APE KING KONG 400 User manual

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APE OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY HAMMER WITH
MODEL 800 POWER UNIT
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
OPERATION AND
MAINTENANCEMANUAL
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MODEL 400 VIBRO
WITH MODEL 800 POWER UNIT
SERIAL NUMBER:
Copyright © 1994 American Piledriving Equipment, Inc. All Rights Reserved

Change
Number Page Number Date Revision Description
Revision Record
01 -- 1/8/94 RevisedTroubleshooting,O-Rings,Bolts&Hoses.
added Power Unit & Engine Information. Added 2-8
02 -- 5/25/94 Added new pendant & misc. updates.
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APE OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY HAMMER WITH
MODEL 800 POWER UNIT
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
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Page i
Copyright © 1994 American Piledriving Equipment, Inc. All Rights Reserved

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APE OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY HAMMER WITH
MODEL 800 POWER UNIT
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
Preface
General
This manual covers the Model 400 Vibratory Hammer and Model 800 Power Unit. The data
provided in this manual gives the necessary information to operate and maintain APE equippment.
Thelistedproceduresareto beperformedby qualifiedpersonnelwho haveanunderstanding ofthe
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
eng. = Engine
cyl. = Cylinder
mm. = Millimeter
mtg. = Mounting
S/N = Serial Number
sol. = Solinoid
Serial Number Locations
1. VIBRATOR: Aboveandinbetweentheeccentriccoversonbothsidesofthemachine.
2. POWER UNIT: On back of the hydraulic tank above the APE logo.
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Page ii
Copyright © 1994 American Piledriving Equipment, Inc. All Rights Reserved

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APE OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY HAMMER WITH
MODEL 800 POWER UNIT
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
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 400 Vibro ................................................................................... 1-2
B. Model 800 Power Unit .......................................................................... 1-2
I-3. General Description of Model 400 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 800 Power Unit ................................................ 1-8
II. MAJOR COMPONENT DEFINITION ............................................................................. 2-1
II-1. Component Identification ............................................................................... 2-1
II-2. Hose Identification ......................................................................................... 2-3
II-3. Caisson Clamp Identification.......................................................................... 2-4
II-4. Model 800 Power Unit Skid Identification....................................................... 2-5
II-5. Quick Disconnect Couplings .......................................................................... 2-6
II-6. Tool Set Identification .................................................................................... 2-7
II-7. Caisson Clamp Wedge Actuator .................................................................... 2-8
III. LOADING AND UNLOADING ....................................................................................... 3-1
III-1. Model 400 Vibratory Hammer ....................................................................... 3-1
lll-2. Model 800 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 Hose...................................................................... 4-3
IV-5. Bleeding Clamp Attachment Hydraulic Hoses .............................................. 4-3
IV-6. Precautions and Rules for Operation............................................................ 4-4
lV-7. Relief Valve Settings Prior to Operation - Model 800 ................................... 4-5
IV-8. Shut-down Procedures ................................................................................. 4-5
lV-9. Operation of the Remote Control Pendant.................................................... 4-6
lV-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
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Page iii
Copyright © 1994 American Piledriving Equipment, Inc. All Rights Reserved

