HPSi 500 User manual

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1
TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
TABLE OF CONTENTS 1-4
1.0 GENERALINFORMATION 5
1.1 Warranty 5
1.2 Model 500 Vibratory Exciter w/ Power Unit 6
1.2.1 Vibratory Exciter 7
1.2.2 Diesel Hydraulic Power Unit 7
1.2.3 Hydraulic Hose Bundle 7
1.2.4 Hydraulic Clamp Assembly 7
1.2.5 Remote Control Pendant 7
2.0 SAFETY INFORMATION 8
2.1 Important Safety Information 8
2.2 Standard Safety Procedures 9-10
3.0 INTRODUCTION 11
3.1 Specifications 11
3.2 General Overview 12
4.0 MAINTENANCE 13
4.1 Daily Maintenance 14
4.2 General Maintenance 15
4.2.1 Power Unit 16
4.2.2 Vibratory Exciter 16
4.3 Maintenance Schedule 17
4.4 Torque Specifications 18
4.5 Fluids and Filters Specifications 19
4.5.1 Lubricants 19
4.5.2 Fuels 19
4.5.3 Coolants 19
4.5.4 Filters 20

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TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
4.6 Disassembly of Exciter Case 21
4.6.1 Remove Clamp Housing 22
4.6.2 Remove Suspension Housing 22
4.6.3 Disassembly of Exciter 23-24
4.6.4 Removal of Eccentric Shafts 24
4.6.5 Removal and Replacement of Eccentric
Bearing into Bearing Support Sleeves 25-26
4.6.6 Reassembly 27-30
4.7 Movable Jaw Replacement 31
4.7.1 Exploded View of Parts 31
4.7.2 Jaw Replacement 32
4.7.3 Rebuilding the Model 500 Clamp Cylinder 32-33
5.0 Operation 34
5.1 Connecting the Hydraulic Hoses 34
5.1.1 Connecting the Hydraulic Hoses between the
Power Pack and the Exciter 34
5.2 Hydraulic Caisson Beam 35
5.2.1 Operation of the Hydraulic Locking Plates 35
5.2.2 Adjustment of Caisson Clamps 35
5.3 Pre-Start of Power Pack 36
5.3.1 Power Unit 37
5.3.2 Vibratory Exciter 37-38
5.4 Starting Units 39
5.4.1 Power Unit 39-40
5.4.2 Vibratory Exciter 40
5.5 Stopping Units 41-42

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TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
6.0 TROUBLESHOOTING 45
6.1 PowerUnit 45
6.1.1 Engine Will Not Start 45-46
6.1.2 Throttle Will Not Operate 45
6.2 Vibratory Exciter 45
6.2.1 Remote Pendant Does Not Function Properly 46
6.2.2 Specific Functions of Remote Pendant Do
NotFunction 47
6.2.3 Hydraulic Clamp Will Not Close 47
6.2.4 Hydraulic Clamp Will Not Open 47-48
6.2.5 Hammer Will Not Vibrate 48
6.2.6 Hammer Runs At Slow Speed 49
6.2.7 Excessive Driving Time/Temperature 50
7.0 DIAGRAM OF PARTS 51
7.1 Exciter Gear Case 52
7.1.1 Bill of Materials 52
7.1.2 Exploded View 53
7.2 Vibration Suppressor 54
7.2.1 Bill of Materials 54
7.2.2 Exploded View 55
7.3 Model 500 Universal Sheeting Clamp 56
7.3.1 Bill of Materials 56
7.3.2 Exploded View 57

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TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
7.4 Model 260-100 Ton Caisson Clamp 58
7.4.1 Bill of Materials 58
7.4.2 Exploded View 59
7.5 Model 260-Caisson Beam 60
7.5.1 Bill of Materials 60
7.5.2 Exploded View 61
7.6 Concrete Pile Puller 62
7.6.1 Bill of Materials 62
7.6.2 Exploded View 63
7.7 Brake Manifold 64
7.7.1 Bill of Materials 64
7.7.2 Exploded View 65
7.8 Hydraulic Manifold 66
7.8.1 Bill of Materials 66
7.8.2 Exploded View 67
7.9 Power Unit Replacement Parts 68
7.9.1 Bill of Materials 68
7.9.2 Exploded View 69
7.10 Remote Control Pendant 70
7.10.1 Bill of Materials 70
7.10.2 Exploded View 71
7.11 Hydraulic Schematic 72
7.11.1 Bill of Materials 72
7.11.2 Hydraulic Schematic 73
7.12 Air Schematic/Remote Control & Pendant 74
7.12.1 Bill of Materials 74
7.12.2 Air Schematic/Remote Control & Pendant
Vibro PP 75
8.0 Placard Section 76
8.1 Placards and Safety Sign 76-82

