Dawson EMV-220 METRIC User manual
EMV-220 METRIC
EXCAVATOR MOUNTED VIBRATOR
OPERATORS INSTRUCTIONS &
SPARE PARTS LIST
220.000.00.00 EMV220v4 METRIC HOSE KIT
June 2015 v4
EMV 220
OPERATORS INSTRUCTIONS & SPARE PARTS LIST
PART No. 220.000.00.00
(Serial no.220-025 onwards)
1.0 EC Declaration of Conformity
2.0 Introduction
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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 EMV220 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
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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 EMV220
9.0 Parts Lists for the EMV220,
CONTENTS
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GENERAL NOTES
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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
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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 EMV220 product is extremely versatile and readily adapts to most suit
excavators from 7 to 22 tonnes, and with care up to 35 tonnes. Hydraulic power
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available. Other than the addition of a small drain line directly back to the excavators
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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.
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Please contact:
Dawson Construction Plant Ltd
Chesney Wold
Bleak Hall
Milton Keynes
England
MK6 1NE
Tel : +44 (0)1908 240300
Fax: +44 (0)1908 240222
Email: [email protected]
INTRODUCTION
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2.0
DIMENSIONS A B C D E F G H
mm 455 130 275 550 550 824 1094 40
in 17.9 5.1 10.8 21.6 21.6 32.5 43 1.5
SPECIFICATIONS EMV220
UNITS METRIC US
STATIC MOMENT 2.3 kgm 200 in Ibs
FREQUENCY 50 hz - 3,000 rpm
CENTRIFUGAL FORCE 220 KN 50,236 lbs.F
AMPLITUDE 12 mm 0.45 in
REQUIRED HYDRAULIC FLOW RATE * 90 L/min 24 gpm
MIN. HYDRAULIC PRESSURE 280 bar 4,060 psi
MAX. HYDRAULIC PRESSURE 350 bar 5,076 psi
MIN. HYDRAULIC POWER 50 kW 80 hp
DYNAMIC MASS 370 kg 814 lbs
TOTAL MASS 580 kg 1,276 lbs
MAX. PILE MASS 800 kg 1,760 lbs
MAX. PUSH/PULL FORCE 7,500 kg 16,500 lbs
CLAMP FORCE 26.5 tonne
TYPICAL EXCAVATOR WEIGHT 7 to 18 tonne 7.5 to 20 ton
ADE
B
C MIN. PILE WIDTH
F
G
H MAX PILE THICKNESS
E
M
V
2
2
0
D
A
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EMV220
* REQUIRED FLOW = MAX. FREQUENCY
MACHINE HAS INTEGRAL FLOW REGULATOR UPTO 250 L/min.
20
20
BASIC TECHNICAL SPECIFICATION
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FIG.1
EMV22
20
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• 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.
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before being taken into service. Any defects that affect operational safety
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section 5.
• Pay attention to the Safe Working Load of all lifting accessories at all times.
• The working area should be properly illuminated.
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• The vibrator can become very hot during operation – do not touch it unless
wearing appropriate protective clothing.
Those who are in charge of, or responsible for, the use and maintenance must
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Piling should only be carried out under the supervision of an appropriately
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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.
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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.
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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
BASIC SAFETY POINTS
2.1.1
WHO IS RESPONSIBLE?
2.1.2
WORKING CONDITIONS
2.1.3
WORKING NEAR
UNDERGROUND
OBSTACLES
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Personnel are at risk when within this area from:
• Falling piles – should the pile be handled incorrectly
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• Unexpected overturning of the excavator
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.
Transporting a pile using the vibrator should only be done over a small distance,
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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 EMV220
installed to handle bundles of piles around the job site.
2.1.4
THE DANGER AREA
2.1.5
TRANSPORTING THE
VIBRATOR
2.1.6
TRANSPORTING PILES
ON SITE
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
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movement) as the gearbox itself. This vibration effect is transmitted to the pile tip
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creating some spaces for the pile to move into. This combined with the weight of
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extremely dense by comparison to sands and gravels where vibrators work best.
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VRQRÀXLGLVLQJHIIHFWFDQRFFXU$OVRWKHJURXQGHIIHFWLYHO\VWLFNVLWVHOIWRWKH
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
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UDWH7KH(09KDVDEXLOWLQÀRZUHJXODWRUWKDWOLPLWVWKHRLOÀRZUDWHVXSSOLHGWR
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.
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WKHYLEUDWRUWRUXQXQWLODGHTXDWHFODPSLQJIRUFHKDVEHHQDSSOLHGWRWKHSLOH
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installation and reliable performance.
HOW DOES THE EMV WORK
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3.0
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no.1
Motion of a pair of eccentrics
Corresponding Sinusoide
no.2
Vibratory
Amplitude
Time
eccentric weight
gearbox
drive gear
direction of
motion
resulting
direction
of force
hydraulic drive motor
transport stands
gearbox
saddle assembly
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& sequence valve
NOTE:
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the user to complete prior to considering the suitability of the excavator for use
with the EMV220.
