Dawson EMV-70 METRIC User manual

www.dcpuk.com
INNOVATION
PILING
EQUIPMENT
www.dcpuk.com
EMV-70 METRIC
EXCAVATOR MOUNTED VIBRATOR
HYDRAULIC PILING HAMMERS
EXCAVATOR MOUNTED
VIBRATORS
EXCAVATOR MOUNTED DRILLS
QUIET, VIBRATIONLESS
PUSH-PULL PILING
PILE EXTRACTION
SHEET PILE GUIDE FRAMES
SHEET PILE
CAPPING SYSTEMS
CFA CLEANERS
PILE POINTS
& SPLICERS
HANDLING / LIFTING
OPERATORS INSTRUCTIONS &
SPARE PARTS LIST
(Serial No.70-056 onwards)
EMV70v8 METRIC HOSE KIT

January 2013 v8
DAWSON CONSTRUCTION PLANT LIMITED
EMV 70
OPERATORS INSTRUCTIONS
& SPARE PARTS LIST
PART No. 070.000.00.00
(Serial no.70-051 onwards)

CONTENTS
1.0 EC Declaration of Conformity
2.0 Introduction
Figure 1 – Basic Technical Specifications
2.1 Basic Safety Points
2.1.1 Who is responsible?
2.1.2 Working conditions
2.1.3 Working near underground obstacles
2.1.4 The Danger Area
2.1.5 Transporting the Vibrator
2.1.6 Transporting piles on site
3.0 How does the EMV70 work?
4.0 Mounting Instructions
4.1 Mounting the Vibrator
4.2 Hydraulic hoses - layout and connections
5.0 Operating Instructions
5.1 Preparations – before driving/extracting piles
5.2 Driving piles
5.3 Extracting Piles
6.0 Maintenance
6.1 Daily Maintenance
6.2 Every 50 working hours
6.3 Every 1000 working hours
7.0 Trouble Shooting
7.1 EMV clamp does not close
7.2 EMV clamp closes but the unit will not vibrate
7.3 Unit will not run at the correct speed – “jumps around” or speed fluctuates
7.4 Oil blowing out of the motor blow-off valve
7.5 Oil blowing out of the gearbox breather valve & the box is full of oil
7.6 Clamp closes itself immediately after being opened
7.7 Clamp looses grip on the pile
8.0 Hydraulic Metric Hose and Fitting List – for the EMV70
9.0 Parts Lists for the EMV70,

Dawson Construction Plant Ltd
Chesney Wold, Bleak Hall, Milton Keynes MK6 1NE, ENGLAND
Tel: [phone] Fax: [phone]
E-Mail: [e-mail] Website: www.dcpuk.com
Certificate
Declaration of Conformity
We declare that the machinery/equipment detailed below is in compliance with
the applicable regulations and harmonised standards as listed. This
declaration ceases to be valid if alterations are made the
machinery/equipment without agreement with Dawson Construction Plant Ltd.
Category Piling Equipment
Type EMV 70
Serial Number 70-056
Year of Manufacture 2013
Power kW 12
Relevant Regulations:
2006/42/EC Machinery Directive
2000/14/EC Noise emission in the environment -
Measured sound power level on machines representative of this type: 107 dB (A)
Applied conformity assessment procedure according to Annex VIII
Technical documentation archive location: MK6 1NE
Applied harmonised standards, in particular:
EN 12100-1:2003 Safety of machinery. Basic terminology and
methodology
EN 12100-2:2003 Safety of machinery. Technical principles
EN 996: 1995 Piling equipment – Safety requirements
Signed by on behalf of DCP
Name / Position __________________/__________________
Date ____________________________________
Dave Brown Director
23-10-2014

