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SERIAL NUMBER:
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Revision Record
Change Page
Date Revision Description
Number Number
2-2013 INITIAL PRINTING
Page i
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Preface
General
This manual covers the Model 400 Vibratory Driver/Extractors and the Model 1200 Power
Unit. Most information contained in this manual is identical for all the models covered. The data
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.
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.
Abbreviations
1. VIBRATOR: Above and in between the eccentric covers on both sides of the machine.
Page ii
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Table of Contents
Page
Revision Record .................................................................................................... i
Preface ................................................................................................................... ii
Table of Contents .................................................................................................. iii-iv
Safety Precautions ................................................................................................ v
Warranty ................................................................................................................ vii
I. GENERAL INFORMATION
I-1. Machine Features 400 Vibratory Hammer ............................................... 1-2
I-2. Machine Specifications
A. Model 400 Vibro.......................................................................................... 1-3
B. Model 1200 Power Unit .............................................................................. 1-3
I-3. General Description of 400 Vibro............................................................... 1-4
A. Suppressor Housing ................................................................................... 1-5
B. Vibrator Gearbox ........................................................................................ 1-6
C. Clamp Attachment ...................................................................................... 1-7
D. Optional Attachments ................................................................................. 1-8
I-4. General Description of Model 1200 Power Unit ......................................... 1-9
Page iii
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
V. MAINTENANCE
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) (for lubrication see V-6) . 5-2
V-4. Maintenance and Adjustments: (Eccentric Bearings) ....................... 5-2
V-5. Maintenance and Adjustments in Severe Conditions ........................... 5-2
V-6A. Lubrication Vibratory Gearbox ............................................................. 5-2
V-6B. Clamp Attachment ................................................................................ 5-2
V-7A. Power Unit Filters, Fluid Types and Capacities.................................... 5-3
V-7B. Power Unit Hydraulic Fluid ................................................................... 5-4
V-7C. Power Unit Two Part Hydraulic Fluid Tank ........................................... 5-4
V-7D. Power Unit Draining and Filling Hydraulic Fluid Tank .......................... 5-4
V-7E. Power Unit Changing Hydraulic Return Filter Element ........................ 5-5
V-7F. Power Unit Steps to Remove the Hydraulic Filter Elements ................ 5-5
V-8. Bolt Torque Information ........................................................................ 5-6
V-9. Power Unit Pump drive ........................................................................ 5-7
Page iv
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
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.
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.
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.
13. Avoid standing downwind of vibrating piles. Dirt and other matter may become airborne and fall
into the unprotected eye.
15. When moving, driving or extracting pile, always attach safetyline between pile and crane hook.
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
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page vi
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Warranty
American Piledriving Equipment, Inc.
STANDARD WARRANTY
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/J&M, products or parts for which a
warranty claim is made are to be returned transportation prepaid to APE/J&M. Any improper use, includ-
ing operation after discovery of defective or worn parts, operation beyond rated capacity, substitution
of any parts whatsoever, or parts not approved by APE/J&M or any alteration or repair
by others in such manner as in APE/J&M’s judgment affects the product materially and
adversely, shall void this warranty.
Refusal: Vibros: If the pile does not move one foot in 30 seconds of vibro operation at full speed. Resort to
a larger vibro. APE/J&M equipment may exceed the refusal driving criteria for short periods of time as may be needed
to penetrate hard soil layers or obstacles. In such cases, a heat gun is used to monitor the temperature of the bearings and
related components to prevent use of the machine beyond 210 degrees F. Contact APE/J&M or your local
APE/J&M distributor for special instructions when faced with refusal conditions.
Refusal: Diesels: Do not exceed 10 blows per inch or 120 blows per foot. In cases of setting of the pile it is
permitted to increase the blow count to 250 blows per foot, but only for one foot of driving penetration. Pile
inspectors should consult the APE factory for permission to exceed these limits. Failure to do so will void the
warranty. This standard specification is accepted by the DFI (Deep Foundations Institute) and the PDCA
(Pile Driving Contractors Association) and by all manufacturers of pile driving equipment.
Page vii
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Patented breakthrough The Model 400 outperforms The heavy duty lifting pin More pulling ability than
suppressor cuts down other vibros in its class. It allows easy rigging of the other comparable vibros.
weight while increasing is lighter and allows more vibro and two safety pins
line pull. pull and reach. ensure maximum safety. Gear box incorporates a
machined O-ring groove
Suppressor is modular to seal the top plate with
and can be removed to no leaky gaskets.
reduce suspended weight
and height.
Page 1-2
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
I. GENERAL INFORMATION
* Line pull is based on elastomers being used: Red elastomers allow 228 tons(2,028 kN) vs
the Black elastomers allow the capacity of 250 tons (2,224 kN).
** Weight includes Quad clamp system and 1/2 of hose bundle.
*** Height includes 8' beam and clamps.
Model 1200
Engine 1050 hp. (783 kW)
Caterpillar C27
Maximum Power 1200 hp (895 kW)
Operating Speed 800 to 2050 rpm
Maximum Drive Pressure 4,800 psi (331 bar)
Hyd. Flow-FWD/REV 190 gpm (720 lpm)
Clamp Pressure 4,800 psi (331 bar)
Clamp Pump Flow 7.8 gpm (29.5 lpm)
Weight 22,500 lbs (10,206 kg)
Length 168.5" (4280 mm)
Width 87.25" (2216 mm)
Height 103" (2616 mm)
Page 1- 3
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
I. GENERAL INFORMATION
The APE Model 400 is a variable frequency vibratory pile driver/extractor designed to drive and
extract all types of piles including sheet, pipe, timber, concrete, H-beam, I-beam and steel plates.
In addition, the vibrator can be used for soil compaction, installing well casings, and installation of
tie-backs and wick drains.
The Model 400 operates in a frequency range of 400 to 1,400 cycles per minute depending on the
hydraulic flow and on the hydraulic motors fitted to the gear train.
