APE 50 - User Manual

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

Summary

Model 50 Vibro with Model 260 Power Unit Operation and Maintenance Manual

Preface

General

Overview of the manual's scope and purpose.

Guide to Using the Manual

Instructions on how to navigate and utilize the manual effectively.

Abbreviations

Lists and defines abbreviations used throughout the manual.

General Information

Machine Features

Highlights key features of the APE Model 50 Vibro and Model 260 Power Unit.

Machine Specifications

Provides detailed technical specifications for the Vibro and Power Unit.

General Description of 50 Vibro

Details the components and function of the APE Model 50 Vibro.

General Description of Model 260 Power Unit

Explains the features and purpose of the APE Model 260 Power Unit.

Major Component Definition

Component Identification

Identifies major components of the APE Model 50 Vibratory Hammer.

Hose Identification

Lists and identifies the various hoses used with the equipment.

Model 260 Power Unit Skid Identification

Identifies components of the Model 260 Power Unit skid.

Quick Disconnect Couplings

Details the quick disconnect couplings used for hydraulic connections.

Tool Set Identification

Lists and describes the tools included for maintenance.

Caisson Clamp Identification

Details parts related to the Caisson Clamp.

Safety Precautions

General Safety Precautions

Lists critical safety measures for operating and maintaining the equipment.

Warranty

Standard Warranty Terms

Outlines the terms and conditions of the product warranty.

Loading and Unloading

Model 50 Vibratory Hammer

Procedures for loading the APE Model 50 vibrator.

Model 260 Power Unit

Procedures for loading the APE Model 260 Power Unit.

What to do if damaged during shipment

Steps to take in case of shipping damage.

Preparation and Operation

Rigging of Vibratory Hammer

Instructions for properly rigging the vibratory hammer for lifting.

Installing the Clamp Attachment

Step-by-step guide for mounting the clamp attachment.

Plumbing the Vibro Hoses to the Power Unit

Connects the vibrator hoses to the power unit.

Filling Vibrator Pressure Hose

Procedure for filling the vibrator pressure hoses with oil.

Bleeding the Clamp Attachment Hydraulic Hoses

Removes air from the clamp attachment hydraulic hoses.

Precautions and Rules for Operation

Guidelines for safe and productive operation of the vibratory hammer.

Relief Valve Settings Prior to Operation

Sets the relief valve pressure for the Model 260 Power Unit.

Shut-down Procedures

Correct procedures for shutting down the APE Model 50 Vibratory Hammer.

Operation of the Remote Control Pendant

Details how to operate the unit using the remote pendant.

Normal Steps to Operate Vibrator

Outlines the standard sequence for operating the vibrator.

Maintenance

Daily Maintenance Required Prior to Operation

Daily checks to ensure the equipment is ready for use.

Checklist Once Power Unit Engine Is Started

Checks to perform after the power unit engine starts.

Maintenance and Adjustments (75 Hours)

Procedures for 75-hour maintenance and adjustments.

Maintenance and Adjustments (Eccentric Bearings)

Maintenance for eccentric bearings.

Maintenance and Adjustments in Severe Conditions

Adjustments for operation in severe conditions.

Lubrication - Vibratory Gearbox

Lubrication requirements for the vibratory gearbox.

Lubrication - Clamp Attachment

Lubrication for the clamp attachment.

Power Unit - Filters, Fluid Types, and Capacities

Lists filters, fluid types, and capacities for the power unit.

Power Unit - Hydraulic Fluid

Details the hydraulic fluid used and its properties.

Power Unit - Draining and Filling Hydraulic Fluid Tank

Procedures for draining and filling the hydraulic fluid tank.

Power Unit - Cleaning Hydraulic Tank Suction Filter

Steps for cleaning the hydraulic tank suction filter.

Power Unit - Changing Hydraulic Return Filter Element

How to change the hydraulic return filter element.

Power Unit - Steps to Remove the Element

Detailed steps for removing the filter element.

Hydraulic Motor - Installation and Start-Up

Guidance on installing and starting the hydraulic motor.

Vibro Trouble-Shooting

Vibro Trouble-Shooting Index

Lists common problems, causes, and remedies for the vibrator.

Model 260 Power Unit

Hydraulic Circuitry

Explains the hydraulic circuitry of the Model 260 Power Unit.

Clamp Circuitry

Details the hydraulic circuit for the clamp operation.

Drive Circuit

Describes the hydraulic circuit for driving the vibrator.

Return Filter

Information on the return filter for the hydraulic system.

Heat Exchanger

Function of the heat exchanger in cooling hydraulic fluid.

Manual Pump

Operation of the manual pump for filling the reservoir.

Hydraulic Oil Temperature

Monitors the hydraulic oil temperature.

Hydraulic Components

Lists and identifies hydraulic system components.

Hydraulic Schematic

Diagram of the power unit's hydraulic system.

Electrical Circuitry

Describes the electrical components of the power unit.

Diesel Engine

Details the diesel engine powering the unit.

Controls: Understanding How They Work

Explains the function of various control switches.

Clamp OPEN;OFF;CLOSE Switch

Operation of the clamp control switch.

Drive FORWARD;REVERSE Switch

Controls for the drive direction of the vibrator or drill.

SYSTEM OK Light

Indicates the operational status of the systems.

Throttle RAISE;OFF;LOWER Switch

Adjusts the engine throttle speed.

OIL PRESSURE Gauge

Monitors engine oil pressure for CAT engines.

ENGINE OIL PRESSURE Gauge

Monitors engine oil pressure for Cummins engines.

ENGINE OIL PRESSURE Switch

Safety switch for engine oil pressure.