1.0 INTRODUCTION
The Excavator Mounted Vibrator (EMV) attachment is a perfect tool for readily converting any
suitable size of excavator into a highly productive pile driving machine.
Piles can be lifted from a stack on the ground, engaged into a powerful hydraulic grip then
positioned at will on a job site for vibrating and pushing into the ground. If the pile line is incorrect
or the position inaccurate then simply pull the piles back out.
This ability to drive and extract sheet piles has made the unit particularly attractive to utility
contractors where temporary sheet pile shoring has to be driven before excavation can commence.
Following completion of the utility installation or repair and trench backfill the excavator can be
quickly converted to a pile extractor to remove the sheets.
Once removed the sheet piles can be easily and safely laid down on the ground in a controlled and
safe manner.
The EMV70 product is extremely versatile and readily adapts to most suit excavators from 5.5 to
17 tonnes, and with care up to 22 tonnes. Hydraulic power supply is taken from the excavators
bucket ram circuit providing adequate power is available. Other than the addition of a small drain
line directly back to the excavators tank there are no other special modifications to the base
machine and no electrical system is required. The operator uses standard controls.
Maximum pile lengths are determined by excavator boom length but typical pile lengths are up to
7m (25’) or more.
The contents of this manual are intended to give guidance on the installation, safe use and
maintenance of the EMV product. It is not intended to be an exhaustive detailing of the
manufacturers detailed knowledge of the product. Technical advise on this product is available
through the manufacturer and their network of worldwide distributors.
Further training with Dawson Construction Plant Ltd can be provided as required. Please contact:
Dawson Construction Plant Ltd
Chesney Wold
Bleak Hall
Milton Keynes
England
MK6 1NE
Tel : [phone]
Fax: [phone]
Email: [e-mail]

ADE
B
C M I N . P I L E W I D T H
F
G
H MAX PILE THICKNESS
DIMENSIONS A B C D E F G H
mm 445 130 275 431 431 850 1120 40
in 17.5 5.1 10.8 17 17 33.5 44 1.5
EMV70 EXCAVATOR MOUNTED VIBRATOR
BASIC TECHNICAL SPECIFICATIONS
SPECIFICATIONS EMV70
UNITS METRIC US
STATIC MOMENT 0.7 kgm 60 in Ibs
FREQUENCY 3,000 rpm
CENTRIFUGAL FORCE 70 KN 15,730 lbs.F
AMPLITUDE 4 mm 0.157 in
MIN. HYDRAULIC FLOW RATE 30 L/min 8 gpm
MAX. HYDRAULIC FLOW RATE 120 L/min 32 gpm
MAX. HYDRAULIC PRESSURE 350 bar 5,076 psi
MIN. HYDRAULIC POWER 12 kW 16 hp
DYNAMIC MASS 355 kg 781 lbs
TOTAL MASS 510 kg 1,122 lbs
MAX. PILE MASS 800 kg 1,760 lbs
MAX. PUSH/PULL FORCE 2,800 kg 6,171 lbs
CLAMP FORCE 30 tonne
EMV70

2.1 Basic Safety Points
• The vibrator should only be operated by suitably qualified personnel.
• There should be visual contact between operator and slinger (spotter) at all times.
• Monitor the piling operation constantly – interrupt the process immediately if any danger
occurs.
• Do not operate the vibrator if any person is within the Danger Area – see section 2.1.4.
• Consider machine stability at all times.
• The operator should inspect the equipment for defects every day and before being taken
into service. Any defects that affect operational safety should be corrected before the
equipment is taken into service – see section 5.
• Pay attention to the Safe Working Load of all lifting accessories at all times.
• The working area should be properly illuminated.
• Work safely at all times and within the requirements of all local legislation.
• The vibrator can become very hot during operation – do not touch it unless wearing
appropriate protective clothing.
2.1.1 Who is responsible?
Those who are in charge of, or responsible for, the use and maintenance must ensure
that the vibrator and all it's auxiliary equipment are in good condition.
Piling should only be carried out under the supervision of an appropriately qualified
and experienced person who can assess that the work is carried out safely.
The excavator operator must ensure that his communication signals are understood, by
those on the ground, and followed. During piling operations he must watch out for any
potential hazards.
2.1.2 Working Conditions
Vibrators should only be operated and driven on firm ground with clear visibility of the
working area and the process monitored constantly.
The vibrator stand must stay upright and horizontal (at all times) to avoid personnel
injury. Do not operate the vibrator if any personnel are within a 15m (50’) radius of
unit – The Danger Area.
2.1.3 Working near Underground Obstacles
Before the start of any piling work it is up to the contractor to find out if there are any
underground obstacles within the working area which could be dangerous to personnel.
In the case of unforeseeable contact or damage of an underground obstacle, then work
must stop immediately and the person in charge informed.

