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APE 475 Operation And Maintenance Manual

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OPERATION AND
MAINTENANCE MANUAL
Model 475 Power Unit
Page
5-1
Copyright © 2023 American Piledriving Equipment, Inc. All Rights Reserved

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Summary of Contents for APE 475

  • Page 1 OPERATION AND MAINTENANCE MANUAL Model 475 Power Unit Page Copyright © 2023 American Piledriving Equipment, Inc. All Rights Reserved...
  • Page 2 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 V. MAINTENANCE (Continued...) V-7A. Power Unit - Filters, Fluid Types and Capacities. (Table 5-A.) FILTERS LOCATION ENGINE FILTER TYPE...
  • Page 3 V. MAINTENANCE (Continued...) V7-B. Power Unit - Hydraulic Fluid. When adding or changing hydraulic fluid APE uses only Mobil 224 Hydraulic Vegetable oil which is non-toxic and will not harm oil or water and is biodegradable. Consult your local oil supplier for recommendations on mixing hydraulic oils.
  • Page 4 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 V. MAINTENANCE (Continued...) V-7E. Power Unit - Changing Hydraulic Return Filter Element. The hydraulic return filter is mounted on the hydraulic tank inside the power unit. It is mounted high on the tank so that when the filter element is removed the oil will not drain from the hydraulic tank.
  • Page 5 "A" is de-energized. Because of the high oil flow in the drive circuit, APE, Inc. has developed a circuit that eliminates high shock loads. Small internal components located in the drive manifold provide a soft shift feature for the drive directional control valve.
  • Page 6 MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-1C. Cooling and Flushing Filter. The cooling circuit pumps oil through the oil cooler and then through the return filters. This system is called the "Kidney Loop"...
  • Page 7 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) ITEM DESCRIPTION 1 Filter Element AE-25 2 Breather Element 3 6" Sight Gage L/D G607-06-A-1-4 4 30"...
  • Page 8 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-1E. Hydraulic Schematic. Page Page Copyright © 2023 American Piledriving Equipment, Inc. All Rights Reserved...
  • Page 9 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 475 POWER UNIT (Continued...) VII-1G. Hydraulic Components (Continued...) Hydraulic Components - Clamp / Drill Manifold 523002A Drain Clamp Open...
  • Page 10 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII-1G. Hydraulic Components (Continued...) Hydraulic Components - Clamp / Drill Manifold 523002A (Continued...) Clamp / Drill Manifold - Rear View...
  • Page 11 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) Hydraulic Components - Drive Manifold 513028A Dr. Rev. Dr. Fwd. Forward Rev.
  • Page 12 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) Hydraulic Components - Drive Manifold 513028A (Continued...) Drive Manifold - Rear View...

  • Page 13: Item Description

    OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) Hydraulic Components - Pump Drive and Pumps ITEM DESCRIPTION APE P/N DURD12463 2-PAD GEARBOX...
  • Page 14 (2) 8 ounces The pump drive used on the APE power units has three areas that require lubrication. The main gearbox takes about 84 ounces of oil. A gallon of oil is 128 ounces, so 88 ounces is just under 3/4 gallon.
  • Page 15 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-1G. Hydraulic Components - Hose List DESCRIPTION USED FOR F471TC0606-4-4-4-139 1/2 DRIVE FWD AND REV GAUGE...
  • Page 16 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-1G. Hydraulic Components - Fittings List ITEM DESCRIPTION FUEL TANK AND FUEL INLET FITTINGS 16 HHP-S 1"...
  • Page 17 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-1G. Hydraulic Components - Fittings List ITEM DESCRIPTION DRIVE MANIFOLD 513028A W48-32-32-U ALLENS...
  • Page 18 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-1G. Hydraulic Components - Fittings List ITEM DESCRIPTION HAND PUMP 20-20-GTX-S SCH 40 1 1/4 X 4LG...