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APE OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY HAMMER WITH
MODEL 800 POWER UNIT
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
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
Table of Contents (Continued...)
V. MAINTENANCE (Continued...)
V-7. Power Unit ..................................................................................................... 5-3
A. Power Unit Filters, Fluid Types and Capacities ................................... 5-3
B. Hydraulic Fluid ..................................................................................... 5-4
C. Draining and Filling Hydraulic Fluid Tank ............................................ 5-4
D. Cleaning Hydraulic Tank Suction Filter ............................................... 5-4
E. Changing Hydraulic Return Filter Elelment.......................................... 5-5
F. Steps to Remove Filter Element........................................................... 5-5
V-8. Hydraulic Motor - Installation and Start-Up.................................................... 5-6
V-9. Hydraulic Motor Coupling Assembly .............................................................. 5-7
VI. TROUBLESHOOTING: Model 400 Vibro .................................................................... 6-1
VII. MODEL 800 POWER UNIT ......................................................................................... 7-1
VII-1. Hydraulic Circuitry ....................................................................................... 7-1
A. Drive Circuit ......................................................................................... 7-1
B. Clamp Circuit........................................................................................ 7-1
C. Oil Cooler............................................................................................. 7-2
D. Manual Pump ....................................................................................... 7-2
E. Hydraulic Oil Temperature ................................................................... 7-2
F. Hydraulic Components ......................................................................... 7-2
G. Hydraulic Schematic ............................................................................ 7-3
VII-2. Electrical Circuitry ........................................................................................ 7-4
A. Diesel Engine ....................................................................................... 7-4
B. Controls: Understanding How They Work............................................ 7-4
C. Preparing The Electrical System For Start-Up..................................... 7-7
D. Engine Safety Shut-Down Button Switch ............................................. 7-7
E. Engine Safety Shut-Down (Three Causes Of Engine Shut-Down)....... 7-8
F. Electrical Schematic ............................................................................. 7-9
VII-3. Remote Control Pendant ............................................................................. 7-10
A. Remote Pendant Wiring Diagram ........................................................ 7-11
VII-4. Troubleshooting: Power Unit Electrical....................................................... 7-12
A. Engine Oil Pressure Switch.................................................................. 7-12
B. Water Temperature Switch .................................................................. 7-12
C. Hydraulic Oil Level Switch ................................................................... 7-12
D. Oil Pressure Sending Unit ................................................................... 7-13
APPENDIX A - CAT 3412 Twin Turbo 800 HP Engine
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Page iv
Copyright © 1994 American Piledriving Equipment, Inc. All Rights Reserved

