPORT AND HOISTING OF THE RIG............................................................... 16
Safety Aspects when transporting........................................................................ 16
Safety Aspects when Lifting with Chains I Straps................................................16
MAINTENANCE.......................................................................................................... 17
Maintenance of rotating parts...............................................................................17
General instructions for the main structure of the Rig....................................... 17
Rope sheaves maintenance instructions..............................................................18
Steel ropes maintenance instructions.................................................................. 18
Instructions for tightening bolts........................................................................... 18
Instructions for fixing permanent parts and sockets..........................................18
Welding instructions..............................................................................................18
Instructions for replacing/repairing parts.......................................................... 19
Modifying the machine.......................................................................................... 19
APPENDICES...............................................................................................................20
______________________________________________________________________________________________
CETEAU WICK DRAIN INSTALLATION RIG | MANUAL CTW-25G2-H140
2
________________________________________________________________________
FOREWORD
Thank you for choosing a CeTeau Vertical Drain Installation Rig. This Rig is a
product of CeTeau’s quality engineering and manufacturing capabilities. It is
fabricated from premium materials and under rigid quality control systems. If well
maintained it will provide a long, satisfactory service. To obtain the best use of your
Rig, please read this manual carefully. It will help you to become familiar with the
operation of the machine and contains essential maintenance information.
The illustrations, drawings and photographs in this manual are intended to clarify the
texts concerned. They may differ from the actual situation.
Using this instruction manual:
• simplifies getting acquainted with the machine
• avoids failures due to inexpert operation
Observing the instructions:
• increases the reliability of machine operation
• increases the service life of the machine
• reduces cost of repair and down time
______________________________________________________________________________________________
3
________________________________________________________________________
SAFETY FIRST
This symbol, the industry's "Safety Alert Symbol", is used throughout this manual
and on labels on the machine itself to warn of the possibility of personal injury. Read
these instructions carefully. It is essential that you read the instructions and safety
regulations before you attempt to assemble or use this unit.
In case the text in this manual should not be clear to you while reading, you must
make sure to understand it completely (for example by consulting the manufacturer
or an expert) before using, operating, assembling or maintaining the machine.
DANGER : Indicates an imminently hazardous situation which, if not

avoided, may result in death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not

avoided, may result in damage to the equipment.
IMPORTANT : Indicates that equipment or property damage could result if

instructions are not followed.
NOTE : Gives helpful information.
______________________________________________________________________________________________
4
________________________________________________________________________
SAFE OPERATIONS
The best insurance against accidents is to abide by the safety regulations.
Read and understand this section carefully, before operating the excavator.
Every user, however experienced, should carefully read and understand this section
before taking the Rig into operation. The owner is obliged to inform the operators of
these instructions in detail. Keep this manual with the Rig.
The text of this manual was written on the assumption that the operator of this
Prefabricated Vertical Drain Installation Rig has expertise in relation to similar
machines and the activities that can be carried out with them. This is reflected in the
terms and concepts used.
If the terms and/or concepts used are not clear to the operator, the operator must
find out about them by contacting the manufacturer or an authorized representative.
If the machine has defects or failures that could endanger the safety of people and
material, these defects or failures must be dealt with before activities involving this
machine continue.
Beside the regulations in this instruction manual, the national, regional or local
regulations and standards of the country in which the machine is being operated
must be strictly observed.
1. BEFORE OPERATION
 Make yourself acquainted with the Rig and be aware of its limits. Read this
operator's manual carefully before use.
 Obey the danger, warning and caution labels on the machine.
 Do not modify structural members by welding, drilling, bending, grinding or
cutting, as this may weaken the structure of the Rig. If any component is
damaged, replace it. Do not attempt repairs. Make certain all parts are re-
installed correctly. Tighten mounting bolts to proper torque.
 Modifications and overhauls must be carried out by specialists with sufficient
expertise in this field and only after approval by or in consultation with the
manufacturer.
 Do not use the Rig under the influence of alcohol, medication or other
substances. Fatigue is also dangerous.
 Check the surroundings carefully before using the Rig.
 Pay attention to the overhead clearance with electric wires.
 During use do not allow any unauthorized persons within the working range.
 Do not allow other persons to use the machine before having informed them
on the exact operation and work instructions, and be assured that the
operator's manual has been read and understood.
 Do not wear baggy, torn or too large clothing when working with the
excavator. Clothing can get caught in rotating parts or control elements
which can cause accidents or injuries. Wear adequate safety clothing, e.g.
safety helmet, safety shoes, eye protection, ear protection, working gloves,
etc. as necessary and as prescribed by laws or statutes.
______________________________________________________________________________________________
5
________________________________________________________________________
 Check mechanical parts for correct adjustments and wear. Exchange worn
or damaged parts immediately. Check nuts and bolts regularly for tight
fitment (for details see "Maintenance").
 Keep your Rig clean. Heavy soiling, grease, dust and grass can hinder the
early detection of potential problems, that may lead to premature wear and
equipment failure.
2. START USING THE RIG
The Rig is an attachment to a standard excavator of minimum 45-ton. The operator

