APE 400 VIBRO User manual

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 Quad VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
MODEL 400 VIBRO Quad
WITH MODEL 990 POWER UNIT
SERIALNUMBER:
Vibro: 011210
011211
011212
011214
SERIALNUMBER:
PowerUnit: 011210
011211
011212
011214
OPERATION AND
MAINTENANCE MANUAL
Covers Model 400 vibro and 990 power unit, including applicatons when used as a single unit.
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

Change
Number Page Number Date Revision Description
RevisionRecord
APE OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY HAMMER WITH
MODEL 800 POWER UNIT
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
Page i
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 Quad VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
Preface
General
This manual covers the Model 400 Vibratory Hammer and Model 990 Power Unit. It has been
modifed to cover the use of four Model 400's mounted together for installation of large caissons in
China. The data provided in this manual gives the necessary information to operate and maintain
APE equippment. The listed procedures are to be performed by qualified 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 reflect current information.
Abbreviations
The following are abbreviations used within this manual.
lbs. = Pounds
psi. = Pounds per Square Inch
hp. = Horse Power
gpm. = Gallons Per Minute
rpm. = Revolutions Per Minute
eng. = Engine
cyl. = Cylinder
mm. = Millimeter
mtg. = Mounting
S/N = Serial Number
sol. = Solinoid
Serial Number Locations
1.VIBRATOR: Above and in between the eccentric covers on both sides of the
machine.
2. POWER UNIT: On back of the hydraulic tank above the APE logo.
Page ii
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 QUAD VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
Table of Contents Page
Revision Record ............................................................................................ i
Preface .............................................................................................. ii
Table of Contents .......................................................................................... iii
Safety Precautions ........................................................................................ v
Illustration List .............................................................................................. vi
Table List ...................................................................................................... vi
Warranty ........................................................................................................ vii
I. GENERAL INFORMATION ....................................................................................... 1-1
I-1. Machine Features ...................................................................................... 1-1
I-2. Machine Specifications .............................................................................. 1-2
A. Model 400 Vibro .............................................................................. 1-2
B. Model 990 Power Unit...................................................................... 1-2
I-3. General Description of Model 400 Vibro ...................................................... 1-3
A. Suppressor Housing ........................................................................ 1-4
B. The Vibrator Gearbox .......................................................... 1-5
C. Clamp Attachment .......................................................................... 1-6
D. Optional Attachments .......................................................... 1-7
I-4. General Description of Model 800 Power Unit .............................................. 1-8
II. MAJOR COMPONENT DEFINITION ........................................................................ 2-1
II-1. Component Identification ........................................................................... 2-1
II-2. Hose Identification .................................................................................... 2-3
II-3. Caisson Clamp Identification ..................................................................... 2-4
II-4. Model 990 Power Unit Skid Identification .................................................... 2-5
II-5. Quick Disconnect Couplings ...................................................................... 2-6
II-6. Tool Set Identification................................................................................ 2-7
II-7. Caisson Clamp Wedge Actuator ................................................................ 2-8
III. LOADING AND UNLOADING ................................................................................. 3-1
III-1. Model 400 Vibratory Hammer ................................................................... 3-1
lll-2. Model 990 Power Unit............................................................................... 3-1
III-3. What to do if damaged during shipment .................................................... 3-1
IV. PREPARATION AND OPERATION ........................................................................ 4-1
IV-1. Rigging of Vibratory Hammer ................................................................... 4-1
IV-2. Installing the Clamp Attachment ............................................................... 4-1
IV-3. Plumbing the Vibro Hoses to the Power Unit.............................................. 4-2
IV-4. Filling Vibrator Pressure Hose .................................................................. 4-3
IV-5. Bleeding Clamp Attachment Hydraulic Hoses ............................................ 4-3
IV-6. Precautions and Rules for Operation......................................................... 4-4
lV-7. Relief Valve Settings Prior to Operation - Model 990....................... 4-5
IV-8. Shut-down Procedures ............................................................................ 4-5
lV-9. Operation of the Remote Control Pendant ................................................. 4-6
lV-10.Normal Steps to Operate Vibrator ............................................................ 4-6
