To use the machine in a proper manner under the best conditions, read this manual

carefully.
Be sure to check the machine before work, and also to make periodic inspection of the
machine.

Machine Number

Model Name

number of this machine

number of the control unit

date of delivery Year : Month : Date :

※ Be sure to use the same model with vibro hammer and control unit.

※ Specification is subject to change without notice.

※ No remodeling is allowed. If remodeling is needed, consult with us. We do not take
any responsibility about accident or failure of the machine caused by remodeling without
consultation and/or improper handling of the machine without following this manual.

1
The Vibro Hammer means a machine to drive-in or extract piles by using vibration
(hereinafter called “VIBRO”)

The said piles are steel sheet pile and H-steel pile. For steel pipe pile or concrete pile,
exclusive use chuck is required.

An operator of VIBRO is required to be qualified as follows.

● Operator of piler : Person of completion of training course of vehicle system construction

machine, or person who passed an examination of Construction machine enforcement
technology (6th category) stipulated in Construction industry method enforcement order.
● Responsible person of VIBRO : Person of completion of training course of devices of
vehicle system construction machine (for foundation works)
● Responsible person of power generator : Person qualified as professional engineer of
generation facilities for private use of 1st, 2nd and 3rd category.
● Operator of slinging work : Person of completion of training course of slinging work.

2
INDEX

I Name of Parts ----------------------------------------------------------------------------------- 4

II Applications and Special Features ------------------------------------------------------- 6

1. Applications -------------------------------------------------------------------------------- 6
2. Features ------------------------------------------------------------------------------------ 6

III Cautions ------------------------------------------------------------------------------------------ 7

IV Selection of Model ----------------------------------------------------------------------------- 12

V In case of emergency ------------------------------------------------------------------------- 13

VI Inspections ------------------------------------------------------------------------------------------ 14
1. Crane ---------------------------------------------------------------------------------------- 14
2. Power Capacity and Cab-tyre Cable ------------------------------------------------ 14
3. Vibro Motor -------------------------------------------------------------------------------- 18
4. Vibrator ------------------------------------------------------------------------------------- 19
5. Chuck and Hydraulic Hose ------------------------------------------------------------ 20
6. Control Unit -------------------------------------------------------------------------------- 22

VII Operation ----------------------------------------------------------------------------------------- 28

1. Operational procedures -------------------------------------------------------------- - 28
2. Operational Procedure of Remote Controller ---------------------------------- - 33
3. In case a rotation direction of hydraulic motor is reverse ------------------- - 34

VIII Maintenance ------------------------------------------------------------------------------------- 35

1. Change of motor grease -------------------------------------------------------------- 35
2. Greasing points and type of grease applied ------------------------------------- 36
3. List for check points and timing (frequency) of inspection --------------------- 37
4. Voluntary inspection --------------------------------------------------------------------- 38

IX Major troubles and Measures ------------------------------------------------------------------ 43

X Specifications ------------------------------------------------------------------------------------ 46
1. Dimensions of the Main Unit ----------------------------------------------------------- 46
2. Control Unit (Electric Control Panel, Hydraulic Unit) ---------------------------- 46
3. Specifications ------------------------------------------------------------------------------ 48
4. Circuit Diagram and Parts --------------------------------------------------------------- 55
5. Hydraulic Unit ------------------------------------------------------------------------------ 60

3
I Name of Parts

4
5
II Applications and Features

1. Applications
1) FM / CM series of the vibro hammer are used to drive-in and extract steel sheet piles and H
steel piles.
2) By using special chuck this machine can also be used to drive-in and extract steel pipe piles
and concrete piles.
3) By applying water jet system together this machine can drive-in piles to hard ground.
4) By combination of multiple machines prefabricated cell can also be placed.
5) By using special attachment, under beam works can also be done.

2. Features
1) Since opening allowance is set as 50mm, pile can be grabbed easily.
2) Electric Control Unit and Hydraulic Unit are incorporate with a Control Unit. This realizes
compact size of the machine and high operability.
3) Simple mechanism having no tension pulley realizes easy maintenance.
4) Applying damper system to prevent snapping of a cab-tyre cable realizes easy maintenance.
5) Applying removable block system to the chuck tooth (fixed side) realizes easy change of chuck
fixed tooth intensively consumed.

6
III Cautions
Read through this manual carefully to use VIBRO safely and be sure to follow instructions given in
this manual. If not, it may cause serious accidents such as drop off of bolts, nuts, in the worst case
it may cause drop off of VIBRO or piles.
If abnormal phenomenon are observed, stop operation immediately. To check electrical system,
be sure the power is off.

Cautions before use [Before use, refer “VI Inspection (p.14 – p27)” and be sure to
follow instructions for the inspection. The following points should
be carefully attentioned.

1) Be sure to use a crane hook that has a wire comes-off

prevention device.
2) Crane Hook and Hanger should be connected by aux. wire rope
for the hook.

3) Be sure to use a slinging wire rope to drive-in or extract piles.

7
4) Be sure to set ground the control unit (electric control panel) to
prevent from an electric shock caused by leakage of electricity.
Confirm an earth wire of the vibro motor is connected to the
electric control unit.

5) Check generator capacity, voltage applied, frequency applied are

correct to the model of the VIBRO used. ( P.19, P22)
If use electric power supplied by power company instead of
power generator (fig-1), distribution board used is the one
supplied by power company.
6) Be sure to use rubber covered cab-tyre cable of more than 2nd
grade. Be sure not to use a cable covered by vinyl.
7) Check diameter and length of the primary side cab-tyre cableare
correct. ( P.16)
8) Check an insulation resistance of vibro motor and electric control
unit are the value designated (more than 2MΩ).( P.19, P.22)
9) Check primary and secondary cab-tyre cables should have no
cut which exposes inner wires. Also check an insulation
resistance should be designated value (more than 2MΩ).
10) Check bolts, nuts and pins have no looseness and also there is
no crack on a shackle.
11) Check there is no abrasion on chuck tooth.