must observe the rules and regulations set out in the excavator operator’s manual
provided by the manufacturer. In relation to the use of the Rig the operator is to
observe following:
 Start and control the Rig only from the inside the excavator operator's seat.
 Before using the Rig, make sure that all control levers are in their neutral
positions.
 Precautions against tipping over. In order to secure safe operation, set up on
a flat, stable platform, keep away from slopes and embankments. Keep the
Rig as low as possible while driving.
 Watch out at all times where the Rig is being moved to. Keep an eye out for
obstructions and be aware of the location of all personnel around the Rig.
 Keep plenty distance from trenches and bank edges.
·
3. AFTER OPERATION
Before leaving the Rig,
 Bring the Rig to hard even ground.

 Lower the attachments on the ground.
 Lock all control levers.
4. MAINTENANCE
Maintenance / repairs may only be carried out by authorized personnel who are
familiar with all the instructions given here.
 Before doing maintenance work on the Rig, place the Rig on even solid
ground, lower the attachments on the ground and release the cylinder
pressure by actuating the levers.
 Clean lubricating nipples and filling points beforehand.
 When dismantling hydraulic parts, make sure that the hydraulic oil has
cooled down sufficiently to avoid burns.
 Start maintenance work carefully, e.g. loosen screws slowly so that oil will
not squirt out.
 Keep a first-aid box and a fire extinguisher at hand at all times.
 Do not spill hydraulic fluids. Observe all laws and regulations concerning the
disposal of used hydraulic fluids.
 To avoid fire, do not heat the hydraulic components (tanks, pipes, hoses,
cylinders) before they have been drained and washed.
______________________________________________________________________________________________
6
________________________________________________________________________
 Use personal protective equipment whenever necessary (eye protection,

gloves, safety helmet etc.)
 Do not crawl under the Rig if the Rig is only supported by the boom and arm
or the base excavator. The excavator can tip over or lower itself due to
hydraulic pressure loss. Always use safety struts or other appropriate
supports.
 Make no changes to settings or components that can influence the safety of
the machine.
 Replace seals and gaskets after dis-assembly (copper rings).
 Always check the machine for leaks after maintenance / repairs.
 Always check that all tools have been removed after maintenance / repairs.
______________________________________________________________________________________________
7
________________________________________________________________________
TECHNICAL DATA
Description The Vertical Drain Installation Rig is an attachment to a
regular excavator of minimum 45-ton. It is designed to
install 100mm wick drains.
The Rig is not self-powered. It uses the hydraulics from

the base excavator to power the hydraulic winch of the
Rig. The penetration force and installation speed will
depend on the hydraulic pressure and oil flow of the
excavator.
The hydraulic winch drives a steel mandrel into the soil

via a 26mm steel wire rope. The winch has an effective
diameter of 664 mm.
Model name CTW-25G2-H140
Type Hydraulic winch driven installation Rig
Rig weight approximately 10.5 ton
Mandrel size 120 x 60 mm
Performance
Max. installation depth 25 meter
Max. installation speed 1600 m/hour
Max. installation force 15 ton
Options
Data logger The Vertical Drain Installation Rig has an option for a
data logger to be attached. The data logger display is
mounted inside the cabin of the support excavator.
All the control functions of the automation/data logging

system are described in the data logger instruction
manual. The manual is available on request.
______________________________________________________________________________________________
8
________________________________________________________________________
DESCRIPTION OF MACHINE PARTS
1. Module Lower Unit & Sheave Housing
2. Module Main Section
3. Module 4m Extension Section
4. Module Mast Upper
5. Top Sheave Assembly
6. A-frame
7. Hydraulic winch
8. Mandrel
9. Drain roll holder
Figure 1: Vertical Drain Installation Rig
______________________________________________________________________________________________
9
________________________________________________________________________
ASSEMBLING THE RIG

