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Model 500 Model 500 Operators, Maintenance And Parts Manuals GeoQuip Power Systems, LLC HIGH QUALITY VIBRATORY HAMMERS, HYDRAULIC AUGERS, AND HYDRAULIC POWER UNITS...
TABLE OF CONTENTS Section 1 General Information 1.1 Warranty 1.2 Model 500 Vibratory Exciter with Power Unit Section 2 Safety 2.1 Important Safety Information 2.2 Standard Safety Procedures Section 3 Introduction 3.1 Specifications 3.2 General Overview Section 4 Maintenance 4.1 Daily Maintenance 4.2 General Maintenance...
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7.11 Model 500-Harness Layout 7.12 Model 500-Harness Diagram 7.13 Model 500-Vibro Control Pendant Electrical Schematic 7.14 Model 500-C15 and C18 Industrial Engine Electrical System 1 of 2 7.15 Model 500-C15 and C18 Industrial Engine Electrical System 2 of 2 Section 8 Placard...
1.1 Warranty GeoQuip Power Systems, LLC hereby warrants that the Model 500 is free from defects in material and workmanship attributable to GeoQuip Power Systems, LLC under normal use and service for a period of ninety (90) days from date of delivery of such machine.
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 assembly 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 a remote control pendant that operates the hammer and clamp.
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1.2.2 Diesel Hydraulic Power Unit The 500 diesel hydraulic power unit is equipped with a Caterpillar C18 Tier 4 Final Diesel Engine with a rated output of 755 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.
For the name of the nearest FACTORY AUTHORIZED REPRESENTATIVE contact GeoQuip Power Systems, LLC. at (816) 221- 4774. d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 9...
SAFELY DISPOSE OF CONTAMINATED RAGS AND CONTAINERS. NEVER LEAVE IN OR ON THE POWER UNIT ENCLOSURE. NEVER STORE FLAMMABLE LIQUIDS NEAR THE POWER UNIT OR EXCITER. d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 10...
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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. d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 11...
Exciter. 12) Upon lifting the 500 Exciter to a free-hanging position, check the level of the gear oil in the sight glass located in the lower left hand corner of the case. Try to position the case as level as possible to achieve the most accurate measurement possible.
Hydraulic Oils, or any other substance that cannot be removed by means of the Filter Elements. 5) Replace the Desiccant Material located in the Midland Air Dryer once a year or every 500 hours of operation, whichever comes first.
Use the “turn of the bolt” method to tighten bolt properly. 5) There are many fasteners available which are not suitable for use with HPSI products. Replace with only “American Manufactured” or factory replacement fasteners.
MAINTENANCE 4.6 Disassembly of Exciter Case ITEM NO. PART NO. DESCRIPTION VIB-32542A 500 E GII GEARBOX ASSEMBLY GEA-32540 PINION GEAR GER-16A ECCENTRIC GEARS MALE GER-17A ECCENTRIC GEARS FEMALE GEA-32440A ECCENTRICS GEA-32449 ECCENTRIC SHAFT BRG-NJ326 ECCENTRIC BEARING GEA-32448 ECCENTRIC SHAFT SPACERS...
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MAINTENANCE 4.6.1 Disassembly of Exciter Unit Thoroughly steam clean vibratory exciter. Disconnect hydraulic hose bundle from the exciter and hose block. d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 23...
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Retrieve shaft spacer and inner race as shaft is removed. NOTE Eccentric assemblies are fitted with shaft spacers at factory for end play tolerances. d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 24...
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DO NOT REUSE HEATED RACES OR BEARINGS. 3) Remove pinion bearing support sleeve in same manner as eccentric sleeves, by using HPSI puller. Pinion gear must also be supported during removal of pinion bearing spacer sleeves and pinion bearings. 4) Remove pinion bearings and motor spacer sleeve by LIGHTLY tapping with small rubber mallet on the outer race only.