8
 12) Before grab a pile, remove mud or rust on the top of the pile
where the chuck grabs. If the part, top of the pile, is distorted
heavily, cut this part away.
13) Place the control unit on a flat and safe place apart from a crane
where any kind of incidences can be avoided such as drop of pin
from above.
14) Cab-tyre cables, hydraulic hoses must be arranged so that they
are not disturbed.

Cautions for operation Refer “VII Operatonal Procedures ( P28 – P.34)” carefully
and follows instructions.

15) Operation of VIBRO and power generator must be done by

the person in charge who is qualified. ( P.2)
16) Do not stand beneath VIBRO while it is under operation
except works to put piles together. Every work must be
done in a safe place where dangerous incidences can be
avoided such as drop off bolts and/or pins.
17) Before operate VIBRO, make it sure that the chuck is
closed by observing a pressure gauge of the hydraulic unit.
( P.27, P.31)
18) Never do drive-in pile operation under the situation that the
chuck does not grab a pile (chuck is opened). It causes
damage of the machine.
19) When grab a pile by the chuck, be sure there is no gap between
the chuck and a top of the pile (grab pile completely).

20) If the crane is needed to move or turn with grabbing a pile, do

not take aux. wire rope off.

9
 21) For extraction work, grab a pile, loosen crane’s main wire rope a
little and then extract the pile.
22) To extract a pile, never pull the pile laterally.
23) When extract a pile, do not give excessive extractive power
bigger than VIBRO’s maximum tensional load (pressurize the
spring fully). VIBRO’s max. tensional load is as follows.

FM2- FM2- FM2- FM2- FM2- CM1- CM1-

model
30 40 55 60 80 120 160

maximum
11 15 17 18 22 26 40
tensional load (ton)

24) Never extract a pile only by winding power of the crane without
driving the VIBRO.
25) If a thermal relay trips so often while drive-in or extract a pile it
may cause burnout of the motor, review proper model selection.
( P.12, P.24)
26) If voltage during an operation of the model FM-80 or lower
model comes less than 180V (in the case of the model CM-120
or higher model, less than 360V) it may cause burnout of the
motor.
27) Be careful cab-tyre cable and hydraulic hose do not disturb
machines under operation.
28) Do not operate VIBRO in windy or rainy days to prevent from
fall-down of a machine or having electrical shock.

10
29) Do not take a crane hook off while the chuck grabs a pile.

30) When stop VIBRO , loosen a crane wire rope a little first.
31) When open a chuck , make it sure that VIBRO is stopped
completely.
32) While taking a break or suspending works, switch off the main
circuit breaker of the control unit and switch off the main circuit
breaker of the power generator’s distribution board at the same
time.
33) When work is finished, lay down VIBRO on a flat place before
remove VIBRO from the crane hook, and then take a hook off.

34) After work, cover VIBRO to prevent from wet.

35) Be sure to follow instructions for daily inspection and periodical
inspection. ( P.37 – P.42)

11
IV Selection of Model

In the case using VIBRO mounted on a movable crane to drive-in / extract piles, select appropriate
VIBRO with considering the following factors.

1) Necessary factors to be considered for drive-in piles

Condition of soil
Length of drive-in
Kind of pile applied
Working conditions

2) Necessary factors to be considered for extracting piles

Condition of soil
Elapsed time after drive-in piles
Depth of drive-in
Kind of pile applied
Working method for drive-in pile
Working conditions
Environmental conditions

Heavy load is applied to the crane by weights of VIBRO and a pile further more vibration force while
extracting works. Select the most appropriate crane with considering the following factors.

Necessary factors to be considered to select model of the crane.

Working radius of the crane
It must be maximum value for necessary works.
Lifting height required
It must be bigger than the total value of,
(pile length) + (height of VIBRO) + (allowance 2m)
Rated overall load of the crane (the crane must have the following capacity)
Ct = crane’s lifting capacity
Wf = weight of a hook (ton)
Wv = weight of VIBRO (ton)
Wp = weight of a pile (ton)
Po = Vibration force of VIBRO
α = working factor (drive-in 1/6, extract 1/4)

12
V In case of emergency

Control Unit break down while operation

Be cautious that a pile will be dropped off from the chuck which is depressurized.

Hydraulic hose is cut or a control unit is pushed down by mistake, or

power failure (including an earth leakage circuit breaker is activated)
Be cautious that a pile might be dropped off from the chuck. Be sure to use aux. wire rope to
prevent from such drop off.

Abnormal noise is heard from VIBRO or a crane

Breaking of a cab-tyre

1) Stop VIBRO immediately

2) Set chuck open/close switch neutral

3) Arrange VIBRO and piles not to fall down or drop off

4) Switch off a main circuit breaker and power

5) Arrange necessary safety measure and then investigate cause of troubles

13
VI Inspections

1. Crane

1) Make it sure that a crane hook has a wire comes-off prevention device.
2) Connect a crane hook and a hanger by aux. wire rope for a hook.
3) Use a slinging wire rope while drive-in / extract piles.
4) Make it sure that safety devices are furnished such as excess winding protection device.
5) Confirm safety of working area.
6) Confirm crane’s capacity is properly matching to VIBRO’s ability
※ If VIBRO is bigger than a crane, an lifting capacity becomes lower, and this may cause fall-down
of the crane. If VIBRO is smaller than a crane, vibration is transmitted to the crane heavily, and
this may cause cracks on welded part of a boom, or drop off of pins etc.