2.1.4 The Danger Area
This is an area defined as that being within a 15m(50’) radius of the vibrator.
Personnel are at risk when within this area from:
• Falling piles – should the pile be handled incorrectly
• Liquids under high pressure and associated components
• Mechanical failures of equipment components
• Noise – wear ear protection equipment when inside this area
• Unexpected overturning of the excavator
2.1.5 Transporting the Vibrator
When transporting the vibrator, ensure it is placed correctly in the stand.
Once in place on the stand the jaws must be closed. Release the hydraulic hoses from
the excavator (the hard jaws will remain closed) and cap the hose ends to prevent
contamination. Disconnect the vibrator from the excavator.
2.1.6 Transporting Piles on Site
Transporting a pile using the vibrator should only be done over a small distance, with
the clamp fully engaged on the pile top and with the lifting chain fitted. Should the
grip on the pile be reduced during this procedure, the excavator must stop, and a better
grip effected. Should a pile slip then the lifting chain could snap and cause an accident.
When transporting a pile extreme care must be taken to ensure that no one is in the
Danger Area and that the pile is handled in such a way as to ensure no danger to site
personnel at any time.
In order to avoid extensive transporting, have the piles laid out as close to the point of
installation as possible. Do not use the excavator with the EMV70 installed to handle
bundles of piles around the job site.

3.0 HOW DOES THE EXCAVATOR MOUNTED VIBRATOR WORK?
Modern pile vibrators basically work in the same way. Pairs of high-speed contra-rotating
eccentric weights are geared together so as to produce net vertical vibratory forces.
The vibrations produced are transmitted to the pile through a powerful hydraulic grip.
Consequently the pile is vibrated at the same speed and displacement (or movement) as the gearbox
itself. This vibration effect is transmitted to the pile tip where the surrounding soils become almost
fluid like.
The fluidising effect on the soil permits particles to shuffle themselves around creating some spaces
for the pile to move into. This combined with the weight of the pile and vibrator is adequate to
push the pile into the ground.
Not all soil types will however fluidise. Clays soils are very cohesive and extremely dense by
comparison to sands and gravels where vibrators work best. The dense clay soil does not allow soil
particles to shuffle them selves around so no fluidising effect can occur. Also the ground
effectively sticks itself to the pile and much of the power generated is lost in shaking the ground.
The EMV is particularly effective for its size and weight because it is able to utilise the crowd force
available from the excavator to add further push force to the pile.
The gearbox in the EMV unit is driven by a hydraulic drive motor that receives hydraulic power
from the excavators bucket ram circuit. Typically this circuit will be able to supply adequate
working pressure but excessive amount of oil flow rate. The EMV has a built-in flow regulator that
limits the oil flow rate supplied to the drive motor so that the gearbox can not be run too fast. This
is essential to prevent excessive bearing loads and correct performance of the unit.
In addition, the flow regulator has a sequence valve built-in that will not allow the vibrator to run
until adequate clamping force has been applied to the pile – an essential safety feature. This
simplified hydraulic system enables simple installation and reliable performance.
Flow Re
g
ulator
and Sequence
Valve
Hydraulic
Drive Motor
Transport
Stand
Saddle
Assembly
with Swivel
Gearbox
containing
eccentric
wei
g
hts

4.0 MOUNTING INSTRUCTIONS
NOTE: The excavator hydraulic power output must be matched to the requirements of the vibrator
before installation. A standard excavator enquiry sheet is available for the user to
complete prior to considering the suitability of the excavator for use with the EMV70.
4.1 Mounting the Vibrator
The vibrator is mounted in place of the excavator's bucket, and should be allowed to
hang freely once installed. Remove the bucket prior to installing the EMV.
A shear pin is used to fix the vibrator to the boom via an adaptor bracket. Different
adaptor brackets may be required for different excavators. Check this prior to the start
of installation. If the excavator is fitted with a quick hitch it will either be necessary to
remove it or purchase half a quick hitch and modify to suit the Dawson adaptor bracket.
Standard brackets are available for different machine size ranges. Typically, one of
these brackets can be adapted to fit a variety of different pin sizes and dipper end
widths by using a kit of bushes and spacers.
SECTION THROUGH BOOM END
Ada
p
tor Bracket
Spacers
Bushes
Shear Pin