A. SUPPRESSOR
HOUSING
B. GEARBOX
D. CLAMP ATTACHMENT
(shown with caisson clamp)
Page 1-4
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
I. GENERAL INFORMATION
The suppressor housing utilizes a total of sixteen, fist stage large elastomers and eight
small, second, stage small elastomers. During extraction, the first stage displaces approximate-
ly 10 inches and then engages the inner second stage and engagement pin plate. The engage-
ment pin will then come into motion and provide an additional 6 inches until the safety pin bot-
toms out in the visual slot registering the total line pull with a total maximum line pull of 190 tons
to 208 tons depending upon the stiffness of the elastomers installed. When the second stage is
engaged you must be fully engaged in the second stage. Bouncing on the safety pin between
stages is damaging. ( WARNING! Hard pulling for long periods of time will heat and dam-
age the large elastomers. The heat generated from constant heavy line pull will destroy
the chemical bond between the rubber and mounting plate which will cause elastomer
failure.) When engaged in hard extracting, break every 15 minutes to allow elastomers to cool.
Elastomers (Inside)
Small
Suppressor
Housing
Safety Pin
Center Plate
Top Plate
Page 1- 5
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
I. GENERAL INFORMATION
The vibrator gearbox contains four high amplitude eccentric weights cast in one piece with the
gear. This design is unique to the industry and was developed by the engineers of APE to solve
a number of problems associated with other types of vibrator machines. The eccentric and the
drive gears have been helically cut to provide high speed operation with reduced noise and wear.
Vibration is caused by the vertical movement created when the eccentrics are rotated. The ec-
centrics and drive gears are all driven in line by hydraulic motors tucked in on the outboard side
of the gearbox. The motors are recessed for maximum protection. The eccentrics rotate on four
shafts housed by eight giant spherical bearings. The gears and bearings receive lubrication as a
result of the fluid splashing inside the gearbox when the gears are rotated. The oil level is quickly
determined by looking at the site gauge. The Model 400 can be operated under water to a depth
of 30 feet without modifications. (Consult factory for depths below 30 feet.)
Rifle Bored
Top Plate
Hydraulic
Motor
Bearing
Cover
Oil
Level
I. GENERAL INFORMATION
The APE 400 comes with a Caisson Beam and Caisson Clamps or a Sheet Clamp. Each of the
clamps contain two gripping jaws. One is "fixed" and one is "moveable". A large hydraulic cylinder
operates the moveable jaw with up to 196 tons of clamping force depending on clamp pump relief
pressure. The jaws open and close by turning a switch on the remote control pendant or may be
operated by turning the switch at the main control panel mounted on the power unit. The APE
Caisson Clamp can be used for driving and extracting caissons from 16 inches to 9.5 feet. (for
larger diameters contact APE) The clamps are held in place with a simple wedge-lock design.
Clamps can be fitted with hydraulically activated wedges for faster adjustments when driving more
than one size caisson. (Contact APE or your local APE distributor for more information on clamp
attachments for special pile types.)
Caisson Beam
Clamp Body
Clamp Cylinder
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
I. GENERAL INFORMATION
90 Degree Adapter
Plate (#905000)
Clamp Attachment
Page 1-8
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
I. GENERAL INFORMATION
The 400 vibrator runs off the APE 1200 power unit. The APE 1200 has a 1200 horsepower (895
kW) CATERPILLAR C32 engine. The engine is mounted to a tubular frame that also serves as a
diesel fuel tank. A sheet metal and tube frame covers the engine and is equipped with lock-
ing doors for protection from the environment. A control panel is located behind one of the doors
and comes complete with a 50 foot (15.2 M) control pendant. There are two hydraulic tanks on
the power unit. One is the main tank and the other is a storage tank for extra oil in case the main
tank becomes depleted. A hydraulic tank supplies oil to five pumps. Three pumps feed the vibrator
motors. A pump feeds the clamp attachment and drill shifter. There is also a recirculation pump to
keep the oil cool and filtered. The Vibrator is connected to the power unit via five hydraulic hoses.
The two 2" (ID) hoses are the pressure line and the return line for the vibrator motors. Two 3/8"
(ID) hoses are for the clamp system. The 1-1/4" (ID) hose is for the vibrator motors case drain line.
The hoses are attached to the power unit by connecting the "quick disconnect fittings" on the end
of the hoses leading from the vibrator. The fittings go on only one way so there is no chance of
hooking up the hoses improperly.
WARNING: Clean with ether or a clean rag before installing quick disconnects. Make sure you seat
the quick disconnect fittings all the way tight. Failure to tighten the quick disconnects will stop the
flow of oil and will prevent the vibro from operating. Failure to tighten the clamp fittings completely
tight will cause the jaws to either not open or not close. If this happens you may have to loosen the
fitting and bleed off the pressure to release the quick disconnects.