2. Power Capacity and Cab-tyre Cable

Use an electric power and cab-tyre cable that are properly matching to the motor output and its
rated current level. Lack of the power capacity may cause failure of start-up VIBRO and burnout of
a motor caused by over load.

2-1 Output of vibro motor and rated current level

motor output rated current level (A)

model Voltage (V)
(Kw) 50Hz 60Hz
FM2-30 22 200 100 92
FM2-40 30 200 121 104
FM2-55 40 200 165 140
FM2-60 45 200 175 149
FM2-80 60 200 244 214
CM2-120 90 400 178 155
CM2-160 120 400 228 220

14
2-2 Power capacity

For smooth drive-in / extract piles, use power capacity more than the value indicated below.

capacity
model voltage (V)
(KVA)

FM2-30 80 200
FM2-40 100 200
FM2-55 125 200
FM2-60 150 200
FM2-80 200 200
CM2-120 300 400
CM2-160 350 400

Note 1) In case of using power supplied by power company, if 3 transformers are provided, it can
be calculated as capacity of one unit times 3, but if 2, it must be calculated as capacity of
one unit times 1.73. For example, if 3 units of 50KVA transformers are provided total
capacity is 150KVA, but if 2, total capacity should be 86KVA instead of 100KVA.

NOTE 2) In case of using diesel power generator, be cautious that output power may be
decreased than nominal value due to aging of the engine. If the power is decreased,
when VIBRO is loaded VIBRO may stop just after it is started because of lack of power
level. Thus drive-in / extract piles cannot be done. In this case power generator must
be changed.

2-3 Cab-tyre cable

<primary side, secondary side>

1) Use rubber coating 4 core or 3 core cab-tyre cable of more than 2nd category coating standard.
Do not use vinyl coating cab-tyre cable.

2) Insulation resistance of the cab-tyre cable should be more than 2MΩ.

3) Make conduction test of the cab-tyre cable to check there is no disconnection.

15
4) Check if there is serious scar on a coating rubber.
Be careful not to use a cab-tyre cable where it is possibly submerged under water.

5) Carve the same seal on crimped terminals on both sides of a cab-tyre cable.
Be sure to use crimped terminal otherwise a cable may create heat that may cause burnout of
the cable, or short circuit by exposed lead wires.

6) If a length of the cab-tyre cable is excessively long or a thickness is excessive small, this may
make current level larger that may cause of burnout of the motor.

<primary side>

1) In the case to use 2 primary cab-tyre cables in parallel, length and thickness of these cables
must be the same.

2) Refer the following list for a proper primary side cab-tyre cable applied according to its length.

less than 75m less than 150m

model
(mm 2) (mm 2)

FM2-30 50 80
FM2-40 50 80
FM2-55 60 100
FM2-60 80 150
FM2-80 100 200
CM2-120 80 150
CM2-160 150 200

16
<secondary side>

1) Each 2 secondary side cab-tyre cables are needed both from motor terminal box to hanger and
from hanger to control unit.
2) Refer the following list for required capacity and its length of the cab-tyre cable from motor
terminals to hanger. Connect the cab-tyre cable from motor terminals, then make inner
connections of the hanger. Handle carefully not to make a slack on the cab-tyre cable with
adjusting length by a cab-tyre fix platee. To connect wires, fasten bolts, flat washers, nuts
firmly. If they are loosened a contact failure is happened and a cable may generate heat which
burns cable. After completion of connections, to prevent contacts among phases make
sufficient insulations with winding linotape 5 – 6 rounds, then rubber tape 5 – 6 rounds,
furthermore vinyl tape 15 – 20 rounds.

model A B L mm 2
FM2-30 22
FM2-40 120 860 1100 22
FM2-55 130 930 1190 30
FM2-60 150 1000 1300 38
FM2-80 150 900 1200 50
CM2-120 150 950 1250 38
CM2-160 75 1300 1650 50

3) Refer the following list for required capacity and length of the cab-tyre from the hanger to te
control unit.
less than 75m less than 150m
model
(mm 2) (mm 2)
FM2-30 50 80
FM2-40 50 80
FM2-55 60 100
FM2-60 80 150
FM2-80 100 200
CM2-120 80 150
CM2-160 150 200