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Never allow bolts or tools to be set around the open top of the gear box. Total gear/bearing failure will occur due to foreign objects falling in the open gearbox! d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 26...
4.7 Movable Jaw Replacement 4.7.1 Exploded View of Parts ITEM NO. PART NO. DESCRIPTION 32055 PILE GUIDES 200T 32446 MODEL 500 RECESSED CLAMP GUARD 32494 200 TON FIXED JAW 32495 200 TON MOVABLE JAW 32530 200 TON CYLINDER HEAD 32651...
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MAINTENANCE d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 28...
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4) Replace the fixed side jaw by sliding the jaw onto the machined grooves on the clamp housing, aligning with bolt holes.* *required torque spec is 1,000 ft-lbs. HPSI advises using Loctite 277 on bolts. NOTE Never reuse a movable jaw shear pin. Replace with a new pin any time the jaw is removed.
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NEVER REMOVE THE 3/8” PIPE PLUG FROM THE CYLINDER AREA OF THE CLAMP HOUSING. 5,000 PSI MAY BE ON THIS PLUG. NEVER REMOVE THE CYLINDER CHECK VALVE WITHOUT RELEASING CLAMP PRESSURE. d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 30...
5) Make sure the couplers are fully hand tight. Do not use wrenches or hammers to avoid damaged internal parts of the quick disconnects. 6) Close all four faucet valves by turning clockwise prior to starting the engine. d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 32...
NOTE Always maintain full available engine RPM when adjusting, clamping or driving any piling to obtain the maximum clamping force available. d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 33...
13) To start the power pack refer to the Section “Starting Unit” 5.4.1 Power Unit. Let the Power Unit run for at least 15 minutes prior to starting the exciter. d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 34...
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OPERATION 5.3.2 Vibratory Exciter 1) The Model 500 has been designed to utilize a CROSBY P/N RIG 33072-85 ton lifting shackle for the lifting of the Exciter. It is important that this Shackle is properly installed per the manufacturer’s specifications and instructions, and that all of their safety recommendations and warnings are carefully followed.
Close the Clamp Jaws with a steel plate between teeth before running the Exciter in the “Free hanging” position. See Section 5.2.2 for further instructions. d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 36...
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5) The 500 Exciter is equipped with a Load Indicator Placard that indicates the maximum allowable pull on the Exciter. There are also “overload stops” to eliminate overloading of the suspension.
5) Be certain that both the Key Switch and the toggle switch are in the OFF position at the end of any overnight or prolonged shutdown of the unit. d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 38...
2) Start engine and shift main control valve with the exciter disconnected. 3) Slowly turn in relief while watching drive pressure gauge. Relief setting for Model 500 is 5,000 P.S.I. 4) When you have reached the proper setting of relief, lock the lock nut and locking ring. Put the plastic cap back in place.
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CAUTION It is necessary for only trained personnel to perform pressure adjustments to the hydraulic system. Consult your authorized factory representative for assistance. d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 40...
GeoQuip Power Systems, LLC for more information regarding the setting of the relief valve or the pressure of the Clamp Pump. d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 42...
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To release the pressure captured inside the hydraulic cylinder, carefully loosen the lock nut on the relief valve (part VLV-33041, on the model 500 clamp cylinder, exploded diagram page.) Next screw in the stem with an allen wrench until it is as tight as possible. Make sure that the nut does not retighten as you do this, allowing pressure to be maintained in the cylinder.
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5) Check the drive pressure when the hammer is in the free hanging mode. If the pressure indicated on the Drive Pressure Gauge located in the Power Pack is above 2,500 P.S.I. then check the Exciter Gear Box for excessive oil or oil which appears to be contaminated with Hydraulic Oil.
