APE 50 User manual

MODEL 50 VIBRO WITH
MODEL 260 POWER UNIT
SERIAL NUMBER:
OPERATION AND
MAINTENANCEMANUAL
APE Model 50
with standard suppressor
APE Model 50
with excavator suppressor
(see page 2-2AB for parts details)

7032SOUTH196th-KENT,WA 98032-[phone]/FAX[phone]
OPERATION / MAINTENANCE MANUAL
MODEL50VIBRATORYHAMMERWITHMODEL260POWERUNIT
Change
Number Page Number Date Revision Description
Revision Record
01 -- 5/25/94 Added new pendant & misc updates.
02 2 - 2 6/1/95 Changeboltpartnumbers
03 2-7,8 7/7/95 Added Caisson Clamp Identification
04 All 9/96 Revisedtoreflectenginechangesinpowerunit.
05 1-4 9/99 AddedModel50excavatorsuppressorhousing
7032SOUTH196th-KENT,WA 98032-[phone]/FAX[phone]
Page i
061-211/18 Updated weight for 260 power unit

7032SOUTH196th-KENT,WA 98032-[phone]/FAX[phone]
OPERATION / MAINTENANCE MANUAL
MODEL50VIBRATORYHAMMERWITHMODEL260POWERUNIT
Preface
General
This manual covers the Model 50 Vibratory Hammer and the Model 260 Power Unit. The data
providedinthismanualgivesthenecessaryinformationtooperateandmaintainAPEequipment.The
listed procedures are to be performed by qualified personnel who have an understanding of the
equipmentandwhofollowallsafetyprecautions.
Guide to Using the Manual
1. RefertotheTable of Contentsforthepage location ofapplicablesections.
2.AllweightsandmeasurementsinthismanualareinbothEnglishandMetricunits.
3.Themanualwillberevisedasnecessarytoreflectcurrentinformation.
Abbreviations
Thefollowingareabbreviationsusedwithinthismanual.
lbs. =Pounds
psi. =PoundsperSquareInch
hp. =Horse Power
gpm. =GallonsPerMinute
rpm. =RevolutionsPerMinute
hyd. =Hydraulic
NPT. = NationalPipe Thread
Page ii

7032SOUTH196th-KENT,WA 98032-[phone]/FAX[phone]
OPERATION / MAINTENANCE MANUAL
MODEL50VIBRATORYHAMMERWITHMODEL260POWERUNIT
Table of Contents Page
RevisionRecord................................................................................................... i
Preface ................................................................................................................. ii
Table of Contents................................................................................................. iii
Safety Precautions............................................................................................... v
IllustrationList...................................................................................................... vi
Table List .............................................................................................................. vi
Warranty ............................................................................................................... vii
I.GENERALINFORMATION .............................................................................................. 1-1
I-1.MachineFeatures............................................................................................. 1-1
I-2.MachineSpecifications..................................................................................... 1-2
A. Model 50 Vibro..................................................................................... 1-2
B. Model 260 Power Unit ........................................................................... 1-2
I-3.GeneralDescriptionof50Vibro ........................................................................ 1-3
A.SuppressorHousing.............................................................................. 1-4
B.TheVibratorGearbox ............................................................................ 1-5
C. Clamp Attachment ................................................................................ 1-6
D. Optional Attachments ........................................................................... 1-7
I-4.GeneralDescriptionofModel260PowerUnit ................................................... 1-8
II.MAJORCOMPONENTDEFINITION............................................................................... 2-1
II-1.ComponentIdentification.................................................................................. 2-1
II-2.HoseIdentification ........................................................................................... 2-3
II-3.Model260PowerUnitSkidIdentification ......................................................... 2-4
II-4.QuickDisconnectCouplings............................................................................ 2-5
II-5. Tool Set Identification.................................................................... .......... 2-6
II-6.CaissonClampIdentification............................................................................ 2-7
III.LOADINGANDUNLOADING ........................................................................................ 3-1
III-1.Model50VibratoryHammer............................................................................ 3-1
III-2.Model260PowerUnit ..................................................................................... 3-1
III-3.Whattodoifdamaged duringshipment .......................................................... 3-1
IV.PREPARATIONANDOPERATION ............................................................................... 4-1
IV-1.RiggingofVibratoryHammer.......................................................................... 4-1
IV-2.Installingthe ClampAttachment..................................................................... 4-1
IV-3. Plumbing the Vibro Hoses to the Power Unit .................................................. 4-2
IV-4.FillingVibratorPressureHoses ...................................................................... 4-3
IV-5.BleedingClampAttachmentHydraulicHoses ................................................ 4-3
IV-6.PrecautionsandRulesforOperation .............................................................. 4-4
IV-7.ReliefValveSettingsPriortoOperation - Model260....................................... 4-5
IV-8.Shut-downProcedures ................................................................................... 4-5
IV-9.OperationoftheRemoteControlPendant ...................................................... 4-6
IV-10.NormalStepstoOperateVibrator.................................................................. 4-6
V.MAINTENANCE .............................................................................................................. 5-1
V-1.DailyMaintenanceRequiredPriortoOperation ............................................... 5-1
V-2. Checklist After Power Unit Engine Has Started ............................................... 5-1
V-3.MaintenanceandAdjustments:....... (75Hours).............................................. 5-2
V-4.MaintenanceandAdjustments:....... (EccentricBearings) ............................ 5-2
V-5.MaintenanceandAdjustmentsinSevereConditions ....................................... 5-2
V-6.Lubrication ...................................................................................................... 5-2
A.VibratoryGearbox ................................................................................. 5-2
B. Clamp Attachment ................................................................................ 5-2
Page iii