17
3. Vibro Motor

1. There are 6 lead wires connected to crimped terminals in the motor terminal box.
Each terminal letters of U・V・W and X・Y・Z are carved. They are connected to hanger part
cab-tyre cable, matching to terminals of 3 cores U・V・W and 4 cores X・Y・Z・E respectively.
They are all insulation processed.
2. A terminal E out of 4 cores of the hanger part cab-tyre cable is connected to the terminal box bt
a bolt.
3. If damages or peeling are found on a cab-tyre cablem repair them before use it, otherwise they
may cause of short circuit or leakage of electricity.
4. Confirm whether crimped terminals are securely crimped. If they are loosened, it may cause
of generation of heat and burnout because of poor contact between crimped terminals and
contacts.
5. Check part of connections of lead wire and cab-tyre cable where wire is about to cut. Repair
them if this kind of troubles are found.
6. Measure contacts of relative phases between a motor and secondary cab-tyre by a tester.
Letters V・W and X・Y・Z・E are carved on the 7 terminals. If it is normal with the following
combinations, all connections are conducted correctly.
U–X 0 V－Y 0 W－Z 0
U–E ∞ V－E ∞ W－E ∞
X－E ∞ Y－E ∞ Z－E ∞
If there is no conduct, remove secondary side cab-tyre cable and hanger part cab-tyre cable,
check conducts of same symbol’s terminal on both end of the cable, and repair them.
7. Insulation resistance of the motor needs more than 2MΩ. Follow the procedures mentioned
below to check the insulation resistance of the motor is more than 2MΩ.
① Measure insulation resistance between each terminal of secondary side cab-tyre cable and
a motor with referring fig-15. If the resistance is more than 2MΩ, insulation resistance of
the motor is no problem.
② If the result of ① is less than 2MΩ, measure insulation resistance between hanger part
cab-tyre cable and a motor with referring fig-16. If it is more than 2MΩ, insulation
resistance of the motor is no problem. In this case, change or repair the secondary side
cab-tyre cable.
③ If result of ② is less than 2MΩ, measure insulation resistance between lead wire and a
motor with referring fig-17. If the result is more than 2MΩ, insulation resistance of the
motor is mo problem. In this case, change or repair hanger part cab-tyre cable.
④ If result of ③ is less than 2MΩ, insulation resistance of the motor is the problem. Check
inside the motor, after take some measures such as drying, check the resistance again. If
it becomes more than 2MΩ, it can be used.

18
4. Vibrator

1) Place VIBRO vertically and check whether designated quantity of lubricant is filled through
refueling plug. Never fill lubricant more than designated quantity. Otherwise the motor will
become overload by viscous resistance of oil, and this may cause burnout of the motor. Also
excess lubricant is supplied to a bearing and this may cause burnout of the bearing due to
stirring heat generated.

Quantity of the lubricant and its timing to change is as follows. Never fill lubricant more than the
designated quantity.

2) Apply VG150 for refill or change of the lubricant. ( P.36)

Excessive use of the lubricant makes machine’s life shorter due to burnout of the bearing or
acceleration of abrasion of gears.

19
3) Use same brand lubricant for refill.
If different brand of oil is mixed, lubrication ability may likely be spoiled because of sludge
collected due to a difference of additive agent.

4) Be careful not to put foreign substance in when fill the lubricant. Such foreign substances
cause breakage of gears, bearings.

5) Check V belt once a month without fail.

Push a center of one of a belt. Appropriate depth
of a push is less than a thickness of a neighboring belt

6) Check if there is no oil leakage from a bearing cover of the vibrator or side cover.
7) Change bolt(s) for cover of which head is lost.

5. Chuck and Hydraulic Hose

5-1 Chuck

1) Check all bolts fasten the chuck are securely screwed.

2) Check chuck tooth is not worn out.

Change the chuck tooth if it is worn out more than the fig-20.

3) Clean the clamper removing soils or pebbles stuck around. ( fig-21)

4) Check fix plates for every pin are securely fitted, and there is no broken bolt. If the fix plate is
not fitted correctly pins are likely fallen off.
Pay higher attention to check if the hydraulic hose is mounted firmly, also there are no loosen
bolts. If a cover is missing a hose may likely hit something and cut itself. ( fig-21).

20
5) Grease up cylinder hinge pin, rod pin, lower pin respectively and desorption block.

5-2 Hydraulic Hose

1) The hose is connected by an adapter. If the hose is twisted it may likely cut. Therefore,
before operation stretch straight it out with taking the torsion.

2) Check no dust on a coupler.

3) When a hose is detached, screw in an exclusive use plug. If the plug is missing, cover sockets
by something like a vinyl tape not to enter dusts.

21
6. Control Unit

6-1 Electric Control Panel

1) The electric control panel requires insulation resistance more than 2MΩ. Measure corelative
insulation resistance of the main circuit breaker (earth leakage breaker) by a tester. Do not
measure by 500V mega. It may burn inner semiconductor circuit.

2) Take a ground from the electric control panel without fail.

3) Confirm a volt meter and an ammeter indicate < 0 >.

4) Clean every switch removing soil and dust stuck around.

5) Confirm the main circuit breaker (earth leakage breaker) and aux. circuit breaker are all
<OFF>.

6) Capacity of main circuit breaker and aux. circuit breaker is as follows.

main circuit aux. circuit

model
breaker (AT) breaker (AT)
FM2-30 100
FM2-40 150
FM2-55 225
FM2-60 225 15
FM2-80 250
CM2-120 225
CM2-160 400

22
6-2 Hydraulic Unit

1) Open doors of the control unit, check oil level gauge of an oil tank located left and confirm
designated quantity of hydraulic oil is filled.

2) Use VG32 hydraulic oil. Quantity of oil and timing to change are as follows.

model FM2-30 FM2-40 FM2-55 FM2-60 FM2-80 CM2-120 CM2-160

quantity (ltr) 60 80 90 110
timing of change 6 months (300 hours)

3) If quantity of hydraulic oil is less than designated quantity, pump makes noise with sucking air
and it makes pump’s life shortened. Use the same brand currently used for refill.
If different brand of oil is mixed, lubrication ability may likely be spoiled because of sludge
collected due to a difference of additive agent. Pump’s failure makes dangerous situation of
falling off a pile because grab power is getting weak.

4) Check oil inlet is securely covered by a cap. If the cap is missing soil or dust may enter a tank
and this may cause malfunction of pump, solenoid valve etc.

5) Confirm oil pressure gauge points < 0 >. ( P.31)

6) A coupler is used to connect hydraulic unit and a hose. Be careful not to harm connection
face, and/or not to stick dusts, foreign substances.

7) Check oil leakage from the hydraulic unit. If leakage is found, repair it.

