ICE 160 230 0296 Hammer

OPERATING AND MAINTENANCE MANUAL
ICE MODEL 160

HYDRAULIC IMPACT HAMMER
WITH MODEL 230 POWER PACK
SERIAL NUMBERS: 800001 AND ABOVE
INTERNATIONAL
CONSTRUCTION
OM-160-230-0296
SPECIALIZING IN PILE DRIVING EQUIPMENT
CORPORATE OFFICES: 301 WAREHOUSE DR., MATHEWS, NC 28105, USA
PHONES: 888 423-8721 & 704 821-8200 FAX 704 821-8201
PREFACE
This manual was prepared to acquaint the owner, operator and serviceman with the
construction, operation and servicing of the ICE Model 160 Hydraulic Impact Pile Hammer and
the ICE Model 230 Power Unit. We strongly suggest that this manual be studied carefully and
understood by all personnel involved in operating or performing maintenance work on the
hammer. ICE equipment is engineered to provide reliable operation and a long service life
under normal operating conditions. Equipment reliability and service life can be improved by
following the maintenance procedures in this manual.
This manual is divided into five sections- General information, Preparation for Operation,
Operation, Maintenance, and Ordering Parts.
The General Information section contains a brief description of the hammer and specification
information.
The Preparation for Operation section contains information about maintenance and other work
required before starting the hammer.
The Operation section includes general operating information plus details on hot and cold
weather operation.
The Maintenance & Adjustments section contains routine maintenance procedures and
instructions for making adjustments and repairs to the hammer.
The Ordering Parts section contains information for ordering parts including parts drawings and
lists.
INTERNATIONAL CONSTRUCTION EQUIPMENT, INC.
STANDARD WARRANTY
International Construction Equipment, Inc. (ICE) warrants new products sold by it to be free
from defects in material and workmanship for a period of 90 days after date of delivery to the
first user and subject to the following conditions: ICE’s obligation and liability under this
warranty is expressly limited to repairing or replacing, at ICE's option, any parts which appear
to ICE upon inspection to have been defective in material or workmanship. Such parts shall be
provided at no cost to the user at the business establishment of ICE or at the ICE distributor of
the product during regular working hours.
This warranty shall not apply to component parts or accessories of products not manufactured
by ICE and which carry the warranty of the manufacturer thereof or to normal maintenance
parts (such as filters).
Replacement or repair parts installed in the product covered by this warranty are warranted
only for the remainder of the warranty as if such parts were original components of said
product.
ICE's obligation under this warranty shall not include any transportation charges, costs of
installation, duty, taxes or any other charges whatsoever, or any liability for direct, indirect,
incidental, or consequential damage or delay.
If requested by ICE, products or parts for which a warranty claim is made are to be returned
transportation prepaid to ICE.
Any improper use, including operation after discovery of defective or worn parts, operation
beyond rated capacity, substitution of parts not approved by ICE or any alteration or repair by
others in such manner as is ICE's judgment affects the product materially and adversely shall
void the warranty.
For impact pile hammers, driving in excess of 10 blows per inch (set of 0.1 inch per blow) is
considered practical refusal. Driving in excess of 10 blows per inch for more than 6 inches of
driving or driving in excess of 20 blows per inch at all is considered improper use and will void
the hammer warranty.
For vibratory drivers, driving when penetration is less than 1" per minute is considered practical
refusal. Driving when penetration is less than 1" per minute for more then 5 minutes of driving
or driving at all when penetration is less than 1" per minute and amplitude is greater than
1" (vibrator and pile are bouncing) is considered improper use and will void the vibrator
warranty.
ICE makes no other warranty, expressed or implied, and makes no warranty of merchantability
or fitness for any particular purpose.
No employee or representative is authorized to change this warranty unless such change is

made in writing and signed by an officer of ICE.
TABLE OF CONTENTS
I. GENERAL INFORMATION PAGE
A. General Description I-1

B. Major Components (line drawing) I-1
C. Specifications I-5
II. PREPARATION FOR OPERATION
A. General II-1
B. Safety Precautions II-1
C. Handling II-4
D. Connecting Crane Line To Hammer II-5
E. Attachment Of Lead Guides II-6
F. Attachment Of Drive Cap II-6
G. Mounting Hammer In Lead II-7
H. Connection Of Hydraulic Hoses II-8
I. Filling The Hammer Pressure Hose II-9
J. Filling Variable Stroke Cylinder Hoses II-10
K. Setting Variable Stroke Cylinder Pressure II-10
L. Fuel, Lubricating Oil And Grease II-11
III. OPERATING INSTRUCTIONS
A. Completion of Set-up and Maintenance III-2

B. Control Panel III-2
C. Starting And Warming Up The Engine III-3
D. Warming Hydraulic Oil III-3
E. Operation Of The Hammer III-4
1. Rated Hammer Energy III-4
2. Maximum blows per inch III-4
3. Stroke Control III-4
4. Stroke Setting III-5
F. Starting The Hammer III-6
G. Stopping The Hammer III-6
H. Single Blow Operation III-6
I. Emergency Stop III-6
J. Engine Shut Down III-6
K. Hot & Cold Weather Operation III-7
IV. MAINTENANCE AND ADJUSTMENTS
A. General IV-1
B. Maintenance - Daily IV-2
C. After Start-Up, Check The Following IV-3
D. Maintenance -Monthly IV-3
TABLE OF CONTENTS
IV. MAINTENANCE AND ADJUSTMENTS (CONTINUED) PAGE
E. Maintenance - Every 4 Months IV-3

F. Annually IV-3
G. Severe Conditions IV-4
H. Lubrication IV-4
I. Hydraulic Oil IV-5
J. Capacities IV-7
K. Draining And Filling Hydraulic Reservoir IV-7
L. Changing The Hydraulic Return Filter Element IV-8
M. Setting Main Relief Valve IV-9
N. Setting Stroke Control (Clamp) Relief Valve IV-10
O. Tensioning Wire Ropes IV-10
P. Charging Accumulators IV-12
Q. Replacing Ram Connection IV-13
R. Bolt Torque Information IV-14
S. Checking & Replacing Recoil Dampener IV-15
T. Checking & Replacing Cushion Material IV-15
V. HYDRAULIC CIRCUITRY
A. Drive Pump V-1

B. Stroke Control Pump V-2
C. Other V-3
Hydraulic Schematic V-4
D. Hydraulic Components List V-5
VI. ELECTRICAL CIRCUITRY
A. Diesel Engine VI-1

B. Stroke Range Select VI-2
C. Hydraulic Hammer VI-2
D. Remote - Local Control VI-2
E. Engine Throttle VI-3
F. Tachometer VI-3
G. Other VI-3
Electrical Layout VI-4
Electrical Schematic VI-5
H. Electrical Components List VI-6
TABLE OF CONTENTS
VII. GENERAL DATA
A. Abbreviations VII-1
B. Screws And Bolts VII-2
C. Serial Number Locations VII-2
VIII. ORDERING PARTS
A. Procedure VIII-1
B. Fitting Description Key VIII-2
Fitting Description Selector Chart - SC1 VIII-3
C. Hose Description Code VIII-4
D. Parts Identification VIII-5
E. Miscellaneous Accessories VIII-48
F. Recommended Spare Parts VIII-51
G. Recommended Tightening Torque VIII-52
I. GENERAL INFORMATION
A. GENERAL DESCRIPTION
The ICE Model 160 Hydraulic Hammer is a Free-Fall hammer. The ram is lifted by
the hydraulic actuator and then allowed to free-fall, impacting the pile. The hammer
has been designed to provide maximum flexibility by enabling the contractor to vary
the energy range of the hammer to suit job conditions. The 160 hammer design
incorporates an all hydraulic control system, with no electrical or electronic controls
used, to ensure reliability and field serviceability. Further, without the need for
vulnerable umbilical cords, this unit is readily adaptable to alternate hydraulic power
sources.
The 160 hammer is normally powered by the same Model 230 power unit that
powers ICE Vibratory Hammers and ICE Earth Augers. This permits the contractor
to use a single power unit on jobs where both the Impact Hammer and a Vibratory
Hammer or Auger are needed. The Hammer can also be powered by any source
providing the required flow, pressure, cooling and filtration. The 160 Hydraulic
Hammer delivers 64,000 ft-lbs (8848.3 Kg-M) of energy at its full stroke of 4’-
0” (1.2M) at a blow rate of 40 blows per minute.
B. MAJOR COMPONENTS
The hammer system consists of 8 major components (Fig. 1) page I-4:

Hydraulic Actuator
Ram
Guide Structure
Lifting Bale
Drive Cap
Controls
Interconnecting Hoses
Power Unit
Hydraulic Actuator
The hammer is driven by the hydraulic actuator. The actuator is coupled to the ram
using a shock absorbing, self aligning, connection. Hydraulic oil flows from the
power unit, at pressure, to the actuator which accelerates the ram upward.
Attached to the ram is a trip bar which activates a trip valve after the ram has risen
a predetermined distance. Activation of the trip valve stops the flow of oil to the
actuator. The ram then decelerates and free falls to impact the pile. Power unit
energy is stored in a hydraulic accumulator while the ram is falling.
I-1
B. MAJOR COMPONENTS (CONTINUED)
Ram
The ram is a one piece high strength steel forging. The one piece construction of
the ram eliminates slack in the driving system and provides maximum energy
transfer to the pile. The one piece construction also eliminates the dangers of
structural failure known to exist in rams constructed of separate segments. High
performance, non-metallic, bearings, retained within the ram, prevent guide column
wear and reduces maintenance and lubrication requirements. The shock and
vibration, generated when the ram impacts the pile, are isolated from the hydraulic
actuator by an elastomeric, self aligning, coupling.
Guide Structure
The guide structure consists of tubular steel guide columns and connection plates.
The guide columns serve to guide the ram and provide the rigidity required to allow
the driving of batter piles. Guide columns, connecting plates and lifting bale are
held together by tensioned wire ropes which run from the base plate to the top of
the lifting bale. These cables provide a resilient means of connection and eliminate
the need for keys or bolted connections. The hammer is designed to fit in 32” x 8”
rail leads produced by ICE and other manufacturers. The connecting plates provide
mounting points for the lead guide rails necessary for ICE leads and various other
hammer guidance systems.
Lifting Bale
The lifting bale surrounds and protects the hydraulic actuator and hoses from
damage and is the attachment point for the lifting sheave. Two energy storing
hydraulic accumulators are mounted to, and protected by, the lifting bale.
Incorporated in the lifting bale design are the connection flanges for the hydraulic
supply hoses, and a shock absorbing hose support.
Drive Cap Assembly

Striking energy of the ram is transmitted to the pile through the three elements of the
drive cap assembly. The ram impacts the forged steel striker block which self aligns
and self centers within the lower connecting plate. Ram energy is transferred
through cushion material into the DCB-X drive cap base. The DCB-X serves to
retain the cushion material, Guide the piling, and adapt to various styles of ICE piling
inserts. Piling inserts adapt the hammer to most popular types of piling and retain
additional cushion material when required.
I-2
Controls
The hammer is controlled by a remote electric/hydraulic system in the power unit
which allows for both manual single blow operation or automatic continuous stroke
operation. The stroke of the ram can be varied between 12” (.3M) and 48” (1.2M),
on-the-fly, allowing control of the hammer energy to suit various types of piling and
soil conditions. Under continuous operation, the hammer will operate at 45 blows
per minute at the maximum energy setting. The blow rate will increase at lower
energy settings. Control of the continuous cycling of the hammer is fully hydraulic
(non-electric), operated by valves contained within the actuator assembly. No
maintenance of adjustment of these valves is normally required. The hammer can
be operated from the control panel at the power unit, the remote pendant control or
the radio remote control unit
Interconnecting Hoses
Hydraulic power is transmitted from the power unit to the hammer through 100 ft.
(30M) of steel braid reinforced hydraulic hoses (4). High pressure, threaded type,
quick disconnects on these hoses facilitate connection to the power unit without oil
loss. Dust covers are provided to keep disconnects clean when the hammer is
disconnected.
Power Unit
Power for the hammer is normally provided by a free-standing, Model 230, diesel-
hydraulic power unit. The Model 230 is powered by a Caterpillar 3116 engine which
develops 220 Hp (164kW) at 2600 rpm. The totally enclosed power unit is mounted
on a skid type fuel tank sub-base, and has lockable doors. Central lifting of the
power unit is facilitated by an integral lifting bale. A control panel at the side of the
unit contains all the operating gages and controls. A common reservoir supplies
hydraulic oil to the main pump and the stroke control pump. Filtration and cooling
means for the hydraulic oil are incorporated within the power unit. Electro/hydraulic
valves are provided for hammer start/stop and stroke control. Pressure limiting
valves are included for all systems. Four hydraulic hoses connect the power unit to
the Model 160 hammer. This power unit can also be crane mounted for ease of
operation.
If the crane is capable of providing the required flow, pressure, cooling and filtration
to the hammer, it is possible to adapt it for hammer operation and eliminate the
power unit
I-3
SHEAVE
LIFTING BALE
HYD ACTUATOR ASM
GUIDE STRUCTURE
TRIP BAR
CONTROL PANEL
HOSES
CONTROL PENDANT
230 POWER UNIT RAM
DRIVE CAP
INSERT
FIG 1
I-4
C. SPECIFICATIONS
Working Specifications
Designation ICE Model 160
Maximum stroke 4'-0" (1.2 Meter)
Rated energy @ maximum stroke 64,000 ft-lbs (86.8 kN-m)
Blow rate @ maximum stroke 45 bpm
Minimum stroke 1' (0.3 Meter)
Rated energy @ minimum stroke 16,000 ft-lbs (21.7 kN-m)
Blow rate @ minimum stroke 60 bpm
Weights and Dimensions

Ram weight 16,000 lbs (7260 kg)
Hammer weight (bare)* 29,270 lbs (13,275 kg)*
Complete operating weight with cap*,** 33,770 lbs (15,316 kg)**
Length (bare)** 20’-3" (6172 mm)
Complete operating length with cap** 23'-3” (7086 mm)**
Width (without guides) 32" (813 mm)
Depth 48" (1220 mm)
Depth centerline to back 24" (610 mm)
Depth centerline to front 24" (610 mm)
Hydraulic hose length (standard) 100' (30 m)
*Weight includes 32” lead guides and one half of hydraulic hoses.
**Set up for 32" leads, 14" square concrete pile and 100’ full hoses.
Power Unit
Designation ICE Model 230
Engine CAT 3116DITA
Max. power 220HP (164 kW)
Operating speed 2600 rpm
Max. drive pressure 4,500 psi (310 bar)
Drive flow 67 gpm (254 lpm)
Stroke control pressure 1,500 psi (103 bar)
Stroke control flow 10 gpm (38 lpm)
Weight 9,400 lbs (4264 kg)
Length 126" (320 cm)
Width 60" (152 cm)
Height 75.5" (192 cm)
I-5
A. GENERAL
When loading and unpacking the hydraulic hammer and accessories, use extreme
care. For your protection, make a thorough inspection of the unit immediately on
delivery. In case of any damage or shortage, notify the transit agent at once and
have the delivering carrier make a notation on the freight bill. Use timber, heavy
duty banding, etc to block ram movement during shipment.
(SEE SECTION II C FOR LIFTING INSTRUCTIONS)
B. SAFETY PRECAUTIONS
Safety is basically a matter of common sense. There are standard safety rules, but
each situation has its own peculiarities which can not always be covered by rules.
Therefore, your experience and common sense will be your best guide to safety.
Be ever watchful for safety hazards and correct deficiencies promptly.
Use the following safety precautions as a general guide to safe operations:
1. Read the manual thoroughly before operating or working on the equipment.