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5
SECTION 1-GENERAL INFORMATION
1.1 Warranty
HYDRAULIC POWER SYSTEMS, INC. hereby warrants that the Model 500 is free from defects in material and workmanship attributable to HYDRAU-
LIC POWER SYSTEMS, INC. under normal use and service for a period of ninety (90) days from date of delivery of such machine.
THE EXCLUSIVE REMEDY OF THE BUYER UNDER THIS WARRANTY is the repair or replacement, without charge, of any defective part or parts of
this machine as long as buyer notifies HYDRAULIC POWER SYSTEMS, INC. by registered mail of such defect within seventy-five (75) days from the
date of delivery of this machine.
Any part or parts claimed to be defective must be shipped to the HYDRAULIC POWER SYSTEMS, INC. factory at 1203 Ozark, N. Kansas
City, Missouri 64116, transportation prepaid. The HYDRAULIC POWER SYSTEMS, INC. acceptance of any part so shipped shall not be deemed an
admission that the part is defective, and if HYDRAULIC POWER SYSTEMS, INC. finds that any part returned is not defective, such part shall be re-
shipped to the Buyer at Buyer’s expense.
THE BUYER’S SOLE AND EXCLUSIVE REMEDY AGAINST HYDRAULIC POWER SYSTEMS, INC. UNDER THIS WARRANTY shall be
for the REPAIR OR REPLACEMENT of defective parts as provided above. THE BUYER AGREES THAT NO OTHER REMEDY, INCLUDING, BUT
NOT LIMITED TO, INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR LOST PROFITS, LOST SALES, INJURY TO PERSONS OR PROPERTY
OR OTHER INCIDENTAL OR CONSEQUENTIAL LOSS SHALL BE AVAILABLE TO THE BUYER.
THE SOLE PURPOSE OF THE STIPULATED EXCLUSIVE REMEDY shall be to provide the Buyer with free repair or replacement of defec-
tive parts in the manner provided herein. This EXCLUSIVE REMEDY shall not be deemed to fail of its essential purpose so long as HYDRAULIC
POWER SYSTEMS, INC. is willing and able to repair or replace defective parts in the prescribed manner. THE BUYER SHALL NOT BE REQUIRED
TO DELIVER A DEFECTIVE PART TO HYDRAULIC POWER SYSTEMS, INC. IF:
(1) The part was destroyed as a result of its defect in any party covered in the warranty.
AND
(2) HYDRAULIC POWER SYSTEMS, INC. is reasonably satisfied that the part was defective at the time of sale.
If both of these conditions are met, HYDRAULIC POWER SYSTEMS, INC. shall replace the part in the same manner provided herein as if
the Buyer had delivered it to HYDRAULIC POWER SYSTEMS, INC. at its factory.
THIS WARRANTY SHALL NOT APPLY to any machinery which has suffered abuse, misuse, neglect or accident or to any machinery which has been
altered so as to affect its ability or reliability, (except where such alteration has been accomplished with the prior written consent of HYDRAULIC
POWER SYSTEMS, INC.) or which has been repaired in any way by the Buyer without the prior written consent of HYDRAULIC POWER SYSTEMS,
INC. or which has been negligently installed by the Buyer.
WARNING: THIS PRODUCT IS NOT TO BE USED IN ANY FASHION DIFFERENT FROM THAT WHICH BUYER HAS ADVISED SELLER SHALL
BE ITS INTENDED USE. NO WARRANTY CONVEYED HEREIN SHALL APPLY TO A USE OTHER THAN THAT WHICH BUYER HAS INDICATED
TO SELLER AT THE TIME OF PURCHASE.
SELLER DOES NOT WARRANT PRODUCTS MANUFACTURED BY OTHER MANUFACTURERS WHICH MAY BE USED IN THE ASSEMBLY OF
THE TOTAL PRODUCT SOLD BY SELLER, BUYER’S SOLE REMEDY AS TO PRODUCTS MANUFACTURED BY OTHERS SHALL BE PURSUED
WITH SUCH OTHER COMPONENT PRODUCT MANUFACTURERS.
THE BUYER EXPRESSLY UNDERSTANDS THAT HYDRAULIC POWER SYSTEMS, INC. HAS MADE NO EXPRESSED OR IMPLIED
WARRANTIES, INCLUDING, BUT NOT LIMITED TO, IMPLIED OR EXPRESSED WARRANTIES FOR MERCHANTABILITY OR FITNESS, OTHER
THAN THE EXPRESSED WARRANTY SET FORTH ABOVE. THE SELLER, HEREBY, DISCLAIMS ALL OTHER EXPRESSED WARRANTIES, IM-
PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, AND ALL OTHER IMPLIED WARRANTIES.
Any oral statements made by any person about the machine described in the Agreement DO NOT CONSTITUTE WARRANTIES and are not part of
this Agreement. The entire Agreement between the parties hereto is embodied in this writing. This writing constitutes the final expression of the par-
ties’ Agreement, and it is a COMPLETE AND EXCLUSIVE STATEMENT of the terms of that Agreement. All oral or written agreements between the
parties made prior to the execution of this Agreement are hereby merged herein. This Agreement SHALL NOT BE MODIFIED OR ALTERED in any
way other than by writing, signed by the parties to the Agreement, their successors or authorized agents, and this Agreement SHALL NOT BE VAR-
IED, SUPPLEMENTED, QUALIFIED, EXPLAINED, OR INTERPRETED BY ANY PRIOR COURSE OR DEALING BETWEEN THE PARTIES OR BY
ANY USAGE OF TRADE.
HYDRAULIC POWER SYSTEMS, INC.
1203 Ozark
North Kansas City, Missouri 64116