V. MAINTENANCE...................................................................................................... 5-1
V-1. Daily Maintenance Required Prior to Operation ........................................... 5-1
V-2. Checklist After Power Unit Engine Has Started ........................................... 5-1
V-3. Maintenance and Adjustments:...... (75 Hours).......................................... 5-2
V-4. Maintenance and Adjustments:...... (Eccentric Bearings).......................... 5-2
V-5. Maintenance and Adjustments in Severe Conditions ................................... 5-2
V-6. Lubrication .............................................................................................. 5-2
A. Vibratory Gearbox ........................................................................... 5-2
B. Clamp Attachment ........................................................................... 5-2 Page iii
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 Quad VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
A-1. ENGINE OPERATION INSTRUCTIONS. ................................................... A-1
A. Pre-Start Inspection and Procedures................................................. A-1
B. Starting The Engine ......................................................................... A-2
C. Engine Operation ............................................................................ A-3
D. Determining Cause of Shutdown ...................................................... A-7
A-2. MAINTENANCE RECOMMENDATIONS .................................................... A-9
A. Lubrication Specifications ................................................................. A-10
B. Fuel Specifications .......................................................................... A-11
C. Coolant Specifications ..................................................................... A-11
D. Lubrication and Maintenance............................................................ A-12
E. Electrical System............................................................................. A-13
A-3. ENGINE TROUBLESHOOTING ................................................................ A-14
Table of Contents (Continued...)
V. MAINTENANCE (Continued...)
V-7. Power Unit .............................................................................................. 5-3
A. Power Unit Filters, Fluid Types and Capacities ...................... 5-3
B. Hydraulic Fluid ................................................................................ 5-4
C. Draining and Filling Hydraulic Fluid Tank ........................................... 5-4
D. Cleaning Hydraulic Tank Suction Filter.............................................. 5-4
E. Changing Hydraulic Return Filter Elelment......................................... 5-5
F. Steps to Remove Filter Element ........................................................ 5-5
V-8. Hydraulic Motor - Installation and Start-Up.................................................. 5-6
V-9. Hydraulic Motor Coupling Assembly ............................................... 5-7
VI. TROUBLESHOOTING: Model 400 Vibro ................................................................ 6-1
VII. MODEL 800 POWER UNIT.................................................................................... 7-1
VII-1. Hydraulic Circuitry ....................................................................... 7-1
A. Drive Circuit .................................................................................... 7-1
B. Clamp Circuit ...................................................................... 7-1
C. Oil Cooler ....................................................................................... 7-2
D. Manual Pump.................................................................................. 7-2
E. Hydraulic Oil Temperature................................................................ 7-2
F. Hydraulic Components ..................................................................... 7-2
G. Hydraulic Schematic........................................................................ 7-3
VII-2. Electrical Circuitry ....................................................................... 7-4
A. Diesel Engine.................................................................................. 7-4
B. Controls: Understanding How They Work .......................................... 7-4
C. Preparing The Electrical System For Start-Up.................................... 7-7
D. Engine Safety Shut-Down Button Switch ........................................... 7-7
E. Engine Safety Shut-Down (Three Causes Of Engine Shut-Down)........ 7-8
F. Electrical Schematic......................................................................... 7-9
VII-3. Remote Control Pendant ......................................................................... 7-10
A. Remote Pendant Wiring Diagram ..................................................... 7-11
VII-4. Troubleshooting: Power Unit Electrical .................................................... 7-12
A. Engine Oil Pressure Switch .............................................................. 7-12
B. Water Temperature Switch............................................................... 7-12
C. Hydraulic Oil Level Switch................................................................ 7-12
D. Oil Pressure Sending Unit ................................................................ 7-13
APPENDIX A - CAT 3412 Twin Turbo 800 HP Engine
Page iv
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 QUAD VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
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 flame. 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 flammable 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 fittings. 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. Always attach safety line to pile when extracting or hoisting into position.
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 fittings unless the
caps and plugs have wire rope safety lines attached. Store in storage box under control panel.