7032SOUTH196th-KENT,WA 98032-[phone]/FAX[phone]
OPERATION / MAINTENANCE MANUAL
MODEL50VIBRATORYHAMMERWITHMODEL260POWERUNIT
A-1.ENGINEOPERATIONINSTRUCTIONS........................................................... A-1
A.Pre-StartInspectionandProcedures..................................................... A-1
B.StartingThe Engine .............................................................................. A-2
C.EngineOperation .................................................................................. A-3
D.DeterminingCauseofShutdown ........................................................... A-7
A-2.MAINTENANCERECOMMENDATIONS ......................................................... A-9
A.LubricationSpecifications ..................................................................... A-10
B. Fuel Specifications................................................................................ A-11
C.CoolantSpecifications .......................................................................... A-11
D.LubricationandMaintenance................................................................. A-12
E. Electrical System ................................................................................. A-13
A-3.ENGINETROUBLESHOOTING....................................................................... A-14
Page iv
Table of Contents (Continued...)
V.MAINTENANCE (Continued...)
V-7.PowerUnit ...................................................................................................... 5-3
A. Power Unit Filters, Fluid Types and Capacities ..................................... 5-3
B. Hydraulic Fluid ...................................................................................... 5-4
C.DrainingandFillingHydraulicFluidTank ............................................... 5-4
D.CleaningHydraulicTankSuctionFilter .................................................. 5-4
E.ChangingHydraulicReturnFilterElelment ............................................ 5-5
F. Steps to Remove Filter Element ............................................................ 5-5
V-8.HydraulicMotor- Installation andStart-Up ...................................................... 5-6
VI.TROUBLESHOOTING:Model50Vibro ....................................................................... 6-1
VII. MODEL 260 POWER UNIT .......................................................................................... 7-1
VII-1.HydraulicCircuitry ......................................................................................... 7-1
A. Clamp Circuit ......................................................................................... 7-1
B.DriveCircuit ........................................................................................... 7-1
C.ReturnFilter........................................................................................... 7-2
D.HeatExchanger ..................................................................................... 7-2
E. Manual Pump ........................................................................................ 7-2
F.HydraulicOilTemperature ...................................................................... 7-2
G.HydraulicComponents .......................................................................... 7-2
H. Hydraulic Schematic.............................................................................. 7-3
VII-2.ElectricalCircuitry ......................................................................................... 7-4
A. Diesel Engine ........................................................................................ 7-4
B.Controls:UnderstandingHowThey Work ............................................... 7-4
C.Preparing TheElectrical System ForStart-Up........................................ 7-7
D.Engine SafetyShut-DownButton Switch ............................................... 7-7
E.EngineSafetyShut-Down(ThreeCausesOfEngineShut-Down) ........... 7-8
VII-3.RemoteControlPendant ............................................................................... 7-9
A.RemotePendant WiringDiagram ........................................................... 7-10
VII-4.Troubleshooting: PowerUnitElectrical ......................................................... 7-11
A. Engine Oil Pressure Switch ................................................................... 7-11
B.WaterTemperatureSwitch..................................................................... 7-11
C.Hydraulic Oil LevelSwitch...................................................................... 7-11
D. Oil Pressure Sending Unit (Cat Engines Older Models)......................... 7-12
E. Oil Pressure Sending Unit (Cummins Engines) .................................... 7-12
VII-5. Electrical Schematic ..................................................................................... 7-13
APPENDIXA -CUMMINS6CT8.3ENGINE