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SECTION 1-GENERAL INFORMATION
1.2-Model 500 Vibratory Exciter with Power Unit
The H.P.S.I. Model 500 Vibratory Pile Hammer is designed for the installation and removal
of a variety of types of piling. It utilizes high-speed directional vibration and customized hydraulic
clamping accessories.
The Model 500 consists of five main parts: A vibratory exciter, A hydraulic clamp assem-
bly suitable for driving or pulling a particular type of pile; A hydraulic hose bundle 150 feet in
length; And is driven by a diesel hydraulic power unit, and remote control pendant that operates
the hydraulic pumps and motors as well as providing pressure for the hydraulic clamp assembly.

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SECTION 1-GENERAL INFORMATION-continued
1.2-Model 500 Vibratory Exciter with Power Unit
1.2.1-Vibratory Exciter
The vibratory exciter head consists of four gears turning four eccentric weights driven
by a Volvo Hydraulic Motor at a rate of 1600 vibrations per minute.
All eccentrics are timed to cancel the side forces and sum the up and down forces of
the eccentric weights to create the amplitude necessary to drive or pull the pile.
The vibration of the exciter case is isolated by the use of 16 rubber suppressors and
provides for a maximum line pull of 60 tons of extracting force. The addition of 4 suppressors may
be used to increase to 75 tons maximum pull.
1.2.2-Diesel Hydraulic Power Unit
The 500 diesel hydraulic power unit is equipped with a Caterpillar 3412 Diesel Engine
with a rated output of 700 H.P. The power unit is mounted on a skid type fuel tank base and is
equipped with full engine and hydraulic instrumentation inside the fully enclosed unit. A 30 foot re-
mote control air operated pendant is standard on the Model 500 and allows the operator to move
around for the best view of the worksite.
1.2.3-Hydraulic Hose Bundle
The 500 unit is also equipped with a 150 foot hydraulic hose bundle, standard, consist-
ing of three 50 foot sections.
1.2.4-Hydraulic Clamp Assembly
Various hydraulic clamp types are available for various types of piling. Consult the fac-
tory or your nearest Factory Authorized Representative for the particular clamp assembly required
for your application.
1.2.5-Remote Control Pendant
The vibratory exciter is operated by a hand-held, remote control pendant. The pendant
control buttons stop and start the vibration, closes and opens the hydraulic clamp.

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SECTION 2-SAFETY
2.1 Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by a
failure to observe basic safety rules and precautions. An accident can often be
avoided by recognizing potentially hazardous situations before the situation occurs. A
person must always be alert to potential hazards. This person should also have the
necessary training, skills, and tools to perform these functions properly.
WARNING: IMPROPER OPERATION AND/OR MAINTENANCE OF THIS PROD-
UCT CAN BE EXTREMELY DANGEROUS AND COULD RESULT IN SERIOUS IN-
JURY OR DEATH.
DO NOT OPERATE, MAINTENANCE, OR PERFORM ANY REPAIRS ON THIS
PRODUCT UNTIL YOU HAVE READ AND UNDERSTOOD THE OPERATION, MAIN-
TENANCE AND REPAIR INFORMATION IN THIS MANUAL.
SAFETY PRECAUTIONS AND WARNINGS ARE ALSO PROVIDED ON THE PROD-
UCT. IF THESE HAZARD WARNINGS ARE NOT HEEDED, SERIOUS BODILY IN-
JURY OR DEATH COULD OCCUR TO YOU OR OTHER PERSONS.
HYDRAULIC POWER SYSTEMS, INC. cannot anticipate every possible circum-
stance that might involve a potential hazard. The warnings in this publication and on
the product are therefore not all inclusive. If a tool, procedure, work method or opera-
tion technique not specifically recommended by H.P.S.I. is used, you must first deter-
mine that it is in no way dangerous for you and others in the vicinity. Concern for the
safety of the product should also be taken into consideration. You should ensure that
the unit will not be damaged or made unsafe by the particular operation, maintenance,
or repair procedures you choose.