1 OF 1 REV:
Lifting Eye
Tube Frame
Exhaust Muffler
Hydraulic Tank
Quick Disconnect
Fittings
Fuel Tank
Locking Doors
Radiator
Page 1- 9
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
ITEM
2 7 8 1
2
9
3
4
5
10
6
7
8
15 9
13 10
14 11
5 12
13
14
11 15
12
1 3 6
11 12
MATERIAL:
DWN. BY: DATE:
Figure 2-A. Model 400 Final Assembly
DESCRIPTION VIEW
Page
Scotto 2-22/8/2013 MODEL: 400 VIBRO FINAL ASSEMBLY
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 2-3
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
II. MAJOR COMPONENT DEFINITION
1 OF 1
II-2. Suppressor Identification
9 2
ITEM
1
21 2
6
3
22
4
19
8 5
20 6
9
7
8
9
10
12
5 12 11
17
9 12
12 13
7 14
12 15
15
11 16
12 16 17
13 14
18
10 19
3 20
21
4
12 22
18
MATERIAL:
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
II. MAJOR COMPONENT DEFINITION
Page 2-5
OPERATION / MAINTENANCE MANUAL REV:
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
II. MAJOR COMPONENT DEFINITION I
41 42 11 2
50
47
49
50 9
A
12
10
34
3
7
12
1
35
11
36
31
30
33
8
46
48 B 17
48 4 37 6
MATERIAL: SCALE:
DESCRIPTION VIEW
AMERICAN PILE
DEL: APE 400 VIBRO 400 GEARBOX ASM 7032 SOUTH 196
21 19
23
43 3
14
REV:
15
24
39 44
25 5
24
20 22 45
19
16 26 27
24
39 13 40 28 29 1
43
DETAIL
15
DETAIL A SCALE 0.0
39 44 SCALE 0.06 : 1
5
MATERIAL: S
DWN. BY: DATE: DESCRIPTION VIEW
A
Scotto 2/1/2013 MODEL: APE 400 VIBRO 400 GEARBOX ASM
37
13 40 28 29 18 38 17
DETAIL B
DETAIL A SCALE 0.06 : 1
SCALE 0.06 : 1
Page 2-7
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
II. MAJOR COMPONENT DEFINITION
34 8 2-279 O-RING
35 64 400275 0.75-10UNC X 1.50 SHCS
36 1 100646 FITT2P-02P
37 4 GEAR SPACER
38 2 SPACER
39 2 100139 FITT2S-08M08R000-000H001
40 2 300099 FITT2S-08M10R000-000H001
41 14 1.00-8UNC X 6.00 LG SHCS
42 14 1.00 HI COLLAR LOCK WASHER
43 1 HOSE050R02J008J008L01750
44 1 HOSE050R02J008J008L01750
45 16 100485 0.50-13UNC HEX NUT
46 1 123005 SIGHT GLASS
47 4 100903 FITT2P-08R
48 3 123004 1” MAG PIPE PLUG
49 4 FITT2P-32R
50 6 FITT2P-241
Page 2-9
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT REV: 3521
Parts List
TEM QTY STOCK 7032 SOUTH 196th - KENT, WA.
NUMBER 98032 - (253) 872-0141 / FAX (253) 872-8710
DESCRIPTION
1 1 CHECK VALVE BODY
II. MAJOR COMPONENT DEFINITION
2 1 CHECK VALVE
3 2 Check Valve Identifi
II-4. 0.25 X 0.50
cation LG ROLL
352103 PIN
4 2 2-121 O-RING
MATERIAL: SCALE:
Figure 2-D. Check Valve Assembly
DESCRIPTION VIEW
AMERICAN PILEDRIVING EQUIP
MODEL: VIBRO HPS C2601C CHECK VALVE ASSEMBLY KENT, WASHINGTON
Page 2-10
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
II. MAJOR COMPONENT DEFINITION
1 OF 1 R
Parts List
ITEM QTY STOCK NUMBER DESCRIPTION
1 1 CHECK VALVE BODY
2 1 CHECK VALVE
3 2 0.25 X 0.50 LG ROLL PIN
4 2 2-121 O-RING
4
Table 2-D. Check Valve Assembly
3
MATERIAL: SCALE:
DWN. BY: DATE: DESCRIPTION VIEW
AMERIC
Scotto 4/7/2010 MODEL: VIBRO HPS C2601C CHECK VALVE ASSEMBLY
Page 2-11
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
UP TO S/N 041
Page 2-12
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 2-13
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 2-14
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 2-15
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 2-17
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
II. COMPONENT DEFINITION
Page 2-18
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
II. MAJOR COMPONENT DEFINITION
Design Features:
- Excellent flow characteristics for continuous duty applications.
- High strength design endures high surge and shock conditions.
- Flat crested stub-ACME threads and all steel construction withstand storage and rig-up damage.
- Structurally compatible with weight of 5,000 P.S.I. flex-hose and system induced shock loads.
6 1 8 9 12 4
12
7
13
5
12
15
14
3 7 8 12 2 10 11
FigureMATERIAL:
2-J. 200 Caisson Clamp Assembly SCALE:
Item Qty Description
DESCRIPTION VIEW
Part #
FOUNDATION EQ
ODEL: 1 1 Caisson Clamp Body #250101 PITTSBURGH, PE
2 1 Plastic Sleeve #250224
3 1 Fixed Jaw #250202H
4 1 Clamp Cylinder Asm #251001
5 3 Male Wedge Half (Bronze) #243102
6 3 Female Wedge Half (Steel) #243105
7 3 ACME Wedge Bolt #124211A
8 6 Wedge Washer #124219
9 3 ACME Wedge Nut #124122
10 8 1-1/4" High Collar Lock Washer #124205
11 8 Bolt - SHCS 1-1/4" NF x 4.00 #124204
12 7 Grease Zert #221001
13 2 #6 JIC Cap
14 2 Lock Washer 5/8" High Collar #124115
15 2 Bolt - SHCS 5/8" x 4" #124214
8 7 2 10 9 14 1
12
13
11 3 4 5 6
MATERIAL: SCALE:
DATE: DESCRIPTION VIEW
FOUNDATION EQUIP
12/16/2009 MODEL: 200 CAISSON Figure 2-K. 200 200
Caisson
CLAMPClamp Cylinder Assembly
CYL ASM PITTSBURGH, PENNSY
Page 2-21
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 2-22
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 2-24
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 2-26
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 2-27
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 2-28
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
The APE 400 vibrator is normally shipped in a travel stand. Two sliding pins release the vibrator from
the stand. To re-install, set vibro in stand and slide pins inward and rotate. Hoist vibro and stand by
rigging to the vibro lifting shackle. Vibrator shipped without stands is usually laid flat on the trailer
deck and the hose bundle is coiled on top. Lift the vibrator by rigging one line to the lifting shackle
and one line around the clamp attachment lifting the vibro and hose bundle as one load. Avoid
smashing hydraulic lines. Vibro should be loaded with hydraulic motors down facing the deck and
breather valves facing the sky. Before the truck has left, carefully inspect the machine and hoses for
any missing equipment or sign of damage that may have occurred during shipment or unloading.
