model 200 vibro with model 595 power unit...2019/03/19 · model 200 vibratory driver with model...

OPERATION / MAINTENANCE MANUAL

7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710

MODEL 200 VIBRATORY DRIVER WITH MODEL 595 POWER UNIT

AMER

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PILEDRIVING EQUIPM

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WITH MODEL 595 POWER UNIT

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KENT, WASHINGTONAMERICAN PILEDRIVING EQUIPMENTDWN. BY: DATE: DESCRIPTION

Scotto 4/15/2010 MODEL:

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ChangeNumber

PageNumber Date Revision Description

Revision Record

06-08-10

9-3-141INITIAL PRINTING

UPDTED TO 595

2 2-18, 2-19 3/19/19 UPDATED PN ON CLAMP COMPONENTS




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Preface

General

This manual covers the Model 200 Vibratory Driver/Extractors and the Model 595 Power Unit. Most information contained in this manual is identical for all the models covered. The data provided in this manual gives the necessary information to operate and maintain APE equipment. The listed procedures are to be performed by qualifi ed personnel who have an understanding of the equipment and who follow all safety precautions.

Guide to Using the Manual

1. Refer to the Table of Contents for the page location of applicable sections.

2. All weights and measurements in this manual are in both English and Metric units.

3. The manual will be revised as necessary to refl ect current information.

Abbreviations

The following are abbreviations used within this manual.

lbs. = Pounds HCLW = High Collar Lock Washerpsi. = Pounds per Square Inch P/N = Part Numberhp. = Horse Power SHCS = Socket Head Cap Screwgpm. = Gallons Per Minuterpm. = Revolutions Per Minute eng. = Enginecyl. = Cylindermm. = Millimetermtg. = MountingS/N = Serial Numbersol. = Solenoid

Serial Number Locations

1. VIBRATOR: Above and in between the eccentric covers on both sides of the machine.

2. POWER UNIT: On both sides in front of reservoir near the top.




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Table of ContentsPage

Revision Record ........................................................................................................... iPreface .......................................................................................................................... iiTable of Contents ......................................................................................................... iiiTable of Contents ......................................................................................................... ivSafety Precautions ....................................................................................................... vWarranty ........................................................................................................................ vii

I. GENERAL INFORMATIONI-1. Machine Features. - Model 200 Vibratory Hammer ....................................................... 1-2I-2. Machine Specifi cations .................................................................................................. 1-3

A. Model 200 Vibro ...................................................................................................... 1-3B. Model 595 Power Unit ............................................................................................. 1-3

I-3. General Description of Model 200 Vibro ........................................................................ 1-4I-3A. The Suppressor Housing .................................................................................. 1-5I-3B. The Vibrator Gearbox ........................................................................................ 1-6I-3C. The Clamp Attachment...................................................................................... 1-7I-3D. Optional Attachments ........................................................................................ 1-8

I-4. General Description of Model 595 Power Unit ...............................................................1-9II. MAJOR COMPONENT DEFINITION

II-1. Model 200 Final Assembly Identifi cation ....................................................................... 2-2II-2. Suppressor Identifi cation ............................................................................................... 2-6II-3. Gearbox Identifi cation ................................................................................................... 2-8II-4. Check Valve Identifi cation .............................................................................................. 2-11II-5. Clamp Identifi cation ....................................................................................................... 2-12II-6. Hose Bundle. ................................................................................................................. 2-14II-7. Model 595 Power Unit Skid Identifi cation ...................................................................... 2-16II-8. 1-1/2" Quick Disconnect Coupling Identifi cation. ........................................................... 2-17II-9. 200 Caisson Clamp Identifi cation. ................................................................................. 2-18II-10. 200 Caisson Clamp Cylinder Identifi cation. ................................................................ 2-19II-11. Control Panel. ............................................................................................................. 2-20II-12. Control Pendant. ......................................................................................................... 2-24

III. LOADING AND UNLOADINGIII-1. Model 200 Vibratory Driver. .......................................................................................... 3-1III-2. Model 595 Power Unit. ................................................................................................. 3-1III-3. What to do if damaged during shipment. ...................................................................... 3-1

IV. PREPARATION AND OPERATIONIV-1. Rigging of Vibratory Driver .......................................................................................... 4-1IV-2. Plumbing the Vibro Hoses to the Power Unit. ............................................................. 4-2IV-3. Filling Vibrator Pressure Hoses. ................................................................................. 4-3IV-4. Bleeding the Clamp Attachment Hydraulic Hoses. ..................................................... 4-3IV-5. Precautions and Rules for Operation. ......................................................................... 4-4IV-6. Relief Valve Settings Prior to Operation - Model 595..................................................4-5IV-7. Shut-down Procedures. .............................................................................................. 4-7




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Table of Contents PageV. MAINTENANCE

V-1. Daily Maintenance Required Prior to Operation. ........................................................... 5-1V-2. Checklist After Power Unit Engine Has Started ............................................................. 5-1V-3. Maintenance and Adjustments. (75 Hours) .................................................................. 5-2V-4. Maintenance and Adjustments. (Eccentric Bearings) .................................................. 5-2V-5. Maintenance and Adjustments in Severe Conditions. .................................................... 5-2V-6A. Lubrication - Vibratory Gearbox. ................................................................................. 5-2V-6B. Lubrication - Clamp Attachment. ................................................................................. 5-2V-7A. Power Unit - Filters, Fluid Types and Capacities. ....................................................... 5-3V7-B. Power Unit - Hydraulic Fluid ....................................................................................... 5-4V7-C. Power Unit - Two Part Hydraulic Fluid Tank ................................................................ 5-4V7-D. Power Unit - Draining and Filling Hydraulic Fluid Tank ............................................... 5-4V-7E. Power Unit - Changing Hydraulic Return Filter Element ............................................. 5-5V-7F. Power Unit - Steps to Remove the Hydraulic Filter Elements .................................... 5-5V-8. Power Unit - Pump Drive ............................................................................................... 5-7

VI. VIBRO TROUBLE-SHOOTINGVI.-1 Model 200 Vibro .......................................................................................................... 6-1

VII. MODEL 595 POWER UNITVII-1. Hydraulic Circuitry. ...................................................................................................... 7-2

VII-1A. Clamp Circuitry. ................................................................................................. 7-2VII-1B. Drive Circuit. ...................................................................................................... 7-2VII-1C. Hydraulic Schematic. ......................................................................................... 7-3VII-1D. Hydraulic Components - Clamp Drill Manifold Assembly .................................. 7-4VII-1D. Hydraulic Components - Clamp Drill Manifold 523003B ................................... 7-5VII-1E. Hydraulic Components - Drive Manifold Assy. 555183 ..................................... 7-6VII-1F. Hydraulic Components Hose Identifi cation and Routing ................................... 7-9VII-1G. Hydraulic Components - Hydraulic Tank Connections ...................................... 7-10VII-1H. Return Filter. ...................................................................................................... 7-12VII-1I. Oil Cooler. ......................................................................................................... 7-12VII-1J. Manual Pump. ................................................................................................... 7-12VII-1K. Hydraulic Oil Temperature. ................................................................................ 7-12VII-1L. Hydraulic Components - Hydraulic Pumps ....................................................... 7-13

VII-2. Electrical Controls: (Understanding How They Work) ................................................. 7-15VII-2A. Main Circuit Breaker .......................................................................................... 7-15VII-2B. Tachometer ....................................................................................................... 7-15VII-2C. Hourmeters ....................................................................................................... 7-15VII-2D. Engine Safety Shutdown Switch (Murphy Magnetic Switch)............................. 7-15VII-2E. Murphy “Engine Oil Press” gage ....................................................................... 7-15VII-2F. Murphy “Engine Coolant Temp” gage ............................................................... 7-16VII-2G. Murphy “Hyd Oil Temp” gage ............................................................................ 7-16VII-2H. Hydraulic Oil Level Float Switch........................................................................ 7-16VII-2I. “Emergency Stop” button .................................................................................. 7-16VII-2J. Pilot lights ..........................................................................................................7-16VII-2K. Engine Control Switch “OFF-ON-START” ......................................................... 7-17VII-2L. “LOCAL— PENDANT” Switch ........................................................................... 7-17VII-2M. Governor Control Switches “RAISE-off-LOWER” ........................................... 7-17VII-2N. Clamp Control Switches (“OPEN-off-CLOSE”) ................................................. 7-17VII-2O. Drive Control Switches (“FORWARD/off/REVERSE”) ...................................... 7-18VII-2P. Preparing the Electrical System for Engine Startup. ......................................... 7-19VII-2S. Power Unit Electrical Schematic ........................................................................ 7-20VII-2S. Electrical Schematic - Symbol Legend .............................................................. 7-21

VII-3. Control Pendant .......................................................................................................... 7-22VII-3A. Control Pendant Wiring Diagram ....................................................................... 7-23

VII-4. Recommended Bolt Tightening Torque ....................................................................... 7-24




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Safety Precautions(This list of precautions must be followed at all times to ensure personal & equipment safety.)