Assembly and dis-assembly of the Vertical Drain Installation Rig may
only be carried out by trained technicians.
The Vertical Drain Installation Rig consists of following main parts:
 Bottom Section & Sheave Block Assembly

 Main Section with the hydraulic winch and tensioning cylinder
 Extension Section
 Top Section
 Top Sheave Assembly
 Drain-roll Holder
 Mandrel Head Assembly and Mandrel
1. To assemble the CTW-25G2-H140 Rig, place all mast sections horizontally in

line on temporary support beams with the lifting eyes uppermost. (Mandrel
guides should be running up the left side of the rig)
2. Slide the lower sheave block assembly inside the bottom section. Ensure the
sheave bearing lube nipple is facing upward. (so this can still be accessed
through the slots in the wall of the bottom section)
3. Bolt all the Rig sections together except for the Top Sheave Assembly. Use
the correct torque values to fasten the nuts.
4. Connect the sliding Sheave Block Assembly to the rod of the tension cylinder
using the pin provided & lock the pin in place with washer & lynch pin.
5. In case some bolts cannot be installed (due to limited access) install these
bolts later when partially raising the rig.
DO NOT FORGET TO INSTALL THE REMAINING BOLTS AFTER

PARTIAL LIFT AND CHECK THE TORQUE VALUE OF ALL NUTS.
6. Connect the base excavator to the Rig by connecting the excavator boom to
the appropriate main bush location (reuse the excavator boom pin) and the
excavator stick cylinder to the A-frame.
7. Partially lift the installation rig approximately 1.5 m and fix all the sections with
the bolts now accessible on the underside.
8. Connect the hydraulic hoses to the base excavator.
9. Connect the sensor cables to the control unit of the base excavator.
10. Check correct operation of the winch.
USE LOW RPM ONLY WHEN CHECKING WINCH OPERATIONS
______________________________________________________________________________________________
10
________________________________________________________________________
Figure 2: Overview of Hydraulic Winch and Wire Rope configuration.
11. Slide the Mandrel Head Assembly (wire rope connection feature) into the top
mandrel guide.
12. Position the mandrel head in its highest position.
Figure 3: Mandrel Head Assembly
13. Assemble the Top Sheave Assembly to the Top Section of the mast.
Figure 4: Mandrel Head in position & Top Sheave Assembly installed.
Wire Installation:
14. Lock the Mandrel Head Assembly in position by chaining it to the Top Sheave
Assembly eye.
______________________________________________________________________________________________
11
________________________________________________________________________
15. Prepare the lower wire rope to the correct length and install a Crosby Wire
Rope Button to one end. (Ensure the resin is fully cured before assembly)
16. Assemble the Crosby Wire Rope Button to the lower side of the mandrel head.
BEFORE INSTALLING THE BOTTOM WIRE ROPE ENSURE THAT THE

TENSIONER CYLINDER IS FULLY RETRACTED
17. Feed the bottom wire rope down through the wire rope guides, through the
bottom Sheave Block Assembly and then back up towards the winch.
ENSURE WIRE ROPE DOES NOT RUN OUTSIDE THE SHEAVE BLOCK
DOUBLE CHECK THE WIRE ROPE LAYS WITHIN THE SHEAVE GROOVE
18. With a 2-ton chain block (manual winch) tension in the wire rope. (Hook up to
the lower eye on winch frame and grip to the wire rope with u-clamps)
19. Feed & coil the wire rope around the lower grooves of the winch drum. There
should be a minimum of 4 static coils wrapped around the drum.
20. Secure the loose end of the steel wire rope to the winch drum and lock in
place with the wire rope clamps (2x).
21. Cut off any excessive wire rope that protrudes more than 100mm from the
2nd clamp.
ENSURE THAT WIRE ROPE IS CONNECTED TO THE CORRECT SIDE OF