The Power Unit is always loaded with the oil cooler / radiator facing to the rear of the truck to
prevent damage to the cooler and the radiator from flying objects. The Power Unit is usually held
to the truck by wrapping a chain around both ends of the fuel tank base and the truck bed. After
loading the Power Unit, tape the exhaust rain cap shut to prevent rain water from getting inside. If
quick disconnects do not have safety cables then store them under the panel in the storage box
rather than risk the possibility of the caps and plugs coming loose and falling off into traffic. Make
sure all doors are fully closed. Tighten fuel vent on the fuel cap to prevent diesel fuel from washing
out the fill spout.
In the event of damage, notify the trucking agent at once. Note all damage on the bill of lading. Fax
the information as soon as possible, any delay may make it impossible to find the responsible party.
Page 3-1
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 3-2
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
IV. PREPARATION AND OPERATION
A steel wire rope sling must be connected to the lifting bail located on top of the vibro. The required
strength of this sling depends on the capacity of the crane and the work to be carried out. A safety
factor of six is recommended. Several turns of a smaller diameter cable will result in a longer lasting
sling than one larger diameter cable. When making a sling, avoid using cheap cable clamps. Check
the clamps daily.
The Vibro is fitted with a standard sheet clamp at the factory. However, several types of clamps
are used on APE vibros to fit many different types of piles. A step by step procedure is provided
as follows:
1.) Clean all drilled and tapped threads on the bottom surface of the gearbox. Use a 1 1/2"UNC
tap to clean any rusted threads and blow out any remaining fragments with compressed
air. If there is a cutting torch on the jobsite then use the oxygen setting to blast the threads
clean. Hold a rag over the tapped hole to prevent flying dirt from blasting into your eyes.
2.) Clean the machined bottom surface of the gearbox and prepare to mount the clamp. If the
clamp bolts should ever break, check the machined surface with a straight edge to make
sure it is true and flat.
3.) Clean the machined surface of clamp. Eye-ball the entire surface for damage. Make sure
the surface is flat and void of all dirt.
4.) Start by getting the center bolt in first and work outwards. Do not tighten bolts until you
have all of the bolts started.
5.) Tighten bolts using a six-foot cheater pipe. If you do not have a cheater pipe then use a
sledge hammer.
6.) Go around all bolts at least three times making sure they are tight.
7.) After vibrating the first pile, check the bolts again.
8.) If one bolt breaks, replace them all since they may be weak or cracked.
9.) Never operate the vibro with missing clamp bolts.
WARNING: Do not use grade five bolts. All bolts should be allen head cap screw bolts. If one bolt
breaks then the others are damaged and must be replaced. Never drive piles if one bolt is broken.
Bolts break only because they were not tight and the crew neglected to check them. A good opera-
tor insists that every bolt is checked twice daily.
Page 4-1
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
There are five hoses leading from the vibro that must be connected to the power unit to begin
operation (Please see section II-5, "Hose Identification, page 2-5.) The hoses attach to the power
unit by screwing the quick dis-connect couplers onto the proper couplers of the power unit. The
couplers on the power unit are mated with the couplers on the vibro so there is no chance of putting
them on backwards. Please take the following steps when installing the couplers:
Drill “Shift”
Clamp “Open”
Clamp “Close”
Drive “Forward”
Drive “Reverse”
Vibro “Case Drain”
Figure 4-A. Power Unit Hose Plumbing
Page 4-2
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
The vibrator is shipped with the hoses filled with oil. However, if the unit has been sitting for a long
period of time or if a damaged hose has been replaced with a new one, then the hoses must be
filled. Hook up all the hoses to the power unit (see page 4-2). Start the power unit and let it run for
ten minutes before running the vibro. The hoses will fill up by themselves in ten minutes even if
the vibro is not in the vibrate mode.
If the opening and closing of the jaws seems spongy or slow, it may be a result of air in the clamp
hoses. Normally there is no need to worry about bleeding the clamp lines because the unit is shipped
fully tested. However, should the vibro sit for a long period of time, if a new attachment is being
installed or if a damaged clamp hose has been replaced, then the system may require bleeding to
remove unwanted air in the system. To bleed the clamp system, follow the following steps:
Clamp "Open"
Clamp "Close"
Clamp Cylinder
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
1.) Follow the Daily Maintenance Required Prior to Operation, [Section V-1].
2.) Read and follow the Safety Precautions, [page iii].
3.) Follow the start-up procedures listed in the manual for the power unit being used.
4.) Start with piles in good condition.
5.) Put all teeth in pile.
6.) Drive in steps eight feet (2.5M) or less.
7.) Keep sheets plumb.
8.) Come up to speed before doing work.
9.) No dancing. Avoid densifying the soil.
10.) Drive past obstacles and then go back.
11.) Backhoe on site to remove obstacles.
12.) Lead with the ball.
13.) Probe the pile if it appears stuck.
14.) Keep piles plumb or down the road you go.
15.) Never rush the sheet pile foreman.
16.) Slow and plumb and the job will get done.
17.) Melted inner locks - piles out of plumb.
18.) Never stand under pile drivers.
19.) Low clamp pressure means jaw failures.
20.) Wait for vibro to get to full speed then pull.
21.) Don't over excavate - lower the ring.
22.) Look at the jaws during driving.
23.) Beware of cracked or broken sheets.
24.) In sandy soils drive faster. Vibration can cause settlement in loose, granular soils.
25.) In clay amplitude is everything.
26.) Low drive pressure means easy work.
27.) High pressure means friction on piles.
28.) Over 5000 psi means get a bigger vibro.
29.) No amplitude means get a bigger vibro.
30.) Caissons need heavy wall to avoid flex.
31.) Check clamp bolts each morning.
32.) Read the manual - know your machine.
33.) Attach whip line to pile when pulling.
34.) Know your line pull.
35.) Extract straight - look at boom and cable.
36.) Give boom stops some room.
37.) Stalled engine means dirty fuel filters.
Page 4-4
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
The Relief Valve and Pressure Switches are set by the factory. They will need to be re-set if the
pressure switch is replaced.
1.) Do not hook up quick disconnects. Start and warm engine . Bring to full rpm.