23
6-3 About Thermal Relay

A picture below shows an appearance of the thermal relay. Two kinds of thermal relays are
provided in the operation panel, one is for the vibro motor and another is for the hydraulic unit.

1) The thermal relay prevents from burnout of a motor because of over current.

2) There is a current adjust dial outside blue reset button of the thermal relay. The dial is set as
follows accordng to model.
setting of thermal relay settinf of thermal relay
model
for motor (A) for hyd. Motor (A)
FM2-30 3.6 6.6
FM2-40 3.6 6.6
FM2-55 3.6 9.0
FM2-60 3.6 9.0
FM2-80 3.8 9.0
CM2-120 3.8 5.0
CM2-160 2.8 6.6

24
3) A thermal relay used for the electric control panel is manual reset type. If excess current more
than thermal relay setting value flows on the hydraulic unit motor in a certain time, the motor is
overheated, the thermal relay is activated and the motor is stopped.

4) Main reason of an activation of the thermal relay is over current flown. Measures are needed
such as to make an eccentric moment of VIBRO smaller, to make a vibratory weight of VIBRO
bigger, to change VIBRO to bigger model erc. Reason of an activation of the thermal relay for
the hydraulic unit motor, excess flow of oil due to higher oil pressure than designated pressure.
Eliminate the cause first, then reset it.

5) To reset the thermal relay, push blue reset button located beside the thermal relay.

6) If the thermal relay trips often, inspect causes. In case of overload by a resistance from the
ground, use aux. construction method, or change VIBRO to one rank higher model. Change a
capacity of a power generator at the same time.

6-4 About Timer

Three timers are provided as shown below. Their functions are,

TL timer sets start time when the vibro motor enters into Delta Drive from start mode.
T1 timer sets period of time until reverse phase braking is activated after stop button is pushed.
T2 timer sets period of time of reverse phase braking.

When stop button is pushed, a brake is activated automatically and machine stops immediately.
If T2 timer’s setting is shorter, a brake does not work enough.
If it is too long, the vibro motor may likely reverse. A little adjustment is needed sometimes
according to conditions of the ground. Be sure a power is off when make such adjustment.
To make braking time longer, turn the dial right, and left for shorter. Set to cut off the brake circuit
just before the vibro motor reverses.
Setting time of each timer is as follows.

setting time
timer
(sec)
TL 5
T1 2
T2 2

25
6-5 About Solenoid Valve

1) Solenoid valve changes direction of oil pressure to “close” and to “open” chuck hydraulic
cylinder. When electric current is sent to SOL.A a spool is pulled right and the chuck is closed,
when current is sent to SOL.B a spool is pulled left and the chuck is opened

2) Push <close> of the operation panel, electric current is sent to SOL.A to close chuck, push
<open>, current sent to SOL.B to open chuck.

3) When the switch is neutral, electric current is not sent to both right/left solenoids, a spool is
positioned in the central by spring force. Hydraulic oil supplied from the hydraulic pump does
not go to the cylinder, and the oil is bypassed to flow back to the tank. Thus movement of the
chuck is stopped.

4) While drive-in / extract operation of piles, set the chuck open/close switch < close >.

5) 3 lead wires, red, white, black come out from solenoid valve. Solenoid coil can be used for
both 50Hz and 60Hz.

6) Allowable voltage fluctuationrate of the solenoid coil is -15%～+10% of its rated voltage.

6-6 About Relief Valve

1) The relief valve adjusts push pressure of the chuck cylinder.

2) Setting pressure level is done by an adjust screw with removing a lock nut.

3) To rise pressure turn the screw right, turning left is for drop down. Adjust pressure level to the
designated value with observing pressure level gauge of the hydraulic unit. Be sure to fasten
the lock nut firmly after completion of pressure setting. ( fig-24)

26
Designated pressure of the chuck

model FM2-30 FM2-40 FM2-55 FM2-60 FM2-80 CM2-120 CM2-160

designated value
60 80 110 110
of relief valve (kg/cm2)

6-7 About Pressure Switch

1) Oil pressure applied to the chuck becomes designated value shown below, oil pressure safe
lamp is lit.

2) Setting pressure level is done by an adjust screw with removing a lock nut.

3) To drop down pressure turn the screw right, turning left is for rise up. Adjust pressure level to
the designated value with observing pressure level gauge of the hydraulic unit. Be sure to
fasten the lock nut firmly after completion of pressure setting.

setting
model of pressure valve
(kg/cm 2)
FM2-30 100
FM2-40 150
FM2-55 225
FM2-60 225
FM2-80 250
CM2-120 225
CM2-160 400

27
VII Operation
1. Operational Procedure
1) Set power generator’s main circuit breaker <OFF>.
preparation
2) Set control unit’s main circuit breaker <OFF>.

3) Set aux. circuit breaker ,OFF>.

4) Set hydraulic motor drive switch <STOP>

5) Set chuck open/close switch <NEUTRAL>.

6) Connect primary side cab-tyre cable to the power source and

terminals (side face of control unit) R・S・T・E respectively. Be
sure to fasten them firmly.

28
 7) Connect secondary cab-tyre cable to termnals (side face of
control unit) U・Y・V・W・X・Y・Z respectively. Be sure to fasten
them firmly.

8) To prevent from electric shock, check again vibro motor and

control unit are taken grounding

9) Connect couplers of 2 hydraulic hoses to the control unit,

<OPEN> and <CLOSE> respectively.

confirm motor 10) To confirm motor rotatory direction, set <ON> the main circuit
rotatory direction breaker of operation panel of power generator side. Power
lamp is lit. ( P22)

11) Drive the power generator. Adjust voltage level as shown

below with observing volt meter on the operation panel of
power generator side.

model freq. (Hz) voltage (V)

50 200 ～ 220
FM2-3 ～ FM2-80
60 220 ～ 240
50 400 ～ 420
CM2-120 ～ CM2-160
60 420 ～440

(note) Voltage fluctuation rate of the power applied must be

within -5%～+10%, and frequency fluctuation rate must be

29
 within ±5%.