2. Read and follow any safety instructions in the CATERPILLAR engine operators
manual.
3. Only well trained and experienced personnel should attempt to operate or maintain
this equipment.
4. Never adjust, lubricate or repair the unit when it is in operation, or lifted above
ground level.
5. Never remove, paint over or cover warning or safety labels. If labels become
damaged or unreadable, replace immediately.
6. All personnel should wear approved safety clothing, including HARD HATS,
SAFETY SHOES, SAFETY GLASSES and HEARING PROTECTION when in the
vicinity of this machinery.
7. Do not stand any closer to this equipment than necessary when it is in operation.
Parts may loosen and fall. Piling may shatter or break. Never stand under
operating, or elevated, equipment.
8. When maintaining or repairing the equipment, never substitute parts not supplied,
or approved in writing, by ICE.
9. Do not weld, or flame cut, on this equipment.
10. Never use or store flammable liquids on or near the engine.
11. Insure that all lifting equipment, including cranes, wire rope, slings, hooks, shackles,
etc., are properly sized for the worst case loads anticipated during operations.
12. If there are any questions about the weights, specifications, or performance of the
unit, contact ICE before handling or operating the equipment.
13. If the equipment is to be used for anything other than driving plumb piles, contact
ICE before using the unit.
14. Check wire rope clips for tightness, and check wire ropes for wear, daily.
15. Insure that ground vibrations will not damage or collapse adjacent structures or
excavations.
II-1
B. SAFETY PRECAUTIONS (CONTINUED)
16. Remove all tools, parts and electrical cords before starting the unit.
17. When operating in an enclosed area, pipe exhaust fumes outside. Continued
breathing of exhaust fumes may be fatal.
18. When servicing batteries, do not smoke or use open flames in the vicinity. Batteries
generate explosive gas during charging. There must be proper ventilation when
charging batteries.
19. When filling fuel tank, do not smoke or use open flame in the vicinity.
20. If abnormal equipment operation is observed, discontinue use immediately and
correct the problem. Do not leave the equipment control pendant (radio control)
unattended.
21. Store oily rags in approved containers, and away from engine exhaust system.
22. Make sure that the hammer is OFF before starting the power unit engine.
23. Do not adjust, or set, hydraulic pressures higher or lower than those specified in the
manual.
24. Never operate this equipment with hydraulic hoses that are damaged or “kinked”.
Replace damaged hoses immediately.
25. Do not lift, or support, hydraulic hoses with wire rope slings.
26. Never attempt to connect quick disconnects when the power unit is running.
27. Do not pull on, or attempt to move equipment, with hydraulic hoses.
28. Do not attempt to locate hydraulic leaks with your hands. High pressure hydraulic
leaks can penetrate the skin, causing severe damage, blood poisoning and
infection. Do not attempt to repair leaks while the equipment is in operation.
29. Do not attempt to tighten, or loosen, fittings or hoses when the machine is in
operation.
30. Power unit must always be placed on level, stable, ground.
31. Do not remove power unit heat shields, or operate power unit without heat shields.
Severe fires may result.
32. A properly maintained fire extinguisher, suitable for oil fires, must be kept in the
immediate vicinity of equipment operations.
33. When moving or transporting this equipment, insure that the vehicle or vessel is of
sufficient capacity to handle the load, and that the equipment is properly tied down.
34. Always block the ram, to prevent movement during transport.
35. When moving or transporting this equipment, be sure that quick disconnect dust
caps are tight, and that cap safety cables are in place. Be sure that all equipment
parts are tight, or properly secured, before shipment. Unsecured parts may vibrate
loose and fall, during transport, causing injury or property damage.
36. Keep crane boom, piles, leads, wire rope and other equipment at least 15’ (5M)
from electrical power lines, transformers and other electrical equipment, or at such
distance as required by applicable safety codes.
II-2
B. SAFETY PRECAUTIONS (CONTINUED)
37. Rounded or damaged bolt heads or nuts should be replaced so that proper torque
values may be obtained. Proper torque values are necessary to prevent parts on
this equipment, leads and crane boom from loosening and falling. Refer to Torque
Chart, in the manual, for proper values.
38. Always be sure that the crane line is aligned with the centerline of the pile. Do not
side load crane boom or hammer. Dangerous crane boom, or hammer, damage
may result.
39. Use tag line to control hammer whenever possible.
40. When driving “batter” piles, insure that the leads, and crane boom, have sufficient
bending strength to handle the worst case load. Consult ICE.
41. Do not attempt to service hydraulic accumulators without first venting all high
pressure gas from these units.
42. Pre-charge accumulators only to pressures specified, and only with Nitrogen gas.
43. Pile ends must be cut square, and flat, before cushion material and/or drive cap are
placed onto pile.
44. Use only pile caps that are correctly sized for the type, cushion material and pile
size being driven.
45. Before starting driving operations, check that the hammer, striker block and pile cap
are properly aligned with the centerline of the pile. Dangerous lateral forces,
generated by misalignment, may damage hammer or break piling, with resultant
hazard from falling objects.
46. Stay well clear of ram point, pile cap and striker block. Fragments of metal may be
broken, or spalled off, and ejected at high speed.
47. Large amounts of heat are generated, within cushion material, during driving.
Cushion material, or flammable materials in the vicinity, may ignite. Personnel
should use extreme caution, and avoid contact with ram point, cushion material and
drive cap.
48. It is the responsibility of the contractor to determine what, if any, hazardous
materials, or gases, may be emitted from cushion materials due to deterioration,
decomposition, excessive temperature or combustion. Contact the cushion
material manufacturer.
49. Frequently inspect and tighten the wire ropes, wire rope clips and pins that secure
the drive cap to the hammer. Replace these components at the first sign of wear or
fatigue. Tighten clips regularly.
REMEMBER, SAFETY IS EVERYONE’S BUSINESS.
II-3
C. HANDLING
Safe handling practices will insure protection of both the hammer and personnel
working near the unit. Do not pick up the hammer by the guide columns. Doing so
can scratch the surface finish on the columns and damage the ram bearings.
To lift hammer horizontally (See Fig 1):
The hammer is designed to be picked up by the lead guide rails. Use shackles at
each of the four lifting holes provided in the lead guides to attach the four lifting
cables. Alternately, the hammer can be picked up using the lifting sheave bracket
and a pin through the cable ears in the bottom plate. Ensure that the lifting cables
are properly sized for the hammer weight and sling angle.
Always block the ram, to prevent movement during transport and / or lifting.
FIG 1
II-4
D. CONNECTING CRANE LINE TO HAMMER
Connect the crane line directly to the hammer using the lifting sheave. The
hammer is designed to be used with a two-part line. If a single-part line is desired,
the sheave can be replaced with a sleeve p/n 160777.
To lift the hammer to the vertical position use shackles on the lifting ears on the
lifting sheave bracket. (See Fig 2) Pass the crane wire rope around the lifting
sheave and re-attach to crane boom.
FIG 2
II-5
E. ATTACHMENT OF LEAD GUIDES
The hammer is usually shipped with lead or spud guides already in place. If they
are not attached, bolt them into place at the sides of the hammer using the twenty–
four bolt holes provided on each side of the hammer.
With fixed leads, it is sometimes convenient to stand the hammer in the leads prior
to attachment of the back lead guides.
The lead guide attachment bolts should be properly torqued, using the lock washers
provided, to prevent their coming loose. Torque 1.25-7UNC SHCS to 1,600 Ft-lbs
(221.1 Kg-M).
Do not weld on hammer.
F. ATTACHMENT OF DRIVE CAP (See Fig. 3)
To attach drive cap: Set drive cap insert [11] on dunnage or firm ground. Set drive
cap base [4] (DCB-2-HD for 32" leads) onto drive cap insert. Attach with wire rope
through two holes provided.
Place 2"(50mm) thick and 25”(635mm) diameter cushion material [8] into top of
DCB-2-HD drive cap base . Place 1/2”(13mm) thick aluminum plate [7] on top of
cushion material. Do this twice. This plate holds the cushion material in place if it
fractures during driving.
Place the 10 3/4” (273mm) thick tapered steel striker block [3] on top of the
aluminum plate
Place the recoil dampener [9] around the top of the striker block.
Set the hammer onto the assembled drive cap set-up. The tapered striker block fits
inside the bottom of the hammer and will lift the ram [1] as the hammer is lowered
onto it. The hammer base plate [2] should sit squarely on the recoil dampener.
Attach the drive cap to the hammer with 3/4”(19mm) wire rope [10]. Insert bolt [6]
through the holes in the cable ears on hammer base plate [2] to keep the
3/4”(19mm) wire rope [10] in place. Secure bolt [6] with the locking nut provided
and fully tighten. Provide enough slack in the wire rope so that, when the hammer
is lifted, 1”-2” (25-50mm) of space should exist between the bottom of the hammer
and the recoil dampener.
II-6
5 6
2
3
7
9
8
10
7
4
8
11
FIG 3
32" LEADS
1 Ram 810803
2 Hammer Base Plate 160451
3 Striker Block 160383
4 Drive Cap Base 700006
5 Bumper 160457
6 Bolt & Nut 160806 (2) & 160315 (2)
7 Alluminum Plate 700004 (2)
8 Cushion 700002 (2)
9 Recoil Dampener 160455
10 3/4" Wire Rope (2)
11 Drive Cap Insert 700022
G. MOUNTING HAMMER IN LEAD
To slide the hammer into swinging leads, in horizontal position, pick up hammer as
described in Section II-C.
For vertical installation into leads, first attach the crane line to the hammer as
described in Section II-D. and lift hammer carefully into vertical position. Position
leads over the hammer and lift the hammer into the lead guide rails.
Alternately, remove the rear lead guide angles from the hammer. Position the
hammer on the lead guide rails and re-install the rear guide angles. Be sure to
torque the guide angle attachment bolts per Section II-E.
II-7
H. CONNECTION OF HYDRAULIC HOSES
Connection of hoses at the Power Unit
The hammer is connected to the power unit by four hydraulic hoses.

(See Fig. 4)
CAUTION: The power unit must be shut down during connection of the hydraulic
hoses.
The hoses connect to the power unit with quick-disconnect couplings. The hose
couplings are arranged so that the hoses can only be connected in the correct
manner.
Clean the couplings with a lint-free cloth before making connections.
Make sure that the couplings are fully run up (tightened). They should be firmly
hand tight. If wrenches are used, be careful not to over-tighten. Pipe wrenches are
not recommended.
Connection of hoses at the Hammer
The Model 160 is normally shipped with the hoses attached to the hammer. If the
hoses have been shipped separately, they must be connected to the hammer.
Figure 4 shows the correct hose arrangement.
After the hoses have been connected, and tightened, to their respective fittings,
they must be secured in the hose clamps on the hose bracket (See hammer
assembly drawing in the PARTS LIST section). Be sure to leave enough slack in
the hoses, above the hose clamps, to permit 3-4” (76-101mm) of downward
movement by the hose clamp shock mounting elastomer.
II-8
PRESSURE HOSE (1 1/4")
RETURN HOSE (1 1/2")
EXTEND CYLINDER SHORTEN STROKE HOSE (3/8")
RETRACT CYLINDER LENGTHEN STROKE HOSE (3/8")
FIG 4
I. FILLING THE HAMMER PRESSURE HOSE
The hammer is normally shipped with the hammer hydraulic hoses full of oil and the
unit may be used immediately. However, if the pressure hose has been removed
from the hammer, the hose may need to be filled with hydraulic oil prior to full speed
operation. It is not necessary to fill the return hose with oil.
Read SECTION III - OPERATING INSTRUCTIONS
Start and warm-up the engine in accordance with SECTION III C. With the engine
warmed-up and running at 1500 rpm, turn and hold the hammer switch to the
REVERSE position. The hoses will fill with oil in approximately two minutes. Do
not engage any other switches on the control pendant during this two minute
period.
II-9
J. BLEEDING THE VARIABLE STROKE CYLINDER LINES
The hammer is normally shipped with the two 3/8” hoses full of oil and the unit may
be used immediately. However, if the hoses have been removed from the hammer,
the hoses may need to be filled with hydraulic oil prior to driving operations.
Remove the hose from its fitting at the cylinder (P/N 160817) retract end. Place
and hold the end of the hose in an adequate container or bucket.
Read SECTION III - OPERATION INSTRUCTIONS
warmed-up and running at 1000 rpm, turn the clamp switch, on the control pendant,
to the CLOSE position. Oil should start flowing from the hose within 20 seconds.
When the flow of oil is bubble free, return the clamp switch to the OFF position, and
stop the diesel engine.
Reconnect and tighten the hose to the cylinder.
Remove the hose from its fitting at the cylinder extend end. Place and hold the end
of the hose in an adequate container or bucket.
warmed-up and running at 1000 rpm, turn the clamp switch, on the control pendant,
to the OPEN position. Oil should start flowing from the hose within 20 seconds.
When the flow of oil is bubble free, return the clamp switch to the OFF position, and
stop the diesel engine.
Reconnect and tighten the hose to the cylinder.
K. VARIABLE STROKE CYLINDER PRESSURE
The variable stroke cylinder pressure should be approximately 1500 PSI (103 Bar).
If the ICE Model 230 power unit is always used with the Model 160 hydraulic impact
hammer, the variable stroke cylinder pressure should already be properly set.
Whenever a new job is started, or when the 230 power unit has been used to drive
a vibratory driver/extractor, or when an alternate power unit is to be used, the
variable stroke cylinder pressure should always be checked before starting driving
operations.
Read SECTION III - OPERATING INSTRUCTIONS.
II-10
K. VARIABLE STROKE CYLINDER PRESSURE (CONTINUED)
Disconnect the variable stroke cylinder lines (3/8” ID hoses) at the power unit quick
disconnects. Start and warm-up the engine in accordance with SECTION III C.
With the engine warmed-up and running at 1000 RPM, turn the clamp switch, on
the control pendant, to the OPEN position. Observe the pressure on the clamp
gage at the control panel. If the pressure is not 1500 PSI (103 Bar), the clamp relief
valve will have to be re-adjusted to 1500 PSI (103 Bar) using the procedure in
Section IV-N of the maintenance and adjustments chapter.
NOTE: DO NOT SET THE VARIABLE STROKE CYLINDER PRESSURE BY

ADJUSTING THE CLAMP PRESSURE SWITCH. The clamp light [q] on the
pendant should NOT come ON.
L. FUEL, LUBRICATING OIL AND GREASE
The following are reminders for lubrication maintenance procedures that should be
performed in preparation for operation of the Model 160 hydraulic impact hammer.
See the Caterpillar engine manual and the MAINTENANCE AND ADJUSTMENTS
section of this manual for a description of these procedures.
1. Power Unit
a. Check engine oil level

b. Check hydraulic oil level
c. Check for adequate fuel supply
d. Check engine coolant level
2. Hammer
a. Grease Columns
b. Grease sheave
c. Oil trip valve lever pivot
II-11
CONTROL PANEL WITH REMOTE CONTROL-PENDANT
OPERATIONS AND MAINTENANCE

