APE 475 User manual

Page 5-1
OPERATIONAND
MAINTENANCEMANUAL
Model 475 Power Unit
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OPERATION / MAINTENANCE MANUAL
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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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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.
Page 5-4
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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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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.
Page 7-1
Page 7-1
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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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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
Page 7-3
1
6
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VII. MODEL 475 POWER UNIT (Continued...)
Page 7-4
Page 7-3
VII-1E. Hydraulic Schematic.
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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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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
Page 7-6
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Page 7-6
VII. MODEL 475 POWER UNIT (Continued...)
Page 7-7
Hydraulic Components - Drive Manifold 513028A
Dr. Fwd.
Dr. Rev.
Forward Rev.
Drive Manifold - Rear View Drive Manifold - Front Panel View
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Item Qty Description Manufacturer
1 1 Drive Manifold - Machined Pacific Power Tech
2 1 Main Control Valve Rexroth H4WEH25H64/6EG24NEK4/B08
3 1 D03 Solenoid Control Valve Rexroth4WE6M60/EG24NK4/B08
4 2 Coil for D03 Rexroth R00221884
5 1 Relief Valve Rexroth DB20-1-52/350X/12
6 1 Needle Valve Sun NFCC-LCN
7 1 Check Valve Sun CKDA-XCN
8 2 Lighted DIN Connector Rexroth RR00057453Z55L PLG ABBLK
Drive Manifold - Rear View Drive Manifold - Front View
3
1
2
44
675
88
Hydraulic Components - Drive Manifold 513028A (Continued...)
VII. MODEL 475 POWER UNIT (Continued...)
Page 7-8
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Page 7-9 Page 7-5
VII. MODEL 475 POWER UNIT (Continued...)
1 DURD124632-PADGEARBOX 532051
2 REXROTHCLAMPPUMP 533012
3 COMM.SHEARINGDRIVEPUMP 523013
4 COMM.SHEARINGDRV/RE-CIRCPUMP 523013
5 CHECKVALVE1.25 555003
1
2
3
4
Hydraulic Components - Pump Drive and Pumps
ITEM DESCRIPTION APEP/N
5
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MODEL475POWERUNIT
PUMPDRIVE(GEARBOX)LUBRICATION
Mainfillplug(1)
84ounces
Adapterplug(3)
8ounces
Pumppad plugs
item(2)8 ounces
Thepumpdriveusedon theAPE power unitshasthreeareasthat require lubrication. The
main gearbox takes about 84 ounces of oil. Agallon of oil is 128 ounces, so 88 ounces is just
under3/4gallon. Checkthelevelusingthedipstick. Seeitem1 for main pump drive reser-
voir.
Thespacebetweenthehydraulic pump andthegeardriveisnotlubricated by themainreser-
voir. There is a small pipe plug (see item 2 & 3 above) mounted above each pump drive
output. Removethisplugandfill this areawith8ouncesofoil. Remember that both pump
driveoutputareasmustbefilledwith8ounces of oil. The purpose of this oilistolubricatethe
pumpshaftandthe gear splines onthepumpandgear.
Theengineadaptermustalsobe lubricated with 8 ouncesofoil. Thislubricatesthemain
engineshaftandadapter components.
Oilchangesaresuggested every sixmonthsor1000hours, which everoccursfirst.
Fill with Mobil SHC 629. Before operating the unit, check the oil level dip stick.
