APE 475 User manual

Page 5-1
OPERATIONAND
MAINTENANCEMANUAL
Model 475 Power Unit
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OPERATION / MAINTENANCE MANUAL
7032SOUTH196th-KENT,WA.98032-[phone]/FAX[phone]
MODEL475POWERUNIT
V-7A. Power Unit - Filters, Fluid Types and Capacities. (Table 5-A.)
FILTERS
LOCATION ENGINE FILTERTYPE QUANTITY
EngineOil: CATC-13 1R-1808 1 each
EngineFuel/WaterSep CATC-13 1R-0771 1 each
EngineFuelFilter CATC-13 1R-0751 1 each
Air Filter, Outer: CATC-13 132-7167 1 each
AirFilter,Inner CATC-13 61-2510 1 each
Hydraulic Oil Filters: Zinga ZLE-10 2 each
HandPumpFilter: Zinga AE-25 1 each
ENGINE OILTYPESAND
CAPACITIES
LOCATION ENGINE OIL TYPE CAPACITY
HydraulicOil-Main: ------------- Mobil EAL 224 Veg. 300 gal/1150 L
HydOil-Reserve: ------------- Mobil EAL 224 Veg. 55 gal/208 L
EngineOil: CAT C13 DEO or APICH-4 40 quarts/38 L
EngineWater: ------------- 50/50Water/Gyicol 27 gal/103 L
FanDrive: ------------- Multi-PurposeGrease
GovernorControl: ------------- Multi-PurposeGrease
GearBox: ------------- 84ounces9OWorSyntheticMobilSHC629
Pump pad 8 ounces of 90W or Mobil SHC 629
Pumpflange(betweenengineanddrive) 8 ounces of 90W or Mobil SHC 629
V. MAINTENANCE (Continued...)
Page 5-3
Seepage5-7Bfordetailsonlubricationofthepumpdriveanditscomponents.
Check water level in radiator
Check battery level
Check fuel level
Check oil level in pump drive
Check hydraulic oil level
Check engine oil
Check hydraulic return filter indicator
Check fan belts on engine
Check entire unit for hydraulic leaks
Check condition of jaws before operating
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OPERATION / MAINTENANCE MANUAL
7032SOUTH196th-KENT,WA.98032-[phone]/FAX[phone]
MODEL475POWERUNIT
V. MAINTENANCE (Continued...)
V7-B. Power Unit - Hydraulic Fluid.
When adding or changing hydraulic fluid APE uses only Mobil 224 Hydraulic Vegetable oil which is
non-toxic and will not harm oil or water and is biodegradable. Consult your local oil supplier for
recommendations on mixing hydraulic oils. Change hydraulic oil if it looks milky. This includes all
hydraulic lines leading to and from the vibro. Milky oil indicates that water is in the oil.
V7-C. Power Unit - Draining and Filling Hydraulic Fluid Tank
1. Remove plug located on bottom of tank
2. Refill by manually pumping with hand crank.
3. Prime both the clamp and the main pump before restarting.
4. Take extreme caution that no dirt or other unwanted particles enters the system.
V7-D. Power Unit - Cleaning Hydraulic Tank Suction Filter. (No suctions on 1993 and newer)
1. Located inside the hydraulic tank or reservoir, is a suction filter.
2. Drain tank.
3. Remove side cover.
4. Reach into to and unscrew filter from pipe fitting.
5. Clean with solvent and re-install. If damaged then replace.
6. Re-install filter.
7. Re-install tank cover.
8. Add new oil to tank.
9. Prime pumps.
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OPERATION / MAINTENANCE MANUAL
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MODEL475POWERUNIT
V. MAINTENANCE (Continued...)
V-7E. Power Unit - Changing Hydraulic Return Filter Element.
Thehydraulicreturnfilterismountedonthehydraulictankinsidethepowerunit. Itismountedhighon
thetanksothatwhenthefilterelementisremovedtheoilwillnotdrainfromthehydraulictank. Thefilter
hasamanualpop-uptypeindicatortotellwhenthefilterisdirty. Thepop-upindicatorturnsredwhen
itisinthedirtypositionorwhenthereturnfiltergaugereads50PSIandwhenthehydraulicoilisupto
temp.