Page v
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 Quad VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
Illustration List
Figure Title Page
1-A. Machine Features .............................................................. 1-1
1-B. General Description of Model 400 Vibro........................ 1-3
1-C. General Description of Suppressor Housing ................. 1-4
1-D. General Description of Vibratory Gearbox..................... 1-5
1-E. General Description of Clamp Attachment .................... 1-6
1-F. Clamp Attachment Hole Configuration........................... 1-6
1-G. Optional Attachments........................................................ 1-7
1-H. General Description of Model 990 Power Unit.............. 1-8
2-A. Component Identification.................................................. 2-1
2-B. Hose Bundle Identification ............................................... 2-3
2-C. Caisson Clamp Identification ........................................... 2-4
2-D. Model 990 Power Unit Skid Identification...................... 2-5
2-E. Quick Disconnect Couplings ............................................ 2-6
2-F. Tool Set Identification ....................................................... 2-7
2-G. Caisson Clamp Wedge Actuator..................................... 2-8
4-A. Power Unit Coupler Layout .............................................. 4-2
4-B. Bleeding Clamp Attachment ............................................ 4-3
5-A. Hydraulic Motor - Installation and Start-Up.................... 5-6
5-B. Hydraulic Motor Coupling Assembly............................... 5-7
7-A. Power Unit Hydraulic Schematic..................................... 7-3
7-B. Power Unit Electrical Schematic ..................................... 7-9
7-C. Remote Control Pendant.................................................. 7-10
7-D. Remote Pendant Wiring Diagram ................................... 7-11
Table List
Table Title Page
1-A. Machine Specifications - Model 400 Vibro .................... 1-2
1-B. Machine Specifications - Model 800 Power Unit.......... 1-2
2-A. Component Identification.................................................. 2-2
2-B. Hose Identification............................................................. 2-3
2-C. Caisson Clamp Identification ........................................... 2-4
2-D. Model 990 Power Unit Skid Identification...................... 2-5
2-E. Tool Set Identification ....................................................... 2-7
2-F. Caisson Clamp Wedge Actuator..................................... 2-8
5-A. Power Unit - Filters, Fluid Types and Capacities.......... 5-3
6-A. Trouble-Shooting ............................................................... 6-1
7-A. Hydraulic Components...................................................... 7-2
Page vi
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 QUAD VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
Warranty
American Piledriving Equipment, Inc. STANDARD WARRANTY
American Piledriving Equipment, Inc. (APE) 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's obligation and liability under this WARRANTY is expressly limited to repair-
ing or replacing at APE's option, any parts which appear to APE 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 or the authorized APE
distributor of the product during regular working hours. This WARRANTY, shall not
apply to component parts or accessories of products not manufactured by
APE and which carry the warranty of the manufacturer thereof, or to normal mainte-
nance (such as engine tune-up) or normal maintenance parts (such as filters).
Replacement or repair parts installed in the product covered by this WARRANTY
are warranted only for the remainder of the warranty as if such parts were original
components of said product. AMERICAN PILEDRIVING EQUIPMENT, INC. 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, products or parts for which a warranty claim is made are to be
returned transportation prepaid to APE. 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 or any alteration or repair
by others in such manner as in APE's judgment affects the product materially and
adversely, shall void this warranty.
ANY TYPE OF WELDING ON EQUIPMENT
WILL VOID THE WARRANTY
NO EMPLOYEE OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS
WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY UNLESS SUCH CHANGE
IS MADE IN WRITING AND SIGNED BY AN OFFICER OF APE, INC.
Page vii
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 Quad VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
I. GENERAL INFORMATION
I-1. Machine Features. - Model 400 Vibratory Hammer.
Figure 1-A. Machine Features
Patented breakthrough
multi-stage suppressor
housing allows variable
suppression levels
which change to match
variable line pull.
Shorter overall height
and a lower center of
gravity.
One piece eccentric/
gear design eliminates
bolts, keyways, splines
and pins.
Four eccentrics filled
with "heavy metals"
produce more ampli-
tude with less parts.
Giant spherical bear-
ings are five times
larger than those found
on other machines.
Heavy clamp cylinders
need no guards and all
hoses are tucked out of
harms way. The one
piecedesigneliminates
rear seals, tie rods &
nuts.