2.) Check Clamp relief valve setting. On the Control Panel, turn the clamp switch to "OPEN"
and hold it there while you read the CLAMP OPEN GAUGE on the panel. It should
read 4800 PSI. If it is not coming up to pressure, then set the relief valve (FACTORY
AUTHORIZED PERSONNEL ONLY), by loosening the lock nut and turning the knob
in slowly until the proper pressure is reached. Turn in (CW) to increase pressure, and out
(CCW) to decrease pressure. Tighten the locknut and recheck the pressure to make sure
that the setting did not move during tightening the lock nut. When the clamp switch is
turned to "OPEN" and held, a small light on the solenoid is illuminated, showing that
there is power to the solenoid. Otherwise, the light on the solenoid should be off.
SOLENOID LIGHT
LOCK NUT
CLOSE
GREEN LIGHT
4500 PSI-
4800 PSI
Page 4-5
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
IV. PREPARATION AND OPERATION
3.) Check the clamp pressure switch setting. Turn the clamp to "CLOSE". If there is
proper clamp pressure the CLAMP CLOSE GAUGE should read 4500 PSI to 4800
PSI, and the GREEN LIGHT comes on (see figure 4-D.)
ADJUSTMENT SCREW
CLOSE
GREEN LIGHT
4500 PSI-
4800 PSI
With clamp relief set at 4800 PSI, turn the clamp switch to "CLOSE". Green light should be on and clamp
pressure should be very low or not reading at all.
Turn Adjustment Screw in (CW) until the green light goes off. Then, turn adjustment screw out (CCW)
until green light comes on. (About 1/4 to 1/2 turn.) The CLAMP CLOSE GAUGE should read 4000 to
4800 PSI.
To check, turn clamp switch to "OPEN". The green light should be on.
Page 4-6
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
IV. PREPARATION AND OPERATION
1.) Stop the vibrator. (Refer to the power unit operating manual .)
2.) Allow the diesel engine to run for five minutes at 1000 engine rpm.
3.) Reduce engine speed to low idle for about 60 seconds.
4.) Shut engine off by turning off the main power switch.
WARNING: Do not shut the power unit engine down while the vibrator is clamped onto a
pile. The clamp check valve will slowly bleed off if there is any leakage in the hose lines or
worn clamp seals in the cylinder that moves the jaw open or closed.
Page 4-7
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
1.) All functions of the vibro can be controlled by the control pendant. It is the choice of the
crew as to where best to locate the control pendant. Some prefer that the crane operator
control all functions. Others prefer to give it to one of the ground crew so it can be
positioned close to the work at hand. A 50 foot (15.2 M) cord is provided as standard
equipment. If this is not long enough, additional 50 foot (15.2 M) sections can be added.
Should the control pendant become damaged, all functions can be manually operated.
See page 7-16 in this manual for more details on operation. See page 7-21 of this manual
for wiring diagram and control pendant components.
Page 4-8
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
V. MAINTENANCE
V-1. Daily Maintenance Required Prior to Operation
1.) Visually inspect the entire vibro for loose nuts or bolts. Put a wrench on the clamp bolts
and check them for tightness.
2.) Grease the Jaw Plunger on the clamp housing.
3.) Check the oil level in the vibrator. Hang vibro from crane and look at sight gauge. Make
sure the oil is half way up gauge. If you cannot read it then you can't run the vibro.
Remove the gauge and clean it by spraying a shot of starting fluid at it. YOU MUST
KNOW THE LEVEL!
If you cannot read it then do not assume the level is ok.
IF THE OIL LOOKS MILKY
O R C O N TA M I N AT E D
THEN DRAIN THE Oil Level
GEARCASE AND ADD Schaeffer 268
NEW OIL. or equivalent.
Sight Gauge (do not use veg. oil)
4.) If the oil is milky or contaminated then change it. Change the oil every 75 hours.
5.) Check the fluid level in the power unit hydraulic tank.
6.) Look at all the hoses. Check for cuts or other damage that might cause an oil leak.
7.) Check the Elastomers (rubbers) in the suppressor housing. Look for cracks.
8.) Check the following items:
Check water level in radiator Check engine oil
Check battery level Check hydraulic return filter indicator
Check fuel level Check fan belts on engine
Check oil level in pump drive Check entire unit for hydraulic leaks
Check hydraulic oil level Check condition of jaws before operating
1.) Check all hydraulic hoses for leaks. Make sure they hang free with no kinks.
2.) Check inside the Power Unit. Look at all hoses and valves, check for leaks.
3.) Check return filter gage at control panel with engine running at full rpm and hydraulic oil
temperature above 80 degrees F. Replace filter when pressure is above 50 psi.
4.) Check wire rope sling and make sure it is in excellent condition.
5.) Check jaws for wear. Replace if necessary.
6.) Close jaws, make sure clamp light comes on.
Page 5-1
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
V. MAINTENANCE
Change the oil in vibrator gearbox. Remove the drain plug from bottom of gearbox and drain the
oil into a bucket. Check oil for any metal shavings. Replace oil in gearbox by adding 20.6 gallons
of standard weight oil. Schaeffer 268.
Clean the gearbox breathers each time the oil is changed. Replace the breathers if necessary.
1.) Model 400 - The Eccentric Bearings should be checked and/or replaced after
every 2500 hours of operation.
When average temperature is above (80 deg. F) or below (-1 deg. F) reduce servicing intervals to
one half of those specified above.
When operating in the presence of dust or sand, reduce servicing intervals to one-third of those
specified.
During stand-by or inactive periods, the servicing intervals may be reduced to one-half. The unit
should be run every 30 days or less to keep internal parts lubricated.
The Gearbox oil should be changed when black or milky. Schaeffer 268 or equal is the preferred
oil. The gearbox requires 20.6 gallons of oil.
The Clamp Attachment hydraulic oil must be checked and changed on a regular basis. The Clamp
Cylinder Plunger should be checked for rust and debris. Lubricate the plunger on a regular basis
using the grease zert on the side of the clamp housing.