PARTS 7.2 Model 500-Universal Sheeting Clamp 7.2.1 Bill of Materials ITEM NO. PART NO. DESCRIPTION CLP-32055 PILE GUIDES 200T GUA-32446 200 TON CLAMP GAURD CLP-32494A 200T FIXED JAW CLP-32495A 200 TON MOVEABLE JAW CLP-32530 200 TON CYLINDER HEAD CLP-32651A 200 TON BRONZE SLEEVE...
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PARTS 7.2.2 Model 500-Universal Sheeting clamp-Exploded View d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 49...
PARTS 7.3 Model 500-125 Ton Caisson Clamp 7.3.1 Bill of Materials ITEM NO. PART NO. DESCRIPTION 32362 125 TON CAISSON CLAMP 32660 125 TON PISTON ROD 32110 CAISSON CLAMP MOVABLE JAW 32041 125/150 TON CYLINDER HEAD/CAISSON HEAD 32101 FIXED JAW FOR CAISON CLAMP...
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PARTS 7.3.2 Model 500-125 Ton Caisson Clamp-Exploded View d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 51...
PARTS 7.4 Model 500 Caisson Beam 7.4.1 Bill of Materials ITEM NO. PART NO. DESCRIPTION STL-00755 RAW BEAM 125T-EXP 125 TON CAISSON CLAMP ASSEMBLY NOT SHOWN BT-3/4H-2 BOLT ¾-10 2 HEX CAP NOT SHOWN BT-1-1/2HB-6 BOLT 1 ½-6 6 HEX CAP...
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PARTS 7.4.2 Model 500-Caisson Beam-Exploded View d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 53...
PARTS 7.5 Model 500-Concrete Pile Puller 7.5.1 Bill of Materials ITEM NO. PART NO. DESCRIPTION 32350-W3 CONCRETE CLAMP, WELDMENT HOUSING 32350-W4 CONCRETE CLAMP, MOVEABLE JAW, WELDMENT 32350-W5 CONCRETE CLAMP, FIXED JAW, WELDMENT 32350-W7 CONCRETE CLAMP, CLAMP JAWS CAM, WELDMENT 32350-PIN1 C1018 X 8 IN DIA X 17.75 IN L...
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PARTS 7.5.2 Model 500-Concrete Pile Puller-Exploded View d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 55...
PARTS 7.6 Model 500-Brake Valve Manifold 7.6.1 Bill of Materials ITEM NO. PART NO. DESCRIPTION MAN-32549 MODEL 500 BRAKE MANIFOLD 405-32486 MODEL 500 HOSE BLOCK NOT SHOWN VLV-33160 CASE DRAIN RELIEF VALVE NOT SHOWN HOS-FF593-32 32 SPLIT FLANGE, C61 NOT SHOWN...
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Brake Valve Manifold PARTS 7.6.2 Brake Valve Manifold-Exploded View d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 57...
NOT SHOWN S-2062-6-4S -06MOR X -04MJ 90 NOT SHOWN S-6401-08-08S -08MOR X -08MP NOT SHOWN S-202702-12-12S -12MOR X -12MJ NOT SHOWN S-202702-6-4S -06MOR X -4MJ d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 58...
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PARTS 500 Hydraulic manifold 7.7.2 Hydraulic Manifold-Exploded View d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 59...
24V BATTERY ACU-A3N0058C1K HYDRAULIC ACCUMULATOR EXH-00128 4" EXHAUST CLAMP REM-01428 AIR TANK SKD-01581 SKD-01581 MODEL 500 TIER 4 SKID VLV-00447 22105 CHECK VALVE ENG-C-18 C18 T4 ENGINE, 500 POWER PACK GAG-01287 10,000 PSI GUAGE GAG-01283 200 PSI GAUGE FLAT FACE...
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S-2022-16-12S -16FP X -12MJ NOT SHOWN S-2023-2-4S -2MP X -4MJ 45 NOT SHOWN S-2024-4-4S -4MP X 4MJ 90 NOT SHOWN S-2024-6-4S -6MP X -4MJ 90 d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 61...