The Model 400 out per-
forms other vibros in its
class. It is lighter and
allows more pull and
reach.
The heavy duty lifting
pinallowseasyrigging
of the vibro and two
safety lift pins ensure
maximum safety.
Gear box drilled to ac-
cept attachments
manufactured by APE
and by other manufac-
turers.
High speed gear train
allows the vibratory
Hammertooperate off
many different power
units.
Up to 250 Tons of line
pull! More pulling ability
than other comparable
vibros.
Gearbox incorporates a
machined O-ring groove
to seal the top plate with
no leaky gaskets.
Rifle bored top plate
eliminates more un-
wanted hoses that can
causeseriousdowntime.
Hydraulic motors are re-
cessedwhicheliminates
the need for bolted on
guards.Less parts- less
problems. Vertical mo-
tormountingisapproved
by Rexroth.
Computer designed
gearbox is perfectly bal-
anced with a very low
center of gravity. Re-
lease crane line without
bending piles.
The 400 vibro can be
shipped fully assembled
on one truck.
Page 1-1
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 QUAD VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
I. GENERAL INFORMATION (Continued...)
I-2. Machine Specifications.
APE "KING KONG" MODEL 400 VIBRATORY PILE DRIVER/EXTRACTOR
I-2A. Model 400 Vibratory Hammer - (Table 1-A.)
For driving and extracting heavy caissons, sheets or plates in clay soil conditions.
I-2B. Model 990 Hydraulic Power Unit - (Table 1-B.)
Page 1-2
For current specifications please
go to: www.apevibro.com
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 Quad VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
GEARBOX
CLAMPATTACHMENT
(shown with caisson clamp)
I. GENERAL INFORMATION (Continued...)
I-3. General Description of Model 400 Vibro.
The APE Model 400 is a variable frequency vibratory pile driver/extractor designed for driving and
extracting extremely large caissons, heavy plates, sheet piles, closed-ended pipe piles and concrete
piles in difficult soil conditions including clay. The 400 can also be used for soil compaction and pre-
boring by displacement method where contaminated soils cannot be removed.
The Model 400 operates in a frequency range of 0 to 1400 cycles per minute depending on the
hydraulic flow and on the hydraulic motors fitted to the gear train.
The three major parts to the Model 400 are as follows:
A.) The Suppressor housing.
B.) The Gearbox.
C.) The Clamping Attachment.
SUPPRESSOR
HOUSING
Figure 1-B. General Description of Model 400 Vibro.
Page 1-3
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 QUAD VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
I. GENERAL INFORMATION (Continued...)
I-3A. The Suppressor Housing.
The suppressor housing of theModel 400 APE Vibrator is a patentedmulti-stage system consisting
of up to sixteen large rubber elastomers and eight small elastomers. The large rubber elastomers
(technically called the first stage) are used during all driving operations and light to medium
extraction. The second stage is made up of eight small high capacity elastomers. During the first
stage, two large safety pins travel up with the outer housing as the line pull is increased. The safety
pins are then engaged by the lifting bracket which activates the second stage. (WARNING! Hard
pullingforlongperiodsoftimewillheatanddamagethelargeelastomers.Theheatgenerated
from constant heavy line pull will destroy the chemical bond between the rubber and
mounting plate which will cause the large elastomer to fail.) When engaged in hard extracting,
break every 15 minutes to allow elastomers to cool.
Lifting Pin
Large Elastomer
Small Elastomer
Suppressor
Housing
Safety Pin
MountingBase
Top Plate
Figure 1-C. General Description of Suppressor Housing.
Page 1-4
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 Quad VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
I. GENERAL INFORMATION (Continued...)
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. Both 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 eccentric and drive
gears are all driven in line by two Volvo motors tucked in on the outboard side of the gearbox. The
motors are 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 fluid splashing
inside the gearbox when the gears are rotated. The oil level is quickly determined by looking at the
site gauge. The Model 400 can be operated under water to a depth of 30 feet without modifications.
(Consult factory for depths below 30 feet.)