Page 5-2
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
V. MAINTENANCE
FILTERS
LOCATION QTY ENGINE FILTER TYPE APE P/N
Engine Oil: 2 Caterpillar C-32 Caterpillar #1R-1808 521033
Engine Fuel: 1 Caterpillar C-32 Caterpillar #1R-0755 555139
Eng. Fuel Water Sep: 1 Caterpillar C-32 Caterpillar #326-1641
Air Filter Outer 2 Caterpillar C-32 Caterpillar #6I-2509 521025B
Air Filter Inner 2 Caterpillar C-32 Caterpillar #6I-2510 521025A
Hyd. Oil Filter: 4 Zinga #ZLE-10 555009
Hand Pump Filter: 1 Zinga #AE-25 533011
Caterpillar Extended Life Anti-freeze p/n 119-5150 mix with water 50/50.
Caterpillar Extended Life Anti-freeze p/n 101-2844 premixed.
See page 5-7 for details on lubrication of the pump drive.
Page 5-3
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
V. MAINTENANCE
When adding or changing hydraulic fluid APE uses only Terresolve Invirological 146 Hydraulic
fluid which is non-toxic and will not harm soil or water and is biodegradable. Consult your local oil
supplier for recommendations on mixing hydraulic oils. Change hydraulic oil if it looks milky. This
includes all hydraulic lines leading to and from the vibro. Milky oil indicates that water is in the oil.
The Hydraulic Tank is a two part tank. The main tank which the pumps feed from, cooled and filtered
oil returns. The upper tank is an auxiliary tank to store extra or surplus hydraulic oil. Hydraulic oil
may be transferred from the auxiliary tank to the main tank.
There is a valve on the bottom of the main hydraulic tank that should be opened into a bucket
periodically before the engine is started. Water that may get into the system will settle to the bot-
tom of the hydraulic tank, opening this valve will allow that water to be removed from the system.
1.) Shut down power unit by turning off the diesel engine.
2.) Place warning tag on control panel so that no one mistakenly starts the unit while tank is
not operational.
3.) Remove cap and open drain valve located on bottom of main hydraulic tank. When tank
is empty we recommend opening side cover(s) to confirm the tank is clean inside.
4.) Replace covers, close drain valve and replace cap.
5.) Refill using hand pump and filter.
6.) Prime both the clamp and the main pump before restarting.
7.) Take extreme caution that no dirt or other unwanted particles enters the system.
Page 5-4
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
V. MAINTENANCE
The hydraulic return filters are mounted to dual head adapters on the hydraulic tank inside the
power unit. They are mounted high on the tank so that when the filter elements are removed the
oil will not drain from the hydraulic tank. The filter adapter has a gage at the control panel to tell
to tell you when it is dirty. When the hydraulic oil is above 80 degrees F and the return filter gauge
reads 50 PSI it is time to change the filters.
1.) Shut down power unit by turning off the diesel engine.
2.) Place warning tag on control panel so that no one mistakenly starts the unit while filters
are being changed.
3.) Clean area around filters so that when they are removed there is no chance of
introducing dirt into the hydraulic system.
4.) Using a filter wrench, turn the filter counter clockwise and spin the filter off of the filter
housing.
5.) Install new clean filter making sure the o-ring is in place.
6.) Always change all four filters at the same time.
Page 5-5
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
V. MAINTENANCE
Torque, in foot-pounds, is determined by the length of the wrench handle (in feet) multiplied by
the weight (or force in pounds) applied at the end of the handle. For example, if the wrench is
one foot long and five pounds of force is applied at the end of the handle, the total torque applied
would be five foot pounds. A six inch wrench would require ten pounds of force to obtain five
foot pounds of torque.
The only way to actually tighten high strength bolts is with proper lubrication and a torque
wrench. Proper use of the torque wrench is important. To obtain the listed torques, a steady pull
should be exerted to the handle until the desired torque is reached.
The following torque specifications apply to the bolts from the vibrator assemblies listed. When-
ever any of these bolts, are installed or replaced, the given torque specifications should be
adhered to.
Vibro Final Assembly Identification Page 2-2
Item 12 3/4”-10 233 Ft-Lbs (32.3 Kg-M)
Item 7, 8 1"-8 1,009 Ft-Lbs (139.4 Kg-M)
Suppressor Identification Page 2-4
Item 22 5/8”-11 233 Ft-Lbs (32.3 Kg-M)
Item 9, 10, 11, 16, 18 3/4”-10 417 Ft-Lbs (57.6 Kg-M)
Item 14 1”-8 1009 Ft-Lbs (139.4 Kg-M)
Gearbox Identification Page 2-6 & 2-7
Item 21, 30 1/2”-13 119 Ft-Lbs (16.4 Kg-M)
Item 27 5/8”-11 233 Ft-Lbs (32.3 Kg-M)
Item 29, 35 3/4”-10 417 Ft-Lbs (57.6 Kg-M)
Item 41 1”-8 1009 Ft-Lbs (139.4 Kg-M)
CLAMP BODY Page 2-12 & 2-14
Item 4 5/8”-11 233 Ft-Lbs (32.3 Kg-M)
Item 15, 19, 29 1”-8 1009 Ft-Lbs (139.4 Kg-M)
Item 26 1 -1/2”-6 2800 Ft-Lbs (387 Kg-M)
Caisson Clamp Body Page 2-20
Item 15 5/8”-11 233 Ft-Lbs (32.3 Kg-M)
Item 11 1 -1/4”-12 1800 Ft-Lbs (248.8 Kg-M)
Caisson Clamp Cylinder Page 2-20
Item 11 5/8”-18 267 Ft-Lbs (36.9 Kg-M)
Page 5-6
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
V. MAINTENANCE
DIP STICK
PUMP DRIVE
Oil changes are suggested every six months or 2,000 hours, which ever occurs first.
Fill with Schaeffer 268. Before operating the unit, check the oil level dip stick.
Page 5-7
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 5-8
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
The following table lists some possible problems, causes and solutions. If a serious problem should
occur, contact the factory for additional service information.