INSTRUCTIONS
j a g f h
c
q
d
ENGINE THROTTLE
HOUR METER
k
TACHOMETER DRIVE
CLOSE
r l
HYDRAULIC FLUID COLD
ENG. OIL PRESSURE CLOSE
e OPEN CLOSE
ON
OFF START
OPEN
WATER TEMP.
m
s REVERSE
OFF
FORWARD
MAIN POWER AMMETER
REMOTE-LOCAL
i
b REMOTE CONTROL
o PENDANT
CLOSE
r
OPEN CLOSE
s
REV.OFFFOR.
n
SLOW FAST
(FIG 1)
III-1
A. COMPLETION OF SET-UP AND MAINTENANCE
1. Complete all preparation as described in Section II.
2. Read Section IV - MAINTENANCE AND ADJUSTMENTS and perform any

required maintenance.
3. Read the Caterpillar engine manual and perform any required maintenance.
B. CONTROL PANEL
1. The control box, (Fig. 1, page III-1) at the side of the power pack, contains the
controls and gages for the diesel engine and the hydraulic impact hammer.
OPERATION AND MAINTENANCE INSTRUCTIONS are posted inside the
door. The remote pendant, which duplicates the controls on the operating
panel, is connected to the bottom of the panel and stored in the box below it.
2. Control panel contains the following controls and gages:
a. Hydraulic fluid cold light - comes on if hydraulic oil is below 60°F (16°C).
b. Main power switch (Circuit Breaker) - on/off switch for 24 volt electrical
power. Must be "ON" for hammer operations.
c. Engine throttle.
d. Engine shut-down reset button - Must be held in, when starting engine, until
oil pressure exceeds 30 PSI (2 Bar).
e. Engine "ON/OFF/START" switch - for diesel engine.
f. Engine tachometer.
g. Engine oil pressure gage.
h. Engine water temperature gage.
i. Engine ammeter.
j. Engine hourmeter.
k. Pressure gage - (Drive - Forward/Reverse).
l. Pressure gage - (Clamp Close) - Short stroke pilot pressure.
m. Pressure gage - (Clamp Open).
n. Engine throttle (Remote electric).
o. Remote-Local switch.
p. Emergency Stop Button - Push to stop engine.
q. Clamp light.
r. Clamp switch - Variable stroke.
s. Hammer Drive/Stop.
3. The OPERATION AND MAINTENANCE INSTRUCTIONS on the control panel

are there as reminders only. They are not complete and therefore not intended
to substitute for a thorough understanding of this Operating Manual.
III-2
C. STARTING AND WARMING UP THE ENGINE
Before starting the engine, read the Caterpillar operation guide carefully. Follow the
engine starting, operation and maintenance procedures in that manual.
The diesel engine should not be started if the temperature of the hydraulic oil is
below 0°F (-18°C). The temperature may be read at the gage on the hydraulic
reservoir. If ambient temperatures below 0°F (-18°C) are anticipated, an immersion
heater for the hydraulic oil is available. Consult ICE for details.
The MAIN SWITCH on the control panel should be ON. Turn the hammer drive
FORWARD/REVERSE switch on the control panel to OFF.
NOTE: Engine will not start unless the hammer switch is in the OFF position.
Pull out the ENGINE THROTTLE about half way.
Hold the shutdown reset button in and turn the ENGINE START SWITCH to START
position. Hold the reset button in until the oil pressure reaches 30 psi 2 Bar. If the
engine fails to start after 30 seconds of cranking, allow the starter to cool for two
minutes before repeating the starting procedure.
As the engine starts, release the ENGINE START SWITCH. It will return to the
RUN position.
Adjust the throttle until the engine is running at 1500 rpm and allow the engine to
warm-up for five minutes.
Allow the temperature of the hydraulic oil to come up to at least 30°F (17°C) before
starting the hammer.
D. WARMING HYDRAULIC OIL
The hydraulic hammer should not be operated at full pressure if the temperature of
the hydraulic oil is below 60°F (16°C). The HYDRAULIC FLUID COLD light on the
control panel will be lit if the oil temperature is below 60°F (16°C). Also, check the
temperature gage on the reservoir.
If the temperature of the hydraulic oil is below 60°F (16°C), set the diesel engine at
1500 RPM and run the hammer until the temperature of the hydraulic oil exceeds
60°F (16°C). The HYDRAULIC FLUID COLD light will then go out. The engine rpm
may now be set to the desired setting.
CAUTION: Do not operate the hammer if the hydraulic oil temperature exceeds
160°F (71°C) as this may damage hydraulic components.
III-3
E. OPERATION OF THE HAMMER
The Model 160 hydraulic hammer is a free-fall type hammer. The ram is lifted by
the hydraulic cylinder and then allowed to free-fall.
1. Rated Hammer Energy

Rated hammer energy of 64,000 ft-lbs (86.8 kN-m) is achieved at an operating
stroke of 4'-0"(1.2 m). Minimum operating energy of 16,000 ft-lbs (21.7 kN-m)
occurs at an operating stroke of 1'(.3 m). The energy at which the hammer is
operating may be determined by measuring the operating stroke, in feet (m),
and multiplying the stroke by the weight of the ram 16,000 lbs (7260 kg) to get
energy in ft-lbs (kN-m). Stroke length may be measured by observing the
stroke length scale (decal) located on the guide angles, and comparing them to
the pointer on the ram. The stroke length scale is marked in 1/4 ft (.076m)
increments.
2. Maximum blows per inch

Driving in excess of 10 blows per inch(25.4mm) is considered practical refusal.
Driving in excess of 10 blow per inch is considered improper use and will void
the hammer warranty.
3. Stroke Control
Stroke of the Model 160 hammer is controlled hydraulically via the location of
the trip valve lever. The hammer may be operated at infinitely variable stroke
length within the 4’-0”(1.2 m) to 1’(.3m) limits. The full stroke setting is the
normal operating mode for the hammer. The reduced stroke setting is engaged
via the control panel.
III-4
E. OPERATION OF THE HAMMER (CONTINUED)
4. Stroke Setting
Stroke setting is controlled by the CLAMP OPEN-CLOSE switch. The full stroke
mode is the normal hammer mode. The hammer will run in at any stroke length
as long as the clamp switch remains in the middle, neutral position. To reduce
stroke setting, turn the clamp switch to the OPEN position briefly. This will
extend the variable stroke cylinder shortening the stroke. When stroke is at the
length required, release the clamp switch. The switch will spring return to its
neutral position. To lengthen the stroke turn the clamp switch to the CLOSE
position briefly. This will retract the variable stroke cylinder lengthening the
stroke. When stroke is at the length required, return the clamp switch to its
neutral position. The stroke length may be changed while hammer is in
operation.
The operation of the hydraulic hammer can be controlled directly from the
control panel, by the remote-control pendant or with the radio control unit.
These control locations have identical switches for hammer stop/start, egine
RPM and stroke setting.
The hammer is controlled by three, two-way switches. These switches are

labeled CLAMP OPEN-CLOSE, FORWARD-REVERSE and FAST/SLOW. The
switches are labeled in this manner because Model 230 also operates ICE
Earth Augers and Vibratory Hammer.
III-5
F. STARTING THE HAMMER
After choosing the desired stroke setting, the hammer is started by turning the
FORWARD-REVERSE switch to the FORWARD position. The hammer will
continue to run as long as the switch is in the FORWARD position.
G. STOPPING THE HAMMER
The hammer is stopped by turning the FORWARD-REVERSE switch from the

FORWARD position to the neutral position. The hammer may be stopped at any
point in its cycle.
H. SINGLE BLOW OPERATION
The hammer can be made to deliver a single blow or a short series of blows using
the FORWARD-REVERSE switch. To deliver a single blow, start the hammer as
described above and as the ram begins to descend, turn the FORWARD-
REVERSE switch back to the neutral position. The ram will fall, delivering a single
blow. The hammer may be stopped after delivering any number of blows.
I. EMERGENCY STOP
When the diesel engine is running, pressing the EMERGENCY STOP button on the
pendant, energizes the coil on the SHUTDOWN RESET. The Shutdown Reset
opens and the engine and the hammer are stoppped.
J. ENGINE SHUT DOWN
Stop the hammer. Allow the diesel engine to run for 5 minutes at 1500 RPM.
Reduce engine rpm to 1000 RPM for 30 seconds. Stop the engine by turning the
ENGINE START switch to OFF. The MAIN SWITCH on the control panel should be
OFF.
III-6
K. HOT & COLD WEATHER OPERATION
Field experience has shown that certain modifications to normal operating

procedures can improve hammer performance in hot or cold weather. Use the
following procedures in hot weather:
1. DO NOT set engine RPM any higher than is necessary to achieve useful
penetration or stroke length. Excessive RPM (oil flow) generates heat.
2. Observe the Drive Pressure Gage while the hammer is operating. The pressure
should approach the relief valve setting only momentarily when the ram impacts
the pile. If the pressure is observed to remain at, or near, the relief valve setting
for a prolonged portion of the operating cycle, reduce engine RPM.
3. When operating at short stroke, reduce engine RPM as far as possible.
4. Be sure that the engine water/anti-freeze ratio is in the recommended range.

insufficient or excessive anti-freeze will reduce the cooling capacity of the
radiator.
5. Check coolant level regularly and keep full.
6. Be sure that the power unit main relief valve is set at the maximum allowable
setting. See Section IV-M.
7. Check the engine radiator and oil cooler often and carefully for dirt, dust or
debris. Blow out cooler and radiator with air or a pressure washer whenever a
build up is observed to maintain maximum cooling efficiency.
8. Be sure that adjacent structures or equipment are not obstructing air flow into or
out of the power unit.
III-7
K. HOT & COLD WEATHER OPERATION (CONTINUED)
Use the following procedures in cold weather: Below freezing weather calls for
particular care so that the hammer is gradually brought up to operating temperature
before submitting it to the shock loading of full driving force.
1. Be sure that the engine water/anti-freeze ratio is in the recommended range.
2. Always warm up the engine before applying any load.
3. In very cold weather (below 20°F / -7°C) the use of a reservoir heater is
recommended. The ICE 230 Power Unit is equipped with a “heater well” to
facilitate installation of an electric heater.
4. In extremely cold, arctic, conditions (below 0°F / -18°C) it may be necessary to

use a special, Arctic type, hydraulic oil. Consult ICE or your hydraulic oil
supplier for recommendations.
5. Consult the Caterpillar engine manual for appropriate, cold weather, engine
lubricant.
6. After the engine is warmed up, set engine speed to 1500 RPM. Turn the
FORWARD/REVERSE switch to REVERSE for 5 minutes. This will circulate
warmer hydraulic oil through, and warm, the Hydraulic Actuator.
7. With the engine running at 1500 RPM, operate the hammer in the short stroke
mode for approximately 3 minutes
8. The hammer may now be operated in the long stroke mode at 1500 engine
RPM.
9. DO NOT operate the engine above 1500 RPM until the hydraulic oil
temperature reaches 60°F (16°C)
10. In extreme cold climates, where 24 hour / day engine running is appropriate,
contact I C E for special “Arctic Circuit” information.
III-8
A. GENERAL
Preventive maintenance includes normal servicing that will keep the hydraulic
hammer in peak operating condition and prevent unnecessary trouble from
developing. This servicing consists of periodic lubrication and inspection of the
moving parts and accessories of the unit. ICE equipment is engineered to provide
reliable operation and a long service life under normal operating conditions.
Equipment reliability and service life can be improved by following the maintenance
procedures in this manual.
Lubrication is an essential part of preventative maintenance, controlling to a great

extent the useful life of the hammer. Different lubricants are needed and some
components require more frequent lubrication than others. Therefore, it is
necessary that the instructions regarding types of lubricants and frequency of their
application be closely followed.
To prevent minor irregularities from developing into serious conditions that might
involve shut-down and major repair, several other services or inspections are
recommended for the same intervals as the periodic lubrications. The purpose of
these services or inspections is to assure the uninterrupted operation of the
hammer. Thoroughly clean all lubrication fittings and caps and their surrounding
surfaces before servicing. Prevent dirt from entering with lubricants and fuel.
The intervals given in the schedule are based on normal operation. Perform these
services, inspections, etc. more often as needed for operation under abnormal or
severe conditions.
IV-1
B. MAINTENANCE - DAILY
PRIOR TO STARTING THE POWER UNIT AT EACH SHIFT CHECK THE

FOLLOWING ITEMS.
Check wire rope on drive cap for wear, and rope clamps for tightness.
Check for proper slack in wire rope holding drive cap. Adjust for 1”-2" (25mm-
51mm) of space between hammer and recoil DAMPENER
Check for loose bolts, nuts, tie-wires or other components. Re-torque bolts and
nuts on new hammer after 4 hours.
Check recoil dampener for damage. Dampener should not be less than 1-
1/4" (32mm) thick with hammer weight on dampener(See Section II-F).
Check for adequate cushion material (See Section II-F).
Check Engine oil level.
Check engine water level.
Lubricate trip valve lever at pivot and wheel on valve.
Lubricate hammer guide columns.
Torque 16 ram / cylinder rod connection bolts.
Check the oil level in the hydraulic reservoir and refill if necessary.
CAUTION: It is absolutely imperative that no dirt or other impurities be permitted to

contaminate the hydraulic oil. Any contamination will drastically shorten
the life of the hydraulic system.
Visually check all hoses for signs of damage or cuts that might cause hose failure
during operation. Be sure all connections are tight, especially the quick-disconnect
couplers.
Electrical components need no maintenance except periodic wiping with a clean,

dry, lint-free cloth to remove dust.
Perform all daily maintenance checks and lubrication indicated in the caterpillar
operation guide.
IV-2
C. AFTER START-UP, CHECK THE FOLLOWING
Check all hydraulic hoses for leaks. Make sure they hang freely with no kinks.
Check both pumps and all hydraulic manifolds for leaks.
Check the filter indicator. The return filter on the power unit must be checked with
the diesel engine running at maximum RPM and oil temperature at or above 60°F
(16°C).
D. MAINTENANCE -MONTHLY
Re-Torque ALL hammer bolts per Torque Table Page VIII-52.
Retorque set screws on cylinder rod super nut.
Inspect ram bumpers at top of stroke.
E. MAINTENANCE - EVERY 4 MONTHS
Have the hydraulic oil tested by a local hydraulic service center. Replace if
required.
Disassemble, inspect and lubricate the connection between cylinder rod and the
ram.
Check the nitrogen gas charge in both accumulators.
F. ANNUALLY
Remove, inspect, lubricate and re-tension the four wire rope assemblies that hold
the hammer together. (Tensioning tool required)
Replace 8 Ram Bearings (P/N 160447).
IV-3
G. SEVERE CONDITIONS
The servicing intervals specified are based on normal operation conditions.

Operation under unusual conditions require some adjustments in servicing
intervals.
When the average temperature is above 89°F (31°C) or below 10°F (-12°C), reduce
servicing intervals to one half of those specified above.
When operating in the presence of dust or sand reduce servicing intervals to one-
third of those specified.
When operating in air with a high salt or moisture, the servicing intervals need not
usually be changed. However, the unit should be inspected weekly to determine if
additional servicing might be required. Have hydraulic oil tested every 2 months.
During stand-by or inactive periods, the servicing interval may be twice those
specified. The unit should be exercised every 30 days or less, depending on
conditions.
H. LUBRICATION
Diesel Engine (Crankcase)
Follow the engine manufacturer’s maintenance schedule and the lubricating oil
specifications outlined in the CATERPILLAR OPERATION GUIDE.
The lubricant shall meet the performance requirements of API Service Classification
“CD” or MIL-L-2104C.
For operation in extreme sub-zero climate, refer to the CATERPILLAR

OPERATION GUIDE, Crankcase Lubricating Oils, or contact the nearest Caterpillar
representative. (CAT bullentin #SEBU5898-06)
New units are shipped with ASHLAND 400M + HDT, 15W40, but the following
multi-grade crankcase oils are recommended for use or replacement in normal
operation (10°F to 90°F) (-12°C to 32°C).
IV-4
H. LUBRICATION (CONTINUED)
AMOCO 15W-40 300

ARCO 15W-40 Fleet S3 Plus
BORON (BP) 15W-40 Vanellus C Extra
CHEVRON 15W-40 Delo 400
CITGO 15W-40 C500 Plus
CONOCO 15W-40 Fleet Supreme
EXXON 15W-40 XD3
GULF 15W-40 Super Duty Plus
MOBIL 15W-40 Delvac Super
PHILLIPS 15W-40 Super HD II
SHELL 15W-40 Rotella T
SUN 15W-40 Sunfleet Super C
TEXACO 15W-40 URSA Super 3
UNION 15W-40 Guardol
VALVOLINE 15W-40 All Fleet
I. HYDRAULIC OIL
Hydraulic System
To maintain the maximum operating efficiency in the precision parts of the

hydraulic system, it is extremely important to eliminate factors which can cause
breakdowns or unsatisfactory performance in the system. Among the most
common of these factors are rust, corrosion, contamination and products of oil
deterioration. Most problems can be minimized or avoided simply by
maintaining a disciplined preventive maintenance program.
Some simple steps to follow as part of that program are:
a. Keep stored oil dry and clean at all times and always store in clean
containers.
b. Always clean tools, spouts, lids, funnels, etc. when used in conjunction with
the transfer of oil.
c. Never put dirty oil into the hydraulic system. Use only clean,
uncontaminated oil of the types recommended below. Never return to the
system any oil which has leaked out.
CAUTION: When replacing or adding oil, be extremely careful to keep foreign

material from entering the system. Foreign material in the hydraulic
system can drastically effect the life and operation of many hydraulic
component parts.
IV-5
I. HYDRAULIC OIL (CONTINUED)
d. Clean or replace filter elements at the first indication that they are dirty or
ineffective.
e. Have hydraulic oil tested by the local supplier on a regular basis.

Laboratory oil analysis can detect contamination, products of hydraulic
component wear, water, oxidation or loss of viscosity long before it is visible
to the eye and before significant component damage has occurred.
f. Prevent water from entering the hydraulic system. Even minute amounts of
water in the hydraulic oil will accelerate oil deterioration and oxidation.
g. DO NOT operate the unit if oil temperature exceeds 160°F (71°C).