THE WINCH DRUM
Figure 5: Lower Wire Rope Installed
22. Remove the 2-ton chain block from the wire rope and remove the chain
securing the Mandrel Head Assembly.
23. Operate the winch hydraulics to slowly pull down the mandrel head. Keep
checking that the wire rope feeds smoothly onto the drum groove & that all
mandrel guide joints line up correctly.
USE LOW RPM AND SPEED ONLY
24. Once the mandrel has reached its lowest position, stop the winch and turn off
the base excavator.
25. Prepare the top wire rope to the correct length and install the Crosby Wire
Rope Button to one end. (Ensure the resin is fully cured before assembly)
26. Assemble the Crosby Wire Rope Button to the top side of the mandrel head.
27. Manually feed the top wire rope up through the top sheave, the wire rope
guides and down towards the winch.
______________________________________________________________________________________________
12
________________________________________________________________________
28. Remove the slack in the top wire rope by pulling tight with a 2-ton chain block.
(Hook up to the winch frame and grip to the wire rope with u-clamps)
29. Feed & coil the wire rope around the remaining grooves of the winch drum.
(There should be a minimum of 4 static coils wrapped around the drum)
30. Secure the loose end of the steel wire rope to the winch drum and lock in
place with the wire rope clamps (2x).
31. Cut off any excessive wire rope that protrudes more than 100mm from the
2nd clamp.
32. Remove the 2-ton chain block that was tensioning the wire rope.
33. Extend the hydraulic tension cylinder to re-tension the wire ropes
Figure 6: Top Wire Rope Installed (Mandrel Head @ Top Position)
Sensor Positioning:
34. Operate the winch to re-position the Mandrel Head to its lowest position.
35. Adjust the position of the lower limit sensor to ensure a strong reliable signal
is detected. Tighten all fasteners to securely maintain the sensor position.
36. Slowly slide the Mandrel Head back 25.5m up the mast.
37. Adjust the position of the upper limit sensor to ensure a strong reliable signal
is detected. Tighten all fasteners to securely maintain the sensor position.
FAILURE TO MAINTAIN A RELIABLE UPPER LIMIT SENSOR SIGNAL

CAN RESULT IN MANDREL OVERSHOOT & SERIOUS RIG DAMAGE.
Mandrel Welding:
38. Return the Mandrel Head to the lowest position to complete mandrel welding.
39. Weld the first mandrel section length to the mandrel head assembly and weld
subsequent mandrel sections to meet the required installation length.
ENSURE ALL MANDREL ENDS ARE BEVELLED PRIOR TO WELDING &

THAT ALL WELDS ARE GROUND FLUSH.
40. After welding each mandrel section, use the winch to retract the previously
installed mandrel into the mandrel guide.
41. Finally weld the mandrel tip wear-part to the end of the mandrel.
______________________________________________________________________________________________
13
________________________________________________________________________
Drain Installation:
42. Starting from the bottom, feed the wick drain through the aluminium drain
guides and around the top roller.
43. Attached the drain securely to the drop weight with staples and insert the
weight inside installation casing (mandrel).
44. Raise the installation rig to a vertical position and feed the drain through until
the weight drops out from the tip of the mandrel.
45. Attach the drain roll holder and load on the drain roll. Ensure that the drain is
not twisted. If twisted then cut the drain & securely re-attach with staples.
KEEP THE DRAIN FREE FROM FOLDS & TWISTING
46. Slide an anchor plate onto the end of the drain, then feed about 30cm of the
free end back into the mandrel tip. Pull on the drain (between roll & guide) to
pull up the anchor plate to seat on the mandrel tip. The installation rig is now
ready to start.
During the initial trials the wire rope will elongate therefore the tension
cylinder has to be extended to maintain uniform tension.
NOTE All sheaves are equipped with grease nipples, which have to be greased
every alternate day.
The winch bearing is equipped with a grease nipple, which have to be