Rifle Bored Top Plate
Hydraulic Motor
BearingCover
Oil
Level
GLASS SIGHT GAUGE
CHANGE OIL ONCE PER WEEK
OR WHEN BLACK
Figure 1-D. General Description of Vibrator Gearbox.
Page 1-5
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 QUAD VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
I. GENERAL INFORMATION (Continued...)
I-3C. The Clamp Attachment. (For Yangtzee Project consult factory)
The APE Model 400 comes with aCaisson Beam and Caisson Clamps. The clamps contain two
grippingjaws.One is"fixed"andone is"moveable."Alargehydrauliccylinderoperatesthemoveable
jaw with up to 250 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 11feet. The one piece cast beam will not bend
or break and was designed to be compatible with all types of vibros. The heavy duty design of the
clamp cylinders eliminates the need for cylinder guards. The clamps are held in place on the beam
with a simple wedge-lock design. (Clamps can be fitted with hydraulically activated wedges for faster
adjustments when driving more than one size caisson. Please call the factory for more information
on clamp attachments for special pile types.)
CaissonBeam
ClampBody
Clamp Cylinder
Moveable Jaw
Fixed Jaw
Figure 1-E. General Description of Clamp Attachment.
Figure 1-F. Clamp Attachment Hole Configuration Page 1-6
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 Quad VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
I. GENERAL INFORMATION (Continued...)
I-3D. Optional Attachments.
The following are some of the optional attachments for the Model 400 Vibratory hammer. (Contact
APE or your local APE distributor for more information about these and other available equipment.)
APE DELUXE WOOD CLAMP
(#907000)
Figure 1-G. Optional Attachments
90 Degree Adapter
Plate (#905000)
4 ft. Extension Adapter
(#906000)
Clamp Attachment
APE 90 DEGREE
ADAPTERWITHEXTENSION
(#240000)
SHEETPILECLAMPATTACHMENT
Page 1-7
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 QUAD VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
I. GENERAL INFORMATION (Continued...)
I-4. General Description of Model 990 Power Unit
TheModel400 vibrator runsoff the APE990 power unit. TheAPE990 has aCAT 3412E TwinTurbo
990 horsepower 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 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. Three pumps feed the two vibrator motors. A small
pump feeds the clamp attachment. The Vibrator is connected to the power unit via five hydraulic
hoses. The two large 2" hoses are the pressure and return lines for the vibrator motors. The two
smaller 3/8" hoses are for the clamp system and the one middle sized 1 1/4" hose is for the vibrator
motor case drain line. The hoses are attached to the power unit by connecting the "quick dis-connect
fittings" on the end of the hoses leading from the vibrator. The fittings 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 fittings all the way tight. Failure to tighten the quick disconnects will
stop the flow of oil and will prevent the vibro from operating. Failure to tighten the clamp fittings
completely tight will cause the jaws to either not open or not close. If this happens you may have
to crack the fitting and bleed off the pressure to release the quick dis-connects.
Tube Frame
Exhaust
Muffler Lifting Eye
HydraulicTank
Quick Disconnect
Fittings
Fuel Tank
LockingDoors
Control Panel
Radiator
Figure 1-H. General Description of Model 990 Power Unit
Page 1-8
Drawing of power unit is used for all
models. This drawing does not repre-
sent the actual shape of each power
unit.
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 Quad VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
II. MAJOR COMPONENT DEFINITION
II-1. Component Identification - Model 400 Vibratory Hammer.
Figure 2-A. Component Identification - Model 400 Vibratory Hammer.