1. Read this manual from beginning to end before operating or working on this machine.

2. When operating in a closed area, pipe exhaust fumes outside. (WARNING: Breathing exhaust fumes can cause serious injury and even death.)

3. When servicing batteries, avoid any type of spark or open fl ame. Batteries generate explosive gases during charging. There must be proper ventilation when charging batteries. 4. Never Adjust or repair the unit while it is in operation.

5. Make sure the Control Pendant is in the "OFF" position before starting the unit.

6. Remove all tools and electrical cords before starting the unit.

7. Keep oily rags away from the exhaust system.

8. Never store fl ammable liquids near the engine.

9. Never stand under vibro at any time and keep your eyes on the vibro when it is in operation. Keep a look out for loose bolts or leaking hydraulic lines.

10. Avoid pulling on hose quick dis-connect fi ttings. Move power unit closer to work if hoses cannot reach. Do not use hoses as a tow line to tug the power unit! If a hose fails at the hydraulic couplers then it is a result of "hose tugging by the pile crew".

11. Avoid kinks in the hoses. Kinks will cut the hose safety factor by 50 percent.

12. Always wear eye and ear protection.

13. Avoid standing downwind of vibrating piles. Dirt and other matter may become airborne and fall into the unprotected eye.

14. Always wear a hardhat, gloves, and safety shoes.

15. When moving, driving or extracting pile, always attach safetyline between pile and crane hook.

16. (WARNING) Never clamp vibro to pile and dis-connect from crane line. Lay vibro down on ground when not in use.

17. Do not truck power unit with quick disconnect caps and plugs screwed on to fi ttings unless the caps and plugs have wire rope safety lines attached. Store in storage box under control panel.




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Figure ListFigure 1-A. Machine Features ......................................................................................... 1-1Figure 1-B. General Description of 200 Vibro. .................................................................. 1-3Figure 1-C. General Description of Suppressor Housing. ................................................ 1-4Figure 1-D. General Description of Vibrator Gearbox. ...................................................... 1-5Figure 1-E. General Description of Clamp Attachment. .................................................... 1-6Figure 1-F. Clamp Attachment Hole Confi guration. .......................................................... 1-6Figure 1-G. Optional Attachments ..................................................................................... 1-7Figure 1-H. General Description of Model 595 Power Unit ...............................................1-8Figure 2-A. Model 200 Final Assembly ............................................................................. 2-2Figure 2-B. Suppressor Assembly .................................................................................... 2-6Figure 2-C. Gearbox Assembly ......................................................................................... 2-8Figure 2-D. Check Valve Assembly ................................................................................... 2-11Figure 2-E. Model 200 Clamp Assembly .......................................................................... 2-12Figure 2-F. Hose Bundle .................................................................................................. 2-14Figure 2-G. Power Unit Skid ............................................................................................. 2-16Figure 2-H. 1-1/2" Quick Disconnect Coupling ................................................................. 2-17Figure 2-I. 200 Caisson Clamp Assembly ....................................................................... 2-18Figure 2-J. 200 Caisson Clamp Cylinder Assembly ......................................................... 2-19Figure 2-K. Control Panel Assembly ................................................................................. 2-20Figure 2-L. Control Panel-Gages. .................................................................................... 2-23Figure 2-M. Control Pendant Assembly ............................................................................ 2-24Figure 4-A. Power Unit Hose Plumbing ............................................................................ 4-2Figure 4-B. Bleeding Clamp Attachment .......................................................................... 4-3Figure 4-C. Setting Relief Valve ........................................................................................ 4-5Figure 4-D. Checking Clamp Pressure Switch Setting ..................................................... 4-6Figure 4-E. Control Pendant ............................................................................................. 4-8Figure 5-A. Pump Drive - Durst PD802F .......................................................................... 5-7Figure 7-A. Hydraulic System Schematic ......................................................................... 7-3Figure 7-B. Clamp Drill Manifold Assembly 523003B ....................................................... 7-4Figure 7-C. Hydraulic Schematic - Clamp Drill Manifold ................................................... 7-5Figure 7-D. Drive Manifold Assembly 555183 .................................................................. 7-6Figure 7-E. Hydraulic Schematic- Drive Manifold ............................................................ 7-7Figure 7-F. Hydraulic Component Identifi cation - Tank Detail .......................................... 7-10Figure 7-G. Hydraulic Pumps ............................................................................................ 7-13Figure 7-H. Electrical Schematic ...................................................................................... 7-20Figure 7-I. Electrical Symbol Legend .............................................................................. 7-21Figure 7-J. Control Pendant ............................................................................................. 7-22Figure 7-K. Electrical Schematic - Control Pendant ......................................................... 7-23

Table ListTable 1-A. Vibro ............................................................................................................... 1-2Table 1-B. Power Unit ..................................................................................................... 1-2Table 2-A. Model 200 Final Assembly ............................................................................. 2-5Table 2-B. Suppressor Assembly .................................................................................... 2-7Table 2-C. Gearbox Assembly ......................................................................................... 2-9Table 2-D. Check Valve Assembly ................................................................................... 2-11Table 2-E. Model 200 Clamp Assembly .......................................................................... 2-13Table 2-F. Hose Bundle .................................................................................................. 2-15Table 2-G. Power Unit Skid ............................................................................................. 2-16Table 2-H. 1-1/2" Quick Disconnect Coupling ................................................................. 2-17Table 2-I. 200 Caisson Clamp Assembly ....................................................................... 2-18Table 2-J. 200 Caisson Clamp Cylinder Assembly ......................................................... 2-19Table 2-K. Control Panel Assembly ................................................................................. 2-21Table 2-L. Control Panel-Gages. .................................................................................... 2-23Table 2-M. Control Pendant Assembly ............................................................................ 2-25Table 6-A. Vibro Trouble-Shooting Index ........................................................................ 6-1Table 7-A. Clamp Drill Manifold Assembly 523003B ....................................................... 7-4Table 7-B. Drive Manifold Assembly 555183 .................................................................. 7-6Table 7-C. Hose Identifi cation and Routing ..................................................................... 7-9Table 7-D. Hydraulic Component Identifi cation - Tank Detail .......................................... 7-11Table 7-E. Hydraulic Pumps ............................................................................................ 7-13Table 7-F. Recommended Bolt Tightening Torque .......................................................... 7-24




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WarrantyAmerican Piledriving Equipment, Inc. J&M Foundation Equipment LLC

STANDARD WARRANTY

American Piledriving Equipment, Inc./J&M Foundation Equipment LLC (APE/J&M) warrants new products sold by it to be free from defects in material or workmanship for a period of one year after

the date of delivery to the fi rst user and subject to the following conditions:APE/J&M’s obligation and liability under this WARRANTY is expressly limited to repairing orreplacing at APE/J&M’s option, any parts which appear to APE/J&M 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 APE/J&M or the authorized APE/J&M distributor of the product during regular working hours. This WARRANTY, shall not apply to compo-nent parts or accessories of products not manufactured by APE/J&M and which carry the warranty of

the manufacturer thereof, or to normal maintenance (scraped and scived lube and fuel lines, worncushion material in the drive base) or normal maintenance parts (such as fouled injectors, weakened

check valve springs, damaged grease zirts caused by use over time). 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. APE/J&M makes no other warranty, expressed or implied and makes no

warranty of merchantability of fi tness for any particular purpose.

APE’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 APE/J&M, products or parts for which a warranty claim is made are to be returned transportation prepaid to APE/J&M. Any improper use,including operation after discovery of defective or worn parts, operation beyond rated capacity,

substitution of any parts whatsoever, or parts not approved by APE/J&M or any alteration or repair by others in such manner as in APE/J&M’s judgment affects the product materially and

adversely, shall void this warranty.

ANY TYPE OF WELDING ON EQUIPMENT WILL VOID THE WARRANTY

Refusal: Vibros: If the pile does not move one foot in 30 seconds of vibro operation at full speed. Resort toa larger vibro. APE/J&M equipment may exceed the refusal driving criteria for short periods of time as may be needed

to penetrate hard soil layers or obstacles. In such cases, a heat gun is used to monitor the temperature of thebearings and related components to prevent use of the machine beyond 210 degrees. Contact APE/J&M or your local

APE/J&M distributor for special instructions when faced with refusal conditions.Refusal: Diesels: Do not exceed 10 blows per inch or 120 blows per foot. In cases of setting of the pile it ispermitted to increase the blow count to 250 blows per foot, but only for one foot of driving penetration. Pile

inspectors should consult the APE factory for permission to exceed these limits. Failure to do so will void thewarranty. This standard specifi cation is accepted by the DFI (Deep Foundations Institute) and the PDCA

(Pile Contractors Association) and by all manufacturers of pile driving equipment.