greased every alternate day.
______________________________________________________________________________________________
14
________________________________________________________________________
OPERATING INSTRUCTIONS
This instruction manual will not go into the details of vertical drain installation. These
specific instructions are to be detailed in the method statement.
For safe operating a few important features need close attention. These features will
be pointed out in this section.
Wire ropes:
Always be aware of slack wire ropes, as they can slip off the sheaves or
become entangled.
Hydraulics:
Always check for leaks as they can cause the mandrel to drop.
Mast:
When lifting or lowering the leader mast make sure there are no people
near the mast.
How to operate the excavator and the control of the several functions are described
in the instruction manual of the excavator. Only add-ons and adjustments are
described in this manual.
Add-on functions:
Left joystick forward leader angle forward
Left joystick backward leader angle backward
Right joystick Left Mandrel moving down
Right joystick Right Mandrel moving up
Should any following conditions arise, Stop using the Rig immediately:
 Sudden / abnormal noises.
CAUT To avoid personal injury: No persons, other than those familiar with the
excavator, are allowed to use the Rig.
______________________________________________________________________________________________
15
________________________________________________________________________
TRANSPORT AND HOISTING OF THE RIG

To avoid personal injury or death: The correct instructions for safe
handling are described here. Read these carefully before moving the
Rig. Make sure that the operating personnel read the operator's manual
carefully.
Safety Aspects when transporting
When transporting the Rig the following measures must be taken:

 Transport the Rig only with a suitable truck with sufficient carrying capacity.
 Ensure all Rig sections or Rig accessories are properly secured.
Safety Aspects when Lifting with Chains I Straps
Abide by following steps when lifting:

 Do not lift loads that exceed the maximum load capacity of the crane.
 Choose correct lifting gear suitable to the weight, size and form of the load.
 Use only certified lifting gear that is free from visual damage.
 First assess the center of gravity of the load, position the hook directly over
the load and lift the load so that the center of gravity of the load lies as low as
possible.
 The lifting gear must be fixed in the middle of the hook.
 The load must be lifted vertically from the ground.
 Do not enter the working area under suspended loads and do not move the
load over other persons. The load must be moved in an area where the
equilibrium can be balanced out easily.
______________________________________________________________________________________________
16
________________________________________________________________________
MAINTENANCE
NOTE Due to the operational environment, regular maintenance is of vital
importance to this machine. This chapter provides explanations relating
to different aspects of the maintenance of the machine.
Contact with the manufacturer is obligatory in relation to the following

maintenance activities:
 Adjusting pressures in the hydraulic system.

 Replacing parts.
Maintenance of rotating parts
In some cases, it is necessary to carry out maintenance while parts are moving
(when adjusting settings etc.). This may only be carried out by expert personnel.
There must always be someone present who has an overview of the machine and
who can stop the machine immediately (for example by using the emergency shut
off).
Check regularly the correct working of (end-) switches.
General instructions for the main structure of the Rig
The main structure of the Rig is the steel structure with the main machine
components.
It is necessary to check the main structural elements of the machine regularly for rust,
wear and cracking because of the fact that this machine has to withstand highly
variable loads.
NOTE It is recommended to inspect the Rig thoroughly at least once a week

and to record the results and/or any comments. This must be done
regularly after the machine is operated for the first time.
Rust and wear (for example in the leader mast box beams) can reduce the original
cross-section of the structure to such an extent that over time there can be a
substantial negative effect on the strength of the whole system. If more than 10% of
the original material thickness has disappeared, there must be detailed discussions
with the manufacturer and, if appropriate, consideration must be given to whether
measures have to be taken. In order to prevent rust formation, it is also important to
check regularly that all drain holes remain open. Also check the paint and make sure
no bare steel is exposed to the environment.
Measures must be taken immediately if cracking occurs. The main