4.2 Hydraulic Hoses - Layout and Connections
The EMV hydraulic fittings are metric for the EMV70. The pressure and return lines
(already connected to the vibrator) have metric 16 S. The pressure line is usually
connected to the bucket ram "extend" circuit and the return line to the bucket ram
“retract” circuit. The third, and smaller, drain line is fed either directly back into the
hydraulic tank on the excavator, or connected to the breaker circuit return line. The
fitting on the drain line connected to the vibrator is a metric 12 L male fitting.
Excavators will rarely have the same fittings as these on their bucket circuit so adaptor
fittings must be used.
Ensure all hydraulic connections are clean prior to fitting and that no contamination is
introduced into the hydraulic circuit during installation – this may cause internal
component damage to the hydraulic system or faulty operation of the vibrator or
excavator.
If quick release couplings are installed on the excavator they should be replaced. It is
strongly recommended that quick release couplings are not used for this application.
For permanent installation ball valves can be added to the excavator boom to ensure
rapid changing between bucket and EMV hydraulic function. As the bucket ram is no
longer in use, it should be retracted and fastened down.
WARNING: THE DRAIN LINE MUST FLOW DIRECTLY TO TANK
WITHOUT RESTRICTION. FAILURE TO DO SO WILL RESULT IN THE
HYDRAULIC DRIVE MOTOR BLOWING ITS CASING SEAL OR FRONT
CASING CASTING – THIS DAMAGE IS VERY COSTLY TO REPAIR.
The EMV is fitted with a motor case blow-off valve. This valve is effectively a check
valve that vents some oil to atmosphere should the motor case drain line pressure
exceed approximately 6 bar. It is not a pressure protection valve and is intended only
as an early warning valve, giving a visual signal that something is wrong. Any sign of
this and use of the EMV should be halted immediately and the cause investigated.
The blow-off valve does not guarantee the motor will be protected in all
circumstances!
Connect to
bucket ram
extend hose
Connect to
bucket ram
retract hose
Connect
drain line
directly to
excavator
tank!

5.0 OPERATING INSTRUCTIONS
5.1 Preparations – before driving/extracting piles.
It is the excavator operator's responsibility to ensure that the equipment is functioning
and performing correctly and that the EMV method of piling is implemented efficiently.
In order to meet this responsibility please note the following points:-
a. Bundles of sheet piles should be set out on the job site so as to minimise the
amount of handling and travelling required with the EMV.
b. Ensure that all piles have ∅40mm(∅1É”) holes cut in them approximately
250mm(10”) down from the top edge prior to commencement of the piling
operation.
c. Allow the excavator engine to warm up, particularly in temperatures below
minus 10°C and warm the excavators hydraulic system by, for example,
tracking backwards and forwards – this avoids the EMV’s blow-off valve
spitting oil on initial start-up.
d. Before work commences slowly operate the bucket ram lever in both
directions. It is particularly important that the vibrator is allowed to run
freely for approximately 30 seconds, this allows the gearbox oil to reach all
the necessary lubricating points.
e. Review section “2.1 Basic Safety Points” in this manual before starting
work.
f. Review section “6.1 Daily Maintenance” before taking the equipment into
service.
g. It is particularly important that you make sure that during a piling operation
the vibrator is kept directly above and in line with the pile, otherwise the
piling energy is transferred to the excavator arm and causes unnecessary
wear and may lead to pile damage.
5.2 Driving Piles
a. Ensure that all safety procedures and maintenance has been carried out before
starting the excavator – see section 5.1.
b. Ensure that it is safe to move the dipper arm. Release the stand from the jaws of
the vibrator by operation of the retract bucket ram control function in the cab.
Manoeuvre the vibrator above one end of the pile to be pitched, so that there is
enough distance to allow safe insertion of the lifting chain through the hole at the
top of the pile.
c. Check which way around the pile has to be lifted before inserting the lifting chain
– was the previous pile pitched left or right handed? Insert the lifting chain
correctly (no twists, knots etc) through the lifting hole in the pile and finally with
the chain clamp. Allow enough free chain length for the pile to rotate to vertical
during the lifting process without jamming against the underside of the clamp
body. If this happens the chain will be overloaded, may subsequently break and
allow the pile to fall – this is a sever hazard to all site personnel and must be
avoided at all times. Do not allow too much chain so that the top of the pile