12) Set main circuit breaker of the control unit <ON>.

Confirm volt meter reading ( P.22)

13) Set aux. circuit breaker <ON>.

14) Set the hydraulic motor switch <START>. The hydraulic

motor starts to rotate.

15) Look at the motor from a fan side and confirm motor rotatory
direction is the direction indicated by an arrow. If the direction
is the same as an arrow, the motor is normal. Now an
operation of VIBRO is possible.
If the direction is opposite, some wire connections are
incorrect. Correct them with following instructions
mentioned later. ( P.34)

30
operation 16) Set the chuck open/close switch <OFF>, then grab a pile Make
it sure that there is no gap between the chuck and top of the
pile. ( P.9)

17) Confirm the chuck is completely closed with observing

pressure gauge of the hydraulic unit.
When the chuck is closed completely, oil pressure safe lamp is
lit Confirm the lamp is lit without fail, confirm pressure gauge
reading is correct. ( P.27)

18) Push <START> button, VIBRO starts vibration. ( P.22)

When VIBRO starts, ammeter is activated.

19) If the thermal relay trips often while drive-in / extract piles, the
motor may likely be burnout. Reconsider selection of proper
model of VIBRO.

※ When grab a pile and while pile drive-in / extract work, set
the chuck open / close switch <CLOSE> without fail.

※ If pressure safe lamp is off while operation, stop operation

of VIBRO immediately.
In this case, secure safe conditions not a pile falls down or
drop of from the chuck.

31
 ・Do not stand just beneath VIBRO except while works of
connect piles together. Work in an safe area where
incidences like drop down of bolts, pins.
・Never do pile drive-in work without grab a pile by the chuck
<OPEN>, this may cause breakage of the machine.
・Do not remove an aux. wire rope when move or turn the crane
with grab a pile.
・When extract a pile, grab a pile and loosen main wire rope a
little, then pull a pile up.
・When extract a pile, do not pull a pile laterally.
・When extract a pile, do not give excessive extractive power
bigger than VIBRO’s maximum tensional load (pressurize the
spring fully). ( P.10)
・When extract a pile do not extract a pile only by winding force of
the crane without driving VIBRO.
・If voltage level of FM2-80 and/or lower model becomes 180V, or
if voltage level of CM2-120 and/or higher model becomes 360V,
the motor may likely be burnout.
・Be cautious that cab-tyre cable and hydraulic hose do not disturb
machines.
・Do not operate VIBRO in windy or rainy days to prevent from
fall-down of a machine or having electrical shock.
・Do not remove a crane’s hook while the chuck grabs a pile.

stop 20) Push <STOP> button, VIBRO stops.

21) When stop VIBRO, loosen main wire rope a little.

22) When open the chuck, be sure that VIBRO stops completely.

・While taking a break or suspending works, switch off the main

circuit breaker of the control unit and switch off the main circuit
breaker of the power generator’s distribution board at the
same time.
・When work is finished, lay down VIBRO on a flat place before
remove VIBRO from the crane hook, and then take a hook off.

32
2. Operational Procedure of Remote Controller

1) When use the remote controller, set chuck open / close switch <NEUTRAL>.

2) While using the remote controller only <STOP button> is available at the control unit side.

3) Connect a plug of the remote controller cable to a socket of the control unit side.

※ For emergency, push <STOP button> of the remote control unit, machine stops immediately.

33
3. In case a rotatory direction of the hydraulic unit motor is opposite

1) If a rotatory direction of the motor is opposite, hydraulic pump ddoes not discharge oil.
Therefore the hydraulic cylinder does not work. Stop operation because this may cause
burnout of the hydraulic pump.

2) Set both aux. circuit breaker and main circuit breaker of the control unit <OFF>.

3) Stop power generator engine with setting generator’s main circuit breaker <OFF>.

4) In order to correct a rotatory direction of the motor, re-confirm circuit breakers mentioned in the
above 2) and 3) are <OFF>, then change either two phase termials among three phase
terminals of R・S・T.

5) Set main circuit breaker of the power generator <ON>.

6) Set main circuit breaker of the control unit <ON>.

7) Set aux. circuit breaker <ON>.

8) Confirm volt meter reading on the operation panel of the control unit. ( P.29)

9) Confirm the rotatory direction of the motor is correct, start operation with following procedures
mentioned in 16) of P.31.

34
VIII Maintenance

1. About grease change for a motor

To refill and change lubrication grease for bivro motor bearing, follow instructions mentioned below.
For greesing that is to be done daily is referred to as grease refill, and greesing that is to be done in
the process of overhaul of the machine is referred to as grease change.

1-1 Procedure for grease refill

1) Refer (P.38) for quantity of grease refill and its frequency. Make the timing of grease refill
shorter according to conditions of use and environmental conditions.
2) Use Cosmo Wide Grease WR 2 made by Cosmo Oil Co., Ltd.
3) To refill grease remove a plug of discharge outlet and refill grease by a grease pump from
oil inlet while the motor is still warm. Deteriorated grease is discharged. After the
deteriorated grease is discharged fully, put the plug back to orginal place, and fasten firmly.
There are two inlets on the plulley side, refill grease from both inlets.
A discharge outlet is not provided with FM2-30.
4) Be sure to refill designared quantity. Excess refill may cause a heat generation of the
motor or leakage of grease.