ITEM PROBLEM ITEM PROBLEM
1. Oil Blowing Out Between Gear 6. Vibrator Won't Start When
box and Hydraulic Motor. Forward Switch is Engaged.
2. Vibro Gearbox is Too Hot. 7. Clamp Won't Open When Clamp
3. Excess Oil in the Gearbox. Open Switch is Engaged.
4. Oil Blowing Out From Pop-Off 8. Vibro Won't Come Up to Normal
Valve. Operating Speed.
5. Opening and Closing Clamp 9. Vibro Won't Stop When Stop
Jaws Seems Spongy or Slow. Button is Engaged.
O-rings may not be sealing properly Check the o-rings between the gearbox top plate and the motor. Clean the
seal areas and replace the o-rings if needed.
Oil may be too dirty. Look at oil in the sight gage. If the oil is milky or contaminated it must be
replaced. If you are still not sure, remove the gear box drain plug and check
the oil.
3. Excess Oil in the Gearbox.
The seal between the gearbox and the Remove the motor from the face of the gearbox. Check and clean the seal
hydraulic motor may be bad and is area, replace the seal if it looks bad.
allowing hydraulic oil to flow directly into
the gearbox.
Valve may be bad. Check case drain line for proper connection tightness.
One or both motors bay be damaged. Remove and check the valve. Replace the valve if needed.
Remove the motors and have them checked for damage. Replace if needed.
Page 6-1
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
The clamp hoses may have air in them Follow the procedures listed in this manual (page 4-3) for bleeding the
and may need bleeding. clamp attachment hydraulic hoses.
One or both hydraulic motors may not Remove the case drain hose from a motor and plug the port connecting it
be operating properly. to the other motor. Hold the case drain hose so that the oil will flow into a
bucket. Run the Vibrator, if a large amount of oil flows from the case drain
hose the motor needs to be replaced or rebuilt. Do the same proceedure
to the other motor.
Vibrator gearbox may be frozen up. If motors are working fine and the drive pressure appears normal, then the
vibro gearbox may be frozen and in need of repair.
Drive pressure is too low. Manually close start valve at the drive manifold. If vibro will not start, replace
the start valve. If vibro will not start, replace the drive pump.
Vibrator is running. The clamp won't open while the vibro is in operation. To open the clamp,
stop the vibro.
The clamp pump may be defective. Replace clamp check valves. If clamp still wont open, replace the clamp
pump.
VII-1A. Clamp Circuit (Used for extending and retracting jaw cylinder Item "F".)
Oil for the clamp circuit is provided by pump "D1". All oil to the inlet of this pump flows from the
reservoir (Item "A") through a shut-off valve, which must be open at all times. Oil is then directed
from the pump to the Clamp/Drill manifold "C" which contains the clamp control valve. When the
clamp switch is in the neutral position, the oil flows through the clamp directional control valve and
back to the oil tank. When clamp switch is moved to OPEN, solenoid "B" (on the clamp directional
control valve) is energized the oil will flow out to the clamp cylinder and retract (open) the jaws.
The clamp open pressure can be seen on the clamp pressure gage. When the clamp switch is
moved to CLOSE, solenoid "A" (on the clamp directional control valve) will be energized and oil
flow will be directed to the clamp cylinder. The clamp cylinder will then extend (close) the jaws.
When clamp comes up to pressure 4800 psi, solenoid "A" will be de-energized, directing pump
oil flow back to oil tank. Clamp pressure is maintained in clamp cylinder by a pilot operated check
valve. At any time should the clamp pressure fall below 4500 psi. the clamp pressure switch will
re-energize solenoid "A" and direct pump flow to the clamp cylinder. Maximum clamp pressure is
limited by the clamp pressure relief valve set at 4800 psi. The quick disconnect couplers permit
decoupling of clamp hoses.
VII-1B. Drive Circuit (Used for operating APE vibrator, APE drill or any other unit, Item "B".)
Oil for the drive circuit is provided by pumps "D2", "D3" and "D4". All oil to the inlets of these pumps
flows from the reservoir (Item "A") through shut-off valves which must be open at all times. Oil is
then directed from the pumps to the Drive manifold "B" which contains the drive control valve. When
the drive switch is in the neutral position, the oil flows through the drive control valve and back to
the oil tank. When the drive switch is moved to FORWARD, that direct oil to the drive circuit (Vibro
Motors). The maximum drive pressure is controlled by the drive pressure relief valve, to 4500 psi
max. When the drive switch is moved to the FWD position, solenoid "B" of the drive directional
control valve is energized. Oil flow is directed to the vibro motors to rotate the eccentrics. When
the drive switch is moved to the OFF position, oil flow is directed back to the tank through the drive
directional control valve and solenoid "B" is de-energized.
The quick-disconnect couplings permit de-coupling of the drive and case drain hoses.
Page 7-2
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
VII, MODEL 1200 POWER UNIT
VII-1C. Hydraulic Schematic.
A RESERVOIR
B DRIVE MANIFOLD
C CLAMP MANIFOLD
D PUMPS
E VIBRO
F CLAMP CYLINDER
3 2 3
13
10
8
4
7 11
12
9 6 1
Page 7-4
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 7-5
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
5 6
4
1 6
11
2 3
TO
FWD/REV HYDRAULIC
GAGE TANK
REV
FWD
FROM PUMP
7 9 12 8 9 12 10 10
Page 7-6
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 7-8
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 7-9
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
VII. MODEL 1200 POWER UNIT
1
12
10 5
4 11 7 9
2
6
8
Page 7-10
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
VII. MODEL 1200 POWER UNIT
Page 7-11
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 7-12
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
4
1
3
2 3
Page 7-13
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
VII-2B. Tachometer
A digital tachometer, located on the front of the control panel, is provided to monitor the engine
RPM. A magnetic sensor picks up a signal from the flywheel, and sends it to the tachometer. If
there is reason to doubt the accuracy of the tachometer, check the engine RPM with a phototach,
then calibrate the tachometer gage. The factory should be consulted for proper setting of the tach
switches.
