APE 100 WICK Operating instructions

MODEL 100
BOTTOM DRIVE
WICK INSERTER
OPERATING AND MAINTENANCE MANUAL
MODEL 100 WICK
BOTTOM DRIVE WICK INSERTER
AMERICAN
PILEDRIVING
EQUIPMENT INC
MAN 100 WICK 201410

MODEL 100
BOTTOM DRIVE
WICK INSERTER
Revision Record
Change
Number Page Number Date Revision Description
6-23-11 Added 6 roll wick carrier 110-14 Added free wheel valves to the manifold asm
2 V-2&VIII-12
10-18 Added Wick Drain Mandrel Splice Specifications

MODEL 100
BOTTOM DRIVE
WICK INSERTER
APE MODEL 100 BOTTOM DRIVE
WICK INSERTER
MAN 100 WICK-200805
PREFACE
This manual was prepared to acquaint the owner, operator
and serviceman with the operation and maintenance of the
vibratory driver/extractor. We strongly suggest that this manual be carefully studied
before operating or undertaking any maintenance work on the unit. It is not meant
to be all inclusive as to content, and any questions and/or doubt should be directed
to APE before proceeding with any operation or maintenance.
This manual is organized into two major categories.
Thefirstcategoryis forOPERATINGINSTRUCTIONSofthe unitand includesa GENERAL
DESCRIPTION section, which presents a basic explanation of the driver/extractor
specifications. The MAINTENANCE AND ADJUSTMENT section should be referred to
for all servicing of equipment. All machines and equipment require systematic, periodic
inspection and maintenance, if they are to perform satisfactorily.
Thesecondcategory isforparts ordering andit includes botha PARTSLISTand a pictorial
drawing of the assembly. Refer to the ORDERING PARTS section of the PARTS LIST for
morespecificprocedures regarding partsordering. Adherence of thelisted procedures will
insure receipt of the required part(s) with the minimal amount of delay or error.
APE reserves the right to update or revise this manual as required, check with APE for
current release date.

MODEL 100
BOTTOM DRIVE
WICK INSERTER

MODEL 100
BOTTOM DRIVE
WICK INSERTER
Warranty
American 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 first user and subject to the following conditions:
APE/J&M’s obligation and liability under this WARRANTY is expressly limited to repairing or
replacing 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 com-
ponent 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, worn cushion 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 fitness 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 to
a 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 190 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 is
permitted 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 the
warranty. This standard specification is accepted by the DFI (Deep Foundations Institute) and the PDCA
(Pile Contractors Association) and by all manufacturers of pile driving equipment.

MODEL 100
BOTTOM DRIVE
WICK INSERTER
TABLE OF CONTENTS
I. GENERAL DESCRIPTION PAGE
A. General I- 1
B. Vibration Gear Box I- 2
C. Vibration Suppressor I- 2
D. Wick Carrier I- 2
E. Mandrel Guide I- 2
F. Legs I- 2
G. Leader System I- 2
H. Specifications I- 3
II. PREPARATION FOR OPERATION
A. General II- 1
B. Safety Precautions II- 1
C. Rigging of Vibrator II- 3
D. Connection of Hydraulic Hoses II- 4
E. Filling Vibrator Pressure Hose II- 5
III. OPERATING INSTRUCTIONS
Feroy Selector Valve III- 1
A. Completion of Set-Up and Maintenance III- 2
B. Feroy Selector Valve III- 2
C. Driving / Extracting Mandrel III- 2
D. Changing Frequency III- 3
E. Shut Down III- 3
IV. MAINTENANCE AND ADJUSTMENTS
A. General IV- 1
B. Daily IV- 1
C. 100 Hours, 500 Hours and Other IV- 2
D. Severe Conditions IV- 2
E. Lubrication IV- 3
F. Bolt Torque Information IV- 5

MODEL 100
BOTTOM DRIVE
WICK INSERTER
TABLE OF CONTENTS
V. HYDRAULIC CIRCUITRY PAGE
A. Vibrator Drive V- 1
Hydraulic Schematic V- 2
B. Hydraulic Components List V- 3
VI. GENERAL DATA
A. Abbreviations VII- 1
B. Screws and Bolts VII- 1
C. Serial Number Locations VII- 2
VII. ORDERING PARTS
A. Procedure VII- 1
B. Fitting Description Key VII- 2
Fitting Style Selector Chart - SC1 VII- 3
C. Hose Description Code VII- 4
D. Parts Identification VII- 5
Parts Lists and Drawings VII- 6
E. Miscellaneous Accessories VII- 26
F. Recommended Spare Parts VII- 27
G. Recommended Tightening Torque VII- 29