1-2 Procedure for grease change

Dusts entered into the motor after long time usage that accelarates deterioration of grease
and causes burnout of bearing or vibro motor coils. Inspect the motor periodically and
change grease without fail.
Follow instructions mentioned below for grease change.
1) Disassemble bracket and bearing box, clean all parts in the bearing box by kerosene.
2) Check bearing carefully, if problem is found, renew it.
3) Press in new grease from grease inlet to discharge deteriorated grease in the grease hole.
4) Refill designated quantity of new grease (P.48～P54) to internal space of of the bearing
and the bearing box, then reassemble them.
5) While reassemble components, be careful not to get dusts or foreign substances entered.

35
2. Greasing points and type of grease applied

Use the following or similar grease.

Greasing Points Vibrator Hydraulic Unit Motor Absorber Chuck

kind of oil Gear Oil Hydraulic Oil Heat Resistant Eextreme Eextreme
brand VG150 VG32 Grease Pressure Grease Pressure Grease

Omala Oil
Showa Shell Terrace 32 Albania EP2 Albania EP2
150
CE Compound Super Hydraulic
Idemitsu Colonex EP2 Colonex EP2
150S 32
Bonnoc Super Highland
Nisseki Epinoc AP2 Epinoc AP2
SP150 32
Super Fluid
Cosmo Gear 150 WR2 Dynamax EP2 Dynamax EP2
32

Mobil Gear 629 DTE24 Mobilux EP2 Mobilux EP2

Kyoseki Redactus 150 Hydlux 32 Lisonix EP2 Lisonix EP2

Esso Spartan EP150 Nuto H32 Ristan EP2 Ristan EP2

36
3. Points to be inspected and inspection timing

inspection timing 1 month 3 months 6 months 1 year

No. daily 7 day
points inspected (50 hrs) (150 hrs) (300 hrs) (500 hrs)

1 loosening, drop-off, crack of bolts & nuts ○

2 damage of cab-tyre cable, its capacity ○

3 cracks on shackle, shackle pin ○

4 insulation resistance of vibro motor and cab-tyre cable ○

5 oil seal of vibrator, oil leakage from cover ○

6 quantity of hydraulic cylinder oil, oil deterioration ○

7 oil leakage from hydraulic cylinder, damage of rod ○

8 abrasion of chuck tooth ○

9 meshing of chuck ○

10 damage of hydraulic hose, oil leakage ○

11 damage of meters, indicators ○

12 earth wire and earth rod ○

13 oil level of hydraulic unit, deterioration of oil ○

14 running out of grease for bush sleeve ○

15 running out of grease for chuck pin, desorption block ○

16 contact of electromagnetic contactor get rough ○

17 abrasion of shackle, shackle pin ○

18 tension of V belt, crack ○

looseness of wiring in operation panel, insulation
19 ○
resistance
20 breakage or settling of spring ○

21 running out of grease for vibro motor ○

22 grease change of vibrator ○

23 grease change of hydraulic unit ○

24 bend of vertical axis, abrasion of bush ○

25 abrasion of vibrator bearing ○

26 performance comprehensive drive test ○

37
Refill quantity and refill timing of bearing grease of vibro motor

4. Voluntary inspection

38
If problems are found as the result of the inspection, repair them immediately. Because VIBRO is
a machine utilizes vibration, it may likely create dangerous situation such as drop off of bolts, nuts,
pins, sheet pile or vibro itself, or electric shock. Never use the machine without maintenances.
Be sure power is off when inspect electrical system.

39
40
41
42
IX Major Troubles and Measures
Troubles Cause Measures

① primary side cab-tyre cable is dis connected ① repair disconnection

main circuit breaker (earth leakage breaker)

② ② remove a cause and reset
trips

③ aux. circuit breaker trips ③ remove a cause and reset

forget to reset thermal relay of hydraulic unit

hydraulic motor ④ ④ remove a cause and reset
1 motor
does not work
⑤ failure start/stop switch of hydraulic unit motor ⑤ repair or change

failure of electromagnetic contactor MC, or

⑥ ⑥ repair or change
disconnection of coils

⑦ disconnection or burnout of hydraulic motor ⑦ change or rewinding of coil

① disconnection of nternal wiring of switch box ① repair disconnections

② failure of operation switch ② repair or change

hydraulic unit motor
2 works but chuck ③ failure of solenoid valve or disconnection of coil ③ repair or change
does not work
④ failure of aux. relay or disconnection of coil ④ repair or change

⑤ failure of hydraulic pump ⑤ repair or change

① lack of hydraulic oil in a tank ① refill or change

② oil leakage from coupler ② repair

adjust pressure to designated

chuck works but ③ drop down setting pressure of relief valve ③
level ( P.27)
3 pressure is not
enough ④ clogging of suction filter ④ clean or change

⑤ drop of efficiency by abrasion of motor ⑤ repair or change

⑥ oil leakage inside hydraulic cylinder ⑥ disassemble and repair

43
 Troubles Cause Measures

main circuit breaker (earth leakage breaker)

① ① remove cause and reset
trips

② aux. circuit breaker trips ② remove cause and reset

③ forget reset of thermal rely of vibro motor ③ remove cause and reset

voltage of FM2-80 or lower model become change to proper capacity of

④ ④
higher than 180V power (generator)
voltage of CM2-120 or higher model become
chuck works but lower than 360V
VIBRO does not
4 ⑤ disconnection of internal wiring of switch box ⑤ repair disconnection
work while pushing
start button
⑥ failure of push button switch ⑥ repair or change