7032SOUTH196th-KENT,WA 98032-[phone]/FAX[phone]
OPERATION / MAINTENANCE MANUAL
MODEL50VIBRATORYHAMMERWITHMODEL260POWERUNIT
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.Donotusehosesasa towlinetotugthepowerunit!Ifahosefailsatthe hydrauliccouplers
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

7032SOUTH196th-KENT,WA 98032-[phone]/FAX[phone]
OPERATION / MAINTENANCE MANUAL
MODEL50VIBRATORYHAMMERWITHMODEL260POWERUNIT
Figure Title Page
1-A. MachineFeatures ........................................................ 1-1
1-B. General Description of 50 Vibro................................... 1-3
1-C. GeneralDescriptionofSuppressorHousing ................ 1-4
1-D. GeneralDescriptionofVibratoryGearbox.................... 1-5
1-E. GeneralDescriptionofClampAttachment ................... 1-6
1-F. ClampAttachmentHoleConfiguration.......................... 1-6
1-G. OptionalAttachments................................................... 1-7
1-H. GeneralDescription ofModel 260Power Unit.............. 1-8
2-A. ComponentIdentification ............................................. 2-1
2-B. HoseIdentification ....................................................... 2-3
2-C. Model260 Power UnitSkid Identification ..................... 2-4
2-D. QuickDisconnectCouplingIdentification ..................... 2-5
2-E. ToolSetIdentification........................................................ 2-6
2-F. CaisoonClampIdentification ....................................... 2-8
4-A. PowerUnitCouplerLayout........................................... 4-2
4-B. BleedingClampAttachment......................................... 4-3
5-A. HydraulicMotor-InstallationandStart-Up .................... 5-6
7-A. PowerUnitHydraulicSchematic .................................. 7-3
7-B. RemoteControlPendant.............................................. 7-9
7-C. RemoteControlPendantWiringDiagram..................... 7-10
Table Title Page
1-A. Machine Specifications - Model 50 Vibro..................... 1-2
1-B. Machine Specifications - Model 260 Power Unit .......... 1-2
2-A. ComponentIdentification ............................................. 2-2
Excavatorsuppressorpartsidentification .................... 2-2AB
2-B. HoseIdentification ....................................................... 2-3
2-C. Model260 Power UnitSkid Identification ..................... 2-4
2-D. QuickDisconnectCouplingIdentification ..................... 2-5
2-E. ToolSetIdentification........................................................ 2-6
2-F. CaisoonClampIdentification ....................................... 2-7
5-A. PowerUnit - Filters, Fluid Types and Capacities .......... 5-3
6-A. Trouble-Shooting ......................................................... 6-1
7-A. HydraulicComponents................................................. 7-2
Table List
Illustration List
Page vi

7032SOUTH196th-KENT,WA 98032-[phone]/FAX[phone]
OPERATION / MAINTENANCE MANUAL
MODEL50VIBRATORYHAMMERWITHMODEL260POWERUNIT
Page vii
Warranty
American Piledriving Equipment, Inc.
STANDARD WARRANTY
American Piledriving Equipment, Inc. (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 component 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 skived 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 fittings 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 (driving or pulling) 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 the bearings and
related components to prevent use of the machine beyond 195 degrees F. 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 Driving Contractors Association) and by all manufacturers of pile driving equipment.