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Patented breakthrough suppressor cuts down weight while increasing line pull.

Suppressor is modular and can be removed to reduce suspended weight and height.

One piece eccentric/ gear design eliminates bolts, keyways, splines and pins.

Eeccentrics filled with "heavy metals" produce more amplitude with less parts.

Giant spherical bearings are fi ve times larger than those found on other machines.

The 200 vibro can be shipped fully assembled on one truck.

The Model 200 outper-forms other vibros in its class. It is lighter and al-lows more pull and reach.

I. GENERAL INFORMATION

I-1. Machine Features. - Model 200 Vibratory Hammer

The heavy duty lifting pin allows easy rigging of the vibro and two safety pins ensure maximum safety.

More pulling ability than other comparable vibros.

Gear box incorporates a machined O-ring groove to seal the top plate with no leaky gaskets.

Rifl e bored top plate eliminates unwanted hoses that can causeserious downtime.

Computer designed gear-box is perfectly balanced with low center of gravity. Release crane line with-out the worry of bending piles.

Hydraulic motors are re-cessed which eliminates the need for bolted on guards. Less parts - less problems.

Heavy cylinder needs no guards and all hoses are tucked out of harms way. The one piece design eliminates rear seals, tie rods & nuts.

Gear box drilled to accept attachments manufac-tured by APE and by other manufacturers.

High speed gear train will allow vibro to operate off many different power units.

Figure 1-A. Machine Features




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I. GENERAL INFORMATION (Continued...)

I-2. Machine Specifi cations

A. Model 200 Vibro

B. Model 595 Power Unit

* Weight includes Universal clamp and 1/2 of hose bundle.** Height includes Universal clamp.

Table 1-A. Vibro

Table 1-B. Power Unit

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Model 595Engine

Maximum PowerOperating SpeedMaximum Drive PressureHyd. Flow-FWD/REVClamp PressureClamp Pump Flow WeightLengthWidthHeight

595 hp. (444 kW) Caterpillar C-15595 hp (444 kW)800 to 2100 rpm

5,000 psi (344 bar)195 gpm (738 lpm)4,800 psi (331 bar)

10 gpm (41 lpm)19,000 lbs (8,618 kg)

152" (3,861 mm)82.25" (2089 mm)

94" (2388 mm)

Eccentric MomentDrive ForceFrequency (cpm)AmplitudePile Clamp ForceLine Pull for ExtractionHydraulic Hose LengthSuspended Weight*LengthWidth at ThroatHeight**

4,400 in-lbs (5,080 kg-cm)160 Tons ( 1,423 kN)

400 to 1,6001.17" (30 mm)

120 Tons (1,176 kN)150 Tons (1,335 kN)

150' (45 m)13,600 lbs. (6,167 kg)

106" (2692 mm)15.25" (387 mm)104" (2638 mm)

Model 200



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I-3. General Description of Model 200 Vibro

The APE Model 200 is a variable frequency vibratory pile driver/extractor designed to drive and extract all types of piles including sheet, pipe, timber, concrete, H-beam, I-beam and steel plates. In addition, the vibrator can be used for soil compaction, installing well casings, and installation of tie-backs and wick drains.

The Model 200 operates in a frequency range of 800 to 1,600 cycles per minute depending on the hydraulic fl ow and on the hydraulic motors fi tted to the gear train.

The three major parts to the Model 200 are as follows:

A. The Suppressor housing. B. The Gearbox. C. The Clamp Attachment.

Figure 1-B. General Description of 200 Vibro.

B. GEARBOX

D. CLAMP ATTACHMENT(shown with sheet clamp)

A. SUPPRESSOR HOUSING

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I-3A. The Suppressor Housing

The suppressor housing utilizes a total of four, fi st stage large elastomers and 8 small, second, stage small elastomers. During extraction, the fi rst stage displaces approximately 7.75 inches and then engages the inner second stage and engagement pin plate. The engagement pin will then come into motion and provide an additional 10 inches until the safety pin bottoms out in the visual slot registering the total line pull with a total maximum line pull of 150 tons. When the second stage is engaged you must be fully engaged in the second stage. Bouncing on the safety pin between stages is damaging. ( WARNING! Hard pulling for long periods of time will heat and damage the large elastomers. The heat generated from constant heavy line pull will destroy the chemical bond between the rubber and mounting plate which will cause elas-tomer failure.) When engaged in hard extracting, break every 15 minutes to allow elastomers to cool.

Figure 1-C. General Description of Suppressor Housing.

Lifting Bale

Safety Pin

Elastomers (Inside)SmallSuppressor Housing

Center Plate

Top Plate

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Elastomers (Large)



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I-3B. The Vibrator Gearbox

The vibrator gearbox contains four high amplitude eccentric weights cast in one piece with the gear. This design is unique to the industry and was developed by the engineers of APE to solve a number of problems associated with other types of vibrator machines. The eccentric and the drive gears have been helically cut to provide high speed operation with reduced noise and wear. Vibration is caused by the vertical movement created when the eccentrics are rotated. The eccentrics and drive gears are all driven in line by a hydraulic motor tucked in on the outboard side of the gearbox. The motor is recessed for maximum protection. The eccentrics rotate on four shafts housed by eight giant spherical bearings. The gears and bearings receive lubrication as a result of the fl uid splashing inside the gearbox when the gears are rotated. The oil level is quickly determined by looking at the site gauge. The Model 200 can be operated under water to a depth of 30 feet without modifi cations. (Consult factory for depths below 30 feet.)

Figure 1-D. General Description of Vibrator Gearbox.

Rifl e BoredTop Plate

HydraulicMotor

BearingCover

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GLASS SIGHT GAUGE

Oil Level

Check daily and change every 150 hours




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I-3C. The Clamp Attachment

The APE 200 comes with a Caisson Beam and Caisson Clamps. The clamps contain two gripping jaws. One is "fi xed" and one is "moveable". A large hydraulic cylinder operates the moveable jaw with up to 120 tons of clamping force depending on clamp pump relief pressure. The jaws open and close by turning a switch on the remote control pendant or may be operated by turning the switch at the main control panel mounted behind one of the doors on the power unit. The valve can be manually operated with a screwdriver if all electrical fails. The APE Caisson Clamp can be used for driving and extracting caissons from 16 inches to 9.5 feet. (for larger diameters contact APE) The clamps are held in place with a simple wedge-lock design. Clamps can be fi tted with hydrauli-cally activated wedges for faster adjustments when driving more than one size caisson. (Contact APE or your local APE distributor for more information on clamp attachments for special pile types.)

Figure 1-E. General Description of Clamp Attachment.

Figure 1-F. Clamp Attachment Hole Confi guration.

Notice: If you are involved in changing a clamp attachment then please train your crew to clean the machined surfaces of both the bottom of the vibro and the top of the clamp so that when they bolt the two together they will mate up properly. Sometimes a crew will forget to do this and the dirt or dent in the metal plates will prevent the bolts from becoming fully tight. When this hap-pens, the clamp bolts break.

Caisson BeamClamp Body

Clamp Cylinder

Moveable JawFixed Jaw



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I-3D. Optional Attachments

The following are some of the optional attachments for the Model 200 Vibratory hammer. (Contact APE or your local APE distributor for more information about these and other available equipment.)

APE DELUXE WOOD CLAMP(#907000)

7 ft. Caisson Beam (#901000) 8 ft. Caisson Beam (#902000)11ft.Caisson Beam (#903000)

Caisson Clamp (#250000)

Figure 1-G. Optional Attachments

90 Degree AdapterPlate (#905000)

4 ft. Extension Adapter(#906000)

Clamp Attachment

APE 90 DEGREE ADAPTER WITH EXTENSION

APE CAISSON CLAMP




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I-4. General Description of Model 595 Power Unit

The 200 vibrator runs off the APE 595 power unit. The APE 595 has a 595 horsepower (444 kW) CATERPILLAR C18 engine. The engine is mounted to a tubular frame that also serves as a diesel fuel tank. A sheet metal and tube frame covers the engine and is equipped with locking doors for protection from the environment. A control panel is located behind one of the doors and comes complete with a 50 foot (15.2 M) control pendant. There are two hydraulic tanks on the power unit. One is the main tank and the other is a storage tank for extra oil in case the main tank becomes depleted. A hydraulic tank supplies oil to four pumps. Two pumps feed the vibrator motors. A small dual pump feeds the clamp attachment and phase shifter. There is also a recirculation pump to keep the oil cool and fi ltered. The Vibrator is connected to the power unit via fi ve hydraulic hoses. The 1 1/2" (ID) hoses are the pressure line and the return line for the vibrator motors. Two small 3/8" (ID) hoses are for the clamp system. The 3/4" (ID) hose is for the vibrator motor case drain line. The hoses are attached to the power unit by connecting the "quick disconnect fi ttings" on the end of the hoses leading from the vibrator. The fi ttings go on only one way so there is no chance of hooking up the hoses improperly.