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APE OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY HAMMER WITH
MODEL 800 POWER UNIT
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
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.Donotuse hosesasatowlinetotugthepowerunit!If ahosefailsatthehydrauliccouplers
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.
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Page v
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APE OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY HAMMER WITH
MODEL 800 POWER UNIT
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
Illustration List
Figure Title Page
1-A. Machine Features ....................................................... 1-1
1-B. General Description of Model 400 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. General Description of Model 800 Power Unit ............ 1-8
2-A. ComponentIdentification............................................. 2-1
2-B. Hose Bundle Identification........................................... 2-3
2-C. Caisson Clamp Identification ....................................... 2-4
2-D. Model 800 Power Unit Skid Identification .................... 2-5
2-E. Quick Disconnect Couplings ....................................... 2-6
2-F. Tool Set Identification.................................................. 2-7
2-G. Caisson Clamp Wedge Actuator ................................. 2-8
4-A. Power Unit Coupler Layout ......................................... 4-2
4-B. Bleeding Clamp Attachment........................................ 4-3
5-A. Hydraulic Motor - Installation and Start-Up.................. 5-6
5-B. Hydraulic Motor Coupling Assembly............................ 5-7
7-A. Power Unit Hydraulic Schematic ................................. 7-3
7-B. Power Unit Electrical Schematic ................................. 7-9
7-C. Remote Control Pendant............................................. 7-10
7-D. Remote Pendant Wiring Diagram................................ 7-11
Table List
Table Title Page
1-A. Machine Specifications - Model 400 Vibro................... 1-2
1-B. Machine Specifications - Model 800 Power Unit ......... 1-2
2-A. ComponentIdentification............................................. 2-2
2-B. Hose Identification....................................................... 2-3
2-C. Caisson Clamp Identification ....................................... 2-4
2-D. Model 800 Power Unit Skid Identification .................... 2-5
2-E. Tool Set Identification.................................................. 2-7
2-F. Caisson Clamp Wedge Actuator ................................. 2-8
5-A. Power Unit - Filters, Fluid Types and Capacities......... 5-3
6-A. Trouble-Shooting......................................................... 6-1
7-A. HydraulicComponents ................................................ 7-2
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Page vi
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APE OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY HAMMER WITH
MODEL 800 POWER UNIT
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
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.
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Page vii
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APE OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY HAMMER WITH
MODEL 800 POWER UNIT
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
I. GENERAL INFORMATION
I-1. Machine Features. - Model 400 Vibratory Hammer.
Figure 1-A. Machine Features
Patentedbreakthrough
multi-stagesuppressor
housingallowsvariable
suppression levels
whichchangetomatch
variable line pull.
Shorter overall height
and a lower center of
gravity.
One piece eccentric/
gear design eliminates
bolts,keyways,splines
and pins.
Four eccentrics filled
with"heavymetals"pro-
duce more amplitude
with less parts.
Giant spherical bear-
ingsarefivetimeslarger
than those found on
other machines.
Heavy clamp cylinders
need no guards and all
hosesaretuckedoutof
harms way. The one
piecedesigneliminates
rear seals, tie rods &
nuts.
TheModel400outper-
formsothervibrosinits
class. It is lighter and
allows more pull and
reach.
The heavy duty lifting
pinallowseasyrigging
of the vibro and two
safety lift pins ensure
maximumsafety.
Gear box drilled to ac-
cept attachments
manufactured by APE
and by other manufac-
turers.
High speed gear train
allows the vibratory
Hammertooperate off
many different power
units.
Up to 200 Tons of line
pull! More pulling ability
than other comparable
vibros.
Gearbox incorporates a
machinedO-ringgroove
toseal the top plate with
no leaky gaskets.
Rifle bored top plate
eliminates more un-
wanted hoses that can
causeseriousdowntime.
Hydraulicmotorsarere-
cessedwhicheliminates
the need for bolted on
guards.Lessparts-less
problems. Vertical mo-
tormountingisapproved
by Volvo.
Computer designed
gearbox is perfectly bal-
anced with a very low
center of gravity. Re-
lease crane line without
bending piles.
The 400 vibro can be
shippedfullyassembled
on one truck.
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Page 1-1
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APE OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY HAMMER WITH
MODEL 800 POWER UNIT
7032 So. 196th - Kent, WA. 98032 - [phone] / Fax [phone]
I. GENERAL INFORMATION (Continued...)
I-2. Machine Specifications.
* Operates APE Model 75 Drill with 75,000 ft. lbs. of torque @ 50 rpm.
APE engineers can adjust flows and pressures to job site requirements.
*Suspendedweightincludesallhoses.
CAT 3412 Twin Turbo 800 HP
800 HP (597 kW)
2000 rpm.
6000 psi. (414 bar)
250 gpm. (946 lpm)
250 gpm. (946 lpm)
6000 psi. (414 bar)
10 gpm. (38 lpm)
24,000 lbs. (10,909 kg)
174 inches (4,420 mm)
82 inches (2,083 mm)
96 inches (2,438 mm)
Engine
MaximumPower
Operating Speed
Maximum Drive Pressure
Maximum hyd. flow: Forward:
Maximum hyd. flow: Reverse:*
Clamp Pressure
Clamp Pump Flow @ 2200 rpm.
Weight
Length
Width
Height
Consult Factory
400 Tons (3,559 kN)
0 to 1500
1 1/8" (28.5 mm)
250 Tons (2,224 kN)
200 Tons (1,780 kN)
200 feet (61 meters)
34,000 lbs (15,445 Kg)
120 inches (660 mm)
26 inches (660 mm)
70 inches (1,778 mm)
96 inches (2,438 mm)
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
APE "KING KONG" MODEL 400 VIBRATORY PILE DRIVER/EXTRACTOR
I-2A. Model 400 Vibratory Hammer - (Table 1-A.)
Fordrivingandextractingheavycaissons, sheetsorplatesinclaysoil conditions.
I-2B. Model 800 Hydraulic Power Unit - (Table 1-B.)
Hydraulicsource forsuper largevibros andhigh torquedrills
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Page 1-2
Copyright © 1994 American Piledriving Equipment, Inc. All Rights Reserved