MODEL 100
BOTTOM DRIVE
WICK INSERTER

I-1
OPERATING
INSTRUCTIONS
MODEL 100
BOTTOM DRIVE
WICK INSERTER
VIBRATION
GEAR BOX
LEG
ASSEMBLY
VIBRATION
SUPPRESSOR
MANDREL GUIDE
A. GENERAL
TheAPE Model 100 BOTTOM DRIVE WICK INSERTER is a vibratory wick drain inserter.
Designedto insertwickdrainbyforcingawick threadedmandrel intowet soilwhile vibrating
through tough soil.
The Model 100 Wick operates in a frequency range of 800 to 1700 vibrations per minute
to provide maximum mandrel penetration rates in a wide variety of soils. Produces 23.7
tons (211 kN) of dynamic force and 27.8 tons (247 kN) of static driving force.
The wick inserter unit consists of six major components. (1) The vibration gear box,
(2) the vibration suppressor which contains mandrel control motors, (3) the wick carrier
assembly, (4) the leg assembly, (5) mandrel guide and (6) the lead system (not shown).
Fig. 1-1

I-2
OPERATING
INSTRUCTIONS
MODEL 100
BOTTOM DRIVE
WICK INSERTER
I. GENERAL DESCRIPTION
B. VIBRATION GEAR BOX
The vibration gear box contains two eccentric weights which rotate in a vertical plane to
create vibration (Dynamic Force). The eccentric weights are driven by a hydraulic motor.
C. VIBRATION SUPPRESSOR
The vibration suppressor contains 8 rubber elastomers to isolate the vibration case from
the leads. The mandrel insert / extract motors are mounted here.Apair of hydraulic motors
with a sprocket assembly mounted to the motors force the mandrel into the ground as well
as removing the mandrel from the ground. There is a roller assembly that works together
with the sprockets keeping the mandrel engaged with the sprockets.
D. WICK CARRIER
The wick carrier assembly is designed to carry six spools of wick drain. This assembly has
capability to hold one spool on the center of the wick tube and five to the side of center
of the wick tube. While you line-up the first spool of wick to the wick tube the rest of the
carrier can hold the spare spools of wick. When the center spool is close to being empty
mechanically join the end of the wick to the beginning of a new spool of wick. When the
center spool is empty, remove spool bracket and wick roll tube. Re-install spool bracket,
slide the wick spools so that the first spool is in-line with the wick tube and slide the other
spool bracket over to keep the remaining wick spools in place. Continue to mechanically
joining the end of a spool to the beginning of the next spool and adjusting the spool bracket.
E. MANDREL GUIDE
The mandrel guide is a set of rollers at the bottom of the vibration case used to maintain
position of the mandrel fore and aft as well as right and left. The mandrel is a rectangular
steel tube that is used to thread the wick drain into the soil.
F. LEGS
The legs are to rest upon the ground to stabilize the wick inserter while inserting wick or
removing the mandrel. They are adjustable to suit the job site and operators preference of
height for best visibility.
G. LEADER SYSTEM
Theleader system isa latticesystem usedtosupport andguide themandreland wickdrain.
This system has a trough for the mandrel to run in maintaining it’s location in relationship
to the wick inserter assembly.Aset of lugs and pins connect the leader system together as
well as the leader system to the inserter assembly. On top of the leader system is a wick
guide bracket that aligns the wick drain that goes to the top of the leader system and over
to top of the mandrel.

I-3
OPERATING
INSTRUCTIONS
MODEL 100
BOTTOM DRIVE
WICK INSERTER
SCALE:
VIEW
880352
1 OF 1
7032 SOUTH 196TH STREET - KENT, WA 98032
AMERICAN PILE DRIVING EQUIPMENT, INC.
DWN. BY: DATE: DESCRIPTION
Scotto 5/8/2008 MODEL: 100 WICK FINAL ASM
MATERIAL:
REV:
100 WICK
OVER ALL DIMS
WW
W
L
H
I. GENERAL DESCRIPTION
H. SPECIFICATIONS
1. Constant improvement and engineering progress make it necessary that we reserve
the right to make specification changes without notice.
AlwaysconsultAPEinyour areaforcurrent oradditionalinformation youmayrequire.
2. Model 100 Bottom Drive Wick Inserter
Type...............................................Hydraulic
Frequency...........................1000-1700 VPM
Max Dynamic Force........23.7 Tons (211kN)
Static (Crowd) Force....... 27.8 Tons (247kN)
Weight .......................8,500# lbs. (3,855 kg)
Length [L]...............................84in. (213 cm)
Width [W] ..............................47 in. (119 cm)
Whole Width [WW] ...............85 in. (216 cm)
Height [H].........................109 in. (276.8 cm)
Fig. 1-2