Page 2-1
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 QUAD VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
1 8 Model 400EccentricBearing #141001
2 4 Eccentric Shaft #141003
3 8 Eccentric Bearing Cover #141004
4 8 Eccentric Bearing Sleeve #141005
5 4 Eccentric Weight - Model 400 #141007
6 2 Vibratory Motors #142001
7 2 Motor Bearing #142002
8 2 Fitting #F40X-S-812MJICxMBSPP #142003
9 2 MotorHoseAssembly #142004
10 2 Motor Bearing Cover #142005
11 1 Drive Gear - Left #142006
12 1 Drive Gear - Right #142007
13 2 BearingSpacer #142008
14 4 GearSpacer #142009
15 2 GearCarrier #142010
16 4 Hydraulic Motor Adapter #142018
17 1 #10 SAE Breather Plug #122014
18 1 Breather Valve #122015
19 4 ParkerO-Ring#2-225 #122027
20 2 GearSpacer(Narrow) #142011
21 8 #32 SAE Socket Drive Plug #143007
22 2 Motor Cover O-Ring #2-258 #142019
23 2 Motor O-Ring #2-163 #142020
24 1 Vibratory Gearbox #143001
25 1 Top Plate #143002
26 1 .070 C/S BUNA 70 CORD O-Ring #143003
27 2 MagneticDrainPlug #123004
28 1 SightGauge #123005
29 1 Gearbox Oil Level Plug #123006
30 2 #20 SAE Socket Drive Plug #123007
31 8 #8 SAE Socket Drive Plug #123008
32 2 #8 SAE / #6 JIC Fitting #123009
33 1 OilFillPlug #123012
34 2 #12 SAE / #12 JIC Fitting #123013
35 8 BearingCoverO-Ring #2-276 #141008
36 1 SuppressorMountingBase #340102
37 1 Lifting Bracket #340103
38 3 DoubleSplitFlange #123018
39 1 Bolt Kit #144000
40 6 FlangeO-Ring #2-225 #143020
41 2 CenterPin #341006
42 2 KeeperPlate #341007
43 1 Pop-Off Valve #321009
44 1 Check Valve #321015
45 1 SuppressorHousing #340101
46 16 LargeElastomers #321003
47 8 SmallElastomers #321004
48 2 Hose,Suppressor,Clamp 3/8" #440103
3 Wire x 12' w/6-6FJX ea. end.
49 1 Hose,Suppressor,CaseDrain #440102
1 1/4" 100R2AT x 12' Coupled
HL20-20NJea.end.
50 2 Hose,Suppressor,MotorFeed #440101
2"100R13x12'Coupled
ER32-32PHea.end.
56 6 Hose,ClampLine 3/8" #421004
3 Wire x 6' w/6-6FJX ea. end.
57 2 Hose, Pigtail, 2" 100R13 x 6' #441007
ER32-32PH&ER32-32NJea.end
58 4 HydraulicFlangeCoupling #142012
59 4 Hydraulic Motor Split Flange #142017
60 4 Parker"Polypak"#18701750-375 #142019
61 4 ParkerO-Ring #2-332 #142020
62 --- Bolt-SHCS 3/4"NC x 6" #144104
63 --- Bolt-SHCS 3/4"NC x 2 1/4" #144303
64 --- Bolt-SHCS 7/16" x 4 1/2" #144108
65 --- Flat Washer - 7/16" #144110
66 --- Lock Washer - 7/16" High Collar #144111
67 --- Bolt M14 x 30 #144112
68 --- Lock Washer M14 #144117
69 --- Bolt-SHCS 3/4"NC x 1 1/2" #144101
70 --- Flat Washer - SAE 3/4" #144305
71 --- Lock Washer 3/4" High Collar #144105
72 --- Bolt-SHCS 5/8"NC x 2" #144114
73 --- Lock Washer 5/8" High Collar #144115
74 --- Bolt-SHCS 1/2"NC x 1" #144107
75 --- Bolt-SHCS 3/4"NC x 2 1/4"w/Nut #144303
76 - -#
77 - -#
78 - -#
79 - -#
80 - -#
81 - -#
82 - -#
83 - -#
84 - -#
85 - -#
86 - -#
87 - -#
88 - -#
89 - -#
90 - -#
QtyItem Part #Description
II. MAJOR COMPONENT DEFINITION (Continued...)
II-1. Component Identification.
Thefollowing is ageneral listingofthe APEModel 400 Majorcomponents andpartnumbers. (Please
see Figure 2-A. for component location.)
QtyItem Part #Description
Table 2-A. Component Identification.
Page 2-2
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 Quad VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
II. MAJOR COMPONENT DEFINITION (Continued...)
II-2. Hose Bundle Identification.