WARNING: Clean with ether or a clean rag before installing quick disconnects. Make sure you seat the quick disconnect fi ttings all the way tight. Failure to tighten the quick disconnects will stop the fl ow of oil and will prevent the vibro from operating. Failure to tighten the clamp fi ttings completely tight will cause the jaws to either not open or not close. If this happens you may have to crack the fi tting and bleed off the pressure to release the quick disconnects.

Figure 1-H. General Description of Model 595 Power Unit

Lifting Eye

Tube Frame

Radiator

Exhaust Muffl er

Hydraulic Tank

Quick DisconnectFittings

Fuel Tank

Locking Doors



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Scotto 4/12/2010 MODEL: 200 VIBRO FINAL ASM

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200 VIBRO

1 2

3

54

84

6

4

7 212726 28

32

38

30

39

30

40

42

Figure 2-A. Model 200 Final Assembly

II. MAJOR COMPONENT DEFINITIONII-1. Model 200 Final Assembly Identifi cation


7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710A

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II. MAJOR COMPONENT DEFINITION (Contnued...)II-1. Model 200 Final Assembly Identifi cation

SCALE:

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3 OF 3


Scotto 4/12/2010 MODEL: 200 VIBRO FINAL ASM

MATERIAL:

REV:

200 VIBRO

14

13

16

17

18

15

33

25

24

12

11

10

9

30

39

29

28

20

22

23

19

40

30

38

41



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II. MAJOR COMPONENT DEFINITION (Contnued...)II-1. Model 200 Final Assembly Identifi cation

Table 2-A. Model 200 Final Assembly

SCALE:

VIEW

1 OF 3

KENT, WASHINGTON

AMERICAN PILE

DRIVING EQUIPMENT

DWN. BY:

DATE:

DESCRIPTION

Scotto

4/12/2010

MODEL:

200 VIBRO FINAL ASM

MATERIAL:

REV:

200 VIBRO

Parts List

DESCRIPTIONSTOCK NUMBERQTYITEM

GEAR BOX ASSEMBLY15300111

TOP PLATE15300212

SUPPRESSOR ASSEMBLY33010113

0.75 HI COLLAR LOCK WASHER140223524

0.75-10UNC X 2.75 SHCS400069145

0.75-10UNC X 5.50 SHCS12422646

0.75-10UNC X 4.50 SHCS12422787

0.75-10UNC X 6.50 SHCS124228348

PLATE WASHER 49

0.44 FLAT WASHER1242291610

0.44 LOCK WASHER1242301611

0.44-14UNC 5.00 LG SHCS1242311612

HYDRAULIC FLANGE ADAPTER142012413

2-226 O-RINGSEAL414

HYD MOTOR ADAPTER142012415

2-222 O-RINGSEAL816

2-222 PAR BACKSEAL417

2-030 O-RINGSEAL418

2-225 O-RINGSEAL619

DOUBLE SPLIT FLANGE123021320

HOSE CLAMP PLATE123023221


0.63-11UNC X 2.25 LG SHCS1000852423

20 SPLIT FLANGE CODE 62124233424

0.50 LOCK WASHER1001211625

FITT2P-16P100063126

FITT2P-20P124234127

FITT2P-20R124235828

FITT2P-08R1009031029

FITT2S-08M08R000-000H0011001391230

FITT2C-08J124236431

FITT2S-12M12R000-000H001100609232

0.50-13UNC X 1.75 SHCS1001631633

O-RING CORD 0.13 C.S. / INCH35207920134

FITT2S-08M10R000-000H001300099235

HOSE050R09J908J008L01700124237136

HOSE050R09J908J008L01700124237137

HOSE050R09J008J008L01700124239138

HOSE050R09J008J008L07200124239139

HOSE125R13F024F024L07800124242240

FITT2S-12M08R124238141

HOSE075R09J012J012L07800124241142

SEAL = SEAL KIT P/N 143005



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Figure 2-B. Suppressor AssemblySCALE:

VIEW

2 OF 2


Scotto 4/8/2010 MODEL: SUPPRESSOR ASSEMBLY

MATERIAL:

REV:

200 VIBRO

2

1

4

3

11

8

7

12

5

11

10

6

13

8

9

18

14

19

15

16

17

8

8

II. MAJOR COMPONENT DEFINITION (Contnued...)II-2. Suppressor Identifi cation



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Table 2-B. Suppressor Assembly

SCALE:

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1 OF 2


Scotto 4/8/2010 MODEL: SUPPRESSOR ASSEMBLY

MATERIAL:

REV:

200 VIBRO

Parts List


INNER SUPPRESSOR 11

SUPPRESSOR HOUSING 12

ELASTOMER32100483

LARGE ELASTOMER32100344

GUIDE PIN 15

HOSE CLAMP 16

0.75-10UNC X 2.25 SHCS 327

0.75-10UNC STOVER NUT 1158

0.75-10UNC X 2.50 SHCS100067169

0.75 HI COLLAR LOCK WASHER 210

0.75-10UNC X 2.00 SHCS4000693411

0.75-10UNC X 1.75 LG SHCS 3212

0.75-10UNC X 6.50 SHCS 313

0.63-11UNC X 3.50 LG SHCS130135314

0.63-11UNC X 3.25 LG SHCS 415

0.63 HI COLLAR LOCK WASHER 416

POP OFF RELIEF321009117

INNER HOSE CLAMP 118

CHECK VALVE ASSEMBLY352103119

II. MAJOR COMPONENT DEFINITION (Contnued...)II-2. Suppressor Identifi cation



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II. MAJOR COMPONENT DEFINITION (Contnued...)II-3. Gearbox Identifi cation

Figure 2-C. Gearbox Assembly SCALE:

VIEW

2 OF 2


Scotto 4/8/2010 MODEL: GEAR BOX ASSEMBLY

MATERIAL:

REV:

172

22

4

7

624 16

10

7

4

22

2

17

89

13

5

23

201714111

16

125

21

24

18

19

3

15

16



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Table 2-C. Gearbox Assembly

SCALE:

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1 OF 2


Scotto 4/8/2010 MODEL: GEAR BOX ASSEMBLY

MATERIAL:

REV:

Parts List


GEAR BOX14300111

ECCENTRIC BEARING COVER14100442

ECCENTRIC BEARING COVER CUT EDGE141004A43

ECCENTRIC BEARING141001B84

MOTOR BEARING14200245

ECCENTRIC SHAFT14100346

BEARING SLEEVE14100587

ECCENTRIC LEFT HAND141007F28

ECCENTRIC RIGHT HAND141007F29

DRIVE GEAR RIGHT HAND163024110

DRIVE GEAR LEFT HAND163023111

GEAR CARRIER142010212

GEAR SPACER142009213

BEARIING COVER 214

SIGHT GLASS123005115

1" MAG PIPE PLUG123004316

0.50-13UNC X 1.00 SHCS1004457617


0.75-10UNC X 2.00 SHCS124225819

GEAR BOX BREATHER122015220

2-163 O-RINGSEAL221

2-276 O-RINGSEAL822

2-258 O-RINGSEAL223

GEAR BOX MOTOR (160)152001A224

SEAL = 163003 SEAL KIT

II. MAJOR COMPONENT DEFINITION (Contnued...)II-3. Gearbox Identifi cation



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Figure 2-D. Check Valve Assembly

II. MAJOR COMPONENT DEFINITION (Contnued...)II-4. Check Valve Identifi cation

Table 2-D. Check Valve Assembly

34

1

2

4

3

ITEM NO. QTY. PartNo DESCRIPTION1 1 1000515 CHECK VALVE BODY

2 1 1000516 CHECK VALVE

3 2 1000517 0.25 X 0.50 ROLL PIN

4 2 1000518 2-123 O-RING



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II. MAJOR COMPONENT DEFINITION (Contnued...)