V-7F. Power Unit - Steps to Remove the Element.
1.Shutdownpowerunitbyturningoffthedieselengine.
2.Placewarningtagoncontrolpanelsothatnoonemistakenlystartstheunitwhile
filtersarebeingchanged.
3.Cleanareaaroundfiltersothatwhenitisremovedthereisnochanceofintroducingdirtinto
thehydraulicsystem.
4.Usingafilterwrench,turnthefiltercounterclockwiseandspinthefilteroffthefilter
housing.
5.Installnewcleanfiltermakingsuretheo-ringisinplace.
6. Depress filter indicator to re-set to "clean position".
Page 5-5
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OPERATION / MAINTENANCE MANUAL
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MODEL475POWERUNIT
VII. MODEL 475 POWER UNIT
VII-1.HydraulicCircuitry.
ThefollowingaredescriptionsofthecomponentsthatmakeuptheHydraulicCircuitryoftheAPEModel
475powerunit.
VII-1A.ClampCircuitry.(Usedforextendingandretractingjawcylinder)
Oilfortheclampcircuitisprovidedbyitemtheclamppump.Thispumpisal.5cu.in/rev5000psipiston
pump. Alloiltotheinletofthispumpisfilteredthroughasuctionstrainerlocatedinthetank. Clampoil
isthendirectedfromthepumptotheclampdirectionalcontrolvalve. Whentheclampswitchisinthe
"off"position,theoilflowsthoughttheclampdirectionalcontrolvalveandbacktotheoiltank. When
theclampswitchismovedtoopen,solenoid"A"ontheclampdirectionalcontrolvalveisenergizedthe
oilwillflowouttotheclampcylinderandretractoropenthejaws. Theclampopenpressurecanbeseen
on the clamp pressure gage located on the panel. When the clamp switch is moved to the closed
position,solenoid"B" willbeenergizedand oilflowwillbe directedtotheclamp cylinder. Theclamp
cylinderwillthenextendorclosethejaws. AClamppressure switchitemwillde-energizesolenoid"B",
directing pump oil flow back to oil tank. Clamp pressure is maintained in clamp cylinder by a pilot
operatedcheckvalve.Atanytimeshouldtheclamppressurefallbelow3500psi.theclamppressure
switch will re-energize solenoid "B" on the clamp control valve, and direct pump flow to the clamp
cylinder.Maximumclamp pressureislimitedby theclamppressurerelief valvesetat4300 psi. The
quickdisconnectcouplerspermitdecouplingofclamphoses.
VII-1B. Drive Circuit. (UsedforoperatingAPEvibrator,APE drill or any otherunit)
Therearetwogearpumpsthatdirectoiltothedrivecircuit(VibroMotors).Themaximumdrivepressure
iscontrolledbythedrivepressurereliefvalve,to4800psi.max.Whenthedriveswitchismovedtothe
forwardposition,solenoid"A"ofthedrivedirectionalcontrolvalveisenergized.Oilflowisdirectedto
thevibromotorstorotatetheeccentrics.Whenthedriveswitchismovedtotheoffposition,oilflowis
directedbacktothetankthroughthedrivedirectionalcontrolvalveandsolenoid"A"isde-energized.
Becauseofthehighoilflowinthedrivecircuit,APE,Inc.hasdevelopedacircuitthateliminateshigh
shockloads. Smallinternalcomponentslocatedinthedrivemanifoldprovideasoftshiftfeatureforthe
drivedirectionalcontrolvalve. A smalladjustablesnubbervalvecontrolsasmallshuttlevalvethrough
smallfixedorifices. Theorificesareusedtodampentheshiftingof spoolvalve. Thisprovides asoft
start/stopofthedrivedirectionalcontrolvalvepreventinghydraulicshocktothedrivesystem. Theshuttle
valveisusedtosendahydraulicsignaltothedrivepressurereliefvalvewhenthedrivedirectionalcontrol
valveiscenteredorde-energized.Thishydraulicsignaltellsthedrivepressurecontrolvalvetoopenand
allowanyhighflow,highpressurebacktotank. Thesnubbervalvesimplycontrolshowfastthissignal
isreceivedbythedrivepressurereliefvalve.Thedrivepressurecanbereadonthedrivepressuregage
item.