The following is a general listing of the standard hoses that are shipped with the APE Model 400
Vibratory Hammer. (Please see Figure 2-B. for component location.)
1 2 2" Red Hose x 50' #441008
2"XT5 CAT Hose #ER2424NJ Ea. End
2 2 2" Red Hose x 50' #441008
2"XT5 CAT Hose #ER2424NJ Ea. End
3 2 1 1/4" Two Wire Hose x 50' #421009
4 4 3/8" Gates Hose x 50' #421010
w/#HU66NJ Ea. End
5 1 Fitting #6 JIC Male/#6 Female #421011
6 4 Fitting #32 Male JIC Union #441012
7 2 Fitting #20 Male JIC Union #441013
8 6 Fitting #6 Male JIC Union #421014
9 2 Fitting #32 JIC/#24 Pipe #441015
QtyItem Part #Description QtyItem Part #Description
10 1 Fitting#12JIC/#20Pipe #441016
11 1 Fitting #6 JIC/#6 Pipe Male #421017
12 1 Aeroquip Male Q.D. #5100S112B #421020
13 1 AeroquipDustCap #5100S712B #421021
14 2 Safeway Female Q.D. #S35-3 #421024
15 2 Safeway Male Q.D. #S31-3 #421025
16 2 Safeway Cap #S39-3 #421026
17 2 Safeway Plug #S34-3 #421027
18 2 Q.D.HydraulicFemaleCoupling #441301
19 2 Q.D. Hydraulic Male Coupling #441303
20 1 APE Dust Plug #441022
21 1 APE Dust Cap #441021
Figure 2-B. Hose Bundle Identification
Table 2-B. Hose Bundle Identification.
Page 2-3
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved

APE OPERATION / MAINTENANCE MANUAL
MODEL 400 QUAD VIBRATORY HAMMER WITH
MODEL 990 POWER UNITS
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
II. MAJOR COMPONENT DEFINITION (Continued...)
II-3. Caisson Clamp Identification.
The following is a general listing of the parts for the APE Caisson Clamp and Beams. (Please
see Figure 2-C. for component location.)
1 1 CaissonClampBody #250101
2 6 GreaseZert #221001
3 1 CaissonClampPlunger/Jaw #250301
4 1 CaissonClampFixedJaw #250202
5 2 Bolt - SHCS 5/8" x 4" #124214
6 2 Lock Washer 5/8" High Collar #124115
7 2 Male Wedge Half #243102
8 2 FemaleWedgeHalf #243105
9 2 Wedge Bolt w/Washer #124211
10 2 WedgeNutw/Washer #124212
11 17 Bolt - SHCS 1 1/2" x 3 1/2" #124201
12 17 Lock Wa. - 1 1/2" High Collar #124202
13 1 ClampCylinder #250001
14 2 #6 SAE/#6 JIC 45 Deg. Fitting #222002
15 8 Bolt - SHCS 1 1/4"NFx3 1/2"GR.8 #124204
16 8 Lock Wa. - 1 1/4"High Collar #124205
17 1 CylinderEndCap #250302
QtyItem Part #Description
18 1 CylinderPiston #250303
19 1 Plunger #250301
20 1 Bolt -SHCS 1 1/2-8 x 3" #250304
21 1 Wiper-#959-41 #
22 1 CaissonBeam11ft. #903000
23 1 PolySeal-#2500-4500-375B #
24 12 Bolt - SHCS 5/8-18 x 1" #
25 8 SpringPin #250103
26 4 WedgeSpring #250104
27 1 Wear Ring - #W2-4750-750 #
28 1 Hydraulic Wedge Activator Kit #243100
29 1 ParkerO-Ring#8-367 #
30 1 ParkerO-Ring#2-367 #
31 1 PistonO-Ring#2-338 #
32 1 PistonWear Ring#W2-8000-750 #
33 1 TFER8000Bronze w/LoaderRing #
34 1 SquareRing-#4426 #
QtyItem Part #Description
Table 2-C. Caisson Clamp Identification
BORE SECTION
Figure 2-C. Caisson Clamp Identification. Page 2-4
Copyright © 2003 American Piledriving Equipment, Inc. All Rights Reserved