hangs too far away from the clamp when it is raised to the vertical – this will
make it difficult to engage the pile in the clamp.
d. Clear all personnel standing in the Danger Area and lift up the pile until it just
hangs freely off the ground.
e. Lower the pile slowly so that the pile can be correctly inserted into the clamp.
Once firmly inserted, close the jaws.
f. Manoeuvre the pile to the insertion point and push the pile slowly into the ground.
Plumb the pile and ensure all personnel are out of the Danger Area.
g. Start the vibrator and adjust (crowd) the hydraulic rams so that the vibrator is level
and always sits directly on top of the pile as it goes into the ground. Do not over
push the vibrator - stop pushing when the gearbox starts to vibrate against the
rubber stops on the underside of the saddle. With the EMV70 the deflection is
146mm (5.75”).
h. When the pile has reached the required depth turn the vibrator off by returning the
control lever to the central position and allow all vibrations to stop. Release the
hard jaws from the pile by slowly operating the control lever in the opposite
direction. Do not operate the control lever from one extreme position to the other
whilst the EMV is running – it will cause hydraulic system pressure spikes to
occur.
i. Remove the chain clamp and lifting chain from the pile lifting hole.
j. Repeat steps b-j to continue.
k. When piling progress is less than 100mm/min (4ins/min) release ground
resistance by augering or by water jetting. Under no circumstances should the pile
be forced any further.
5.3 Extracting Piles.
a. Ensure that all safety procedures and maintenance has been carried out before
starting the excavator – see section 5.1.
b. Ensure that it is safe to move the dipper arm. Release the stand from the jaws of
the vibrator by operation of the retract bucket ram control function in the cab.
Manoeuvre the vibrator above one end of the pile to be extracted so that there is
enough distance to allow safe insertion of the lifting chain through the hole at the
top of the pile.
c. Insert the lifting chain correctly (no twists, knots etc) through the lifting hole in
the pile and secure with the chain clamp. Allow enough free chain length for the
pile to rotate to horizontal during the lowering process without jamming
against the underside of the clamp body. If this happens the chain will be
overloaded, may subsequently break and allow the pile to fall – this is a sever
hazard to all site personnel and must be avoided at all times. Under no
circumstances should a pile be pulled using the lifting chain only.

d. Clamp the vibrator onto the pile head ensuring that it is level. Ensure all
personnel are out of the Danger Area.
e. Start the vibrator and allow the soil to loosen around the pile. Start to lift up the
pile. Ensure the pile clutches are not rubbing together. Pay attention to the
distortion of the rubber sandwich mounts - under no circumstances should these
mounts be allowed to deflect by more than the stipulated amount shown on Figure
1 in section 2.0. Reduce the extraction force to continue pulling. Continue
extracting the pile until the pile foot is almost extracted. Stop vibration at this
point and carefully pull the pile out the remaining short distance.
f. Move the pile to a suitable area, and place the pile on the ground. Ensure that all
personnel are out of the Danger Area.
g. Hold the pile on the ground and release the jaws. Raise the vibrator off the pile
slowly ensuring that there is no snatch on the lifting chain. Slowly lower the pile
towards the ground.
h. Remove the chain clamp and lifting chain from the pile lifting hole.
i. Repeat steps b-i to continue.
RUBBER SANDWICH MOUNTS
MAXIMUM DEFLECTION OF SANDWICH MOUNTS
IS ACHIEVED WHEN THE FASTENERS ARE IN LINE
AS SHOWN
MAXIMUM PULL = 7,500kg

6.0 MAINTENANCE
The Excavator Mounted Vibrators have been designed to give years of trouble free service.
Providing the equipment is treated with respect and the basic maintenance procedures are adhered
to there will be little work additional work required.
The most important points are correct installation on good quality excavators, cleanliness when
connecting to the excavator’s hydraulic system and regular gearbox oil changes using appropriate
oils - again cleanliness is paramount.
Visual inspection of the EMV by a competent person on a daily basis and before being taken into
service can prevent many potential problems from occurring. Ensure that lifting accessory test
certificates are correct and valid at all times.
• All service and maintenance work must be carried out by qualified personnel using
original Dawson parts. The use of other parts will invalidate the whole warranty for the
equipment.
• The equipment should be inspected at ground level only and should be positioned so as
to be stable at all times.
• Secure the equipment against unexpected starting during the maintenance process.
• The equipment should be inspected by a Dawson technician or by one of their approved
distributors once a year or every 1000 working hours.
6.1 Daily Maintenance.
a. Grease the two grease points on the EMV70 – one on the Saddle Swivel and the
other on the side of the Clamp Body. Two or three pumps with a molybdenum-
based grease will be adequate.
b. Check visible screws, bolts, fittings etc for tightness.
c. Visually inspect all hydraulic hoses and fittings for leaks or damage.
d. Check the gear oil level in the vibrator. The level must be half way up the sight
glass.
e. Inspect the lifting chain and chain clamp for damage. The chain should be in
good order, free from any structural damage or permanent deformation of any
kind. The chain clamp should also be free from any structural damage and its
correct operation and safe function should be checked by depressing and releasing
several times – any binding or hesitancy with its operation should result in it being
changed for a new certified item. The chains Coupler and anchorage point should
be in good order showing no signs of damage, wear or cracking. Remember if in
doubt change it – Chains, Chain Clamps & Couplers require new test certificates
to be recorded when changed!
f. Inspect the condition of the Hard Jaws. To be acceptable these should look to
be in almost as new condition. The teeth on these pads have some flats on them
when new (approximately 1mm). Over time they will round off, flatten out more
and even become chipped. If not changed when required they will loose their grip