Excessive hydraulic oil temperature will accelerate oil deterioration and
oxidation.
Mixing of different manufacturers' hydraulic oil is not recommended. However, it

can be done if the oils are miscible (contain the same base and additive). It may be
necessary to contact an oil supplier to determine this.
New power units are shipped with CHEVRON Clarity AW46 hydraulic oil. This oil
exceeds the requirements of both the E.P.A. and U.S. Fish and Wildlife Service for
non-toxicity and is inherently biodegradable. ADDING ANY OTHER OIL FROM
THE LIST BELOW, WILL CONTAMINATE THE CLARITY OIL AND THE SYSTEM
WILL NO LONGER BE ENVIRONMENTALLY FRIENDLY.
Should the customer choose to use an alternate oil, the following recommendations
may be used when replacing oil in the hydraulic system.
FIRST Preference Group:

CHEVRON Clarity AW46
MOBIL DTE-15
SUN 2105
SECOND Preference Group:

ARCO Duro AW46
CHEVRON Hydraulic AW46
PHILLIPS Magnus A46
SHELL Tellus 46
IV-6
I. HYDRAULIC OIL (CONTINUED)
THIRD Preference Group:

BORON Energol HLP46
CITGO A.W. Hydraulic 46
CONOCO Super 46
EXXON Nuto H46
GULF Harmony 46AW
SUN Sunvis 846
TEXACO Rando HD AZ46
UNION Unax AW46
Whenever oils from the second preference group are used, it is necessary to test
the oil more often to insure that viscosity remains within recommended limits while
in service. Using oils from the third preference group requires even a more
discerning inspection than use of oils from the second group.
The recommended oils were chosen based on the hydraulic system operating
temperature range being 5°F (-15°C) (cold ambient start-up) to 160°F (71°C)
(maximum operating).
When operating in arctic conditions, it is recommended to use an immersion heater

to pre-heat the oil prior to starting . Contact ICE for other arctic operating
procedures. It may also be necessary in extremely cold or hot climates to use a
different viscosity oil which is better adapted to adverse conditions. Contact the
nearest oil supply representative for suggested procedures.
CHEVRON Clarity AW46 hydraulic oil is available from ICE in five gallon cans. See
SECTION VIII - ORDERING PARTS, page VIII-48.
J. CAPACITIES
1. Diesel Engine Crankcase 21 Quarts

2. Hydraulic System (Reservoir) 275 Gallons
3. Fuel Tank Sub-Base (Diesel) 130 Gallons
4. Engine Cooling System 40 Quarts
K. DRAINING AND FILLING HYDRAULIC OIL RESERVOIR
1. The Hydraulic reservoir is drained by removing a plug on the bottom of the

reservoir.
2. The hydraulic reservoir is filled by the manual pump mounted on the back
(engine side) of the reservoir. All oil is pumped into the reservoir through the
return filter (F2) to insure no dirt enters the hydraulic system.
IV-7
L. CHANGING HYDRAULIC RETURN FILTER ELEMENTS
1. The return filters are located on the hydraulic reservoir above the hex key rack.
2. To remove the return filter elements, you must use a filter wrench capable of
accepting a 5" diameter filter. (Available at your local auto-parts store.)
Unscrew the return filter elements counterclockwise to remove. Remove both
filter elements and gaskets from the filter housing.
3. Clean filter housing with a lint free rag.
4. Install the new gaskets to the new filter elements. Apply a light coating of multi-
purpose grease to the top of each gasket.
5. Screw the return filter elements and gaskets clockwise onto the filter housing
until the gaskets make contact to the filter housing base.
6. Using the filter wrench, tighten both return filter elements approximately 3/4 of a
turn.
7. Repeat above with the other two return filters.
8. With four new return filter elements installed, start the power unit and run for
approximately three minutes. CHECK FOR LEAKS.
IV-8
M. SETTING MAIN RELIEF VALVE
1. Locate main relief valve (P/N 400742) on power unit directional control manifold.
Manifold is located behind the large quick disconnects at the coupler panel.
See page VIII-42 item 6.
2. While holding the valve adjusting screw with a hex key, loosen the adjusting
screw jam nut with an open end wrench.
3. Make an initial adjustment of the screw by turning it approximately 1/8th turn in

the desired direction. (Turning the screw clockwise will increase the pressure
setting. Turning counter-clockwise will decrease pressure.)
CAUTION: NEVER ADJUST THE RELIEF VALVE WHILE THE SYSTEM IS UNDER
PRESSURE.
4. Close all power unit doors.
5. Disconnect the pressure and return (largest) disconnects at the power unit.
6. Start and warm up diesel engine. When engine is warmed up, increase engine
RPM to maximum.
7. While observing the DRIVE pressure gage, turn the FORWARD/REVERSE

switch to FORWARD. The pressure should read 4500 PSI (310 Bar).
8. If the pressure is not correct, repeat steps 3 thru 8.
9. When the desired pressure is achieved, hold the adjusting screw with a hex key
and tighten the adjusting screw jam nut.
IV-9
N. SETTING VARIABLE STROKE CONTROL (CLAMP) RELIEF VALVE
1. Locate stroke control relief valve (P/N 100898) on power unit clamp manifold.
Manifold is located behind the small quick disconnects at the coupler panel.
See page VIII-44 item 4.
2. While holding the valve adjusting screw with an open end, loosen the adjusting
screw jam nut with an open end wrench.
3. Make an initial adjustment of the screw by turning it approximately 1/8th turn in

the desired direction. (Turning the screw clockwise will increase the pressure
setting. Turning counter-clockwise will decrease pressure.)
CAUTION: NEVER ADJUST THE RELIEF VALVE WHILE THE SYSTEM IS UNDER
PRESSURE.
4. Close all power unit doors.
5. Disconnect the variable stroke control (smallest) disconnects at the power unit.
6. Start and warm up diesel engine. When engine is warmed up, increase engine
RPM to maximum.
7. While observing the CLOSE pressure gage, turn the CLAMP switch to CLOSE.
The pressure should read 1500 PSI (103 Bar).
8. If the pressure is not correct, repeat steps 3 thru 8.
9. When the desired pressure is achieved, hold the adjusting screw with an open
end wrench and tighten the adjusting screw jam nut.
10. Do not reset the variable stroke control pressure by adjusting the "Clamp
Pressure Switch".
O. TENSIONING WIRE ROPES
1. Clean dirt and excess paint from the threads on the wire rope assembly. Check
that the centering nut and the lock nut can be fully threaded onto these threads
by hand.
2. Install the wire rope assembly from the bottom plate of the hammer. If the rope
gets stuck between the bottom plate and the top plate, it is often helpful to twist
the rope while pushing the rope through. After the threaded end of the rope
assembly exits the top plate, it will be necessary to hand guide the end of the
rope through the lifting bale to the top rope mounting hole. USE EXTREME
CAUTION NOT TO DAMAGE THE THREADS. Grease the threads.
IV-10
O. TENSIONING WIRE ROPES (CONTINUED)
3. When fully inserted, rotate the wire rope assembly until the anti-rotation roll pin
on the wire rope lower fitting slides into the hole in the bottom plate.
4. Thread the centering nut onto the threaded wire rope fitting until it is fully hand
tight. Be sure the machined extension on the nut fits into the hole in the lifting
bale. Repeat steps 1 thru 4 to all four wire rope assemblies.
5. Install the 1.00-8UNC pulling stud (P/N 160781) into the female threaded hole in
the wire rope assembly. Pulling stud must be screwed into the threaded hole as
far as it will go.
6. Slide the cylinder support frame (P/N 160739) over the pulling stud and position
on the lifting bale.
7. Slide tensioning cylinder (P/N 160783) onto pulling stud and secure with two
nuts (P/N 400051). Tighten nuts to remove “slack” from the wire rope. When
tightening this 1.00-8UNC nut, hold rope from turning with the flats on the
threaded rope fitting.
8. Connect a hydraulic hand pump (P/N 160785), with gage, to the tensioning
cylinder.
9. Operate hand pump, extending cylinder, until gage reads 8,500 PSI (586 Bar)
(15 ton).
10. Tighten the centering nut onto the lifting bale by hand.
11. Retract the extending cylinder, re-tighten the 1” nuts, and repeat steps 9 - 11
until correct tension (step 9) is achieved.
12. Remove the tensioning cylinder, pulling stud and cylinder support frame.
13. While holding the centering nut, thread the locking nut onto the threaded rope
fitting and fully tighten against the centering nut. Repeat steps 5-13 to all 4 wire
rope assemblies.
THE TOOLS LISTED ABOVE ARE INCLUDED IN WIRE ROPE TENSIONING KIT
(P/N 810713).
IV-11
P. CHARGING ACCUMULATORS
CAUTION: DO NOT CHARGE (FILL) ACCUMULATORS WITH ANY OTHER GAS

THAN NITROGEN. DO NOT ATTEMPT TO DISASSEMBLE EITHER
ACCUMULATOR WITHOUT REMOVING (VENT) THE ENTIRE GAS
CHARGE.
1. Connect the charging kit (P/N 810833) to a 2000+ PSI (138 Bar) nitrogen gas
bottle.
2. Unscrew the dirt cover from the accumulator gas valve.
3. Connect accumulator adapter assembly (charge kit) to the accumulator, gas

valve, to be charged.
4. Loosen the upper hex nut, by turning CCW to open the accumulator gas valve,
while holding the lower hex from turning.
5. Read the existing accumulator charge pressure on the charge kit gage. See
page V-4 for correct pressures.
6. To increase charge pressure, carefully “crack” open the nitrogen gas bottle
valve until the charge kit gage pressure reaches the specified pressure level.
CAUTION: DO NOT OPEN NITROGEN VALVE RAPIDLY, AS GAS BOTTLE

PRESSURE MAY EXCEED ACCUMULATOR PRESSURE RATING.
7. To decrease charge pressure, open the bleed valve, on the accumulator

adapter, until the charge kit gage reaches the specified pressure level.
8. After the desired charge pressure has been attained, allow the system
temperature to stabilize for 10 to 15 minutes, then recheck the charge pressure.
9. Tighten upper hex nut, by turning CW to close the accumulator gas valve.
10. Remove charge kit and re-install the gas valve dirt cover.
Upper Hex Nut

Dirt Cover
Lower Hex Nut
IV-12
Q. REPLACING RAM CONNECTION
Lay hammer down on flat surface or dunnage, with the trip bar up.
Loosen the set screws, in the super nut (P/N 160465).
Remove 16 3/4” SHCS in the top plate (P/N 160923) holding the cylinder rod in the
ram.
Push the cylinder rod into the actuator cylinder until the threaded end of the cylinder
rod is well clear of the ram.
Remove the nylon insert (P/N 160929), the two elastomers (P/N 160921) the two
back-up rings (P/N 160919) and the bottom plate (P/N 160925) from the ram cavity.
Remove the rod flange (P/N 160927), the super nut, the other nylon insert and the
top plate (P/N 160923) from the cylinder rod.
Carefully clean and lubricate the threads on the cylinder rod, the super nut and the
rod flange. All nuts should thread onto the cylinder rod by hand. Clean any grime
or loose pieces from cavity.
Place the top plate and one of the nylon inserts on the cylinder rod without touching
or marking threads.
Thread the super nut onto cylinder rod, with the hex heads up (toward the top
plate), until the top of the nut is aproximately 0.25 inch from the top end of the
cylinder rod threds.
Thread the rod flange, with the flange end down, onto the cylinder rod until it
contacts the super nut.
Torque super nut set screws to 233 Ft-Lbs (32.2Kg-M) (torque wrench required) in
a circular pattern. Increase torque value in three equal steps. Re-check the final
torque values at least three times to be sure it is not affected by adjacent screws.
Re-install bottom plate, the back-up rings, the elastomers, the other nylon insert
and all of the insert spacers in the cavity of the ram.
Apply Hi-Molly grease to both sides of the rod flange.
Slide cylinder rod assembly in the ram cavity until the rod flange comes in contact
with the nylon insert.
Position the other nylon insert on the insert spacers and then the top plate. Line up
bolt holes, thread and torque all 16 SHCS.
IV-13
R. BOLT TORQUE INFORMATION
The only way to actually tighten high strength bolts is with a torque wrench. Proper
use of the torque wrench is important. To obtain the listed torques, a steady pull
should be exerted to the handle until the desired torque is reached.
The following torque specifications apply to the bolts from the component
assemblies listed. Whenever any of these bolts, are replaced, the given torque
specifications should be adhered to.
LIFTING BALE Page VIII-6
Item 72 5/8"-11 233 Ft-Lbs (32.2Kg-M)
Item 35 1"-8 1009 Ft-lbs (139.4Kg-M)
RAM ASSEMBLY Page VIII-8
Item 20 3/4"-10HHCS 275 Ft-Lbs (38Kg-M)
ACTUATOR MOUNTING Page VIII-9
Item 4 3/4"-10SHCS 417 Ft-Lbs (57.6Kg-M)
ACTUATOR ASSEMBLY Page VIII-14 & 15
Item 3, 7, 30, 37, 38 1/2"-13 119 Ft-Lbs (16.4Kg-M)
Item 14, 23 3/4"-10 417 Ft-Lbs (57.6Kg-M)
Item 34 1"-8 1009 Ft-lbs (139.4Kg-M)
IV-14
S. CHECKING & REPLACING RECOIL DAMPENER
The thickness of a new recoil dampener with hammer weight on dampener is 1

1/2"(38mm). If the thickness is less than 1 1/4"(32mm), the dampener should be
replaced.
To replace recoil dampener: Loosen wire rope holding drive cap to hammer. Pick
up hammer to allow old dampener to be removed. Replace with new dampener.
Re-tighten clamps on wire rope. Wire rope should be adjusted so that with hammer
lifted 1-2"(25-50mm) gap exists between recoil dampener and hammer base plate
(160451).
See FIG 3, Page II-7, for location of recoil dampener
T. CHECKING & REPLACING CUSHION MATERIAL
With new cushion material, the striker plate flange should be 2" (45mm) above the
top of Drive Cap Base DCB-2 (32" leads). If this dimension is reduced by more
than 1/2"(13mm), replace the cushion material.
See Section II F Page II-6 ATTACHMENT OF DRIVECAP for instructions on

replacing cushion material.
IV-15
A. DRIVE PUMP
With the diesel engine running, hydraulic oil is taken from the reservoir by the drive
pump (P1). Prior to entering the drive pump, the oil is filtered by the pick-up filter
(F1). The drive pump flow returns to the reservoir as long as the drive switch
remains in its NEUTRAL position.
Turning the FORWARD/REVERSE switch to FORWARD operates the