WATER TEMPERATURE Gauge

Monitors engine water temperature.

WATER TEMPERATURE Switch

Safety switch for engine water temperature.

FUEL PRESSURE Gauge

Monitors engine fuel pressure.

TACHOMETER

Monitors engine speed (RPM).

Preparing The Electrical System For Start-Up

Steps to prepare the electrical system for engine start.

Engine Safety Shut-Down Button Switch

Function of the engine safety shutdown button.

Engine Safety Shut-Down (Three Causes Of Engine Shut-Down)

Details the three causes for engine automatic shutdown.

Remote Control Pendant

Operation and function of the remote control pendant.

Remote Pendant Wiring Diagram

Pin configuration and wire colors for the pendant cable.

Troubleshooting: Power Unit Electrical

Electrical troubleshooting for the power unit.

Engine Oil Pressure Switch

Troubleshooting the engine oil pressure switch.

Troubleshooting: Oil Pressure Sending Unit (CAT Engines Only)

Troubleshoots the CAT oil pressure sending unit.

Troubleshooting: Oil Pressure Sending Unit (CUMMINS Engines)

Troubleshoots the Cummins oil pressure sending unit.

Electrical Schematic

Diagram of the power unit's electrical system.

Cummins 6 CT8.3 Engine

Engine Operation Instructions

Basic instructions for operating the Cummins engine.

Pre-Start Inspection and Procedures

Checks and procedures before starting the engine.

Starting the Engine

Procedures for starting the Cummins engine via electric or air.

Engine Operation

Monitoring gauges and operating the Cummins engine.

Tachometer

Explanation of the tachometer function and reading.

Engine Oil Pressure

Interpreting and troubleshooting engine oil pressure readings.

Engine Jacket Water Temperature

Monitoring and troubleshooting engine coolant temperature.

Water Temperature Gauge

Checking water temperature gauge accuracy.

Fuel pressure

Fuel pressure gauge interpretation and troubleshooting.

Ammeter

Ammeter reading interpretation.

Air Cleaner Service Indicator

Indicator for air cleaner service.

Calibrated Gauges

Importance of calibrated gauges for system monitoring.

Preparing The Electrical System For Start-Up

Steps to prepare the electrical system for engine start.

Engine Safety Shut-Down Button Switch

Function of the engine safety shutdown button.

Altitude Operation

Adjusting settings for different altitudes.

Stopping

Procedures for safely stopping the engine.

After Stopping Checks And Procedures

Checks to perform after the engine has been stopped.

Stopping The Engine

Procedures for stopping the engine, including solenoid and governor methods.

Determining Cause Of Shutdown

Diagnosing reasons for engine shutdown.

Low Oil Pressure Checks

Troubleshooting steps for low oil pressure shutdowns.

High Water Temperature Checks - Engine Running

Checks for overheating while the engine is running.

High Water Temperature Checks-Engine Stopped and Cold

Checks for overheating with the engine stopped and cold.

Maintenance Recommendations

General maintenance recommendations for the engine.

Cooling

Recommendations for engine cooling system maintenance.

Electrical

Recommendations for electrical system maintenance.

Scheduled Oil Sampling

Procedure for scheduled engine oil sampling.

Fuel

Fuel handling and maintenance recommendations.

Air intake

Air intake system service.

Lubrication Specifications

Specifications for engine lubricating oils and grease.

Fuel Specifications

Recommended fuel types for diesel engines.

Coolant Specifications

Recommended coolant types and concentrations.

Lubrication and Maintenance

Schedule for engine lubrication and maintenance tasks.

Electrical System

Care and maintenance of electrical system components.

Battery

Battery maintenance, cleaning, and installation.

Charging the Battery

Safe procedures for charging the battery.

Engine Troubleshooting

Troubleshooting guide for common engine problems.

Engine Fails to Start

Causes and remedies for engine starting failures.

Misfiring

Causes and remedies for engine misfiring.

Erratic Engine Speed

Causes and remedies for unstable engine speed.

Low Power

Causes and remedies for reduced engine power.

Excessive Vibration

Causes and remedies for excessive engine vibration.

Heavy Combustion Knock

Causes and remedies for heavy combustion knock.

Valve Train Clicking Noise

Causes and remedies for valve train clicking noise.

Oil in Coolant

Causes and remedies for oil contamination in coolant.

Mechanical Knock

Causes and remedies for mechanical knocks.

Valve Spring Retainer Free

Causes and remedies for valve spring retainer issues.

Slobber

Causes and remedies for engine slobber.

Valve Lash Close-up

Causes and remedies for valve lash adjustment issues.

Excessive Valve Lash

Causes and remedies for excessive valve lash.

Premature Engine Wear

Causes and remedies for premature engine wear.

Coolant in Engine Lubricating Oil

Causes and remedies for coolant in oil.

Excessive Black or Gray Smoke

Causes and remedies for excessive black/gray exhaust smoke.

Excessive White or Blue Smoke

Causes and remedies for excessive white/blue exhaust smoke.

Low Engine Oil Pressure

Causes and remedies for low engine oil pressure.

Abnormal Engine Coolant Temperature

Causes and remedies for abnormal coolant temperature.

Starting Motor Fails to Crank

Causes and remedies for starting motor failure.

Alternator Fails to Charge

Causes and remedies for alternator charging failure.

Alternator Charging Rate Low or Unsteady

Causes and remedies for low/unsteady alternator charge rate.

Alternator Charging Rate High

Causes and remedies for high alternator charging rate.

Alternator Noisy

Causes and remedies for noisy alternator.

Stalls at Low Speed

Causes and remedies for engine stalling at low speed.

APE 50 Specifications