on the pile during driving and certainly during extraction. Besides causing a
reduction in performance this can become a safety hazard. We define the
following wear limit:
Hard Jaw Wear Limit - 90% of all teeth on any hard jaw should make contact
with the pile and 80% of all teeth should have points
with flats no greater than 3mm.
Changing the Hard Jaws – Static Side
Remove the Cap Screw that hold this jaw in place. Tap out the old jaw and clean/inspect the clamp
body seating area to ensure the faces are in good order. Slide in the new jaw and check that it is a
snug fit – the jaw should not move up and down. Fit the Cap Screw and tighten using a hexagonal
wrench. Remember to install the washers on these screws.
Changing the Hard Jaws – Moving (Cylinder) Side
Release the 8off Cap Screws that hold the Clamp Cylinder in place and remove the Clamp
Cylinder. Undo the two clamp supply hoses, carefully marking them to ensure correct re-assembly.
Once removed, unscrew the round Hard Jaw counter-clockwise and replace with a new one using a
new O-ring. Ensure the Jaw is fully tightened on the Clamp Cylinder piston rod so that the O-ring
is no longer visible. Inspect the bronze Guide Bush inside the Clamp Body whilst the cylinder is
out – check the grooves in the front area of the bush and the condition of the bore. Replace the
bush if badly worn.
Assemble the Clamp Cylinder back into the Clamp Body, fit the clamp hoses then fit and tighten
the Cap Screws using the hexagonal wrench. Ensure the clamp functions correctly after completing
the work.
g. Inspect the rubber Sandwich Mounts (Elastomers) for wear or damage. Wear
is typified by splitting/tares. This usually occurs in the rubber adjacent to the
bonded steel plates and is usually a result of fatigue in the material over a long
period of time. Crazing/softening may occur but this is usually associated with
long term exposure to sunlight or exposure to petroleum based products. As a
general rule change the Sandwich Mount if any single tare or split exceeds 40mm
(1É”) or if the rubber has become contaminated.
h. Check the overall condition of the Swivel Assembly. Check that the Lifting
Bolt and Nut (that are the centre piece of this assembly) only allow rotational
movement with minimal axial movement. Excessive axial movement will allow
the assembly to rattle around, make more noise and cause in turn more wear. If
the axial play exceeds 1mm it will be necessary to tighten the nut. To do this
remove the coil/spring pin with a punch and hammer, tighten the nut further and
drill and pin it in the new position.
i. Check the condition of the boom Adaptor Bracket, Shear Pins, Spacers and
Bushes. The whole assembly should be relatively tight with minimal play in the
components. The bracket needs to be able to float a little from side to side – as
much as 5/10 mm is acceptable. The pins and bushes should however be little
more than a running fit – clearances of more than 0.5mm would be considered
excessive.

Clamp Body
Grease Point
– for the
Movin
g
Jaw
Gearbox Oil
Drain Plug
Breather/Filler
Plug
Swivel
Assembly
Lifting
Chain &
Chain
Clamp
Clamp
Cylinder
Hard Jaws
Base View
Side View