II-5. Clamp Identifi cation

Figure 2-E. Model 200 Clamp Assembly



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Table 2-E. Model 200 Clamp Assembly

II. MAJOR COMPONENT DEFINITION (Contnued...)

II-5. Clamp Identifi cation



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Figure 2-F. Hose Bundle

II. COMPONENT DEFINITION (Continued...)

II-6. Hose Bundle.



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II. COMPONENT DEFINITION (Continued...)

II-6. Hose Bundle.The following is a list of the hoses that are shipped with the Model 200 Vibratory Driver.

Table 2-F. Hose Bundle

Item Qty Description Part No.

1 3 2" x 50' c/w #32 FJIC e/e #421008 Hose (5000 psi rated) 2 2 Fitting #32 MJIC/ #32 M.Pipe #421051 3 3 1-1/2" x 50' c/w #24 FJIC e/e #421008 Hose (5000 psi rated) 4 6 3/8" x 50' c/w 3/8" FJIC e/e #421010 Hose (CPB 5500 psi) 5 1 1" Dust Cap # 6 3 Fitting #32 Male JIC Union #421048 7 3 Fitting #24 Male JIC Union #421012 8 6 Fitting #6 Male JIC Union #421014 9 1 3/8" Safeway Plug #S34-3 #421027 10 1 3/8" Safeway Cap #S39-3 #421026 11 1 Fitting #16 MJIC/ #16 M. Pipe # 12 1 Fitting #6 MJIC/ #6 F. Pipe #421011 13 1 Fitting #6 MJIC/ #6 M. Pipe #421017 14 1 1-1/2" QD Female Coupling #400301 15 1 1-1/2" QD. Male Coupling #400303 16 1 3/8" Safeway Female QD #S35-3 #421024 17 1 3/8" Safeway Male QD #S31-3 #421025 18 1 APE 1-1/2" Dust Plug #400704 19 1 APE 1-1/2" Dust Cap #400703 20 1 1" QD Male Coupling #421020 21 3 Fitting #16 Male JIC Union #421013 22 1 Fitting #24 MJIC/ #24 M. Pipe #421015 23 3 1" x 50' c/w #16 FJIC e/e # Hose (5000 psi rated)



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Table 2-G. Power Unit Skid

Item Qty Description Part No.1 1 Model Power Unit Skid 2 1 Radiator Grill3 2 Door 27 1/2" x 67 1/2"4 2 Door 23 5/8" x 67 1/2"5 1 Door 33 1/2" x 36"6 1 Door 33 1/2" x 67 1/2"7 2 Door 23 5/8" x 67 1/2"8 1 Door 27 1/2" x 67 1/2"9A 1 2" Hyd. Quick Disconnect Female"REV" 441301 9B 1 2" Hyd. Quick Disconnect Male "FWD" 44130210 1 1" Hyd. Quick Disconnect Female "Vibro Case Drain" 11A 1 3/8" Hyd. Quick Disconnect "Female Clamp" 42102411B 1 3/8" Hyd. Quick Disconnect "Male Clamp" 42102511C 1 3/8" Hyd. Quick Disconnect Male "Drill Shift" 55515512 5 Dead Bolt Latch Allegis P/N 105ES SS 48 T- Handle-Allegis P/N 4874 SS13 17 Hinges #FES 150 GF Weld On Hinge14 1 Lifting Eye Actex #46404-SP-APE-E=10"

Figure 2-G. Power Unit Skid

II. MAJOR COMPONENT DEFINITION (Continued...)

II-7. Model 595 Power Unit Skid Identifi cation



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II-8. 1-1/2" Quick Disconnect Coupling Identifi cation.The APE 1-1/2 Inch Quick Disconnect Couplings are high pressure hydraulic couplings designed for rugged applications. Service in many such applications has proven the design compatible to extreme pressures, structural and system induced shock loads. The construction of the coupling assembly promotes ease of use and maintenance.

Design Features:- Excellent fl ow characteristics for continuous duty applications.- High strength design endures high surge and shock conditions.- Flat crested stub-ACME threads and all steel construction withstand storage and rig-up damage.- Structurally compatible with weight of 5,000 P.S.I. fl ex-hose and system induced shock loads.

Figure 2-H. 1-1/2" Quick Disconnect Coupling

Table 2-H. 1-1/2" Quick Disconnect Coupling

Quick Disconnect Assem. #Dust Plug #Dust Cap #Complete Seal Kit #Rebuild Kit (Includes Seal Kit) #

1 1 Hydraulic Female Coupling #4003012 1 Hydraulic Male Coupling 4003033 1 Hydraulic Female Sleeve #4003024 1 O-Ring Carrier "A" #4002025 1 O-Ring Carrier "B" #4002016 1 Plunger #4001017 1 Plunger #4001018 1 Poppet Valve / Plunger Spring #4007019 1 Retaining Ring "Truarc External" #I-27510 2 Retaining Ring - "Truarc Internal" #N5000-16811 2 O-Ring #2-230 and Par Back 12 2 O-Ring 2-216

QtyItem Description



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II-9. 200 Caisson Clamp Identifi cation.

Figure 2-I. 200 Caisson Clamp Assembly

Table 2-I. 200 Caisson Clamp Assembly

Item Qty Description Part #1 1 Caisson Clamp Body #2501012 1 Plastic Sleeve #250224 3 1 Fixed Jaw #250202H4 1 Clamp Cylinder Asm #2510015 3 Male Wedge Half (Bronze) #2431026 3 Female Wedge Half (Steel) #2431057 3 ACME Wedge Bolt #124211A 8 6 Wedge Washer #124219 9 3 ACME Wedge Nut #124122 10 8 1-1/4" High Collar Lock Washer #12420511 8 #12420412 7 #22100113 2 14 2 #124115 15 2

Bolt - SHCS 1-1/4" NF x 4.00 Grease Zerk #6 JIC Cap BRE304C6Lock Washer 5/8" High Collar Bolt - SHCS 5/8" x 4" #124214

SCALE:VIEW

1 OF 1

PITTSBURGH, PENNSYLVANIAFOUNDATION EQUIPMENT LLCDWN. BY: DATE: DESCRIPTION

scotto 12/16/2009 MODEL:

MATERIAL:

REV:


CLAMP BODY11

ROD BUSHING12

FIXED JAW NARROW250202H13

200 CLAMP CYL ASM25000114

BRONZE WEDGE25010235

STEEL WEDGE25010536

WEDGE BOLT37

1.25 H.S. FLAT WASHER12011168

1.25-5 ACME HEX NUT39


1.25-12UNF X 4.00 LG SHCS811

GREASE FITTING 0.13 NPT712

FITT2C-06J213


0.63-11UNC X 4.00 LG SHCS110308215

1 8 9 12 4

13

1110212873

14

15

12

5

7

8

12

6

#100057



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II-10. 200 Caisson Clamp Cylinder Identifi cation.

Figure 2-J. 200 Caisson Clamp Cylinder Assembly #250001SCALE:

VIEW

2500011 OF 1

PITTSBURGH, PENNSYLVANIAFOUNDATION EQUIPMENT LLCDWN. BY: DATE: DESCRIPTION

scotto 12/16/2009 MODEL: 200 CLAMP CYL ASM

MATERIAL:

REV:

200 CAISSON

Parts List


8" HYD CYLINDER BARREL11

8"CAISSON PISTON AND ROD12

FRONT PLATE SEAL13

2-367 O-RING14

8-367 PAR BAK15

ROD SEAL16

ROD WEAR BAND17

ROD WIPER18

PISTON WEAR BAND19

PISTON RING AND EXPANDER110

0.63-18UNF X 1.00 LG SHCS1211

P O CHECK VALVE112

FITT2P-06R400992113

FITT2L-06M06R130057214

12

3 4 5

8

6

7 910

11

12

13

14

Item Qty Part #1 12 1 #2500033 1 #2220044 1 5 1 6 1 7 1 8 1 9 1 10 1 11 12 #1003804 12 1 #22201613 1 #100395914 2

Description Clamp Cylinder BucketPiston Rod Cylinder Gland *O-Ring 2-367*8-367 Par Bak*Rod Seal*Rod Wear Band*Rod Wiper*Piston Wear Band*Piston Ring and Expander Bolt SHCS 0.625-18UNF X 1.00 P O Check Valve CKEB-XCN#6 SAE Allen Plug#6 M O-Ring - #6 M JIC 90 deg Fitting #130057

#1001409

*Included in Seal Kit-8" Clamp Cylinder #1003614

Table 2-J. 200 Caisson Clamp Cylinder Assembly



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II-11. Control Panel.