I-4
OPERATING
INSTRUCTIONS
MODEL 100
BOTTOM DRIVE
WICK INSERTER

II-1
MODEL 100
BOTTOM DRIVE
WICK INSERTER OPERATING
INSTRUCTIONS
II. PREPARATION FOR OPERATION
A. GENERAL When unloading and unpacking the bottom drive wick inserter,
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.
B. SAFETY PRECAUTIONS
Safety is very important and is everyone’s responsibility that operates this equipment or
services this equipment.
Use the following safety precautions as a general
guide to safe operations, when in doubt consult APE
beforeproceedingwithanyoperationthatmayproduce an unsafe result.
These safety guidelines do not constitute all possible safety issues that
may occur during operation or maintenance.
1. Read this manual thoroughly before operating or working on the equipment.
2. Read and follow any safety instructions in the excavator’s 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 than 15 feet to this equipment when it is in operation.
8. Parts may loosen and fall. Never stand under operating, or elevated, equipment.
9. When maintaining or repairing the equipment, never substitute parts not supplied, or
approved in writing, by APE.
10. Do not weld, or flamecut,onthisequipment.
11. Never use or store flammableliquidsonorneartheengine.
12. Insure that all lifting equipment, including cranes, wire rope, slings, hooks, shackles,
etc., are properly sized for the worst case loads anticipated during operations.
13. If there are any questions about the weights, speci fications,orperformanceofthe
unit, contact APE before handling or operating the equipment.
14. If the equipment is to be used for anything other than inserting plumb wick drains,
contact APE before using the unit.

II-2
MODEL 100
BOTTOM DRIVE
WICK INSERTER OPERATING
INSTRUCTIONS
II. PREPARATION FOR OPERATION
B. SAFETY PRECAUTIONS (CONTINUED)
14. Insure that ground vibrations will not damage or collapse adjacent structures or
excavations.
15. Remove all tools, parts and electrical cords before starting the unit.
16. Whenoperating inanenclosedarea, pipeexhaust fumesoutside. Continued breathing
of exhaust fumes may be fatal.
17. When servicing batteries, do not smoke or use open flames in the vicinity. Batteries
generateexplosivegasduringcharging. Theremustbeproperventilationwhencharging
batteries.
18. When filling fuel tank, do not smoke or use open flame in the vicinity.
19. If abnormal equipment operation is observed, discontinue use immediately and correct
the problem.
20. Do not adjust, or set, hydraulic pressures higher or lower than those specified in this
manual.
21. Never operate this equipment with hydraulic hoses that are damaged or “kinked”.
Replace damaged hoses immediately.
22. Do not lift, or support, hydraulic hoses with wire rope slings.
23. Do not pull on, or attempt to move equipment, with hydraulic hoses.
24. Donotattempt tolocate hydraulicleaks withyourhands. Highpressurehydraulic leaks
can penetrate the skin, causing severe damage, blood poisoning and infection. Do not
attempt to repair leaks while the equipment is in operation.
25. Do not attempt to tighten, or loosen, fittings or hoses when the machine is in operation.
26. Aproperlymaintainedfireextinguisher, suitableforoil fires,mustbekeptintheimmediate
vicinity of equipment operations.
27. 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.
28. 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.
29. Keep crane boom, mandrel, lead system, wire rope and other equipment at least 15’
(5M)from electricalpowerlines, transformersand otherelectrical equipment,orat such
distance as required by applicable safety codes.