DIRECTIONAL CONTROL VALVE (V2) directing the pump flow to the hammer
through a 1.25” hose. Hammer operating pressure is indicated by the drive
PRESSURE GAGE (GA1). Maximum drive pressure is limited to approximately
4540 PSI (303 Bar) by the drive pressure RELIEF VALVE (RV1). The quick-
disconnect couplings (QD1 and QD2) permit de-coupling of the drive hoses at the
power unit.
The CONTROL VALVE (V3), in the hammer, sends the pump flow directly to the
lower (rod end) of the CYLINDER (CYL1). The CONTROL VALVE also sends
pressure to the DUMP VALVE (DV) holding it closed. The ram lifts. Additional
hydraulic oil, stored under pressure in the PRESSURE ACCUMULATOR (A1), adds
to the pump flow causing an upward velocity of the ram that is greater than the
pump flow, alone, would generate. As the CYLINDER raises the ram, oil in the
upper (blind end) of the CYLINDER is exhausted back to the power unit through a
1.50” return hose. Flow resistance in the return hose causes a portion of this
exhaust flow to be, temporarily, stored in the TANK ACCUMULATOR (A2).
As the ram nears the top of its stroke, the trip bar activates the TRIP VALVE (V4),
which is hydraulically connected to the main pump flow via check valve CV6.
Activating the TRIP VALVE directs a pressure signal to shift the CONTROL VALVE
(V3). Pump flow is disconnected, and blocked, from the rod end of the CYLINDER
when the CONTROL VALVE shifts. Shifting the CONTROL VALVE also removes
pressure from the DUMP VALVE, which opens, and allows the ram to fall. High
upward velocity of the ram, however, causes it to continue upward movement,
decelerating, even after the DUMP VALVE is opened. While the CYLINDER is
decelerating to a stop, the rod end is kept full of oil by REPLENISHMENT CHECK
valve (CV4).
V-1
A. DRIVE PUMP (CONTINUED)
After the upward movement of the ram stops, it begins to fall because the DUMP
VALVE is already open. While the ram is falling, and during the deceleration phase
of the cycle, pump flow is stored in the PRESSURE ACCUMULATOR. While the
ram is falling, the CONTROL VALVE is held in its shifted position by a pilot signal
generated by the DUMP VALVE. Oil exiting the DUMP VALVE, at high speed,
goes directly to the blind end of the CYLINDER and does not restrict the downward
movement of the ram. When the ram impacts the pile, the downward movement of
the cylinder stops, and the pilot signal is removed from the CONTROL VALVE. A
spring returns the CONTROL VALVE to its normal (lift) position, and another lift
cycle begins. The CYLINDER will continue cycling, as described above, until the
DIRECTIONAL CONTROL VALVE (V2) is de-energized by returning the
FORWARD/REVERSE switch to the NEUTRAL position. When the trip valve is
activated by the trip bar, a pilot pressure signal is sent to the CONTROL VALVE
(V3) pilot piston, shifting the CONTROL VALVE. The balance of the cycle is the
same as in the long stroke position, above.
B. STROKE CONTROL PUMP
With the diesel engine running, hydraulic oil is taken from the reservoir by the
stroke control pump (P2). Prior to entering the stroke control pump, the oil is
filtered by the pick-up filter (F1). The stroke control pump oil returns to the reservoir
if the clamp switch is in the NEUTRAL position. Returning oil is filtered by the
return filter (F2).
Turning the clamp switch to CLOSE retracts the variable stroke cylinder (CLY2).
Returning the switch to neutral allows the hammer to run at that stroke length.
Turning the clamp switch to OPEN momentarily, extends the variable stroke
cylinder (CLY2) Pressure is indicated by the pressure gage (GA-2). Pilot pressure
in the stroke control circuit is limited to 1500 PSI (103 Bar) by the STROKE RELIEF
valve (RV2). Adequate pressure to extend and retract the variable stroke cylinder
is insured by relief valve (RV2).
The quick-disconnect coupler (QD3 and QD4) permits de-coupling of the stroke
control hoses at the power pack.
V-2
C. OTHER
Returning oil is filtered by the return filters (F2) before entering the reservoir.
INDICATOR GAGE (GA5) shows condition of FILTER (F2).
The shut-off VALVE (MV1) may be closed to permit removal of the pumps (P1 and
P2) without draining the reservoir. CAUTION: DO NO start engine with MV1
closed.
The oil cooler (HE) cools the hydraulic oil returning from the hammer.
65 PSI Check VALVE (CV5) prevents excess pressure from damaging HEAT
EXCHANGER (HE).
A manual pump (MP) is provided to fill the hydraulic reservoir. A CHECK VALVE
(CV2) prevents loss of oil from the reservoir back through the manual pump.
A temperature switch (TS) located in the reservoir operates the hydraulic oil cold
light.
Check valve CV8 and orifice OF2 control the movement of the DUMP VALVE,
allowing rapid closing and slower opening.
CONTROL VALVE orifice OF1 provides controlled leakage of pilot signals.
Check valve CV7 prevents loss of pilot pressure signal into the CONTROL VALVE.
V-3
V. HYDRAULIC CIRCUITRY HYDRAULIC SCHEMATIC
A2
CYL2
100
CYL1
CV7
OF2
V3 CV4
DV
CONTROL 50
VALVE
CV8
TRIP VALVE OF1
OF4 OF3
CV6
3/8"Ø
1 1/2"Ø 1 1/2"Ø
QD4 QD3 1500 QD1 REVERSE QD2 FORWARD
A1
GA2 GA3
V2
4200 REV FOR
PS
GA1
CV1 RV1
A B
V1 C O
P T
4500
1500
RV2 HE
65 CV5
CONTROL
CLAMP
MANIFOLD MANIFOLD
CV2 MP
1200-2600 RPM
ENGINE
3116 P1 P2
GA-4 GA-4 CAT
F2 F2
25 25 25 25
E
MIC MIC MIC MIC
MV1 TS
RESERVOIR F1
V-4
D. HYDRAULIC COMPONENT LIST

Part Page
Notation Description Number Number
A1 Pressure accumulator 160467 VIII-11

A2 Tank accumulator 160467 VIII-11
CV1 Clamp check valve 110149 VIII-45
CV2 Manual pump check valve 100451 VIII-37
CV4 Replenishment check valve Asm 810683 VIII-20
CV5 Bypass check valve 130339 VIII-43
CV6 Trip valve supply check valve 160323 VIII-16
CV7 Control valve check valve 160323 VIII-19
CV8 Dump valve check valve (in cover) 160323 VIII-16
CYL1 Ram lifting (Actuator Asm.) cylinder 810795 VIII-14
CYL2 Variable stroke cylinder 160817 VIII-11
DV Dump valve 810701 VIII-21
E Diesel engine 170239 VIII-36
F1 Pick-up filter 400087 VIII-39
F2 Return filter Element (4) 100518 VIII-36
GA-1 Drive pressure gage 150079 VIII-31
GA-2 Close clamp pressure gage 150079 VIII-31
GA-3 Open clamp pressure gage 150079 VIII-31
GA-4 Return filter gage 100436 VIII-39
HE Oil Cooler 400099 VIII-36
MP Manual Pump 100447 VIII-37
MV1 Shut-off valve 400117 VIII-38
OF1 Control valve orifice 810777 VIII-19
OF2 Dump valve orifice 810777 VIII-17
P1 Drive Pump 170309 VIII-36
P2 Stroke control pump 170393 VIII-38
PS1 Clamp pressure switch 810033 VIII-45
QD1 Hammer return disconnect 110690 VIII-36
QD2 Hammer pressure disconnect 110692 VIII-36
QD3 Shorten stroke disconnect 100777 VIII-38
QD4 Lengthen stroke disconnect 100245 VIII-38
RV1 Drive relief valve 400742 VIII-43
RV2 Stroke relief valve 100898 VIII-45
TS Temperature switch 400115 VIII-38
V1 Stroke control valve 110147 VIII-45
V2 Directional control valve 400786 VIII-43
V3 Control valve Asm 810621 VIII-18
V4 Trip valve 810815 VIII-11
V-5
A. DIESEL ENGINE
The BATTERY provides 24 volt current to start the diesel engine. With the
FORWARD-REVERSE switch turned to OFF, turning the ENGINE START SWITCH
to START energizes the START RELAY which energizes the START MOTOR and
turns over the diesel engine. If fuel is available, the diesel engine will start. In order
for fuel to be available to the engine, the SHUTDOWN RESET must be closed to
energize the FUEL SOLENOID. The FUEL SOLENOID opens the fuel rack and
allows fuel to flow to the engine. With the diesel engine running, the AMMETER
indicates charging amperes. The HOUR METER indicates engine operating hours.
The MAIN POWER (CB2) switch, when in the ON position, provides electrical
power to the balance of the power unit and hammer controls. The MAIN POWER
switch is also a circuit breaker, providing over current protection to the electrical
system. Turning the MAIN POWER switch to the OFF position disables the
pendant and power unit controls. Turning OFF the MAIN POWER switch DOES
NOT disable the safety shut down system (SHUTDOWN RESET) or the engine
HOUR METER.
A system of safety controls shuts off the fuel supply, thereby stopping the diesel
engine, in the event that engine water temperature is too high or engine oil pressure
is too low. The heart of the safety system is the SHUTDOWN RESET which is
normally closed, thereby providing current to operate the HOUR METER and to
energize the fuel rack and allows fuel to flow to the diesel engine. The
SHUTDOWN RESET must remain closed so that fuel continues to flow to the diesel
engine.
If the coil in the SHUTDOWN RESET is momentarily energized, the SHUTDOWN

RESET will open shutting off the fuel to the diesel engine. The engine will stop.
The coil may be energized by any one of the following devices:
1. Engine Oil Pressure Gage - If oil pressure is below 15 PSI (1 Bar), the contacts
of the gage will be closed providing current to energize the coil. On start-up, the
reset button of the SHUTDOWN RESET (on the control panel) must be held
until oil pressure exceeds 30 PSI (2 Bar).
2. Engine Water Temperature Gage - If water temperature exceeds 210°F (99°C),

the contacts of the gage will close energizing the SHUTDOWN RESET coil.
3. Emergency Stop: - Pressing the emergency stop button, on the remote pendant,
will energize the SHUTDOWN RESET coil.
The diesel engine is stopped by turning the ENGINE START SWITCH to OFF. This
will de-energize the FUEL SOLENOID shutting off the fuel to the engine. Turning
the ENGINE START SWITCH to OFF also disconnects all other electrical circuits.
VI-1
B. STROKE RANGE SELECT
With the diesel engine running and the MAIN POWER switch ON, turning the
Clamp switch (OPEN-CLOSE) to OPEN energizes the open-clamp solenoid (OPEN
SOL). This extends the variable stroke cylinder, fully extending this cylinder puts
the hammer in minimum stroke mode. Release the switch to the neutral position,
for regular operation. This is the recommended starting position.
Clamp switch (OPEN-CLOSE) to CLOSE energizes the close-clamp solenoid
(CLOSE SOL) on the clamp valve (V1). This retracts the variable stroke cylinder,
fully retracting this cylinder puts the hammer in full stroke mode. Returning the
switch to the neutral position. De-energizes the close clamp solenoid and holds the
stroke control cylinder at the desired position.
Adjusting the position of the variable stroke cylinder to where the stroke length most
adequately suits the job conditions. This can be done at any time as described
above.
NOTE: The pressure switch (PS1) shown in the stroke control portion of the
electrical schematic is not used in the operation of the Model 160 hydraulic
impact hammer. The adjustment of this switch should remain at the setting
required for a Model 1123 Vibratory Driver/Extractor.
C. HYDRAULIC HAMMER
hammer switch (FORWARD-REVERSE) to FORWARD energizes the hammer-start
solenoid (V2A) on the DIRECTIONAL CONTROL valve. The DIRECTIONAL
CONTROL valve shifts, sending hydraulic oil to the hammer and the hammer
begins to run. Turning the hammer switch to the OFF position will stop the hammer
from lifting again.
D. REMOTE - LOCAL CONTROL
Located on the control panel. Turning the LOCAL-REMOTE switch to LOCAL

activates only the hammer and stroke control switches located on the control panel.
Turning the LOCAL-REMOTE switch to REMOTE only permits operation of the
hammer from the control pendant. The EMERGENCY STOP button, on the
pendant, is functional at all times.
VI-2
E. ENGINE THROTTLE
The ENGINE THROTTLE switch is located on the remote pendant. With the diesel
engine running, the MAIN POWER switch ON and the REMOTE-LOCAL switch in
the REMOTE position, momentarily turning the ELECTRIC THROTTLE switch to
the FAST position will retract the motor driven throttle actuator and increase engine
RPM. Turning the ELECTRIC THROTTLE switch to SLOW will extend the motor
driven throttle actuator decrease engine RPM
F. TACHOMETER
The TACH SENDER generates an electrical pulse every time a flywheel gear tooth
passes this sensor. This high frequency signal is converted to a visual indication of
engine RPM by the TACHOMETER GAGE (TACH). The MAIN POWER switch
must be ON and the engine running for the TACH to function.
G. OTHER
With the MAIN POWER switch ON, if the temperature of the hydraulic oil is below
60°F(16°C), the TEMPERATURE SWITCH closes and the HYDRAULIC OIL COLD
light comes on. When the temperature of the hydraulic oil exceeds 60°F(16°C), the
TEMPERATURE SWITCH turns off the HYDRAULIC OIL COLD light.
VI-3
VI. ELECTRICAL CIRCUITRY ELECTRICAL LAYOUT
HOUR
26 5
21 1
TACH PENDANT
1
HYD. OIL LT CLAMP LIGHT

25 1
5 1
ENG. 3 1
OIL 16 GA 1
RED WHITE 2 7
BLACK
14 7
16 GA 1 OPEN
10
16 SHUTDOWN RESET
25 GA 1 19
B 8
14GA
S 25 CLOSE
ENG.
TEMP. C 21
30 11
ENG. START SW. CLAMP SW
2 13
10
16 GA BAT 8 30
25 14 GA ST 12 1 1 1 2 2 3 4 5 5 7 8 9 10 11 12 13 14 21 21 25 25 26 28 29 30 31 32 33 4
ING
16 GA 28
AM 19 SLOW
VIBRO SW FAST
5 31
MAIN POWER 13 29 32
19 4
14GA LINE 31 28 1
8 11
2 GA 3 LOAD
3 28 33
16GA 30 29
REMOTE-LOCAL
12
NC 14 GREEN
16 GA-3
NO WHITE
S/O CORD
C 5 BLACK
CLAMP TEMP SW
P-25
L-33
1 K-32
2
CLOSE OPEN J-31
12 H-30
G-13
16 GA-12 S/O CORD X 600" LG F-11
E-10
D-8
WHITE C-7
1
B-4
9 GREEN A-1
16 GA-3 S/O CORD X 144" LG
10 BLACK
NC 9 WHITE WHITE BLACK
NO 7 BLACK
16 GA-3 S/O
C 8 GREEN
CORD X 144" LG
PRESS SW
GREEN
TYP. S/O CORD END

REVERSE FORWARD
EB-1 EB-2
DRIVE + - + -
4 BLACK
16 GA-3 S/O CORD X 144" LG 8 GA.
1 WHITE
TO ENG.
13 GREEN
1 WHITE 16 GA-3 S/O CORD X 144" LG 84"

1
8 GA.
2 24
1
TACH 16GA X 60"
SENDER 10 GA.
26 16 GA X 84"
16GA X 60"
C 11
8 GA.
FUEL TO ENG. 84" START RELAY
21 3 23
SOLINOID 16GA X 55" 8 GA
10 GA
32 RED
ELECTRIC 16GA X 60"
THROTTLE ALTERNATOR
33 YELLOW
16GA X 60"
VI-4
VI. ELECTRICAL CIRCUITRY ELECTRICAL SCHEMATIC
BATTERY - 24 VDC - (2) 31P
SHUTDOWN RESET
C TO ENGINE
19 B 1
M1 C S B
21 BLACK
HOUR METER
RED
21 STARTER START RELAY

MOTOR
24
C
25 ENG 23
25 WATER TEMP
V
11
FUEL SOL 3 +
ENG 12 W 2 RED
OIL PRESS 2 STA
BAT
ING OUTPUT
CB2 19 AM 1
NEG
5 19
ALTERNATOR
ENG START SW BLACK (RIGHT)/OPEN
MAIN POWER 25
C
V1B
OPEN 10
10 PS-1 WHITE (LEFT)/CLOSE
CLAMP
8 8 C
9 V1A
12 28
CLOSE P.SW.
10 8
BLACK
11
CLOSE
OPEN
CLAMP
CLAMP LIGHT
29
SLOW
30 30 11 7
7 25
FAST
LOCAL 32 31 EMERG
REV STOP
REMOTE
CLAMP LIGHT
33 FOR ENCLOSED ITEMS IN

5
1 31 4 13 31 CONTROL PENDANT
31 1
1 1
ELECTRIC THROTTLE
YELLOW 33
M
11
29 RED 32
REV 13 LEFT (GREEN) V2B REVERSE (WHITE)

28 C
FOR 4 FORWARD (WHITE)
C
RIGHT (BLACK) V2A
5
5 BLACK
GREEN 14 3
2 1
TEMP SW 70° F
HYD. FLUID COLD LIGHT
5 1
TACH
26 1
TACH
SENDER 1
VI-5
H. ELECTRICAL COMPONENTS LIST
NOTATION REFERENCE PART NUMBER
ALTERNATOR Battery charging alternator See Caterpillar Parts Book