Thequick-disconnectcouplings permitde-couplingofthedriveandcasedrainhosesatthepowerunit.
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OPERATION / MAINTENANCE MANUAL
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MODEL475POWERUNIT
VII. MODEL 475 POWER UNIT (Continued...)
VII-1C. Cooling and Flushing Filter.
Thecooling circuit pumps oilthrough the oilcooler and thenthrough the returnfilters. This systemis called the"Kidney
Loop"andisdesignedtocooltheoilandclean the oil in the hydraulic tank. This independent system isolates the return
filiters from shock associated with the other two circuits, main drive, and clamp.
VII-1D. Oil Cooler.
The oil cooler cools the hydraulic fluid.
VII-1E. Manual Pump.
Amanualpumpisprovidedtofillthehydraulicreservoir. Ahandvalvepreventslossoffluidfromthereservoirbackthrough
themanualpump.
VII-1F. Hydraulic Oil Temperature.
A temperature gaugeindicates hydraulic oil temperature. The sending unit is mounted on the main tank.
Page 7-2 Page 7-2
Hydraulic Panel
Suction Ball Valves 555001
Drive Clamp Drive / Re-circ Tank Drain Drive Manifold
SO Cords
See hose list
Clamp Manifold
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OPERATION / MAINTENANCE MANUAL
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MODEL475POWERUNIT
VII. MODEL 475 POWER UNIT (Continued...)
1 FilterElementAE-25
2 Breather Element
3 6" Sight Gage L/D G607-06-A-1-4
4 30" Sight Gage L/D G607-30-A-1-4
5 Level Switch L120 (513033)
6 Filter Head 25 psi ZAF-10-25-1-3
ITEM DESCRIPTION
1
2
3
4
5
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1
6
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OPERATION / MAINTENANCE MANUAL
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MODEL475POWERUNIT
VII. MODEL 475 POWER UNIT (Continued...)
Page 7-4
Page 7-3
VII-1E. Hydraulic Schematic.
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OPERATION / MAINTENANCE MANUAL
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475 POWER UNIT (Continued...)
VII-1G. Hydraulic Components (Continued...)
Page 7-5 Page 7-4
Hydraulic Components - Clamp / Drill Manifold 523002A
Clamp Closed
Clamp Open
Clamp Close
Clamp Open
Drain
Drill
Clamp / Drill Manifold - Rear Panel View Clamp/DrillManifold-FrontPanelView
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OPERATION / MAINTENANCE MANUAL
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MODEL475POWERUNIT
VII-1G. Hydraulic Components (Continued...)
Item Qty Description Manufacturer
1 1 Manifold - Machined Hydra Power D9078A
2 1 Directional Control Valve Hytos REP3-10311/02400E1
3 2 Coil for D05 Hytos 936-4627
4 3 Lighted DIN Connector Hytos 936-9907
5 1 PO Check Valve Sun CKEB-XCN BBA/S
6 1 Relief Valve - Clamp (Set at 4500 psi) Sun RPEC-KWN
7 1 Relief Valve - Drill (Set at 400 psi) Sun RPEC-FEN
8 1 Pressure Switch Oildyne OE4-SBHS-8K
9 1 90 Degree Turn Block Hydra Power WD022805
10 1 Priority Flow Control (Set at 1.2 GPM) SunFRDA-XAN
11 1 Solenoid Valve - Drill Shift Hydraforce SV08-40N-0-24-DG
12 1 Coil - Drill Shift Hydraforce 6306024
1
3
3
4
4
8
11
Hydraulic Components - Clamp / Drill Manifold 523002A (Continued...)
10
7
2
5
Clamp / Drill Manifold - Rear View Clamp / Drill Manifold - Front View
6
9
4
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