7032SOUTH196th-KENT,WA 98032-[phone]/FAX[phone]
OPERATION / MAINTENANCE MANUAL
MODEL50VIBRATORYHAMMERWITHMODEL260POWERUNIT
Figure 1-A. Machine Features
-Cumminsengine
-260(179kW)horsepower
-Lockable sheetmetal enclosure
- Hyd. flow from 0 to 80 gpm (328 lpm)
- 4,500 (310 bar) psi system
-Completetool boxprovided
-Bi-directionalflow foraugerwork
-50 foot(15m)electric pendant
-Backup controlsmounted onpanel
- Engine safety shutdowns built in
-Sound reductionbydesign
- Easy to change hydraulic filters
- One loop hydraulic system
-Large coolerkeeps oiltempdown
-Enoughpower torunlargervibros
APE MODEL 50 VIBRATORY
DRIVER/EXTRACTOR
FOR ALL TYPES OF PILE DRIVING AND EXTRACTING
APE MODEL 260 POWER UNIT
HYD POWER SOURCE FOR VIBROS, AUGERS, DECK WINCHES,
HYD. IMPACT HAMMERS, ETC.
I-1. Machine Features
I. GENERAL INFORMATION
-Just 6900 pounds (4300 with excavator mounting)
- One piece gear/eccentric design
- No pins, splines or keyways
- Eccentrics enhanced with lead
- 1300 inch pounds - very powerful
- Visual indicator shows crane line pull
- 56 Ton line pull maximum (20 tons on excavator)
- Large rubber elastomers - smooth
- Can mount and operate off backhoe
- Can be used under water
- Drives double & single sheets
- 4 wire hoses prevent failures
- Clamp fits H-beams & plates
- 56 Tons of drive force
- Motor recessed - out of harm's way
- Attachments for wood & pipe piles
Page 1-1

7032SOUTH196th-KENT,WA 98032-[phone]/FAX[phone]
OPERATION / MAINTENANCE MANUAL
MODEL50VIBRATORYHAMMERWITHMODEL260POWERUNIT
1300
56 Tons (498 kN)
0 - 1800
7/8" (22mm)
100 Tons (890 kN)
56 Tons (497 kN)
100' (30 m)
6900 lbs. (3136 kg)
52" (1,320 mm)
16" (406 mm)
61" (1,549 mm)
75" (1,905 mm)
I. GENERAL INFORMATION (Continued...)
I-2. Machine Specifications
I-2A. Model 50 Vibro - (Table 1-A.) Eccentric Moment
Drive Force
Frequency (cpm)
Amplitude
Pile Clamp Force
Line Pull for Extraction
Hydraulic Hose Length
Suspended Weight
Length
Width
Height
Height with Clamp*
* Weight and height includes sheeting clamp and 1/2 of hose bundle.
260h.p.Cummins6CT8.3
260(194kW)
2200rpm
4,500psi(310bar)
80gpm(303lpm)
80gpm(303lpm)
4,500psi(310bar)
6.5gpm (25lpm)
11,000 lbs (4,990 kg)
102"(260cm)
50"(127 cm)
60"(152 cm)
Engine
MaximumPower
OperatingSpeed
MaximumDrivePressure
Max.Hyd.Flow-Forward
Max.Hyd.Flow-Reverse
ClampPressure
ClampPumpFlow @2100rpm
Weight
Length
Width
Height
I-2B. Model 260 Power Unit - (Table 1-B.)
Page 1-2
1300
56Tons(498kN)
0- 1800
7/8"(22mm)
100Tons(890kN)
20 tons
4300lbs.
52"(1,320mm)
14 inches (355 mm)
61"(1,549mm)
75"(1,905mm)
Eccentric Moment
DriveForce
Frequency(cpm)
Amplitude
PileClampForce
Line Pull for Extraction
SuspendedWeight
Length
Width
Height
HeightwithClamp*
* Weight and height includes sheeting clamp and 1/2 of hose bundle.