AMMETER Ammeter 110371
BATTERY 12-volt battery 400890
CB2 Main power circuit breaker 400141
EMERG STOP Emergency stop button 130507
ENGINE OIL PRESS Engine oil pressure switch and gage 100329
ENGINE WATER TEMP Engine water temperature 130251
switch and gage
ENG. START SW. Engine start switch 130259
FUEL SOL Fuel valve solenoid See Caterpillar Parts Book
HYD. FLUID COLD Hydraulic oil warning 100355
LOCAL-REMOTE Local/remote switch 140361
M Engine throttle actuator 110246
M1 Hour Meter 100343
OPEN-CLOSE Clamp switch 130155
PS Pressure Switch 810033
SHUTDOWN RESET Engine Saftey Shutdown 130257
START MOTOR Engine starter See Caterpillar Parts Book
START RELAY Engine start relay See Caterpillar Parts Book
TACH Tachometer gage 130953
TACH SENDER Tachometer flywheel pickup 130959
TEMP SWITCH Temperature switch 400115
THROTTLE Engine throttle switch 100566
V1A Clamp closed solenoid 110147
V1B Open-clamp solenoid 110147
V2A Hammer start solenoid 400786
V2B Reverse solenoid (Auger only) 400786
VI-6
VII GENERAL DATA
A. ABBREVIATIONS
The abbreviations shown below are used throughout the parts lists and various
other parts of the manual.
ASM. Assembly
BHCS Button Head Cap Screw
Cyl. Cylinder
DC Direct Current
FHCS Flat Head Cap Screw
FLCS Flanged Head Cap Screw
Gr Grade
HC High Collar
HHCS Hex Head Cap Screw
HHPP Hex Head Pipe Plug
HSSS Hex Socket Set Screw
Hyd. Hydraulic
ID Inside Diameter
Lg. Long
mm Millimeter
Mtg. Mounting
NPT. National Pipe Thread
OD Outside Diameter
PHMS Phillips Head Machine Screw
P/N Part Number
Qty. Quantity
RHMS Round Head Machine Screw
Sch. Schedule
SHCS Socket Head (Allen) Cap Screw
SHPP Socket Head Pipe Plug
SHSS Socket Head Shoulder Screw
S/N Serial Number
Sol. Solenoid
UNF Unified National Fine thred
UNC Unified National Course thread
VII-1
VII. GENERAL DATA
B. SCREWS AND BOLTS
1. Practically all connections on the unit are made with socket head (Allen) cap
screws. These high-strength screws are available at most industrial supply
houses.
2. Screws and bolts are designated in the PARTS LIST in abbreviated form.
(Refer to sub-section A, above, for specific abbreviations). Listed below is a
typical screw description: .50 - 13 UNC x 1.50 Lg SHCS
.50 = Diameter 13 UNC = Threads Per Inch

1.50 Lg = Length SHCS = Screw Type Abbreviation
3. Some screws or bolts require a specific torque when replacing. For

identification of these bolts and a more thorough understanding of torque, refer
to page IV-14.
C. SERIAL NUMBER LOCATIONS
1. The following ICE units are serial numbered separately:
a. Impact Hammer
b. Power Unit
2. In addition to the serial number plate itself (on impact hammers and power
units), the serial number is stamped into each unit in one or more places as
follows:
a. Impact Hammer stamped twice - once on the base of the transfer tube, once
on the top plate near trip bar.
b. Power unit stamped twice - once on control panel side of unit at upper right
corner of reservoir, once on sub-base inside door below hex-key rack.
VII-2
A. PROCEDURE
1. When ordering parts, be sure to include the model and serial number of the unit
or component. The serial number may be located by referring to SECTION VII,
SERIAL NUMBER LOCATION. Confirm all telephone orders immediately to
avoid duplicating shipment.
2. ORIGINAL EQUIPMENT; Where component serial numbers are given, these

apply only to equipment and components originally furnished with the unit.
Where equipment has been changed or upgraded these numbers may not be
an adequate description.
3. SHIPMENT; Specify shipping address, phone number, billing address and

method of shipment. UPS and air express shipments must have street address
for delivery. All shipments will be made freight collect unless instructed
otherwise.
4. SHORTAGES; Claims for shortages, damage or errors should be made

immediately upon receipt of parts. No responsibility will be assumed for delay,
damage or loss of material while in transit. Broken, damaged or lost material
should be refused or a full description made of damage or loss to the carrier
agent on the freight or express bill.
5. RETURN OF PARTS; If for any reason you desire to return parts to the factory
or to any distributor from whom these parts were obtained, you must first secure
permission to return the parts. Shipping instructions will be given along with this
permission. A fifteen percent handling charge must be assessed against the
returned shipment unless an error is made by the factory or by the distributor
when filling your order.
VIII-1
B. FITTING DESCRIPTION KEY
A Fitting Decription code is used to describe all fittings in the Parts Identification
section of this manual. The key below explains the structure of the code number in
detail.
FITT 2 L - 16 M 12 J 00 0 - 00L 0 0 0 1
SELECTOR INDEX MATERIAL

2 - INCH FITTING 1 - CARBON STEEL
9 - METRIC FITTING 2 - BRASS
4 - STAINLESS STL
CONFIGURATION OR
5 - AAR MAL IRON
SHAPE OF FITTING
6 - MALEABLE IRON
S - STRAIGHT FITTING
8 - FORGED STEEL
L - 90 Deg. ELBOW
V - 45 Deg. ELBOW SPECIAL NOTATIONS
T - TEE
C - CAP PRESSURE RATING
P - PLUG 0 - NONE
U - UNION 1 - 125 LB.
X - CROSS 3 - SCH 40
(FOURTH END FITT'G REQ'D.) 4 - SCH 80
FIRST END SIZE INSTALLATION AID OR

* IN 1/16THS OF AN INCH STYLE OF HEAD
(INDEX 2) 0 - NOT APPLICABLE
IN MILLIMETERS (INDEX 9) H - REGULAR HEX
SEE GENERAL SPECIFICATION Q - SQUARE HEAD (EXT.)
SHEET FOR SEQUENCE OF ORDER R - SQUARE HEAD (INT.)
S - HEX HEAD (INT SOCKET)
FIRST END FITTING STYLE
T - HEX HEAD (EXT.)
SEE FITTING STYLE SELECTOR
CHART SC-1 LENGTH CODE
(ELBOWS & NIPPLES)
SECOND END SIZE
__L - LONG (ELBOW)
IF APPLICIABLE - SEE
__X - EXTRA LONG (ELBOW)
FIRST END SIZE
__C - CLOSE (NIPPLE)
SECOND END FITTING STYLE
PIPE NIPPLES (LONG) ONLY
IF APPLICABLE - SEE
IN DEC. INCHES FOR INDEX 2
FIRST END FITTING STYLE
050 = 5.0 INCHES
THIRD END SIZE 105 = 10.5 INCHES
IF APPLICABLE - SEE
IN MILLIMETERS FOR INDEX 9
FIRST END SIZE
120 = 12.0 MILLIMETERS
THIRD END FITTING STYLE 084 = 8.4 MILLIMETERS
IF APPLICABLE - SEE
FOURTH END SIZE &
FIRST END SIZE
FITTING STYLE
(CROSSES ONLY)
SEE FIRST END FITTING SIZE OR
* EXCEPTIONS
END STYLE
90 = 10" 96 = 6"
92 = 12" 98 = 8"
94 = 14" 99 = NON CODE SIZE
VIII-2
B. FITTING DESCRIPTION KEY (CONTINUED)
FITTING STYLE SELECTOR CHART
SC-1
FOR END FITTING STYLE SELECTION
JIC MALE JIC FEMALE

M 37 Deg. FLARE J 37 Deg. FLARE
(& SWIVEL)
MALE PIPE FEMALE PIPE

P NPT Q NPTF
S.A.E. MALE
S.A.E. FEMALE
R 0-RING
(& ADJUSTABLE)
K O-RING
JIC MALE FEMALE PIPE

B 37 Deg. FLARE
BULKHEAD
N NPSM-SWIVEL
MALE PIPE SPLIT FLANGE

D NPT SWIVEL F 3000 PSI.
CODE 61
B.S.P. MALE SPLIT FLANGE

S PIPE H 6000 PSI.
CODE 62
VIII-3
C. HOSE DESCRIPTION CODE
The HOSE DESCRIPTION CODE is a 24 digit number enabling easier and quicker
identification whenever a hose replacement is desired. The key below explains the
structure of the coded number in detail.
HOSE 125 R11 F 9 24 P 0 20 L0395 S
HOSE I.D. IN INCHES

2 PLACE DECIMAL SPECIAL CODE
(125=1-1/4”) (050=1/2”) etc. O=None
S=Spring Guard
L=S.S. Braid
SAE OR MANUFACTURER D=Offset
RATING (or Special Code)
(PT4=Power Track)
(AQ1=Aeroquip H-Pac)
(TF1=Teflon)
(R01=SAE Rating 100R1) etc. LENGTH IN INCHES
(PT6=Power Track 6000 PSI) (1 PLACE DECIMAL)
(0395=39-1/2”)
FIRST END-TYPE OF FITTING (1242=124-1/4”)
(F=3000 lb Flange) (P=Male Pipe) etc.
(H=6000 lb Flange) (M=37° Male JIC)
(J=JIC Swivel 37°)
FIRST END-BEND ANGLE

(0=None) (9=90°)
(3=30°) etc.
FIRST END-SIZE IN 1/16 ths
SECOND END-TYPE OF FITTING

(See codes for FIRST END)
SECOND END-BEND ANGLE

(See codes for FIRST END)
SECOND END-SIZE IN 1/16 ths
VIII-4
D. PARTS IDENTIFICATION
1. Parts lists and drawings are included on the following pages for the equipment
components shown below:
a. Impact Hammer Asm 800537 VIII-6

b. Actuator Asm 810795 VIII-14
c. Control Valve Asm 810621 VIII-18
d. Check Valve Asm 810683 VIII-20
e. Din Cartridge Asm 810701 VIII-21
f. 32" Lead Guides 800535 VIII-22
g. Hose Assemblies - Interconnecting 800561 VIII-24
h. Power Unit - Enclosure 800379 VIII-26
i. Control Panel Asm 173011 VIII-28
j. Pendant Assembly 800393 VIII-32
k. Power Unit - Internal 175003 VIII-34
l. Control Manifold Asm 173013 VIII-42
m. Clamp Manifold Asm 810035 VIII-44
n. Pendant Extension Cable 800059 VIII-47
2. The spare parts list SECTION VIII - RECOMMENDED SPARE PARTS contains
spare parts which may be very useful in keeping down-time to a minimum,
especially in remote or secluded job sites where unforeseen communication
problems could cause delay of the delivery of an awaited part.
These RECOMMENDED SPARE PARTS may be ordered beforehand,

individually or as a package group as shown in the PARTS LIST.
VIII-5
IMPACT HAMMER ASM 800537
44 48 118 76 34 61
105 119
37
84 85
36
114
68 72
10
35
86
43
18 70 71
49
81
42
54
63
116 117
22
80
28
VIII-6
54
40 92
24 77 90
78 89
78 88
43 91
38
38
77
39
24 90
83 91
40
53 113
43 78 EXTEND
89 91
92
41 RETRACT
43 91
82
SECTION A-A
1 5 6 7 73
33
43 91
43 91
82
81 82
52 57
60
55
45 62
43 91
64 65
82
45 103
64 65
SECTION B-B 67 68 69 56 57 58 59
VIII-7
121 122 26 30 25 8
SECTION C-C
17 15 12 13 13 12
14
115
17
16
11
20 57
SECTION D-D
VIII-8
100 96 108 109 110 111 112 96 66 22
2.25-2.50
SECTION E-E
25
22
6.50
TYP
.38
4 77 68 72 98 120
9.50 9.50
SECTION F-F
VIII-9
19
32
75
51
87
21
93
19 32 75
94
57 99
58
79
106 47 23
46 50
74
24
76
101
31
95 95
97 97
29
102
104
27 105
27 107
107
VIEW G
VIII-10
Part
Item Number Qty. Description
1 160425 1 Left Lifting Bale

2 160453 1 Top Plate
3 810795 1 160B Actuator Assembly
4 160489 6 .75-10UNC X 9.00 Lg SHCS
5 160881 1 Trip Bar Bushing
6 160285 2 .50 Belleville Washer
7 100445 2 .5-13 X 1.0 Lg SHCS Loc Wel
8 160992 4 Guide Post 160B / 220
9 810803 1 Ram 160
10 100209 24 1.00 Lock Washer Medium
11 160465 1 2.75 Supernut
12 160919 2 Back-Up Ring
13 160921 2 Elastomer
14 160923 1 Ram Connection Top Plate
15 160925 1 Ram Connection Bottom Plate
16 160927 1 Rod Flange
17 160929 2 Nylon Insert
18 100717 2 FITT2L-06P04M000-0000001
19 810813 2 Orifice Plug
20 160311 16 .75-10UNC X 6.50 Lg SHCS
21 160817 1 Cylinder 24”
22 160986 1 Trip Bar 160B
23 810815 1 Trip Valve Modified
24 100121 14 .50 Lock Washer Medium
25 160990 4 Wire Rope Asm 160B / 220
26 120521 4 Spring Pin .375 X 2.00 Lg
27 160821 2 Hose Clamp
28 160451 1 Base Plate
29 160823 2 Brass Bushing
30 160447 8 Column Bearing
31 160825 1 Trip Lever
32 810811 2 Orifice Fitting
33 160495 4 Roll Pin .750 X 150 Lg
34 160994 1 Sheave Bracket 160B / 220
35 100213 24 1.0-8 X 2.50 Lg SHCS Loc Wel
36 810659 4 Centering Nut
37 160471 4 3.00 H Finish Hex Nut
38 160467 2 Accumulator
39 160475 8 Accumulator Bracket
40 160433 2 Accumulator Manifold
41 160477 1 HOSE150PT4F024J924L0212C
42 160479 1 HOSE150PT4M024F024L0722C
43 100596 14 #24 Split Flange Half
VIII-11
Part
44 130321 8 .75 X .75 Bar Per In

45 100163 4 .5-13 X 1.75 Lg SHCS Loc Wel
46 160875 1 Slide
47 160877 2 Retainer Plate
48 160419 1 Sheave Pin
49 160481 1 HOSE150PT4F924F024L0592C
50 100631 4 .25-20 X 2.0 Lg SHCS
51 160935 2 Cylinder Pin
52 400037 4 .75-10 X 1.25 Lg SHCS
53 100027 8 .50 Hi-Collar Lock Washer
54 160483 1 HOSE150PT4J024F024L0585C
55 160209 1 Elastomer Bracket
56 400069 4 .75-10 x 2.00 Lg SHCS
58 100587 4 .75-10 Hex Nut
59 100796 1 Elastomer
60 160211 1 Clamp Mounting Plate
61 160469 1 Sheave
63 160793 4 Belleville Washer
65 130117 4 .375 X1.5 Lg SHCS
66 160905 1 1.00-8UNC Flex-Lock Nut
67 100005 4 .625-11 X 1.75 Lg SHCS Loc Wel
69 100273 4 .625-11 Hex Nut
70 100299 2 Primer/Gal
71 100298 2 Ice Green Paint/Gal
72 100575 5 .625-11 X 1.25 Lg SHCS
73 160427 1 Right Lifting Bale
74 100559 4 .25 Lock Washer
75 100719 2 HOSE025R02J004J004L03000
76 160886 1 Trip Lever Spring
77 110119 2 2-225 O-Ring
78 130049 16 .5-13 Esna Nut
79 160869 1 Cylinder Support
80 160457 1 Bumper
81 160485 1 HOSE150PT4F924F024L0706C
82 100119 12 .5-13 X 1.25 Lg SHCS Loc Wel
83 110057 2 1.5 Solid Flange
84 160557 1 FITT2V-20P20N000-0000001
85 400159 1 FITT2S-24P20Q000-000H001
86 160493 2 FITT2V-06P06N000-0000001
VIII-12
Part
87 300447 4 .1875 X 2 Lg Cotter Key

88 160501 8 .50-13UNC X 10.00 Lg FHCS
89 100079 8 .5-13 X 4.00 Lg SHCS
90 100829 8 .5-13 X3.50 Lg SHCS
91 160804 9 2-225 Face Seal
92 160503 2 FITT2P-20R000000-0000001
93 160865 1 2" U-Bolt
94 160867 4 .44-14UNC Hex Nut
95 130057 2 FITT2L-06M06R000-000H001
96 120299 2 1.00 H. S. Flat Washer
97 130561 2 HOSE038R02J006J006L0700C
98 160549 2 Top Bumper
99 100443 2 .437 Lock Washer
100 810761 1 Modified 1.00-8 UNC X 8.00 SHCS
101 100513 6 .5-13 X 1.5 Lg SHCS
102 300089 1 .375-16 X 4.0 Lg SHCS
103 110317 1 Hose Clamp
104 400149 1 .375 Lock Washer
105 100762 2 .375-16 UNC Esna Nut
106 100067 2 .75-10 X 2.5 Lg Shcs Loc Wel
107 110913 4 .38-16 X 3.00 Lg SHCS
108 160909 1 Nylon Washer
109 160911 1 Urethane Bushing
110 160913 1 Nylon Anchor
111 160915 2 Pin
112 160917 4 Spring Pin .19dia X 1.25 Lg
113 100011 8 .50-13 X 2.0 Lg SHCS
114 160559 1 FITT2V-24P24N000-0000001
115 160941 16 Insert Spacer
116 160757 1 160 Serial Number Plate
117 130381 4 Rivet
118 100229 1 Grease Fitting
119 100827 1 .375-16 X 3.5 Lg. SHCS
120 160892 2 Top Bumper Plate
121 160383 1 Strike Block
122 160455 1 Recoil Dampner
VIII-13
ACTUATOR ASM 810795
27
4
37
36
41
22 25 35
VIII-14
ACTUATOR ASM 810795
4 29 24 26
30 31
31 39
5 11
38
28 38
16
16
23
21
13
20
18
48
14 15
19
16
12
49
43 47
25
16
22 17
8 44 34 40
10 46 45 6 7 3 2 1 32 33 42 49
VIEW A
VIII-15
ACTUATOR ASM 810795
Part
1 160883 1 160 Actuator Base

