Assembly of hydraulic equipment for piling B250

Step No. 1
Check for the M/C components, accessories and tools which are :-
- Tool box .
- Bolts for mast sections connection.
- Light spots and glass sliding parts and flasher.

Step No. 2
Assembly of counterweight which weights 4.8 ton, so we can assemble
the mast sections.
(1) First position the clamps to raise the counterweight then adjust the
counterweight to fit the 4 bolts shown carefully to adjust it
horizontally.
(2) Note that there is a gab between the counterweight and the machine
body.
(3) Note that there is a special tool for tighten the 4 bolts of the
counterweight .

Step No. 3
Assembly of mast. The mast consists mainly of 2 sections :
Assembly of section 1.
(4) First, check that the ball joint of the mast is correctly fitting it's seat
on the jip and disassemble the cover cap of the ball joint as to fix it
to it's seats . Put grease on ball joints seats.
(5) Lift section no. 1 horizontally [ with the crane ] to fix it up to the
machine. Put grease on ball joints seats and then put the mast down
carefully and reassemble the cover caps of the ball joints and note
that the 2 cover caps of the ball joint centers the ball joints
positions.
(6) When assembling the mast, take care of the light sensors (for mast
inclination ) not to be broken.
(7) Check that every bolt is well tighten.

(8) Assemble the 2 cylinders of the mast :-

- First take the cylinders pins off by it's special tool from the tool
box.
- Move the 4 lifting blocks to raise the mast and assemble the 2
cylinders one by one and put the pins back to it's place .
- Make sure that the cylinders work correctly, if not check for the
electronic card [ ESX ] [ card for mast verticality and inclination ]
is connected to it's place correctly ( under the jip ).
- Connect the crowd ram piston hoses.

Assembly of section 2
(9) Lift section 2 by crane carefully and be sure that it's absolutely
horizontal then assemble the 2 section together and while doing
that take care of the data cable extended through the mast sections
(connect the 2 data cable together in a correct way ) [ be sure that
the 4 bolts between section 1 & 2 are well tightened and locked by
2 nuts for every bolt. ]

Step No. 4
Assembly of the cat head
(10) Disassemble the lock nut of the 1st pin ( big one ) then
disassemble the 2nd pin(small one) . Assemble the cat head to the
mast end assembling the 2nd pin first then the big pin after.
(11) The cat head contains 4 Polly ( 1 for the service winch rope and
the auxiliary rope together ,1 for the service winch and 2 for the
auxiliary winch rope )
(12) Put the 2 Pulley of the auxiliary winch aside ,so the auxiliary rope
could be assembled
(13) Assemble the 2 limit switches to the cat head ( note that the
double wire of the limit switch tighten to the lever ) [ there are 2
levers for the 2 limit switch ]

Assembly of lower extension

(14) Take the pin of the lower extension off then assemble the lower
extension to the mast lower end [ first tighten the 2 bolts very well
then put the pin back to it's place ].
(15) Assemble the protection bar ,so the ropes don't damage the hoses
of the crowd ram piston.
Step No. 5
(16) Assemble the service lines and make the lines go through the
Pully and limit switches.
Step No. 6
Assembly of rotary to the mast
(17) Put grease on the mast both sides to make the sliding easy.
(18) Take the pin from the rotary off then adjust the mast as to slide
through it's grooves in the rotary .[ use the service winch to hold
the rotary through three wires already connected together in the
tool box , so the mast is sliding through the rotary grooves then
 disassemble the three wires from the rotary and from the main
service line hawk.
(19) Connect the rotary to the crowd ram piston rod and put the pin
back to its place.
(20) Connect the hoses of the rotary and data cable .[ note that the
hoses is labeled by number to both sides.]
Assembly of Kelly bar
(21) Assemble the guide to the Kelly bar then connect the swivel
[universal joint] to the Kelly bar.
(22) Connect the service line end to the universal joint and then lift the
Kelly bar and fix it to the rotary.
(23) Assemble the cupper slid bars to the Kelly bar guide
Notes:
- Every pin must be assembled with grease .
- Check that every bolt is very well tightened.
- Don't scratch the painting of the machine [ use the nylon wires].
- Put grease on the sliding parts of the mast .
- Check the oil level for the rotary gear box.