Figure 2-K. Control Panel Assembly

Items not shown: 57, 58, 59, 60



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Page 2-21Table 2-K. Control Panel Assembly

ITEM DESCRIPTION QTY PART BREAKDOWN MFG. MFG. PART # 1 Lighted Clmp. Open/Cl. Sw. 1 Illuminated 3-Pos. Spr. Ret. from L Brad Harrison 800T-24JG4KB7AX 2 Green L.E.D. 2 Green L.E.D. Brad Harrison LSTD-2G 3 Auxiliary Pwr. Receptacle 1 PM 2-Socket Aux. Receptacle Amphenol MS3102A-12S-3-S 4 1 PM Aux Receptacle Gasket Amphenol 10-40450-12 5 1 PM Aux Receptacle Cover Amphenol MS25043-12D 6 Pendant Receptacle 1 PM 15 Socket Pendant Receptacle Amphenol MS3102A28-17S 7 1 PM Pen Receptacle Gasket Amphenol 10-40450-28 8 1 PM Pen Receptacle Cover Amphenol MS25043-28D 9 Engine Receptacle 1 PM 23-Pin Engine Receptacle Amphenol MS3102A32-6P 10 1 PM Engine Receptacle Gasket Amphenol 10-40450-32 11 PM S.O. Cord Hookups 6 Side PM Male Receptacle Brad Harrison 1R3006A24A120 12 6 1/2" Lock Nut Regal 801 13 Vibro / Auger - Test 2 Toggle Switch 2 position CPI 10011 14 Switch Bracket 2 SS Small Z Bracket CPI 18200 15 Drive Rev/Fwd Switch 1 3-Position Operator (Maint.) C-H 10250T3023 16 2 Contact Block, 2 N.O. C-H 10250T2 17 1 Contact Block, 2 N.C. C-H 10250T3 18 Local/Pendant Switch 1 2-Position Operator (Maint.) C-H 10250T3011 19 2 Contact Block, 2 N.O. / 2 N.C. C-H 10250T44 20 Governor Lower/Raise Sw. 1 3-Position Operator (Mom.) C-H 10250T3043 21 Engine Control Switch 1 3-Position Operator (Maint/Mom) C-H 10250T3053 22 1 Contact Block C-H 10250T1 23 Lampholder 1 System O.K. Lampholder C-H 10250T206N 24 Green Lens 1 Green Lens C-H 10250TC2N 25 Volt Meter Gauge 1 Volt Meter Gauge Datcon 100165 26 HourMeter Gauge 1 HourMeter Gauge Datcon 100223 27 Speed Switch 1 Speed Switch ECU ECU-SS40 28 Drive Hour Meter Bracket 1 Drive Hour Meter Bracket Hobbs 23944 29 Cord Connector 1 3/4"-3/8"-1/2" Cord Connector Hubbell SHC1035CR 30 2 3/4" Lock Nut Regal 802 31 2 3/4" Rubber Gasket T&B 5303 32 Cord Connector 1 3/4" Cord Connector Hubbell SHC1036CR 33 Panel Alarm Lights 5 Red L.E.D. Idec AP8M222-R 34 Diagnosis 1 Amber L.E.D. Idec AP8M222-A 35 Panel Terminal Blocks 41 Terminal Block Idec BNH15MW 36 4 Terminal Block Idec BNH30W 37 1 Terminal End Section Idec BNE15W 38 1 Terminal End Section Idec BNE30W 39 4 Terminal End Clamp Idec BNL5 40 1 Strip Clear Terminal Block Cover Idec BNC230PN10 41 2 Metal Jumper Idec BNJ26FW 42 1 Terminal Block Number Strip Idec BNM7PN10 43 1 Number Strip Holder Idec BNM3


II-11. Control Panel.



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Table 2-K. Control Panel Assembly (Continued...)

ITEM DESCRIPTION QTY PART BREAKDOWN MFG. MFG. PART # 44 2 Pole Relay 2 Lighted Relay, DPDT Idec RH2BUL-24VDC 45 2 Relay Base, 2 Pole Idec SH2B-05C 46 Diode 15 Diode, 6 Amp Idec 60S6 47 Engine Fault Switch 1 Magnetic Switch Murphy 117PH 48 Dust Cover 1 Clear Dust Cover Murphy 250547 49 10 Amp Circuit Breaker 1 Circuit Breaker, 10 Amp P&B W58-XC4C12A-10 50 16 Amp Circuit Breaker 1 Circuit Breaker, 16 Amp P&B 5SX2116-8 51 Tachometer Transducer 1 Tachometer Transducer Red Lion IFMA0035 52 Rubber Stand Offs 4 Shock Mount Legs (1/4") Vib. Elim. 40B 53 SS Enclosure Back Pan 1 SS Enclosure Back Pan Vulcan Stainless 54 SS Door Silk Screen 1 Door Silk Screen CPI 3700S116 55 S.O. Cord Description 1 Side Legend Plates CPI 3700SP40 56 Drive Rev/Fwd Hourmeter 1 Drive Hourmeter Hobbs 85094-12 57 4 M Yellow S.O. Cord 3 4 M Yellow S.O. Cord Brad Harrison 103000A02F120 58 8 M Yellow S.O. Cord 2 8 M Yellow S.O. Cord Brad Harrison 103000A02F250 59 6 M Double-Ended S.O. Cord 1 6 M Double-Ended S.O. Cord Brad Harrison 113022A01F200 60 Shock Mount Foot 2 Shock Mount Foot Vib. Elim. T22-3 61 Oil Pressure Gauge 1 Oil Pressure Gauge Murphy 20P100 62 Coolant Temperature Gauge 1 Water Temperature Gauge Murphy 20T25010 63 Engine RPM Gauge 1 Engine RPM Gauge Caterpillar 197-7348


II-11. Control Panel (Continued...)



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II-11. Control Panel and Parts (Continued...)

Figure 2-L. Control Panel-Gages.

ITEM APE P/N

1. DRILL SHIFT PRESS. 5550512. OIL TEMP. GAGE 5230163. CLAMP CLOSE GAGE 5130074. CLAMP OPEN GAGE 5130075. DRIVE GAGE 5130076. RET. FILTER PRESS. 513007A

Table 2-L. Control Panel-Gages.



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II-12. Control Pendant.

Figure 2-M. Control Pendant Assembly



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Table 2-M. Control Pendant Assembly

Item # QTY. DESCRIPTION PART DESCRIPTION MFG. MFG. PART # 1 1 Illum. 3 Pos. Spr Ret From L Clamp Open/Close Sw. A-B 800T-24JG4KB7AX 2 2 Green L.E.D. Green L.E.D. Brad Harrison LSTD-2G 3 4 Diode Diode I/R 60S6 4 1 Flush Head Red PB 1 n.o. Emergency Stop PB A-B 800T-A6D1 5 1 3 Pos. Maintained Switch Drive Rev/Fwd Switch A-B 800T-J2KC1 6 1 Contact Block 1N.O./N.C. Contact Block, 1N.O./N.C. A-B 800T-XA 7 1 3 Pos. Spr. Ret. From Both Governor Lower/Raise Sw. A-B 800T-J91A 8 1 Pendant 12 Pin Plug CM 12 Pin Plug Amphenol MS3106A28-18P 9 1 Pendant Plug Clamp CM Pendant Plug Clamp Amphenol MS3057-16A 10 1 Cable Rubber Insert Clamp Rubber Insert Amphenol MS3420-12 11 1 Pendant Plug Cover CM Pen Plug Cover Amphenol MS25042-28D 12 1 A.P.E Pendant Decal CPI NP01 13 1 Engine RPM Pendant Decal CPI NP03 14 1 E/Stop-Lower/Raise Pendant Decal CPI NP04 15 1 Open/Close-Rev/Fwd Pendant Decal CPI NP05 16 1 Analog Meter 0-2500 rpm RPM Gauge Crompton 082-80R2-215256 17 1 Kellems Cord Grip Deluxe Cord Grip Hubbell 073-10-003 18 1 Deluxe Cord Grip Pendant Mount Cord Grip Hubbell 074-01-017 19 50 16 Awg 14 Con. Pend. Cbl. 16 Awg 14 Con. Pend. Cbl. Perfafl ex F19061614 20 1 4 Unit Pendant Box Pendant Station 4 Hole Square-D 9001-SKYP-4


II-12. Control Pendant.



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III. LOADING AND UNLOADING

III-1. Model 200 Vibratory Driver.

The APE 200 vibrators are normally shipped in travel stands. Two sliding pins release the vibrator from the stand. To re-install, set vibro in stand and slide pins inward and rotate. Hoist vibro and stand by rigging to the vibro lifting shackle. Vibrators shipped without stands are usually laid fl at on the trailer deck and the hose bundle is coiled on top. Lift the vibrator by rigging one line to the lifting shackle and one line around the clamp attachment lifting the vibro and hose bundle as one load. Avoid smashing hydraulic lines. Vibro should be loaded with hydraulic motors down facing the deck and breather valves facing the sky. Before the truck has left, carefully inspect the machine and hoses for any missing equipment or sign of damage that may have occured during shipment or unloading.

