APE 100 User manual

MODEL 100 WICK DRAIN VIBRO WITH
BOTTOM SPROCKET DRIVE AND
350 POWER UNIT with Cummins M11
SERIALNUMBER:
OPERATION AND MAINTENANCE
MANUAL
(condensed version)
BOTTOMDRIVE

7032 SOUTH 196th - KENT, WA 98032 - [phone] / FAX [phone]
OPERATION / MAINTENANCE MANUAL
Change
Number Page Number Date Revision Description
RevisionRecord
01 all 1/97 Misc. changes and updates to all pages
02 all 2/97 Misc. changes per mark-ups, added manifold dwgs.
03 all 9/99 Change manual from vibro to add wick drain machine
Page i

7032 SOUTH 196th - KENT, WA 98032 - [phone] / FAX [phone]
OPERATION / MAINTENANCE MANUAL
Preface
General
This manual covers theModel100 Vibrowithcenterholecompletewithsprocketdrive andthe
Model 350 Power Unit.Thedata provided in this manual gives the necessary information to operate
and maintain APE equipment. 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
hyd. = Hydraulic
NPT. = National Pipe Thread
Page ii

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OPERATION / MAINTENANCE MANUAL
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 100 Vibro .............................................................................. 1-2
B. Model 350 Power Unit ...................................................................... 1-2
I-3. General Description of 100 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 350 Power Unit............................................... 1-8
II. MAJOR COMPONENT DEFINITION.......................................................................... 2-1
II-1. Component Identification ............................................................................ 2-1
II-2. Hose Identification ..................................................................................... 2-3
II-3. Model 350 Power Unit Skid Identification .................................................... 2-4
II-4. Quick Disconnect Couplings ....................................................................... 2-5
II-5. Tool Set Identification.................................................................... ........... 2-6
II-6. Caisson Clamp Identification ....................................................................... 2-7
II-7. Engine Component Identification ................................................................. 2-8
II-8. Major Hydraulic Component Identification ..................................................... 2-11
II-9. Control Panel and Parts ............................................................................. 2-19
II-10.Remote Pendant and Parts ........................................................................ 2-22
II-11.Radio Reciever and Parts........................................................................... 2-23
II-12.Radio Antenna Parts ................................................................................. 2-27
II-13.Radio Transmitter Parts ............................................................................. 2-28
III. LOADING AND UNLOADING .................................................................................. 3-1
III-1. Model 100 Vibratory Hammer ..................................................................... 3-1
III-2. Model 350 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 Hoses ................................................................. 4-3
IV-5. Bleeding Clamp Attachment Hydraulic Hoses ............................................. 4-3
IV-6. Precautions and Rules for Operation .......................................................... 4-4
IV-7. Relief Valve Settings Prior to Operation - Model 350 ................................... 4-5
IV-8. Shut-down Procedures .............................................................................. 4-5
IV-9. Operation of the Remote Control Pendant ................................................... 4-6
IV-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
V-7. Power Unit ............................................................................................... 5-3
V-8. Hydraulic Motor - Installation and Start-Up................................................... 5-6
VI. TROUBLESHOOTING: Model 100 Vibro ................................................................. 6-1
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OPERATION / MAINTENANCE MANUAL
APPENDIX A - CUMMINS 6CTA8.3 ENGINE
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
Page iv
Table of Contents (Continued...)
VII. MODEL 350 POWER UNIT.................................................................................... 7-1
VII-1. Hydraulic Circuitry ................................................................................... 7-1
A. Clamp Circuit ................................................................................... 7-1
B. Drive Circuit ..................................................................................... 7-1
C. Return Filter ..................................................................................... 7-2
D. Heat Exchanger ............................................................................... 7-2
E. Manual Pump................................................................................... 7-2
F. Hydraulic Oil Temperature ................................................................. 7-2
G. Hydraulic Components...................................................................... 7-2
H. Hydraulic Schematic......................................................................... 7-3
VII-2. Electrical Controls (Understanding How They Work) ................................... 7-4
A. Main Circuit Breaker ......................................................................... 7-4
B. Tachometer...................................................................................... 7-4
C. Hourmeter........................................................................................ 7-4
D. Engine Safety Shut-Down Switch....................................................... 7-4
E. Murphy "Engine Oil Pressure" Gage................................................... 7-4
F. Murphy "Engine Oil Temp" Gage ........................................................ 7-4
G. Murphy "Hyd. Oil Temp." Gage.......................................................... 7-4
H. Hyd. Oil Level Float Switch................................................................ 7-4
I. Pendant "Emergency Stop" Button ..................................................... 7-4
J. Radio "Emergency Stop" Button ......................................................... 7-4
K. Pilot Lights ...................................................................................... 7-4
L. Engine Control Switch "OFF-ON-START" ............................................ 7-5
M. "Local Pendant" Switch .................................................................... 7-5
N. Governor Control Switches "RAISE-OFF-LOWER" ............................... 7-5
O. Clamp Control Switches "OPEN-OFF-CLOSE" ................................... 7-5
P. Drive Control Switches ...................................................................... 7-7
Q. Preparing theElectrical System for Engine Startup .............................. 7-7
R. Electrical Schematic for "Pendant Control" ......................................... 7-8
S. Electrical Schematic for "Radio Control" ............................................. 7-9
VII-3. Remote Control Pendant .......................................................................... 7-10
A. Remote Pendant Wiring Diagram ....................................................... 7-11
VII-4. Radio Control Equipment .......................................................................... 7-12
A. Overview .......................................................................................... 7-12
B. Antenna Mounting and Connection ..................................................... 7-12
C. Reciever Mounting and Connection..................................................... 7-12
D. Radio Reciever Set-Up ...................................................................... 7-13
E. Radio Operation ............................................................................... 7-13
F. Radio Malfunction ............................................................................. 7-14
VIII. POWER UNIT UPGRADES ................................................................................... 7-15
VIII-1. Upgrading to Murphy Gages .................................................................... 7-15
VIII-2. Upgrading Governor Control Wiring ........................................................... 7-16
VIII-3. Upgrading the Drive and Clamp Switches .................................................. 7-16
VIII-4. Upgrading Radio Controls ........................................................................ 7-16

