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
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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