structure must be restored to the original condition, possibly in
consultation with the manufacturer, before operations with the machine
are continued.
Other principal parts, pins for instance, must also be checked regularly.
______________________________________________________________________________________________
17
________________________________________________________________________
Rope sheaves maintenance instructions
NOTE The rope sheaves in this machine require checking on a daily basis, or
more in case of intensive use, and adding lubricant when necessary.
Make sure to use the right type of lubricant.
Regular checks need to be made that all sheaves are working properly. This is
particularly necessary in case of frost or after a long shutdown. If a sheave jams, it
will wear more quickly. It is therefore very important for the lifetime of the sheaves
that there are regular checks to see they are operating smoothly.
The sheaves must also be checked for wear regularly. As soon as the sides of the
sheaves are less than 75% of their original thickness and/or there are deep grooves
in the neck of the sheave, the sheaves must be replaced in consultation with the
manufacturer.
Steel ropes maintenance instructions
It is very important that the hoisting ropes are checked regularly in

accordance with the interval in the schedule.
Steel ropes are manufactured in accordance with NEN3231 and NEN2500. Ropes
that depart from these two standards may also be used in this machine. However,
the enclosed sections from the NEN standard can also be used for deviating ropes.
The shortening of ropes is not permitted. When ropes are replaced, they
must be replaced by ropes of at least the same type, breaking strength,
wind characteristics, length, diameter and type of material.
Instructions for tightening bolts
All bolted connections can become a hazard to people and the machine
if they are loose.
All bolted connections must be inspected and checked for tightening torque at set
intervals, with a minimum of once per week.
Instructions for fixing permanent parts and sockets
The ends of the steel ropes are fixed to the wire rope socket and to a permanent
connection part.
The rope must be inserted at least 100 mm through the rope clamp.
Welding instructions
IMPORTANT: In case the rig is attached to the excavator during welding,

disconnect the mass (negative) terminal of batteries first!
Attach the earth clamp at the place where the welding is done
______________________________________________________________________________________________
18
________________________________________________________________________
Instructions for replacing/repairing parts
Use only original parts. If an alternative is used for a part, this must always be
selected in consultation with the manufacturer or designer. Failure to comply with this
will invalidate the guarantee and liability in respect of the machine.
Modifying the machine
Modifications that are made to the machine without permission from the
manufacturer invalidate the guarantee on the machine.
Modifications to the machine without consultation with and approval by

the manufacturer can result in immediate dangerous situations.
______________________________________________________________________________________________
19
________________________________________________________________________
APPENDICES
1. Bolt Torque Values
2. Electrical Schematic for Sensors
3. Hydraulic Schematic
4. Rig Section Mass & Dimensions
5. Spares List
6. Drawings - Mast & Modules
______________________________________________________________________________________________
20
________________________________________________________________________
Appendix 1 – Torque Values in Nm
Strength Class
Diameter 8.8 10.9 12.9
M10 45 65 75
M12 75 110 130
M14 120 175 205
M16 190 270 320
M18 270 370 435
M20 370 530 620
M22 520 720 840
M24 640 910 1060
M27 960 1340 1560
M30 1300 1810 2120
NOTE: All torque values are stated in Newton Meters (Nm) and represent a dry
assembly condition (no extra lubrication). If fastener is heavily greased or
oiled then reduce the above value by 25%.
Do not exceed the above torque values. Over tightening of mast bolts
may result in failure due to the combined pre-load & dynamic loads
exceeding the yield strength of the bolts.
______________________________________________________________________________________________
21
________________________________________________________________________
Appendix 2 – Electrical diagram
______________________________________________________________________________________________
22
________________________________________________________________________
Appendix 3 – Hydraulic diagram
______________________________________________________________________________________________
23
________________________________________________________________________
Appendix 4 – Rig Section Drawings
Module
Mast Upper
Top Sheave
Assembly
Module 4m
Extension
Module Main
Section
Assembly Module
Tension Block Lower Unit
______________________________________________________________________________________________
24
________________________________________________________________________
H140 - Winch
Assembly
Mast Section Mass (kg) LxWxH (m)
Top Sheave Assembly 204 kg 0.95 x 0.89 x 0.56
Module Mast Upper 1,300 kg 11.9 x 0.72 x 0.63
Module 4m Ext 695 kg 4.0 x 0.72 x 0.63
Module Main Section 4,590 kg 11.9 x 1.05 x 0.63
A-Frame Assembly 500 kg 6.45 x 2.0 x 0.46
H140 - Winch Assembly 1,380 kg 1.2 x 0.83 x 0.75
Module Lower Section 874 kg 2.2 x 0.95 x 0.56
Assembly Tension Block 518 kg 1.3 x 0.8 x 0.29
Assembly Mast Complete 10,500 kg 31m
______________________________________________________________________________________________
25
________________________________________________________________________
Appendix 5 – Spares List
______________________________________________________________________________________________
26
________________________________________________________________________
______________________________________________________________________________________________
27
________________________________________________________________________
______________________________________________________________________________________________
28
________________________________________________________________________
______________________________________________________________________________________________
29
________________________________________________________________________
______________________________________________________________________________________________
30
________________________________________________________________________
© CeTeau BV
It Gruthof 6,
8754GZ, Makkum
The Netherlands
W www.ceteau.com
E info@ceteau.com
______________________________________________________________________________________________
31