7032 SOUTH 196th - KENT, WA 98032 - [phone] / FAX [phone]
OPERATION / MAINTENANCE MANUAL
SafetyPrecautions
(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

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OPERATION / MAINTENANCE MANUAL
Figure Title Page
1-A. Machine Features ............................................................................. 1-1
1-B. General Description of 100 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. GeneralDescriptionofModel350PowerUnit................. 1-8
2-A. ComponentIdentificationModel100Vibro....................................... 2-1
2-B. Hose Identification Model 100 Vibro.............................................. 2-3
2-C. Model350PowerUnitSkidIdentification ......................................... 2-4
2-D. Quick Disconnect Coupling Identification .................................... 2-5
2-E. Tool Set Identification................................................ ....................... 2-6
2-F. Caisson Clamp Identification ......................................................... 2-7
2-G1. Engine Component Identification .................................................. 2-8
2-G2. Fuel Line Plumbing .......................................................................... 2-9
2-H1. Engine Hydraulic Component Identification ................................ 2-11
2-H2. Gage Assembly................................................................................. 2-12
2-H3. Hydraulic Schematic Diagram ........................................................ 2-12
2-H4. Hydraulic Clamp Manifold Assembly ............................................ 2-15
2-H5. Hydraulic Drive Manifold Assembly ............................................... 2-17
2-I1. Control Panel Front View ................................................................. 2-19
2-I2. Control Panel Internal ...................................................................... 2-20
2-J. Remote Pendant and Parts ............................................................ 2-22
2-K1. Radio Reciever Assembly............................................................... 2-23
2-K2. Radio Reciever Exploded View ...................................................... 2-24
2-K3. Radio Reciever Board Layout......................................................... 2-25
2-L. Radio Antenna Parts ........................................................................ 2-26
2-M1. Radio Transmitter Layout................................................................ 2-28
2-M2. Radio Transmitter Parts .................................................................. 2-28
4-A. Power Unit Coupler Layout ............................................................. 4-2
4-B. Bleeding Clamp Attachment........................................................... 4-3
7-A. Power Unit Hydraulic Schematic.................................................... 7-2
7-B1. Electrical Schematic for Pendant Control..................................... 7-8
7-B2. Electrical Schematic for Radio Control ......................................... 7-9
7-C. Remote Control Pendant................................................................. 7-10
7-D. Remote Control Pendant Wiring Diagram..................... 7-11
Table Title Page
1-A. Machine Specifications - Model 100 Vibro ................................... 1-2
1-B. MachineSpecifications-Model350PowerUnit ............................. 1-2
2-A. Component Identification Model 100 Vibro................................ 2-2
2-B. Hose Identification Model 100 Vibro.............................................. 2-3
2-C. Model350PowerUnitSkidIdentification.......................................... 2-4
2-D. Quick Disconnect Coupling Identification .................................... 2-5
2-E. Tool Set Identification................................................ ....................... 2-6
2-F. Caisson Clamp Identification ......................................................... 2-7
2-G. Engine Component Identification .................................................. 2-10
2-H. Hydraulic Component Identification .............................................. 2-13
2-H1. Hydraulic Clamp Manifold Assembly ............................................ 2-16
2-H2. Hydraulic Drive Manifold Assembly ............................................... 2-18
2-I. Control Panel and Parts .................................................................. 2-21
2-J. Remote Pendant and Parts ............................................................ 2-22
2-K. Radio Reciever Parts ....................................................................... 2-26
2-L. Radio Antenna Parts ........................................................................ 2-27
2-M. Radio Transmitter Parts .................................................................. 2-28
5-A. Power Unit - Filters, Fluid Types and Capacities ........................ 5-3
6-A. Trouble-Shooting .............................................................................. 6-1
Table List
Illustration List
Page vi