6.2 Every 50 working hours
Change the oil in the vibrator gearbox. Remove the Drain Plug from the bottom of the
gearbox and the Breather/Filler Plug from the top. Allow the oil to drain out
completely into a suitable container – this is best done at the end of a shift when the oil
is relatively warm and thin. Replace the Drain plug and fill with new clean oil through
the Breather/Filler hole until the oil level in the gearbox is approximately half way up
the sight glass – this is approximately 4 litres (1.05 US gallons).
Re-fit the Breather/Filler Plug using a new seal and tighten.
The old oil must be taken to a certified waste disposal centre or handed over to a
certified waste disposal contractor.
Generally any good quality mineral based gear oil in the class API GL-5 with viscosity
class SAE 75W/90 will be suitable. Alternatively, in hotter climates fully synthetic oil
of the same classification may be used. For example:
Manufacturer Mineral Oil Reference Synthetic Oil Reference
BP ENEGEAR HT 75W/90
MOBIL MOBILUBE 1 SHC
CASTROL SAF-EXB
ELF TRANSELF B 75W/90 TRANSELF TR2 75W/80
TEXACO GEARTEX EPC80W/90 GEARTEX 5S 75W/90
Note: Maximum ambient operating temperature for the unit +40ºC
Minimum ambient operating temperature for the unit –20ºC
6.3 Every 1000 hours
It is recommended that the unit be inspected and serviced by the manufacturer. Apart
from undertaking to do the relevant preventative maintenance work and checks as
described above Dawson will inspect the structural integrity of the equipment and
ensure there are no safety related matters that may go unchecked. Bearings and gears
will also be inspected to check for signs of unusual wear or potential problems. In
some countries it is a requirement by law that the unit be inspected by qualified
personnel.

7.0 TROUBLE SHOOTING
Please ensure that troubleshooting, inspection work and repairs are undertaken by suitably qualified
personnel. Training can be carried out by the manufacturer or by your local approved Dawson
distributor. The following guidelines are intended to assist with basic diagnostics and are not
intended to be a definitive list – it assumes the inspector has a basic understanding of servicing
techniques associated with this type of equipment. Work should not be undertaken by a novice
without adequate supervision.
7.1 EMV clamp does not close
7.1.1 Check that base machine hydraulics lines are correctly connected – see
section 4.2. Operate control lever in both directions to check flow
directions.
7.1.2 Remove the check valve cartridge from the rear of the clamp cylinder and
inspect for contamination or damage. The poppet inside the cartridge should
move freely. If in doubt replace and use new seals.
7.1.3 Independently check the operation of the clamp cylinder with it removed
from the hydraulic circuit. This should only be carried out by a competent
person.
7.1.4 Remove the cylinder and inspect for mechanical damage inside the clamp or
inside the cylinder.
Pilot
Operated
Check Valve

7.2 EMV clamp closes but the unit will not vibrate
7.2.1 Check the base machine operating pressure and flow rate. If the pressure
output of the excavator is too low the EMV will not run at all. This is
because the sequence valve pressure setting has to be overcome before oil
can pass to the drive motor.
7.2.2 Check the sequence valve setting by installing a pressure test gauge in the
clamp close line and monitoring the pressure at which the valve opens.
Ensure this is set to 165 bar.
7.2.3 Damaged sequence valve – remove and inspect but replace if in doubt using
new seals.
7.2.4 Motor failure or gearbox problem. Try connecting the two main oil supply
lines directly to the hydraulic motor ports and running the unit with low
engine speed – effectively low oil flow rate. Caution - it will be easy to
over-speed the motor in this case because the flow regulator is now out of
the circuit.
7.2.5 If the unit does not vibrate either the motor has become damaged or there is a
fault with the gearbox. Check the oil level in the gearbox to see that it has
not become filled with hydraulic oil from the motor shaft seal – in this case
the unit usually runs very slowly unless metal fragments have become
entrapped in the transmission system as a result.
7.2.6 Remove the motor from the gearbox and test.
7.2.7 As a last resort take the saddle assembly off the EMV and remove the
gearbox lid for an internal inspection. The gears, shafts and bearings should
rotate freely. Caution - pay attention to trapping body parts in the
mechanism during inspection!
7.2.8 Consult the manufacturer from section 7.2.5 onwards.
7.3 Unit will not run at the correct speed – “jumps around” or speed fluctuates.
7.3.1 Check that the base machine hydraulic output complies with the minimum
specified for the unit. Specifically check with the excavator
supplier/manufacturer what system pressure is available on the bucket ram
circuit at 90 l/min.
7.3.2 Check the setting of the flow regulator to ensure adequate flow is reaching
the drive motor.
7.3.3 Check the sequence valve pressure setting – see section 7.2.2. If this setting
is too close to the operating pressure the EMV will speed up then slow
down, speed up then slow down etc.
7.3.4 Check the gearbox oil level. If it is much higher than the sight glass the
motor shaft seal has probably blown – see section 7.4.
Sequence Valve
Cartridge with
Adjusting Screw
& Locknut
Flow Regulator
Cartridge with
Adjusting Screw
& Locknut