Ceteau Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ceteau Manual

Uploaded by

Copyright:

Available Formats

VERTICAL DRAIN INSTALLATION RIG

Using this instruction manual:

• simplifies getting acquainted with the machine

• avoids failures due to inexpert operation

Observing the instructions:

• increases the reliability of machine operation

• increases the service life of the machine

• reduces cost of repair and down time

DANGER : Indicates an imminently hazardous situation which, if not

CAUTION : Indicates a potentially hazardous situation which, if not

IMPORTANT : Indicates that equipment or property damage could result if

NOTE : Gives helpful information.

2. START USING THE RIG

The Rig is an attachment to a standard excavator of minimum 45-ton. The operator

Before leaving the Rig,

 Bring the Rig to hard even ground.

 Use personal protective equipment whenever necessary (eye protection,

The Rig is not self-powered. It uses the hydraulics from

The hydraulic winch drives a steel mandrel into the soil

Model name CTW-25G2-H140

Type Hydraulic winch driven installation Rig

Rig weight approximately 10.5 ton

Mandrel size 120 x 60 mm

Max. installation depth 25 meter

Max. installation speed 1600 m/hour

Max. installation force 15 ton

All the control functions of the automation/data logging

DESCRIPTION OF MACHINE PARTS

1. Module Lower Unit & Sheave Housing

2. Module Main Section

3. Module 4m Extension Section

4. Module Mast Upper

5. Top Sheave Assembly

9. Drain roll holder

Figure 1: Vertical Drain Installation Rig

ASSEMBLING THE RIG

The Vertical Drain Installation Rig consists of following main parts:

 Bottom Section & Sheave Block Assembly

1. To assemble the CTW-25G2-H140 Rig, place all mast sections horizontally in

DO NOT FORGET TO INSTALL THE REMAINING BOLTS AFTER

USE LOW RPM ONLY WHEN CHECKING WINCH OPERATIONS

Figure 2: Overview of Hydraulic Winch and Wire Rope configuration.

Figure 3: Mandrel Head Assembly

Figure 4: Mandrel Head in position & Top Sheave Assembly installed.

BEFORE INSTALLING THE BOTTOM WIRE ROPE ENSURE THAT THE

ENSURE THAT WIRE ROPE IS CONNECTED TO THE CORRECT SIDE OF

Figure 5: Lower Wire Rope Installed

USE LOW RPM AND SPEED ONLY

Figure 6: Top Wire Rope Installed (Mandrel Head @ Top Position)

FAILURE TO MAINTAIN A RELIABLE UPPER LIMIT SENSOR SIGNAL

ENSURE ALL MANDREL ENDS ARE BEVELLED PRIOR TO WELDING &

KEEP THE DRAIN FREE FROM FOLDS & TWISTING

The winch bearing is equipped with a grease nipple, which have to be

Left joystick forward leader angle forward

Left joystick backward leader angle backward

Right joystick Left Mandrel moving down

Right joystick Right Mandrel moving up

TRANSPORT AND HOISTING OF THE RIG

Safety Aspects when transporting

When transporting the Rig the following measures must be taken:

Safety Aspects when Lifting with Chains I Straps

Abide by following steps when lifting:

Contact with the manufacturer is obligatory in relation to the following

 Adjusting pressures in the hydraulic system.