II-3
MODEL 100
BOTTOM DRIVE
WICK INSERTER OPERATING
INSTRUCTIONS
II. PREPARATION FOR OPERATION
B. SAFETY PRECAUTIONS (CONTINUED)
30. 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 this manual, for proper values.
31. Never induce mandrel crowd or extraction force before starting the unit in vibration.
Alwaysstart bothdriving andextractionofmandrelinsertion/extraction circuitin neutral.
32. Keep hands away from mandrel sprocket assemblies.
33. Keep hands away from vibrator suppressor during operation. Clearances may change
causing pinch points.
34. When driving “batter” wick drain insure that the lead system, and crane boom, have
sufficient bending strength to handle the worst case load. Consult APE.
REMEMBER, SAFETY IS EVERYONE’S BUSINESS.
C. RIGGING OF INSERTER
An adapter has been designed for the entire assembly for the original project to a certain
excavator. The pins supplied for the adapter and lead system are the only pins to be used
and installed with supplied fastening hardware.
All rigging of either the inserter must be done in accordance with standard rigging
guide lines set forth in ASTM standards; APE does not assume responsibility for
incorrect rigging or procedures.

II-4
MODEL 100
BOTTOM DRIVE
WICK INSERTER OPERATING
INSTRUCTIONS
II. PREPARATION FOR OPERATION
D. CONNECTION OF HYDRAULIC HOSES
Fig. 2-1
STICK CYLINDER
EXTEND
STICK CYLINDER
RETRACT
DRAIN TO HYDRAULIC RESERVOIR
BUCKET CIRCUIT CURL
BUCKET CIRCUIT OPEN

II-5
MODEL 100
BOTTOM DRIVE
WICK INSERTER OPERATING
INSTRUCTIONS
II. PREPARATION FOR OPERATION
D. CONNECTION OF HYDRAULIC HOSES (CONTINUED)
1. Connection of hoses inserter.
a. The inserter gear box motor and crowd / extraction motors are connected to the
excavator by five hydraulic hoses (Fig. 1) on the previous page.
The excavator must be shut down during connection of the
hydraulic hoses.
b. Clean connection fittings with a lint-free cloth before making connections.
c. Make sure that the connectors are fully tightened with wrenches.
2. Connection of hoses at excavator.
a. The vibrator circuits that control the stick and bucket will be used.
Use caution when bleeding any hydraulic lines, even low
hydraulic pressure can cause injury to personnel.
E. FILLING VIBRATOR PRESSURE HOSE
1. The vibrator is usually shipped with the vibrator hydraulic hoses full of fluid and the
unit may be used immediately. However, if the pressure hose has been removed from
the vibrator, the hose should be allowed to fill with hydraulic fluid prior to full speed
operation.
2. Read SECTION III - OPERATING INSTRUCTIONS.
3. Start and warm up the diesel engine in accordance with SECTION III-C - STARTING
AND WARMING UP ENGINE. Hold the vibrator in a vertical position.
4. With the engine warmed up and running at 1000 RPM, turn and hold the vibrator switch
REVERSE. The hoses will fill in approximately 5 minutes.
If vibration begins in the vibrator, stop immediately and recheck
hose connections.

II-6
MODEL 100
BOTTOM DRIVE
WICK INSERTER OPERATING
INSTRUCTIONS

OPERATING
INSTRUCTIONS
III-1
MODEL 100
BOTTOM DRIVE
WICK INSERTER
SCALE:
VIEW
880352
1 OF 1
PITTSBURGH, PENNSYLVANIA
FOUNDATION EQUIPMENT LLC
DWN. BY: DATE: DESCRIPTION
Scotto 6/19/2008 MODEL: 100 WICK FINAL ASM
MATERIAL:
REV:
100 WICK
III. OPERATING INSTRUCTIONS
FEROY SELECTOR VALVE
Handle shown in the position to operate the vibration gear box drive motor.
Fig. 3-1

OPERATING
INSTRUCTIONS
III-2
MODEL 100
BOTTOM DRIVE
WICK INSERTER
III. OPERATING INSTRUCTIONS
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.
B. FEROY SELECTOR VALVE
1. The Feroy selector valve controls the cylinder that positions the lead system fore and
aft angle and the vibration gear box motor.
2. When the handle of the Feroy selector valve is turned to the left, it is in the position to
adjust the lead system. Rotating the handle to the right as shown in Fig 3-1 oil flow will
be directed to the vibration gear box motor.
3. The adjustment of the lead system should only be done when NO mandrel is below the
surface of soil.
C. DRIVING / EXTRACTING MANDREL
1. Driving mandrel into the soil by using the mandrel drive motors is to be used until
resistance stops the mandrel. Stop trying to insert the mandrel, start the vibration gear
box and continue to run the mandrel drive motors. When the mandrel begins to move
with less resistance stop the vibration gear box and continue driving the mandrel.
2. Extractingmandreloutof thesoil worksjustthe oppositeas drivingmandrel.Thesupport
legs will help maintain the vertical position of the entire wick machine.