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SECTION 2-SAFETY-continued
The information, specifications, and illustrations in this publication are on the ba-
sis of information available at the time it was written. The specifications, pressures,
measurements, adjustments, illustrations, and other items can change at any time.
These changes can affect the service given to the product. Obtain the complete and
most current information before starting any job. H.P.S.I. dealers have the most cur-
rent information available. For the name of the nearest FACTORY AUTHORIZED
REPRESENTATIVE contact HYDRAULIC POWER SYSTEMS INC. at (816) 221-
4774.
2.2-Standard Safety Procedures WARNING!!
NEVER START ENGINE WITH THE GOVERNOR LINKAGE DISCONNECTED.
INSTALL GUARDS OVER ALL EXPOSED ROTATING PARTS.
ALWAYS STOP ENGINE BEFORE ADJUSTING OR REPAIRING ENGINE HYDRAU-
LIC POWER UNIT.
DO NOT WEAR LOOSE CLOTHING WHEN WORKING NEAR ENGINE OR EX-
CITER.
ALWAYS WEAR PROTECTIVE GLASSES, CLOTHING, HEADGEAR, RESPIRATOR,
ETC. WHEN CONDITIONS REQUIRE THEM.
NEVER INSPECT ENGINE COOLING SYSTEM WHILE UNIT IS RUNNING.
IF EQUIPPED WITH JACKET WATER COOLING SYSTEM, REMOVE COOLANT
FILLER CAP SLOWLY TO RELIEVE PRESSURE THAT MAY HAVE BUILT UP DUR-
ING OPERATION. NEVER REMOVE CAP WHILE ENGINE IS HOT OR OPERAT-
ING. STEAM FROM COOLING SYSTEM COULD CAUSE SERIOUS INJURY.
EXTINGUISH ALL OPEN FLAMES INCLUDING CIGARETTES OR OTHER BURN-
ING SUBSTANCES WHILE REFUELING UNIT AND WHEN SERVICING BATTER-
IES.

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SECTION 2-SAFETY SECTION 2-SAFETY-continued
2.2-Standard Safety Procedures-continued
EXTINGUISH ALL OPEN FLAMES INCLUDING CIGARETTES OR OTHER BURNING SUB-
STANCES WHILE CHECKING BATTERY ELECTROLYTE LEVEL. BATTERIES GIVE OFF FLAM-
MABLE FUMES.
ELECTROLYTE SOLUTION IS AN ACID. CONTACT WITH EXPOSED SKIN WILL CAUSE SERI-
OUS INJURY. ALWAYS WEAR PROTECTIVE GEAR WHEN REFILLING AND HANDLING ELEC-
TROLYTE SOLUTION.
POWER UNIT MUST HAVE PROPER VENTILATION TO INSURE SAFE AND EFFICIENT OPERA-
TION.
NEVER ATTEMPT REPAIRS YOU DO NOT UNDERSTAND. ALWAYS FOLLOW MANUAL IN-
STRUCTIONS.
ALWAYS REPAIR AND/OR REPLACE BROKEN OR DAMAGED PARTS BEFORE OPERATION.
USE OF INCORRECT TOOLS IN OPERATION AND REPAIR SITUATIONS CAN FURTHER IN-
CREASE RISKS TO MACHINERY AND OPERATORS.
REMOVE ALL TOOLS, ELECTRICAL CORDS, AND OTHER LOOSE ITEMS FROM THE POWER
UNIT AND VIBRATORY EXCITER PRIOR TO USE.
DISPOSE OF WASTE OIL AND OTHER WASTE PRODUCTS SAFELY. ALWAYS WIPE UP
SPILLED OIL, COOLANT, FUEL, ETC.
SAFELY DISPOSE OF CONTAMINATED RAGS AND CONTAINERS. NEVER LEAVE IN OR ON
THE POWER UNIT CONTAINER. NEVER STORE FLAMMABLE LIQUIDS NEAR THE POWER
UNIT OR EXCITER.
DANGER!
INSULATE ALL ELECTRICAL CONNECTIONS AND DISCONNECTED WIRES.
DISCONNECT AND TAPE THE BATTER GROUND LEAD BEFORE WORKING ON THE ENGINE
TO PREVENT ACCIDENTAL IGNITION.
WHEN RIGGING THE VIBRATOR A STEEL WIRE ROPE SLING MUST BE CONNECTED TO THE
LIFTING PIN OR SHACKLE OF THE VIBRATION SUPPRESSOR. THE REQUIRED STRENGTH
OF THIS SLING DEPENDS ON THE CAPACITY OF THE CRANE AND THE WORK TO BE DONE.
A SAFETY FACTOR OF 5 IS RECOMMENDED.