2 810621 1 Control Valve Asm.
3 160337 4 .5-13UNC X 5.50 Lg SHCS
6 160437 1 Gland 160
7 100079 10 .5-13 X 4.0 Lg SHCS
8 160507 1 -349 O-Ring 90 Duro
9 160511 2 Wear Ring
10 160513 1 Rod Seal
11 110119 1 2-225 O-Ring
12 160984 1 Rod 160B
13 160415 1 Cylinder
14 400045 8 .75-10 X 3.5 Lg SHCS
16 160519 4 -356 O-Ring 90 Duro
17 100646 1 FITT2P-02P000000-000S007
18 160413 1 Piston
19 160265 2 Piston Seal
20 160521 1 Nut 2.25 Esna
21 160417 1 Tube
22 130057 2 FITT2L-06M06R000-000H001
23 160349 8 .75-10UNC X 7.50 Lg SHCS
24 160281 8 .75 Belleville Washer
25 160323 2 Cartridge
26 160315 8 .75-10UNC Esna Nut
27 160523 1 Transfer Housing
28 160815 1 FITT2L-24F24M000-0000008
29 160813 1 2.50PA - 1.50PA Adapter
30 100513 4 .5-13 X 1.5 Lg SHCS
31 400379 2 2-232 O-Ring 90 Duro
32 160525 1 Cartridge Cover
33 810701 1 Din Cartidge Size 80
34 100212 4 1.0-8 X 4.00 Lg SHCS Loc Wel
35 100845 2 FITT2P-04P000000-000S007
36 810683 1 H I H Check Valve Asm
37 160343 6 .5-13UNC X 4.25 Lg SHCS
38 100119 8 .5-13 X 1.25 Lg SHCS Loc Wel
39 160533 1 2.50 Blank Flange Code 61
40 400787 4 1.00 H. C. Lock Washer
VIII-16
ACTUATOR ASM 810795
Part
41 110929 2 2-226 O-Ring 90 Duro

42 160871 1 -352 O-Ring 90 Duro
43 400213 1 FITT2P-06P000000-000S007
44 160509 1 -349 Back-Up Washer
45 160515 1 Rod Wiper
46 160517 1 Modular Backup
48 160591 1 Wear Band
49 110602 1 111 0-Ring
VIII-17
CONTROL VALVE ASM 810621
19
12
12
15
3 4 7 21
7
6 18
10 16
8 17
1
5
9
12
11
13
15
14
12
VIII-18
CONTROL VALVE ASM 810621
Part
1 160157 1 Valve Body

2 160159 1 Spool
3 160147 1 Spring Cap
4 160153 1 Spool Stop
5 160275 1 Spool Spring
6 100105 1 .312-18 X 1.0 Lg SHCS Loc Wel
7 100037 2 2-222 O-Ring 90 Duro
8 160856 4 .25-20UNC X 5.00 Lg SHCS
9 160161 1 Cover
10 160333 4 .375-16UNC X 1.75 Lg SHCS
11 160329 1 109-O-Ring 90 Duro
12 100646 4 FITT2P-02P000000-000S007
14 160323 1 Cartridge
15 140255 4 2-113 O-Ring 90 Duro
16 400149 4 .375 Lock Washer
17 100559 4 .25 Lock Washer
18 100293 1 .312 Flat Washer
19 100845 1 FITT2P-04P000000-000S007
21 110119 1 2-225 O-Ring
VIII-19
CHECK VALVE ASM 810683
1 2 7 4 3 5 6
HIH CHECK VALVE 810683
Part
1 160411 1 Check Body

2 160441 1 Check Poppet
3 160443 1 Check Cover
4 400379 1 2-232 O-Ring 90 Duro
5 110735 4 .50-13 X 2.50 Lg SHCS
6 100121 4 .50 Lock Washer
7 160765 1 Spring
8 110929 2 2-226 O-Ring 90 Duro
VIII-20
DIN CARTRIDGE ASM 810701
3 4
DIN CARTRIDGE ASM 810701
Part
1 160795 1 Cartridge Housing

2 160797 1 Cartridge Piston
3 160373 1 Outer Spring
4 160375 1 Inner Spring
5 160836 1 80 Din Face Seal
6 160893 1 -431 O-Ring 90 Duro
7 160255 1 -345 O-Ring 90 Duro
8 160897 1 -431 Back-up Ring
9 160899 1 -345 Back-up Ring
10 160834 1 80 Din Shim Pack
VIII-21
26" LEAD GUIDES 800535
3
5 4
3
4
VIII-22
26" LEAD GUIDES 800535
Part
1 160988 4 Lead Guide 160B / 220

2 160229 4 Guide Clip
3 160317 48 1.25-7UNC X 3.00 Lg SHCS
4 300491 48 1.25 Lock Washer
5 160319 16 1.25-7UNC Hex Nut
VIII-23
INTERCONNCTING HOSES 800561
2 1 3 4 5 4
PRESSURE
7 6 8 9 8
RETURN
11 10 12 13 12
SHORTEN STROKE
15 14 12 13 12
LENGTHEN STROKE
VIII-24
INTERCONNECTING HOSES 800561
Part
1 110690 1 1.50 Male Disconnect

2 110955 1 1.50 Dust Cap
3 400159 1 FITT2S-24Q20P000-000H001
4 100233 2 HOSE125PT4P020P020L60000
5 100235 1 FITT2S-20Q20N000-000H001
6 110692 1 1.50 Female Disconnect
7 110957 1 1.50 Dust Plug
8 110141 2 HOSE150PT4P024P024L60000
9 110139 1 FITT2S-24Q24N000-000H001
10 100245 1 .375 Male Disconnect
11 100257 1 .375 Dust Cap
12 100247 4 HOSE038R02P006P006L62000
13 100249 2 FITT2S-06Q06N000-000H001
14 100777 1 .375 Female Disconnect
15 100737 1 .375 Dust Plug
16 130243 10 Rubber Tie Down
VIII-25
POWER UNIT ENCLOSURE 800379
4 6 5 6 7 3 6
2 6 7 1 6
VIII-26
POWER UNIT ENCLOSURE 800379
Part
1 100550 1 Cover Door

6 100834 10 5" Door Hinge
7 100290 2 I C E Decal
VIII-27
CONTROL PANEL ASM 173011
47 28 11 38
2 10 16 7 12 6 8 49
40 41 42 43
18 19
46
15 ENGINE THROTTLE
21 44 48
HOUR METER
TACHOMETER DRIVE
CLOSE
22 20 44 48
HYDRAULIC FLUID COLD
ENG. OIL PRESSURE CLOSE
14 OPEN CLOSE
ON
OFF START
OPEN
WATER TEMP.
20 44 48
22
OFF
REVERSE FORWARD
MAIN POWER AMMETER

52
REMOTE-LOCAL
13 17
9
3 4
5 34 1
23
EMERGENCY STOP
39
CLOSE
24 OPEN CLOSE
OFF
REV. FOR.
SLOW FAST
31 32 33
CONTROL BOX WITH

DOOR REMOVED
35 36 37 25 27 30 45
50 51 26 29
VIII-28
Part
1 130151 1 Control Box Enclosure

2 100740 1 250 Control Box
3 100576 4 .25-20 X .625 Lg SHCS
4 100559 4 .25 Lock Washer
5 100598 4 .25-20 Hex Nut
6 130953 1 Tachometer Digital
7 100329 1 Oil Pressure Gauge
8 130251 1 Water Temp Gauge
9 110371 1 Ammeter
10 100343 1 Hourmeter
11 110415 5 .250 Oil Pressure Tube/Ft
12 100333 1 FITT2L-04E02Q000-000H002
13 400141 1 Circuit Breaker-10 A
14 130259 1 Start Switch
15 130257 1 Reset Button
16 100355 1 Dialight, Test
17 100331 2 #6-32 X .25 Lg BHCS
18 100359 1 Light, Pilot
19 100361 1 Lens, Clear-Pilot Lite
20 130205 2 HOSE019R01J004J004L09000
21 130207 1 HOSE019R01J004J004L10000
22 130155 2 Switch
23 130149 1 Box Panel
24 130387 1 Hose Bracket
25 400161 2 #10 Lock Washer
26 400163 2 #10-32 Hex Nut
27 110649 2 #10-32 X .375 Lg PHMS
28 130305 2 Warning Light Bulb (Bayonet)
29 110567 13 Terminal Block
30 110569 10 Terminal Mtg. Channel/In
31 100853 5 90 Deg S/O Comp Fitting
32 110841 5 .5 Plastic Bushing
33 110843 5 .5 Lock Nut
34 100597 4 .25 Flat Washer
35 110763 1 Female Amphenol Insert
36 100397 1 Amphenol Receptacle
37 110754 4 #6-32 X .375 Lg RHMS
38 300611 1 FITT2S-02P04E000-000H002
39 800393 1 175-325 Pendant Asm.
40 130255 1 Engine Throttle
VIII-29
Part
41 100429 1 Throttle Cable Seal

42 100431 1 Throttle Cable Pivot
43 100577 1 Stop Cable Clamp
44 100321 4 FITT2L-04M04Q000-0000001
45 140361 1 Toggle Switch
46 100656 6 10-32 X .5 Lg PHMS-Self Tap
47 173001 1 230 Label Group
48 150079 3 2-1/2 Gauge 0-3000 PSI (GA1, 2 & 3)
49 100738 1 Gage Panel
50 110696 4 #6 Lock Washer
51 110694 4 #6-32 Hex Nut
52 130463 1 2" Plug
VIII-31
REMOTE CONTROL PENDANT ASM 800393
1 3 4
8 9
5 6
7 17
15 16
8 10 11 12
14
2 13
VIII-32
REOMTE CONTROL PENDANT ASM 800393
Part
1 130505 1 Pendant Box

2 110603 1 1.0 Strain Relief
3 130507 1 Emergency Stop Button
4 130509 1 Emergency Stop Label
5 100359 1 Light, Pilot
6 100361 1 Lens, Clear-Pilot Lite
7 100403 1 Close Nameplate
8 130155 2 Switch
9 100401 1 Open/Close Nameplate
10 100864 1 Rev-Off-For Namplate
11 100566 1 Switch
12 100562 1 Slow-Fast Nameplate
13 100560 50 Pendant Cable/Ft
14 100375 1 Strain Relief-Amphenol
15 110761 1 Male Amphenol Insert-Plg
16 100395 1 Amphenol Plug
17 130305 1 Warning Light Bulb (Bayonet)
VIII-33
POWER UNIT INTERNAL 175003
2 6 12 62 107 12 118 169 45 63 9 10
153 39 46 47 44 60 106 118 49 124 48 170 11 12
119
52
115
116
117
113
114
115
F R
17
55 18
F.S.
1 29 30 150 103 170 12 26 28 92 111 23 25 21 23
170 134 19 27 81 24 22
54 32 3
57 57 33 135 167 11 4
56 59 31 34 165 168 31 12 5 101 64 99 100
109 70 36 35 37 166 36 122 172 18 164 65 102 163
85 105
TOP
18 68
69 71
NELSON# 90933K
12 91
51 146
50
COOLER
TO
40
145 148
85 92
147
BOTTOM
35 41 95 98
42 43 96
137 103 16 100 66 8 18 61 15
110 89 93 136
VIII-34
139 169 154 169 126 169
170 170 170
104
79
143
120 12
121 124
125
155
169
157
171
128
159
162
156
169
129
158
171 151
161
162
140 173
172
14 86 110 14 86 81
13 105 84 13 111 84 112
138 78 82
53
73 74
75
131
72
132
133 58 76
77 78
80 81
81 84
20
130
144 173 144 83 7 127 87
38 88
VIII-35
Part
1 810563 1 175C / 325 Subbase Asm.

2 170239 1 Engine 3116 (220 Hp)
3 130743 1 Pump Adapter
4 170309 1 Pump
5 100614 4 .5-13 UNC X 1.50 Lg HHCS
6 100958 1 4 In Exhaust End
7 100149 1 HOSE025R02J004J004L01900
8 170311 1 -151 O-Ring
9 400129 1 Reservoir Cover
10 400225 1 Reservoir Gasket
11 100648 32 .375-16 X.875 Lg SHCS
12 400149 56 .375 Lock Washer
13 100520 2 Return Filter Asm.
14 100518 4 Return Filter Element
15 173013 1 230 Control Manifold Asm
16 810035 1 325 Clamp Manifold Assembly
17 100119 3 .5-13 X 1.25 Lg SHCS Loc Wel
19 100051 3 .375-16 X 1.0 Lg SHCS Loc Wel
20 120055 1 FITT2L-16M16P000-0000001
21 110690 1 1.50 Male Disconnect
22 110955 1 1.50 Dust Cap
23 110392 2 FITT2S-24R24P000-000H001
24 110692 1 1.50 Female Disconnect
25 110957 1 1.50 Dust Plug
27 400121 1 .75 Dust Plug
28 100387 1 FITT2S-12P12B000-000H001
29 173011 1 230 Control Box Asm
30 100558 1 Tool Box
31 400890 2 Battery
32 400888 1 Battery Holddown
33 400231 3 Hold Down Stud
34 100831 3 .312 Wing Nut
35 100293 19 .312 Flat Washer
36 100537 2 Battery Cable-24"
37 110653 1 Battery Cable-6
38 100145 1 FITT2L-04M04P000-0000001
39 130727 1 45 Deg Exhaust Elbow 4"
40 400099 1 Heat Exchanger
VIII-36
Part
41 100105 8 .312-18 X 1.0 Lg Shcs Loc Wel

42 100287 8 .312 Lock Washer
43 100289 8 .312-18 Hex Nut
44 130745 1 Muffler
45 130749 1 Exhaust Elbow 4"
46 130751 1 Exhaust Outlet Elbow 4"
47 400919 5 4" U-Clamp
48 100890 1 Rain Cap
49 130747 1 Muffler Support
50 100726 5 Antifreeze/Gal
51 100700 2 .375-16 UNC X 1.25 Lg HHCS
52 400277 1 I C E Logo Plate
53 130179 1 Sight Gauge And Thermometer
54 130921 1 FITT2L-06M08R000-0000001
55 130733 1 FITT2P-24P000000-000Q001
56 100715 1 FITT2S-16P06Q000-000H001
57 400227 2 FITT2L-06M06P000-0000001
58 110377 1 FITT2L-16P16Q000-0000306
59 100228 1 HOSE038R02J006J006L0610C
60 130753 1 Air Cleaner Element
61 100011 4 .5-13 X 2.0 Lg SHCS
63 100350 1 Unit Cover
64 100417 1 FITT2C-48Q000000-0000306
65 100419 1 Petcock
66 300231 1 FITT2V-12M12J000-000H001
67 130779 2 Tube .38OD .28ID X 1.25 Lg
68 110735 4 .5-13 X 2.5 Lg SHCS
69 100483 4 .50 Flat Washer
70 130057 1 FITT2L-06M06R000-000H001
71 100485 4 .5-13 Hex Nut
72 100447 1 Hand Pump
73 100439 2 .437 X 1.75 Lg SHCS
74 400153 2 .437 Flat Washer
75 100443 2 .437 Lock Washer
76 100449 1 FITT2S-16P16P000-000H001
77 100451 1 Check Valve
78 110089 1 FITT2S-20P16Q000-000H001
79 130755 1 .38-16 UNC All Thread 5.00 Lg
80 300119 1 FITT2S-16P12M000-000H001
VIII-37
Part
81 130201 2 HOSE075R01J012J012L04000
82 400215 1 HOSE100R01P016P016L08400
83 100183 1 FITT2P-12P000000-000S007
84 100489 3 FITT2L-12M12P000-0000001
85 100588 2 FITT2L-24M24P000-0000001
86 810575 2 Special 90 Elbow
87 400115 1 Temperature Switch
88 110237 1 Str S/O Cord Adapter
89 130777 1 FITT2S-40P000000-0750001
90 130773 1 FITT2S-06R02Q000-000H001
91 170393 1 Clamp Pump
92 130515 1 HOSE150R02J024F924L10000
93 170349 1 Pick-Up Flange
94 100143 12 .375-16 X 1.25 Lg SHCS Loc Wel
95 130119 1 FITT2S-40P000000-0450301
96 130139 1 2.5 Flexible Coupling
97 130769 1 FITT2S-08R08Q000-000H001
98 400117 1 Stop Cock
99 170307 1 HOSE150PT4F024F920L03200
100 130613 1 HOSE050PT4J008J008L02500
101 100045 2 #20 Pa Split Flange Half
102 100037 1 2-222 O-Ring 90 Duro
103 100364 1 Left Fire Wall
104 100762 2 .375-16 UNC ESNA NUT
105 110586 1 HOSE150R01J024J024L12900
106 100968 2 Intake Elbow
107 130771 20 4" O.D. Tube X 16 Ga / Inch
108 400411 1 FITT2L-06M06J000-000H001
109 170241 1 HOSE038R01J006J006L07000
110 100484 1 HOSE075R01J012J012L08400
111 100482 1 HOSE150R02J024J024L07200
112 100455 1 Breather
114 100737 1 .375 Dust Plug
115 110794 2 FITT2S-06P06P000-000H001
116 100245 1 .375 Male Disconnect
117 100257 1 .375 Dust Cap
118 130117 4 .375 X1.5 Lg SHCS
119 140415 275 Hydraulic Fluid/Gal
120 100299 3 Primer/Gal
VIII-38
Part
121 100298 3 Ice Green Paint/Gal