Dipstick
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MODEL475POWERUNIT
VII. MODEL 475 POWER UNIT (Continued...)
VII-1G. Hydraulic Components - Hose List
QTY DESCRIPTION USED FOR
1 F471TC0606-4-4-4-139 1/2 DRIVE FWD AND REV GAUGE
1 F471TC0606-4-4-4-231 RETURN FILTER GAUGE
1 F471TC0606-4-4-4-123 1/2 CLAMP OPEN GAUGE
1 F471TC0606-4-4-4-121 1/2 CLAMP CLOSE GAUGE
1 F471TC0606-4-4-4-114 DRILL SHIFT
1 9190606-4-4-4-86 ENGINE OIL PRESSURE
1 F8110606-16-16-16-42 HAND PUMP PRESSURE
1 F8110606-20-20-20-103 HAND PUMP SUCTION
1 F782TC0606-20-20-20-68 1/2 DRIVE PUMP PSI BOTTOM FTG TO RH PUMP
1 F782TC0606-20-20-20-79 DRIVE PUMP PSI TOP FTG TO LEFT PUMP
1 F811-32 23 1/2 DRIVE AND RECIRCULATION SUCTION LEFT
1 F811-32 17 1/2 DRIVE AND RECIRCULATION SUCTION RIGHT
1 F3010606-20-20-20-921/2 RECIRCULATION PUMP PRESSURE TO COOLER
1 F3010606-20-20-20-421/2 RECIRCULATION PUMP CHECK TO FILTER
1 F3010606-20-20-20-125 COOLER TO RETURN FILTER
1 F8110606-20-20-20-291/2 HYDRAULIC TANK TRANSFER
1 F471TC0606-12-12-12-78 CLAMP/DRILL MANIFOLD RETURN
1 F471TC0606-8-8-8-25 1/2 FUEL TANK TO FILTER
1 F471TC0606-6-6-6-67 FUEL RETURN
1 F811-16 36 CLAMP PUMP SUCTION
1 F471TC0606-8-8-8-41 1/2 CLAMP PUMP PRESSURE TO CLAMP MANIFOLD
1 F471TC0606-12-12-12-27 1/2 DRIVE MANIFOLD DRAIN
1 F471TC0606-12-12-12-30 VIBRO CASE DRAIN
1 F3010606-24-24-24-31 DRIVE MANIFOLD RETURN
62" 6" SILICONE AIR HOSE 6" DIA. AIR INTAKE HOSE
2 HSS-64 6" HOSE CLAMP
Page 7-10
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Page 7-10
Page 7-11
VII. MODEL 475 POWER UNIT (Continued...)
VII-1G. Hydraulic Components - Fittings List
ITEM QTY P/N DESCRIPTION
FUEL TANK AND FUEL INLET FITTINGS
1 1 16HHP-S 1" HOLLOWHEX PLUG
2 1 6-8-FTX-S FUELRETURN
3 1 6-12-CTX-S FUE LINLET
4 1 STREETELBOW1/4MALLEABLE FUELVENTELBOW
5 1 DC604-4 FUELVENTVALVE
HYDRAULIC TANK DRAIN FITTINGS
6 1 16-16-CR-S
7 1 16-16-VTX-S
8 1 16-FNTX-S
9 1 16-V500P BRASSBALLVALVE
HYDRAULIC TANK FITTINGS
10 1 20-20CR-S TANKTRANSFERFTG
11 1 20-VP500P LOCKINGBALLVALVETANKTRANSFER
12 2 20-20CTX-S TANKTRANSFERFTG
13 3 12-12CTX-S
14 1 24-24-VTX-S MANIFOLDRETURN
15 3 24-HHPS PLUGS
16 2 12-HHPS PLUGS
17 1 32-16-F50G5-S CLAMPPUMPSUCTION
18 1 0588-16-16-S CLAMPPUMPSUCTION
19 1 L/DG607-06-A-1-4 6"SIGHTGAUGE
20 1 L/DG607-30-A-1-4 30"SIGHTGAUGE
21 1 16-16-FF-S FILTERHEADFTG
22 1 16-16-VTX-S FILTERHEADFTG
23 1 ZAF-10-25-1-3 FILTERHEAD 25 PSI BYPASS
24 2 AE-25 FILTERELEMENT
25 1 TB-075 TANKBREATHERADAPTOR
26 1 12-12-FTX-S CASEDRAINCOUPLERPANEL
GAUGE AND FITTINGS
27 3 0-7500PSIGAUGE 25.310.7500/25-3CFF
28 1 0-100PSIGUAGE 25.310.100/25CFF
29 1 4-2DTX-S CLAMPDRILLGAUGE
30 4 4-4DTX-S DRIVE,CLAMPPRESSUREGAUGE
31 1 150F-4-2 OILPRESSUREGAUGEBRASS
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MODEL475POWERUNIT
ITEM QTY P/N DESCRIPTION
DRIVE MANIFOLD 513028A
32 2 W48-32-32-UALLENS
33 2 32-24-F50G5-S
34 2 24-24-F50F-S
35 2 W48-24-24-UALLENS
36 2 20-24-C50X-S
37 1 4-4-C50X-S
38 1 12-8-C50X-S
39 1 24-24-C50X-S
40 1 24-HP50N-S
41 1 4-HP50N-S
42 1 24-FOPX-S
43 1 HFHFHK-24
CLAMP/DRILL MANIFOLD 523002A, AND CASE DRAIN
44 1 8-12-F50X-S
45 1 12-12-F50X-S
46 3 4-4-C50X-S
47 1 4-HP50N-S
48 1 8-6-F50G-S
49 2 8-6-F50F-S
50 1 S35-3FEMALE
51 1 S31-3MALE
52 1 3005-3PLUG
53 1 3009-3CAP
54 1 H3-63NIPPLE
55 1 H3-66ALUMCAP
56 1 12-12-FF-S
57 1 12-6125
58 1 12-6109
RETURN FILTER
59 1 RETURNFILTERHOUSING ZDF-2215-50-1-00
60 2 FILTERELEMENT ZLE-10
61 1 20-20-C6X-S
62 1 4-2-CTX-S GAUGEFTG
63 1 20-20-20-RTX-S
64 1 20-24-PTR-S
COOLER
65 2 20-24-F50X-S
VII. MODEL 475 POWER UNIT (Continued...)
VII-1G. Hydraulic Components - Fittings List
Page 7-12
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MODEL475POWERUNIT
VII. MODEL 475 POWER UNIT (Continued...)
VII-1G. Hydraulic Components - Fittings List
ITEM QTY P/N DESCRIPTION
HAND PUMP
66 1 20-20-GTX-S
67 2 SCH 40 1 1/4 X 4LG
68 1 16-20-CTX-S
69 1 SPX414HANDPUMP
70 1 BR22114 GATECHECK
CLAMP PUMP
71 2 HC-100
72 1 8-12-C50X-S
73 1 0588-16-16-S
ENGINE FITTING
74 1 4-4-4-R6X-S
75 1 6-6-C6X-S
76 1 8-3/8-F50G-SMOD1/4
DRIVE AND RECIRCULATION PUMPS
77 3 W46-24-24-UALLEN
78 2 20-24-C50X-S
79 1 24-20-F50G5-S
80 1 20-20-20-R50X-S
81 1 20-20-F6X
82 1 20-20-VTX-S
83 2 1988-32-32
84 2 5151HK-32
85 4 HC-200
DRILL OPERATOR GAUGE,HOSE,AND FITTING IF ORDERED
112 1 0-6000PSIBOTTOMMTGGUAGE
113 1 4-4GTX-S
114 1 F471TC0606-4-4-4-660
115 1 4-4-4-S5OX-S
Page 7-13
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MODEL475POWERUNIT
VII-2. Electrical Controls
VII. MODEL 475 POWER UNIT (Continued...)
HYDRAULIC
SYSTEM
GAUGES
ELECTRICAL CONTROL & GAUGES
PENDANT
CONTROL MAIN CONTROL
PANEL
Page 7-14
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MODEL475POWERUNIT
VII. MODEL 475 POWER UNIT (Continued...)
Page 7-15
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