VII-2C. Hourmeters
Two hourmeters are on the Control Panel, one on the face of the panel, and one inside the panel.
The hourmeter on the face of the panel monitors the time that the engine is running. The hourmeter
inside the panel monitors the time that the “Forward Drive” is operating.
Page 7-14
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
VII. MODEL 1200 POWER UNIT
Page 7-15
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
In addition to the above, there is a pilot light in each of the terminal connectors on the solenoid
valves. By observing these lights, one can tell which solenoids are energized.
CAUTION should be used when changing the position of this switch. Check to make sure that all
of the Drive “Forward/Reverse” switches, and “Clamp” switches (including the Radio) are turned
“off” before turning this switch. If any one of the above switches are “on”, the vibro eccentrics or
clamp could be accidentally activated, causing mechanical damage or personal injury.
Page 7-16
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
The Clamp Control Switches on the Control Panel and the Hand Held Pendant are detented in
the “off” and ”close” positions. The “open” position is spring loaded back to the “off” position.
When the ‘active’ Clamp Control Switch is in the “off” position, oil from the Clamp Pump is
routed through the Clamp Solenoid Valve back to tank.
When the ‘active’ Clamp Control Switch is turned to the “open” position, The “open” solenoid on the
Clamp Valve is energized, causing oil to be directed to the rod end of the Clamp Cylinder, provided
the drive “Forward/Reverse” Switch is in the “off” position. (The clamp “open” solenoid cannot be
energized when the “Drive Forward” switch is activated.) If the Clamp Control Switch is held
in the “open” position after the clamp is fully open, oil pressure will build in the system until oil is
flowing over a pressure relief valve, creating heat.
When the ‘active’ Clamp Control Switch is turned to the detented “Close” position, the ”close”
solenoid on the Clamp valve is energized, causing oil to be directed to the blind end of the Clamp
Cylinder. Once the Clamp is closed, and sufficient oil pressure (4800psi) has built in the system,
a pressure switch will open the circuit to the solenoid valve, and energize a pilot light located in
the Clamp Control Switch Operator. A lit pilot light in the Clamp Control Switch Operator is an
indication that there is enough oil pressure in the clamp circuit to safely run the vibro eccentrics.
If oil pressure in the Clamp circuit should bleed off to a predetermined level(4500psi), the pressure
switch will de-energize the pilot light, and re-energize the “close” solenoid on the Clamp valve until
pressure in the clamp circuit reaches 4800 psi again. This cycle will continue until the Clamp switch
is turned to the “off “ position.
Page 7-17
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Page 7-18
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
Turning the switch to FORWARD will start the vibro eccentics spinning. To stop vibro turn the switch
to off. When operating the eccentrics on a vibro, only the “Forward” drive should be used. If the
“Reverse” drive is used, the majority of the oil will pass through the anti-cavitation valves located
in the vibro suppresser housing, and the vibro eccentrics will not run properly.
Page 7-19
OPERATION / MAINTENANCE MANUAL
MODEL 400 VIBRATORY DRIVER WITH MODEL 1200 POWER UNIT
7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710
The Control Pendant is particularly handy as a trouble shooting tool, in that the operator can position
himself near the Control Valves while checking them. To make the Control Pendant Switches
operable, turn the ‘Local-Pendant’ Switch to the ‘Pendant’ position, and the Engine Control Switch
to the ‘On’ Position. (The Engine does not need to be running.) Each time a solenoid is energized,
a pilot light on the connector to that solenoid should light up.
FORWARD/OFF/REVERSE
Three position switch. Turn to forward to operate vibro. Turn to
off to stop vibro. Turn to reverse when using power unit to run a
drill motor. Vibro is not supposed to vibrate in reverse. If it does
then switch the two yellow cables labeled "drive" and "reverse"
located on the other side of the control panel.
#10-24 5/32 6 Ft-Lbs. (.83 Kg-M) #10-32 5/32 6 Ft-Lbs. (.83 Kg-M)
1/4-20 3/16 13 Ft-Lbs. (1.8 Kg-M) 1/4-28 3/16 15 Ft-Lbs. (2.1 Kg-M)
5/16-18 1/4 27 Ft-Lbs. (3.7 Kg-M) 5/16-24 1/4 30 Ft-Lbs. (4.2 Kg-M)
3/8-16 5/16 48 Ft-Lbs. (6.6 Kg-M) 3/8-24 5/16 55 Ft-Lbs. (7.6 Kg-M)
7/16-14 3/8 77 Ft-Lbs. (10.6 Kg-M) 7/16-20 3/8 86 Ft-Lbs. (11.9 Kg-M)
1/2-13 3/8 119 Ft-Lbs. (16.4 Kg-M) 1/2-20 3/8 133 Ft-Lbs. (18.4 Kg-M)
5/8-11 1/2 234 Ft-Lbs. (32.3 Kg-M) 5/8-18 1/2 267 Ft-Lbs. (36.9 Kg-M)
3/4-10 5/8 417 Ft-Lbs. (57.6 Kg-M) 3/4-16 5/8 467 Ft-Lbs. (64.5 Kg-M)
7/8-9 3/4 676 Ft-Lbs. (93.4 Kg-M) 7/8-14 3/4 742 Ft-Lbs. (102.5 Kg-M)
1-8 3/4 1,009 Ft-Lbs. (139.4 Kg-M) 1-12 3/4 1,126 Ft-Lbs. (155.6 Kg-M)
1-1/4-7 7/8 1,600 Ft-Lbs. (221.1 Kg-M) 1-1/4-12 7/8 1,800 Ft-Lbs. (248.8 Kg-M)
1-1/2-6 1 2,800 Ft-Lbs. (387 Kg-M) 1-1/2-12 1 3,000 Ft-Lbs. (414.6 Kg-M)
NOTE: These values are for Socket head cap screws only. Button heads,
Flat heads and Set screws have different values. Check the Allen
Hand Book for correct torque specifications.
Page 7-24