122 100362 1 Right Fire Wall
123 100053 1 6 O-Ring X 6 Jic Conn
124 100535 4 .375 -16 Hex Nut
125 100404 2 Intake Grill (300)
126 100400 1 Left Exhaust Grill
127 100423 4 FITT2P-08P000000-000S007
128 110244 1 Tube .38OD .28 ID X .88 Lg
129 110827 1 10-32 X .75 BHCS S.S.
130 100862 1 HOSE100R01J016J016L03300
131 810045 1 Hex Key Group
132 100651 1 24 V Test Light
133 100600 1 Hex Key Rack
134 100597 4 .25 Flat Washer
135 100504 1 24 V Solenoid
136 100962 1 FITT2L-40P40Q000-0000306
137 110231 5 S/O Cord 12' Lg
138 100436 2 Gage (0-60 Psi.)
139 100351 1 Right Roof Grill
140 100559 4 .25 Lock Washer
141 100598 2 .25-20 Hex Nut
142 100557 2 .25-20 X .75 Lg SHCS
143 810725 1 Modified Throttle Bracket
144 130737 2 Suction Plug
145 400087 1 Pick-Up Filter
146 100938 1 FITT2L-16M12R000-000H001
147 400445 2 Flex Wrap Magnet
148 400173 1 FITT2S-48P40Q000-000H306
149 160283 2 6mm X 60mm SHCS
150 100524 1 Tube-4.00 X 4.00 X 11 Ga X 33.00 Lg
151 400163 1 #10-32 Hex Nut
153 400247 21 Engine Oil/Quart
154 100394 1 Top Air Baffle
155 110246 1 Electric Actuator (24v)
156 130757 1 Throttle Actuator Linkage
157 810727 1 Modified Throttle Arm
158 110448 1 Adjustable Link
159 100631 1 .25-20 X 2.0 Lg SHCS
VIII-39
Part
161 100595 1 .25-20 X 1.25 Lg Shcs

162 100422 2 .25-20 Unc Esna Nut
163 100933 1 FITT2L-10R08M000-000H001
164 100851 4 .438-14 X 1.25 Lg SHCS
165 100428 1 Solenoid Bracket
166 130061 2 #10-32 X .5 BHCS STN STL
167 300671 2 #10 Flat Washer
168 400161 2 #10 Lock Washer
169 100398 22 Saddle Clip
170 110830 40 .25 X 2 In. Hex Tex Screw
171 100396 8 .312-18 UNC X 1.50 Lg. SHCS
172 130959 1 Tach Sender
173 100063 1 FITT2P-16P000000-000S007
VIII-41
CONTROL MANIFOLD ASM 173013
COUPLER
PANEL
7
BY-PASS
TO FILTER
8 8
9 FROM TO 9
PUMP COOLER
15
ORIFICE
5 P PORT 5
14
2
13 A P B
12 3 4
11 16 17
10
DRAIN DRIVE
PRESS
VIII-42
CONTROL MANIFOLD ASM 173013
Part
1 130501 1 175B Control Manifold

2 400786 1 4-Way Valve (V2)
3 400039 6 .75-10UNC X 2.75 Lg SHCS
5 100853 2 90 Deg S/O Comp Fitting
6 400742 1 Relief Cartridge (RV1)
7 110055 1 FITT2P-20P000000-000S007
9 100119 8 .50-13 X 1.25 Lg SHCS Loc Wel
10 100145 2 FITT2L-04M04P000-0000001
11 110057 1 1.50 Solid Flange
12 100446 1 FITT2L-24P24Q000-0000001
13 110037 1 FITT2S-24P24P000-000H001
14 130339 1 1.50 Check Valve
15 100565 1 FITT2S-24M24P000-000H001
16 100163 4 .50-13 X 1.75 Lg SHCS Loc Wel
17 100027 4 .50 Hi-Collar Lock Washer
18 110119 3 2-225 O-Ring
VIII-43
CLAMP MANIFOLD ASM 810035
5 11
10
6 6
1
OPEN CLOSE
GAGE GAGE
PUMP 8 3 3
7 RETURN
OPEN CLOSE
RELIF ADJ
9
CLOSE OPEN
POWER BEYOND SUPPLY POWER BEYOND RETURN
VIII-44
CLAMP MANIFOLD ASM 810035
Part
1 110642 1 Clamp Manifold Block

2 110149 1 Check Valve (CV1)
3 810033 1 Pressure Switch Assembly (PS1)
4 100898 1 Sandwich Relief (RV2)
5 110147 1 4-Way Valve 24 V DC (V1)
6 140539 2 FITT2L-04M02P000-0000001
7 110632 1 FITT2L-12M06P000-000H001
8 110630 1 FITT2S-08M06P000-000H001
9 400213 2 FITT2P-06P000000-000S007
10 110235 1 90 Deg S/O Cord Adapter
11 110634 4 .25-20 X 7.50 Lg SHCS
VIII-45
PENDANT EXTENSION CABLE - 50' (OPTIONAL) 800059
5 6 3 4 3 1 2
50'-0"
Part
1 120169 1 Amphenol Cable Jack

2 110763 1 Female Amphenol Insert
3 100375 2 Strain Relief - Amphenol
4 100560 50 Pendant Cable / Ft
5 100395 1 Amphenol Plug
6 110761 1 Male Amphenol Insert-Plug
VIII-47
VIII.ORDERING PARTS
E. MISCELLANEOUS ACCESSORIES
1. TOOLS
Part
Number Qty. Description
100651 1 24-Volt Test Light
810045 1 Set of Allen Wrenches -
Includes All Wrenches Shown Below:
100655 (1) 1/16" Allen Wrench - Long Arm
100663 (1) 1/ 8" Allen Wrench - Long Arm
100687 (1) 7/ 8" Allen Wrench - Short Arm
100689 (1) 1" Allen Wrench - Short Arm
810713 1 Wire Rope Tensioning Kit
160787 1 Charging Kit
2. BULK
Part
Number Qty. Description
810013 5 GAL Hydraulic Oil
100726 1 GAL Coolant/Anti-Freeze
100298 1 GAL I C E Green Paint
100299 1 GAL Primer
VIII-48
VIII.ORDERING PARTS
E. MISCELLANEOUS ACCESSORIES (Continued)
3. 160 HOSE GROUP KIT-INTERNAL 850161
Page
Item P/N Qty. Description Ref.
41 160477 1 HOSE150PT4F024J924L0212C VIII-11

42 160479 1 HOSE150PT4M024F024L0722C VIII-11
49 160481 1 HOSE150PT4F924F024L0592C VIII-12
54 160483 1 HOSE150PT4J024F024L0585C VIII-12
75 100719 2 HOSE025R02J004J004L03000 VIII-13
81 160485 1 HOSE150PT4F924F024L0706C VIII-12
97 130561 2 HOSE038R02J006J006L0700C VIII-13
4. 230 HOSE GROUP KIT-INTERNAL 850139
Page
20 130205 2 HOSE019AQ1J004J004L09000 VIII-29

21 130207 1 HOSE019AQ1J004J004L10000 VIII-29
7 100149 1 HOSE025R02J004J004L01900 VIII-36
59 100228 1 HOSE038R02J006J006L0610C VIII-37
81 130201 2 HOSE075R01J012J012L04000 VIII-38
82 400215 1 HOSE100R01P016P016L08400 VIII-38
92 130515 1 HOSE150R02J024F924L10000 VIII-38
99 170307 1 HOSE150PT4F024F920L03200 VIII-38
100 130613 1 HOSE050PT4J008J008L02500 VIII-38
105 110586 1 HOSE150R01J024J024L12900 VIII-38
109 170241 1 HOSE038R01J006J006L07000 VIII-38
110 100484 1 HOSE075R01J012J012L08400 VIII-38
111 100482 1 HOSE150R02J024J024L07200 VIII-38
130 100862 1 HOSE100R01J016J016L03300 VIII-39
VIII-49
VIII.ORDERING PARTS
E. MISCELLANEOUS ACCESSORIES (Continued)
5. 160 SEAL KIT 850159
Page
1 110119 4 2-225 O-Ring VIII-12, VIII-16 & VIII-19

2 160804 9 2-225 Face Seal VIII-13
3 160507 1 -349 O-Ring 90 Duro VIII-16
4 160511 2 Wear Ring VIII-16
5 160513 1 Rod Seal VIII-16
6 160519 4 -356 O-Ring 90 Duro VIII-16
7 160265 2 Piston Seal VIII-16
8 400379 2 2-232 O-Ring 90 Duro VIII-16
9 110929 2 2-226 O-Ring 90 Duro VIII-17
10 160871 1 -352 O-Ring 90 Duro VIII-17
11 160509 1 -349 Back-Up Washer VIII-17
12 160515 1 Rod Wiper VIII-17
13 160517 1 Modular Backup VIII-17
14 160591 1 Wear Band VIII-17
15 110602 1 -111 0-Ring VIII-17
16 100037 2 2-222 O-Ring 90 Duro VIII-19
17 160329 1 -109-O-Ring 90 Duro VIII-19
18 140255 4 2-113 O-Ring 90 Duro VIII-19
19 400379 1 2-232 O-Ring 90 Duro VIII-20
20 110929 2 2-226 O-Ring 90 Duro VIII-20
21 160836 1 80 Din Face Seal VIII-21
22 160893 1 -431 O-Ring 90 Duro VIII-21
23 160255 1 -345 O-Ring 90 Duro VIII-21
24 160897 1 -431 Back-up Ring VIII-21
25 160899 1 -345 Back-up Ring VIII-21
6. 230 O-RING KIT 850173
Page
1 170311 1 -151 O-Ring VIII-36

2 100037 1 2-222 O-Ring 90 Duro VIII-38
3 110119 3 2-225 O-Ring VIII-43
VIII-50
VIII.ORDERING PARTS
E. RECOMMENDED SPARE PARTS
HAMMER 800407 Refer to page II-7
Item P/N Qty. Description
27 160455 1 Recoil Damper

[8] 700002 2 Cushion
[7] 700004 2 Aluminum Plate
160805 1 Stroke Decal
HOSE ASSEMBLIES - INTERCONNECTING 800425 Refer to page VIII-24
4 100233 1 HOSE125PT4P020P020L60000
8 110141 1 HOSE150PT4P024P024L60000
12 100247 1 HOSE038R02P006P006L62000
POWER UNIT - INTERNAL 800489 Refer to page VIII-35
14 100518 4 Hydraulic Oil Filter

60 130753 1 Air Cleaner Element
99 170307 1 HOSE150PT4F024F920L03200
100 130613 1 HOSE050PT4J008J008L02500
111 100482 1 HOSE150R02J024J024L07200
— 130863 1 Engine Oil Filter
— 130865 1 Fuel Filter Element
— 130969 1 Fuel Water Separator Element
VIII-51
F. RECOMMENDED TIGHTENING TORQUE
Nominal Nominal Tightening Nominal Nominal Tightening

Screw Socket Torque Screw Socket Torque
Size Size Ft-Lbs. (Kg-M) Size Size Ft-Lbs. (Kg-M)
#10-24 5/32 6 Ft-Lbs. (.83 Kg-M) #10-32 5/32 6 Ft-Lbs. (.83 Kg-M)
1/4-20 3/16 13 Ft-Lbs. (1.8 Kg-M) 1/4-28 3/16 15 Ft-Lbs. (2.1 Kg-M)
1-8 3/4 1,009 Ft-Lbs. (139.4 Kg-M) 1-12 3/4 1,126 Ft-Lbs. (155.6 Kg-M)
1-1/4-7 7/8 1,600 Ft-Lbs. (221.1 Kg-M) 1-1/4-12 7/8 1,800 Ft-Lbs. (248.8 Kg-M)
1-1/2-6 1 2,800 Ft-Lbs. (387 Kg-M) 1-1/2-12 1 3,000 Ft-Lbs. (414.6 Kg-M)
NOTE: These values are for Socket head cap screws only.
Button heads, Flat heads and Set screws have different
values. Check the Allen Hand Book for correct torque
specifications.
VIII-52

ICE 160 230 0296 Hammer

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OPERATING AND MAINTENANCE MANUAL

ICE MODEL 160

WITH MODEL 230 POWER PACK

SERIAL NUMBERS: 800001 AND ABOVE

No employee or representative is authorized to change this warranty unless such change is

I. GENERAL INFORMATION PAGE

A. General Description I-1

II. PREPARATION FOR OPERATION

III. OPERATING INSTRUCTIONS

A. Completion of Set-up and Maintenance III-2

IV. MAINTENANCE AND ADJUSTMENTS

IV. MAINTENANCE AND ADJUSTMENTS (CONTINUED) PAGE

E. Maintenance - Every 4 Months IV-3

A. Drive Pump V-1

VI. ELECTRICAL CIRCUITRY

A. Diesel Engine VI-1

VII. GENERAL DATA

VIII. ORDERING PARTS

The hammer system consists of 8 major components (Fig. 1) page I-4:

B. MAJOR COMPONENTS (CONTINUED)

Drive Cap Assembly

B. MAJOR COMPONENTS (CONTINUED)

B. MAJOR COMPONENTS (CONTINUED)

HYD ACTUATOR ASM

230 POWER UNIT RAM

Weights and Dimensions

Use the following safety precautions as a general guide to safe operations:

1. Read the manual thoroughly before operating or working on the equipment.

B. SAFETY PRECAUTIONS (CONTINUED)

B. SAFETY PRECAUTIONS (CONTINUED)

REMEMBER, SAFETY IS EVERYONE’S BUSINESS.

D. CONNECTING CRANE LINE TO HAMMER

E. ATTACHMENT OF LEAD GUIDES

Do not weld on hammer.

F. ATTACHMENT OF DRIVE CAP (See Fig. 3)

G. MOUNTING HAMMER IN LEAD

H. CONNECTION OF HYDRAULIC HOSES

Connection of hoses at the Power Unit

The hammer is connected to the power unit by four hydraulic hoses.

Clean the couplings with a lint-free cloth before making connections.

Connection of hoses at the Hammer

PRESSURE HOSE (1 1/4")

RETURN HOSE (1 1/2")

EXTEND CYLINDER SHORTEN STROKE HOSE (3/8")

RETRACT CYLINDER LENGTHEN STROKE HOSE (3/8")

I. FILLING THE HAMMER PRESSURE HOSE

Read SECTION III - OPERATING INSTRUCTIONS

J. BLEEDING THE VARIABLE STROKE CYLINDER LINES

Read SECTION III - OPERATION INSTRUCTIONS

Reconnect and tighten the hose to the cylinder.

Reconnect and tighten the hose to the cylinder.

K. VARIABLE STROKE CYLINDER PRESSURE

Read SECTION III - OPERATING INSTRUCTIONS.

K. VARIABLE STROKE CYLINDER PRESSURE (CONTINUED)

NOTE: DO NOT SET THE VARIABLE STROKE CYLINDER PRESSURE BY

L. FUEL, LUBRICATING OIL AND GREASE

a. Check engine oil level

CONTROL PANEL WITH REMOTE CONTROL-PENDANT

OPERATIONS AND MAINTENANCE