III-2. Model 595 Power Unit.

The Power Unit is always loaded with the oil cooler facing to the rear of the truck to prevent dam-age to the cooler and the radiator from fl ying objects. The Power Unit is usually held to the truck by wrapping a chain around both ends of the fuel tank base and the truck bed. After loading the Power Unit, tape the exhaust rain cap shut to prevent rain water from getting inside. If quick disconnects do not have safety cables then store them under the panel in the storage box rather than risk the possibility of the caps and plugs coming loose and falling off into trafi c. Make sure all doors are fully closed. Tighten fuel vent on the fuel cap to prevent diesel fuel from washing out the fi ll spout.

III-3. What to do if damaged during shipment.

In the event of damage, notify the trucking agent at once. Note all damage on the bill of laiding. Fax the information as soon as possible, any delay may make it impossible to fi nd the responsible party.



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7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710AMER

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IV. PREPARATION AND OPERATION

IV-1. Rigging of Vibratory Driver

A steel wire rope sling must be connected to the lifting bail located on top of the vibro. The required strength of this sling depends on the capacity of the crane and the work to be carried out. A safety factor of six is recommended. Several turns of a smaller diameter cable will result in a longer lasting sling than one larger diameter cable. When making a sling, avoid using cheap cable clamps. Checkthe clamps daily.

The Vibro is fi tted with a standard sheet clamp at the factory. However, several types of clamps are used on APE vibros to fi t many different types of piles. A step by step procedure is provided as follows:

1.) Clean all drilled and tapped threads on the bottom surface of the gearbox. Use a 1-1/2"UNC tap to clean any rusted threads and blow out any remaining fragments with compressed air. If there is a cutting torch on the jobsite then use the oxygen setting to blast the threads clean. Hold a rag over the tapped hole to prevent fl ying dirt from blasting into your eyes.

2.) Clean the machined bottom surface of the gearbox and prepare to mount the clamp. If the clamp bolts should ever break, check the machined surface with a straight edge to make sure it is true and fl at.

3.) Clean the machined surface of clamp. Eye-ball the entire surface for damage. Make sure the surface is fl at and void of all dirt.

4.) Start by getting the center bolt in fi rst and work outwards. Do not tighten bolts until you have all of the bolts started.

5.) Tighten bolts using a six-foot cheater pipe. If you do not have a cheater pipe then use a sledge hammer.

6.) Go around all bolts at least three times making sure they are tight.

7.) After vibrating the fi rst pile, check the bolts again.

8.) If one bolt breaks, replace them all since they may be weak or cracked.

9.) Never operate the vibro with missing clamp bolts.

WARNING: Do not use grade fi ve bolts. All bolts should be allen head cap screw bolts. If one bolt breaks then the others are damaged and must be replaced. Never drive piles if one bolt is broken. Bolts break only because they were not tight and the crew neglected to check them. A good opera-tor insists that every bolt is checked twice daily.


7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 AMER

ICAN

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IV. PREPARATION AND OPERATION (Continued...)

IV-2. Plumbing the Vibro Hoses to the Power Unit.

There are fi ve hoses leading from the vibro that must be connected to the power unit to begin opera-tion (Please see section II-5, "Hose Identifi cation, page 2-5.) The hoses attach to the power unit by screwing the quick dis-connect couplers onto the proper couplers of the power unit. The couplers on the power unit are mated with the couplers on the vibro so there is no chance of putting them on backwards. Please take the following steps when installing the couplers:

WARNING: TURN THE POWER UNIT OFF BEFORE INSTALLING COUPLERS

1.) Turn the power unit OFF.2.) Clean all couplers with a can of ether if available. A clean dry cloth will also work but will

require extreme care. Fittings must be spotless clean.3.) Install couplers by screwing them onto their respective counterparts. Try to avoid cross-

threading and maintain a straight line. Jerk the hose back and forth while turning coupler to aid installation effort. Push hard to get the big coupler threads started.

4.) Make sure fi ttings are tight. If they are properly cleaned they should run up tight with just a fi rm hand grip. However, they should be double checked with a chain wrench.

5.) Avoid over-tightening.6.) If near salt water, spray with a light oil to prevent oxidation.7.) Position the Power Unit so that vibrator has enough hose to reach the work. Avoid pulling

too hard on hoses.

Figure 4-A. Power Unit Hose Plumbing



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IV-3. Filling Vibrator Pressure Hoses.

The vibrator is shipped with the hoses fi lled with oil. However, if the unit has been sitting for a long period of time or if a damaged hose has been replaced with a new one, then the hoses must be fi lled. Hook up all the hoses to the power unit (see Section IV-3 on [page 4-2] and Figure 4-A.). Start the power unit and let it run for ten minutes before running the vibro. The hoses will fi ll up by themselves in ten minutes even if the vibro is not in the vibrate mode.

IV-4. Bleeding the Clamp Attachment Hydraulic Hoses.

If the opening and closing of the jaws seems spongy or slow, it may be a result of air in the clamp hoses. Normally there is no need to worry about bleeding the clamp lines because the unit is shipped fully tested. However, should the vibro sit for a long period of time, if a new attachment is being installed or if a damaged clamp hose has been replaced, then the system may require bleeding to remove unwanted air in the system. To bleed the clamp system, follow the following steps:

1.) Shut Power Unit OFF.2.) Make sure the clamp line quick dis-connects are coupled to the power unit.3.) Start the power unit engine and run at 1500 rpm. Give the engine time to warm up.4.) Loosen the clamp lines at the hydraulic cylinder by backing the fi ttings off just a little.5.) Turn the clamp switch on the power unit control pendant to "CLOSE" and wait for oil to

fl ow from the fi ttings. WATCH FOR AIR BUBBLES. When air bubbles have stopped then quickly re-tighten the fi ttings.

6.) Repeat the same procedure for "OPEN" side.7.) Operate the jaws. If they are still a bit spongy then repeat bleeding steps once more.

WARNING: DO NOT BLEED SYSTEM AT FULL ENGINE THROTTLE BECAUSE TOO MUCH OIL WILL FLOW FROM THE HOSES AND COULD CAUSE INJURY.

Figure 4-B. Bleeding Clamp Attachment

Bleed system by cracking fi ttings on the clamp cylinder and allowing air to escape.

Clamp "Open"

Clamp "Close"

Clamp Cylinder



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IV-5. Precautions and Rules for Operation.The following is a list of precautions, suggestions and rules that are intended to help promote thesafe and productive use of the APE Model 200 Vibratory Driver.

1.) Follow the Daily Maintenance Required Prior to Operation, [Section V-1]. 2.) Read and follow the Safety Precautions, [page iii]. 3.) Follow the start-up procedures listed in the manual for the power unit being used. 4.) Start with piles in good condition. 5.) Put all teeth in pile. 6.) Drive in steps eight feet (2.5M) or less. 7.) Keep sheets plumb. 8.) Come up to speed before doing work. 9.) No dancing. Avoid densifying the soil. 10.) Drive past obstacles and then go back. 11.) Backhoe on site to remove obstacles. 12.) Lead with the ball. 13.) Probe the pile if it appears stuck. 14.) Keep piles plumb or down the road you go. 15.) Never rush the sheet pile foreman. 16.) Slow and plumb and the job will get done. 17.) Melted inner locks - piles out of plumb. 18.) Never stand under pile drivers. 19.) Low clamp pressure means jaw failures. 20.) Wait for vibro to get to full speed then pull. 21.) Don't over excavate - lower the ring. 22.) Look at the jaws during driving. 23.) Beware of cracked or broken sheets. 24.) In sandy soils drive faster. Vibration can cause settlement in loose, granular soils. 25.) In clay amplitude is everything. 26.) Low drive pressure means easy work. 27.) High pressure means friction on piles. 28.) Over 5000 psi means get a bigger vibro. 29.) No amplitude means get a bigger vibro. 30.) Caissons need heavy wall to avoid fl ex. 31.) Check clamp bolts each morning. 32.) Read the manual - know your machine. 33.) Attach whip line to pile when pulling. 34.) Know your line pull. 35.) Extract straight - look at boom and cable. 36.) Give boom stops some room. 37.) Stalled engine means dirty fuel fi lters.



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IV-6. Relief Valve Settings Prior to Operation - Model 595

The Relief Valve and Pressure Switches are set by the factory. They will need to be re-set if the pressure switch is replaced.