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.
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'LIIHUHQWDGDSWRUEUDFNHWVPD\EHUHTXLUHGIRUGLIIHUHQWH[FDYDWRUV&KHFNWKLV
SULRUWRWKHVWDUWRILQVWDOODWLRQ,IWKHH[FDYDWRULV¿WWHGZLWKDTXLFNKLWFKLWZLOO
HLWKHUEHQHFHVVDU\WRUHPRYHLWRUSXUFKDVHKDOIDTXLFNKLWFKDQGPRGLI\WRVXLW
the Dawson adaptor bracket.
Standard brackets are available for different machine size ranges. Typically, one
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end widths by using a kit of bushes and spacers.
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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
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PDOH¿WWLQJ([FDYDWRUVZLOOUDUHO\KDYHWKHVDPH¿WWLQJVDVWKHVHRQWKHLUEXFNHW
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MOUNTING INSTRUCTIONS
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4.0
4.1
MOUNTING THE VIBRATOR
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nation 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.
,ITXLFNUHOHDVHFRXSOLQJVDUHLQVWDOOHGRQWKHH[FDYDWRUWKH\VKRXOGEHUHSODFHG
,WLVVWURQJO\UHFRPPHQGHGWKDWTXLFNUHOHDVHFRXSOLQJVDUHQRWXVHGIRUWKLV
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.
7KH(09LV¿WWHGZLWKDPRWRUFDVHEORZRIIYDOYH7KLVYDOYHLVHIIHFWLYHO\D
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!
4.2
HYDRAULIC HOSES -
LAYOUT & CONNECTIONS
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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
UHWXUQOLQH7KH¿WWLQJRQWKHGUDLQOLQHFRQQHFWHGWRWKHYLEUDWRULVDPHWULF/
PDOH¿WWLQJ([FDYDWRUVZLOOUDUHO\KDYHWKHVDPH¿WWLQJVDVWKHVHRQWKHLUEXFNHW
FLUFXLWVRDGDSWRU¿WWLQJVPXVWEHXVHG
Connect drainline
directly to
excavator tank
Connect to bucket
ram retract hose
Connect to bucket
ram extend hose
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functioning and performing correctly and that the EMV method of piling is
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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
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b. Ensure that all piles have Ø40mm(Ø1½”) 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.
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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.
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.
OPERATING INSTRUCTIONS
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5.0
5.1
PREPARATIONS - BEFORE
DRIVING / EXTRACTING
PILES
5.2
DRIVING PILES
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
WKHSLOHDQG¿QDOO\ZLWKWKHFKDLQFODPSAllow 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
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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
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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
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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.
a. Ensure that all safety procedures and maintenance has been carried out
before starting the excavator – see section 5.1.
5.3
EXTRACTING PILES
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
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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
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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.
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gearbox casing hits the safety stops (100mm). When driving piles a maximum
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with the lower.
Safety stops
Lower fasteners
Top fasteners
146
The Excavator Mounted Vibrators have been designed to give years of trouble
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maintenance procedures are adhered to there will be little work additional work
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7KHPRVWLPSRUWDQWSRLQWVDUHFRUUHFWLQVWDOODWLRQRQJRRGTXDOLW\H[FDYDWRUV
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.
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$OOVHUYLFHDQGPDLQWHQDQFHZRUNPXVWEHFDUULHGRXWE\TXDOL¿HG
personnel using original Dawson parts. The use of other parts will
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7KHHTXLSPHQWVKRXOGEHLQVSHFWHGDWJURXQGOHYHORQO\DQGVKRXOG
be positioned so as to be stable at all times.
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maintenance process.
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one of their approved distributors once a year or every 1000 working
hours.
a. Grease the two grease points on the EMV220 – one on the Saddle
Swivel and the other on the side of the Clamp Body. Two or three
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F 9LVXDOO\LQVSHFWDOOK\GUDXOLFKRVHVDQG¿WWLQJVIRUOHDNVRUGDPDJH
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
MAINTENANCE
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6.0
6.1
DAILY MAINTENANCE
several times – any binding or hesitancy with its operation should result
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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
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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
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URXQGRIIÀDWWHQRXWPRUHDQGHYHQEHFRPHFKLSSHG,IQRWFKDQJHG
ZKHQ UHTXLUHGWKH\ZLOOORRVHWKHLUJULSRQWKHSLOHGXULQJGULYLQJDQG
certainly during extraction. Besides causing a reduction in performance
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Hard Jaw Wear Limit - 90% of all teeth on any hard jaw should
make contactwith the pile and 80% of all teeth should have
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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
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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.
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functions correctly after completing the work.
g. Inspect the rubber Sandwich Mounts (Elastomers) for wear or damage.
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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 (1½”) 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
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