⑦ disconnection of secondari side cab-tyre cable ⑦ repair disconnection

contact failure of electromagnetic contactor, or

⑧ ⑧ repair or change
disconnection of coil

⑨ failure of aux. relay or disconnection of coil ⑨ repair or change

⑩ disconnection of vibro motor or burnout ⑩ repair or change

change to proper capacity of

① lack of power (generator) ①
power (generator)
incorrect wiring of secondary side cab-tyre
② ② connect correctly
VIBRO works but cable
start up mode is
not change to drive ③ failure of start up timer (TL) ③ change
5 mode, or
immediately after ④ contact failure of electromagnetic contactor ④ repair or change
drive is activated, MC or MC△
VIBRO stops
⑤ failure of aux. relay or disconnection of coil ⑤ repair or change

lead wire to be connected to contact b of

⑥ ⑥ connect correctly
electromagnetic contactor MC is come off

44
 Troubles Cause Measures

correct pressure to
① designated pressure of chuck is reduced ①
designated level

② abrasion of tooth ② change

arm lever is bent by abnormal pressure, or

6 chuck tooth slips ③ ③ repair or change
cracks on chuck itself
disassemble and remove
④ foreign substances get caught in clamp ④
foreign substances

⑤ abrasion of chuck pins and bush ⑤ disassemble and change

① bulb has gone ① change

② wire is come off or disconnection ② repair or change

③ failure of switches ③ repair or change

every indication
7
lamp oi]s not lit
④ setting failure or malfunction of pressure switch ④ adjust or change

⑤ thermal relay of hydraulic unit motor trips ⑤ remove cause and reset

⑥ forget to reset thermal relay of vibro motor ⑥ remove cause and reset

※ When repair the motor, and when connect cab-tyre cable after finish repair disconnection of
secondary side cab-tyre cable, be careful not make incorrect connection with observing symbols
on crimp terminals.

45
X Specifications

1 Dimensions of the Main Unit

2 Control Unit (Electric Control Panel, Hydraulic Unit)

46
■ Dimensions of the Main Unit

■ Control Unit (Electric Control Panel, Hydraulic Unit)

only FM2.-30, operation panel and hydraulic unit are separated

47
3 Specifications

1) FM2-30 (200V version specifications)

Specifications -30-
name unit value

eccentric moment kg・cm 1000

vibration frequency cpm 1100

vibration force ton 13.5

weight of piler kg 1877

vibration weight of
kg 1585
piler
vibration amplitude
mm 6.3
while idling
acceleration while
g 8.5
idling
motor power kw 22
entire load of
ton 12
shock absorber
spring constant of
kg/cm 572
shock absorber

48
2) FM2-40 (200V version specifications)

Specifications -40-
name unit value

eccentric moment kg・cm 1320

vibration frequency cpm 1250

vibration force ton 23.0

weight of piler kg 2350

vibration weight of
kg 1930
piler
vibration amplitude
mm 6.8
while idling
acceleration while
g 12.0
idling
motor power kw 30
entire load of
ton 15
shock absorber
spring constant of
kg/cm 888
shock absorber

49
3) FM2-55 (200V version specifications)

Specifications -55-
name unit value

eccentric moment kg・cm 2100

vibration frequency cpm 1100

vibration force ton 28.4

weight of piler kg 3300

vibration weight of
kg 2700
piler
vibration amplitude
mm 7.8
while idling
acceleration while
g 10.5
idling
motor power kw 40
entire load of
ton 17
shock absorber
spring constant of
kg/cm 848
shock absorber

50
4) FM2-60 (200V version specifications)

Specifications -60-
name unit value

eccentric moment kg・cm 2500

vibration frequency cpm 1150

vibration force ton 37.0

weight of piler kg 3750

vibration weight of
kg 3250
piler
vibration amplitude
mm 7.7
while idling
acceleration while
g 11.4
idling
motor power kw 45
entire load of
ton 18
shock absorber
spring constant of
kg/cm 1000
shock absorber

51
5) FM2-80 (200V version specifications)

Specifications -80-
name unit value

eccentric moment kg・cm 3600

vibration frequency cpm 1100

vibration force ton 48.7

weight of piler kg 4750

vibration weight of
kg 3800
piler
vibration amplitude
mm 9.5
while idling
acceleration while
g 12.8
idling
motor power kw 60
entire load of
ton 22
shock absorber
spring constant of
kg/cm 1180
shock absorber

52
6) CM2-120 (400V version specifications)

Specifications -120-
name unit value

eccentric moment kg・cm 5000 4000 3000

vibration frequency cpm 1100

vibration force ton 67.7 54.2 40.6

weight of piler kg 6600

vibration weight of
kg 5550
piler
vibration amplitude
mm 9.0 7.2 5.4
while idling
acceleration while
g 12.2 9.8 7.3
idling
motor power kw 90
entire load of
ton 26
shock absorber
spring constant of
kg/cm 1423
shock absorber

53
7) CM2-160 (400V version specifications)

Specifications -160-
name unit value

eccentric moment kg・cm 7100 6000 5000

vibration frequency cpm 980

vibration force ton 76.3 64.4 53.7

weight of piler kg 8800

vibration weight of
kg 7200
piler
vibration amplitude
mm 9.9 8.3 6.9
while idling
acceleration while
g 10.5 8.9 7.5
idling
motor power kw 120
entire load of
ton 40
shock absorber
spring constant of
kg/cm 1200
shock absorber

54
4 Circuit Diagram and Parts
55
56
57
58
59
5. Hydraulic Unit

FM2-30～FM260

60
61
FM2-30 ～ CM2-160

62
63