1. Do not hook up quick disconnects. Start and warm engine . Bring to full rpm.

2. Check CIamp relief valve setting. On the Control Panel, turn the clamp switch to "OPEN" and hold it there while you read the CLAMP OPEN GAUGE on the panel. It should read 4800 PSI. If it is not coming up to pressure, then set the relief valve (FACTORY AUTHORIZED PERSONNEL ONLY), by loosening the lock nut and turning the knob in slowly until the proper pressure is reached. Turn in (CW) to increase pressure, and out (CCW) to decrease pressure. Tighten the locknut and recheck the pressure to make sure that the setting did not move during tightening the lock nut. When the clamp switch is turned to "OPEN" and held, a small light on the solenoid is illuminated, showing that there is power to the solenoid. Otherwise, the light on the solenoid should be off.

Figure 4-C. Setting Relief Valve



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4. Adjust the clamp pressure switch setting. (If necessary). To set the pres-sure switch, turn the adjustment screw out using a screwdriver. (Turn it out a few turns counter-clockwise.) Turn clamp switch to "OPEN" for a second. Make sure the CLAMP OPEN GAUGE reads 4800 PSI. If it does not, then go back to the Step 2 and set the clamp relief valve fi rst.

With clamp relief set at 4800 PSI, turn the clamp switch to "CLOSE". Green light should be on and clamp pressure should be very low or not reading at all.

Turn Adjustment Screw in (CW) until the green light goes off. Then, turn adjustment screw out (CCW) until green light comes on. (About 1/4 to 1/2 turn.) The CLAMP CLOSE GAUGE should read 4000 to 4800 PSI.

To check, turn clamp switch to "OPEN". The green light should be on.

Repeat procedure if necessary.

Figure 4-D. Checking Clamp Pressure Switch Setting


IV-6. Relief Valve Settings Prior to Operation - Model 595 (Continued...)

3. Check the clamp pressure switch setting. Turn the clamp to "CLOSE". If there is proper clamp pressure the CLAMP CLOSE GAUGE should read 4500 PSI to 4800 PSI, and the GREEN LIGHT comes on (see fi gure 4-D.)



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IV-7. Shut-down Procedures.The following procedures explain what to do with the power unit to correctly shut down the APE Model 200 Vibratory Driver.

1.) Stop the vibrator. (Refer to the power unit operating manual .)2.) Allow the diesel engine to run for fi ve minutes at 1000 engine rpm.3.) Reduce engine speed to low idle for about 60 seconds.4.) Shut engine off by turning off the main power switch.

WARNING: Do not shut the power unit engine down while the vibrator is clamped onto a pile. The clamp check valve will slowly bleed off if there is any leakage in the hose lines or worn clamp seals in the cylinder that moves the jaw open or closed.




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IV-8. Operation of the Control Pendant.

1. All functions of the vibro can be controlled by the control pendant. It is the choice of the crew as to where best to locate the control pendant. Some prefer that the crane operator control all functions. Others prefer to give it to one of the ground crew so it can be positioned close to the work at hand. A 50 foot (15.2 M) cord is provided as standard equipment. If this is not long enough, additional 50 foot (15.2 M) sections can be added. Should the control pendant become damaged, all functions can be manually operated. See page 7-16 in this manual for more details on operation. See page 7-21 of this manual for wiring diagram and control pendant components.

IV-10. Normal steps to operate vibrator: (Note: In order to operate power unit, Drive must be "OFF").

1. Position vibro on pile.

2. Set power unit speed to full throttle (factory set 1950 RPM).

3. Turn Clamp to "CLOSE" the switch will stay in the "CLOSE" position and wait for light to come on.

4. Turn Drive to "FWD" to direct hydraulic oil to Vibro.

5. To drive piles, lower crane line as vibrovibrates pile.

6. To extract, pull up on vibro while vibrating.

7. See "Precautions and Rules for Operation" in this manual for more detailed operations on driving and extracting piles.

8. To stop the vibro turn Drive to "OFF".

10. To release clamp, turn clamp switch to "OPEN" clamp light will turn off. Once the jaws are open release the switch.


ENGINE EMERGENCYSHUTDOWN SWITCH:

ENGINE THROTTLERAISE / LOWER RPM:

CLAMP OPEN/CLOSE:

FORWARD / OFF / REVERSE:

Figure 4-E. Control Pendant




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V. MAINTENANCE

V-1. Daily Maintenance Required Prior to Operation.

1.) Visually inspect the entire vibro for loose nuts or bolts. Put a wrench on the clamp bolts and check them for tightness.

2.) Grease the Jaw Plunger on the clamp housing.

3.) Check the oil level in the vibrator. Hang vibro from crane and look at sight gauge. Make sure the oil is half way up gauge. If you cannot read it then you can't run the vibro. Remove the gauge and clean it by spraying a shot of starting fl uid at it. YOU MUST KNOW THE LEVEL!

4.) If the oil is milky or black then change it. Change the oil every 150 hours regardless.

5.) Check the fl uid level in the power unit hydraulic tank.

6.) Look at all the hoses. Check for cuts or other damage that might cause an oil leak.

7.) Check the Elastomers (rubbers) in the suppressor housing. Look for cracks.

8) Check the following items:

V-2. Checklist After Power Unit Engine Has Started

1.) Check all hydraulic hoses for leaks. Make sure they hang free with no kinks.

2.) Check inside the Power Unit. Look at all hoses and valves, check for leaks.

3.) Check return fi lter gage at control panel with engine running at full rpm and hydraulic oil temperature above 80 degrees F. Replace fi lter when pressure is above 50 psi.

4.) Check wire rope sling and make sure it is in excellent condition.

5.) Check jaws for wear. Replace if necessary.

6.) Close jaws, make sure clamp light comes on.

IF THE OIL LOOKS BLACK OR MILKY THEN DRAIN THE GEARCASE AND ADD NEW OIL.

Oil LevelScheaffer 268or equivalent.(do not use veg. oil)Sight Gauge

If you cannot read it then do not assume the level is ok.

Check water level in radiatorCheck battery water levelCheck fuel levelCheck oil level in pump driveCheck hydraulic oil level

Check engine oilCheck hydraulic return fi lter indicatorCheck fan belts on engineCheck entire unit for hydraulic leaksCheck condition of jaws before operating




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V. MAINTENANCE (Continued...)

V-3. Maintenance and Adjustments. (75 Hours)

Change the oil in vibrator gearbox. Remove the drain plug from bottom of gearbox and drain the oil into a bucket. Check oil for any metal shavings. Replace oil in gearbox by adding 20.6 gallons of standard weight oil. Schaeffer 268.

Clean the gearbox breathers each time the oil is changed. Replace the breathers if necessary.

V-4. Maintenance and Adjustments. (Eccentric Bearings)

1.) Model 200 - The Eccentric Bearings should be checked and/or replaced after every 2500 hours of operation.

V-5. Maintenance and Adjustments in Severe Conditions.

When average temperature is above (80 deg. F) or below (-1 deg. F) reduce servicing intervals toone half of those specifi ed above.

When operating in the presence of dust or sand, reduce servicing intervals to one-third of those specifi ed.

During stand-by or inactive periods, the servicing intervals may be reduced to one-half. The unit should be run every 30 days or less to keep internal parts lubricated.

V-6A. Lubrication - Vibratory Gearbox.

The Gearbox oil should be changed when black or milky. Schaeffer 268 or equal is the preferred oil. The gearbox requires 6.7 gallons of oil.

V-6B. Lubrication - Clamp Attachment.

The Clamp Attachment hydraulic oil must be checked and changed on a regular basis. The ClampCylinder Plunger should be checked for rust and debris. Lubricate the plunger on a regular basis using the grease zert on the side of the clamp housing .




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V. MAINTENANCE (Continued...)

V-7A. Power Unit - Filters, Fluid Types and Capacities.

FILTERS LOCATION QTY ENGINE FILTER TYPE APE P/N Engine Oil: 1 Caterpillar C-15 Caterpillar #1R-1808 521033 Engine Fuel: 1 Caterpillar C-15 Caterpillar #1R-0749 521026 Eng. Fuel Water Sep: 1 Caterpillar C-15 Caterpillar #1R-0771 555131 Air Filter Outer 1 Caterpillar C-15 Caterpillar #106-3969 521029A Air Filter Inner 1 Caterpillar C-15 Caterpillar #106-3973 521029B Hyd. Oil Filter: 2 Zinga #ZLE-10 555009 Hand Pump Filter: 1 Zinga #AE-25 533011

model 200 vibro with model 595 power unit...2019/03/19 · model 200 vibratory driver with model...

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