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-4MP X -4FP X -4FP RUN TEE NOT SHOWN S-2092-24-24S -24MP X -24FP X -24FP RUN TEE NOT SHOWN S-2092-32-32S -32MP X -32FP X -32FP RUN TEE d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 62...
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VJ5-SP-170 PSI NOT SHOWN VLV-00010 VJ8-SP-60 PSI NOT SHOWN VLV-00634 ¼” PETCOCK NOT SHOWN VLV-01437 3WE6A6X/EG24N9K4 HAM. DIRECTIONAL VALVE NOT SHOWN VLV-01438 4WE10H5X/EG24N9K4 CLAMP DIRECTIONAL VALVE d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 63...
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500PP-EXP.SLDDRW PARTS 7.8.2 Power Unit Replacement Parts-Exploded View d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 64...
PARTS 7.9 Vibration Suppressor 7.9.1 Bill of Materials ITEM NO. PART NO. DESCRIPTION VIB-32546A MODEL 500, RECESSED SUSPENSION, WELDMENT LOG-33433 LOGO 500 12" EXH-00127 4” EXHAUST CLAMP MTL-70B-001 FILTER & CLAMP BRACKET VIB32547A SUSPENSION STOP BLOCK FIL-00343 FILTER & CLAMP BRACKET...
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-32MJ X -32MJ NOT SHOWN S-2042-8-8S -8MK X -8MJ 45 BULKHEAD NOT SHOWN S-2061-12-12S -12MOR X -12MJ 45 NOT SHOWN VIB-01362 1/4” SAFETY LOCKING PIN d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 66...
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Vibration Suppressor - exploded view PARTS 7.9.2 Vibration Suppressor-Exploded View d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 67...
PARTS 7.10 Hydraulic Schematic-Model 500 Vibro Hammer & Power Pack d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 68...
PARTS 7.13 Vibro Control Pendant Electrical Schematic d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 71...
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PARTS 7.14 C15 and C18 Industrial Engine Electrical System 1 of 2 d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 72...
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PARTS 7.14 C15 and C18 Industrial Engine Electrical System 1 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 73...
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PARTS 7.14 C15 and C18 Industrial Engine Electrical System 1 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 74...
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PARTS 7.14 C15 and C18 Industrial Engine Electrical System 1 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 75...
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PARTS 7.14 C15 and C18 Industrial Engine Electrical System 1 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 76...
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PARTS 7.14 C15 and C18 Industrial Engine Electrical System 1 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 77...
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PARTS 7.14 C15 and C18 Industrial Engine Electrical System 1 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 78...
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PARTS 7.14 C15 and C18 Industrial Engine Electrical System 1 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 79...
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PARTS 7.15 C15 and C18 Industrial Engine Electrical System 2 of 2 d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 80...
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PARTS 7.15 C15 and C18 Industrial Engine Electrical System 2 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 81...
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PARTS 7.15 C15 and C18 Industrial Engine Electrical System 2 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 82...
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PARTS 7.15 C15 and C18 Industrial Engine Electrical System 2 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 83...
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PARTS 7.15 C15 and C18 Industrial Engine Electrical System 2 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 84...
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PARTS 7.15 C15 and C18 Industrial Engine Electrical System 2 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 85...
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PARTS 7.15 C15 and C18 Industrial Engine Electrical System 2 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 86...
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PARTS 7.15 C15 and C18 Industrial Engine Electrical System 2 of 2 Continued d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 87...
PLACARDS AND SAFETY SIGNS 8.1 Placards And Safety Signs d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 89...
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PLACARDS AND SAFETY SIGNS 60 TON MAX PULL d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 90...
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PLACARDS AND SAFETY SIGNS d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 91...
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PLACARDS AND SAFETY SIGNS d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 92...
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PLACARDS AND SAFETY SIGNS d/b/a Hydraulic Power Systems • Phone: (816) 221- 4774 • hydraulicpowersystems.com Model 500 - 93...
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