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OPERATION / MAINTENANCE MANUAL
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 repairing
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

7032 SOUTH 196th - KENT, WA 98032 - [phone] / FAX [phone]
OPERATION / MAINTENANCE MANUAL
Figure 1-A. Machine Features
- Cummins engine M11
- 350 HP
- Lockable sheet metal enclosure
- 5000 (345bar) psi system
- Complete tool box provided
- Bi-directional flow
- 50 foot (15m) electric pendant
- Backup controls mounted on panel
- Engine safety shutdowns built in
- Sound reduction by design
- Easy to change hydraulic filters
- One loop hydraulic system
- Large cooler keeps oil temp down
- Radio control available
APE MODEL 100 VIBRO/SPROCKET
DRIVE
FOR INSTALLING WICK DRAINS. VIBRO CAN BE USED FOR
DRIVING OR EXTRACTING ALL TYPES OF PILES
APE MODEL 350 POWER UNIT
HYD POWER SOURCE FOR VIBROS, AUGERS, DECK WINCHES,
HYD. IMPACT HAMMERS, ETC.
I-1. Machine Features
I. GENERAL INFORMATION
-Wick mandrel passes through center of vibro
- One piece gear/eccentric design
- No pins, splines or keyways on eccentrics or gears
- 1,000 inch pounds - very powerful
- Can mount and operate off backhoe
- Can be used under water
- Clamp fits H-beams & plates
- Attachments for wood & pipe piles
- Sprockets transfer torque to both sides of mandrel
- No side loads on mandrel
- Speeds up to 330 feet per minute
- Static load or dynamic load or both at same time
Page 1-1
BOTTOMDRIVE

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OPERATION / MAINTENANCE MANUAL
I. GENERAL INFORMATION (Continued...)
I-2. Machine Specifications
I-2A. Model 100 Vibro - (Table 1-A.)
Cummins M11
350
1800
5000 psi (345 bar)
230 gpm
230 gpm
2700 psi
10,000 lbs.
122 inches
66 inches
70 inches
Engine
Maximum Power
Operating Speed in rpm
Maximum Drive Pressure
Max.Hyd.Flow-Forward
Max.Hyd.Flow-Reverse
Operating Pressure
Weight
Length
Width
Height
Note: This power unit is equipped with the necessary pumps to operate
the sprocket drive and the spotter functions. Vibro runs off the crane.
I-2B. Model 350 Power Unit - (Table 1-B.)
Dimensions may vary depending on the year and model.
Consult the factory for certifications on unit being used.
Page 1-2
BOTTOMDRIVE
Vibro dynamic force: 25 tons
Eccentric moment: 1000 in-lbs
Frequency: 0 to 1600 cpm
Suspended weight: 9,500 lbs
Length: 6 feet
Width: 30 inches
Height: 13 feet
Static force: 25 tons
Tons per square foot: 500
Dynamic force of 25 tons is calculated at
1350 cycles per minute. The vibro can
operate safely up to 1600 cycles per minute
with standard splash oil system. With
optional forced lubrication the unit can vibro
up to 2300 cylces per minute.