  • Page 19: Main Control Panel

    OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-2. Electrical Controls ELECTRICAL CONTROL & GAUGES PENDANT HYDRAULIC MAIN CONTROL CONTROL...
  • Page 20 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) Page 7-15 Copyright © 2023 American Piledriving Equipment, Inc. All Rights Reserved...
  • Page 21 MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-2. Electrical Controls: (Understanding How They Work) The Main Control Panel(located behind one of the doors on the left side of the Power Unit) contains all of the equipment necessary to Start, Control, and Monitor the Engine, as well as control the Vibro functions.
  • Page 22 MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-2F. Murphy “Engine Coolant Temp” gage The Engine Coolant Temperature Gage is located on the door of the Main Control Panel. A high cutoff switch is located in the Murphy “Engine Coolant Temp”...
  • Page 23 MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-2L. Engine Control Switch “OFF-ON-START” The Engine Control Switch is located on the front of the control panel, and is used to start and stop the diesel engine, as well as control power to all other electrical equipment on the power unit.
  • Page 24 MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-2O. Clamp Control Switches (“OPEN-off-CLOSE”) (Continued...). 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”...
  • Page 25 MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-2P. Drive Control Switches (“FORWARD/off/REVERSE”) Drive Control Switches can be found on the Main Control Panel, the Hand Held Pendant, and/or the Radio Transmitter.
  • Page 26 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) This page intentionally left blank. Copyright © 2023 American Piledriving Equipment, Inc. All Rights Reserved...
  • Page 27 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) Page 7-19 Page 7-22 Copyright © 2023 American Piledriving Equipment, Inc. All Rights Reserved...
  • Page 28 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-2R. Electrical Schematic with Pendant Control Page 7-20 Page 7-23 Copyright © 2023 American Piledriving Equipment, Inc. All Rights Reserved...
  • Page 29 It could be burnt out or shorted. Check clamp pressure gauge and make sure it reads at least 3800 psi before vibrating any pile. Contact APE if light is not working. FORWARD/OFF/REVERSE Three position switch. Turn to forward to operate vibro. Turn to off to stop vibro.
  • Page 30 MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) VII-3A. Remote Pendant Wiring Diagram The following is the pin wiring configuration and the wire colors of the amphenol connectors for the remote control pendant cable.
  • Page 31 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 VII. MODEL 475 POWER UNIT (Continued...) Engine Connector Wiring Page 7-23 Page 7-26 Copyright © 2023 American Piledriving Equipment, Inc. All Rights Reserved...

  • Page 32: Appendix A - Cat C13 Engine

    CAT C13 ENGINE A-1. ENGINE OPERATION INSTRUCTIONS The following sections are basic instructions for maintenance and operation of the APE Model475 Power Unit Engines. All maintenance should be performed by qualified personnel who are familiar with the equipment. (Consult the factory for additional information.) A-1A.
  • Page 33 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 - APPENDIX A - CAT C13 ENGINE A-1B. STARTING THE ENGINE. CAUTION: Do not engage the starter when the flywheel is moving.
  • Page 34 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 - APPENDIX A - CAT C13 ENGINE A-1. OPERATION INSTRUCTIONS. (Continued...) A-1C. ENGINE OPERATION. After the engine starts, and at frequent intervals while the engine is operating, the gauges should be observed.
  • Page 35 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 - APPENDIX A - CAT C13 ENGINE A-1C. ENGINE OPERATION (Continued...) -Water Temperature Gauge If the temperature gauge reading registers in or near the cold range (white) while operating under load: 1.
  • Page 36 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 - APPENDIX A - CAT C13 ENGINE A-1C. ENGINE OPERATION (Continued...) Altitude Operation The fuel system settings and altitude limits are stamped on the engine information plate.
  • Page 37 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 - APPENDIX A - CAT C13 ENGINE A-1C. ENGINE OPERATION (Continued...) Starting The Engine 1. Perform all prestart checks outlined previously.
  • Page 38 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 - APPENDIX A - CAT C13 ENGINE A-1D. Determining Cause Of Shutdown CAUTION: If the engine has been shutdown by a safety device, don't start the engine and...
  • Page 39 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 - APPENDIX A - CAT C13 ENGINE A-1D. Determining Cause Of Shutdown (Continued...) High Water Temperature Checks-Engine Running 1.
  • Page 40 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 - APPENDIX A - CAT C13 ENGINE A-2. MAINTENANCE RECOMMENDATIONS CAUTION: Never add coolant to an overheated engine; allow the engine to cool first.
  • Page 41 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 - APPENDIX A - CAT C13 ENGINE A-2. MAINTENANCE RECOMMENDATIONS (Continued...) Fuel CAUTION: Fill fuel tank at the end of each day of operation to drive out moisture laden air and to prevent condensation.
  • Page 42 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 - APPENDIX A - CAT C13 ENGINE A-2. MAINTENANCE RECOMMENDATIONS (Continued...) A-2B. FUEL SPECIFICATIONS No. 2 fuel oil and No. 2D diesel fuel are recommended for use in Diesel Engines. In extreme cold temperatures use No.
  • Page 43 OPERATION / MAINTENANCE MANUAL MODEL 475 POWER UNIT 7032 SOUTH 196th - KENT, WA. 98032 - (253) 872-0141 / FAX (253) 872-8710 CAT C13 ENGINE A-2. MAINTENANCE RECOMMENDATIONS (Continued...) A-2D. LUBRICATION AND MAINTENANCE The LUBRICATION AND MAINTENANCE CHART lists all serviceable items commonly ordered on this engine.
  • Page 44 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 MODEL 475 POWER UNIT 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5...
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  • Page 46 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 MODEL 475 POWER UNIT 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5...
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  • Page 55 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 NOISE LEVEL OF APE MODEL 475 POWER UNIT 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8...