MKT V-22/HP-365A User manual

MANUFACTURING, INC.
1198 PERSHALL RD.
ST. LOUIS, MO 63137
OPERATING, MAINTENANCE AND
PARTS MANUAL FOR
V-22/HP-365A
HYDRAULIC VIBRATORY PILE
DRIVER/EXTRACTOR SYSTEM
WITH CUMMINS ENGINE
OCCUPATIONAL HEALTH WARNINGS:
1. Construction equipment frequently operates at very high sound levels. Such sound levels
can be harmful to the human hearing system. Sustained exposure to such high sound
levels can permanently impair one's hearing. Hearing protection should be worn by
anyone and everyone within close proximity to a Vibratory Pile Driver/Extractor
System.
2. Do not start or operate the V-22/HP-365A until having thoroughly read this manual and
having received instructions from an MKT factory authorized service representative or
properly trained, experienced operator.
Manual No. 140602
CALIFORNIA
PROPOSITION 65 WARNING
DIESEL ENGINE EXHAUST AND
SOME OF ITS CONSTITUENTS
ARE KNOWN TO THE STATE OF
CALIFORNIA TO CAUSE
CANCER, BIRTH DEFECTS, AND
OTHER REPRODUCTIVE HARM.

MKT MANUFACTURING, INC.
STANDARD NEW PRODUCT WARRANTY
EXPRESS LIMITED PARTS WARRANTY FOR NEW PRODUCTS
MKT MANUFACTURING, INC. (“MKT”) warrants to the first user (“User”) of any new product (whether such new
product is sold directly to the customer by MKT or through a distributor) that such new product will be free from
defects in material or workmanship for a period of ninety (90) days beginning on the date that such new product is
delivered to the User. This Express Limited Parts Warranty (“Warranty”) applies only to the first User of the new
product, and not any subsequent users, regardless of whether such subsequent user becomes the owner of the new
product or uses the product within such ninety (90) day warranty period. In no event shall this Warranty extend for
more than twelve (12) months from the date that MKT ships the product, whether to a User or to a distributor which
may or may not use the product. This Warranty applies to new products only. This Warranty is subject to the
following terms and conditions.
If User believes that the product has a defect in the materials or workmanship, User shall send notice of such defect
in writing to MKT within the ninety (90) day warranty period. MKT shall have the right to inspect the product for
defects, and any parts which appear to MKT upon inspection to have been defective in material or workmanship shall
be repaired or replaced at MKT’s option. MKT shall have no other liability to User except for such repair or
replacement of those parts determined to be defective. Such repair or replacement parts shall be provided at no cost
to the User at such location and during such hours as determined by MKT. This Warranty shall not apply to
component parts or accessories of products not manufactured by MKT, or to normal maintenance of the product or to
normal maintenance parts required therefor. Replacement or repair parts installed in the products covered by this
Warranty are warranted only for the remainder of the Warranty as if such parts were original components of said
product. EXCEPT AS EXPRESSLY SET FORTH IN THIS WARRANTY, MKT MAKES NO OTHER WARRANTIES,
AND FURTHER DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND MAKES NO WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
THIS WARRANTY IS NOT APPLICABLE TO ANY ITEM WHICH MKT SELLS THAT IS WARRANTED DIRECTLY
TO THE USER BY THE MANUFACTURER OF SUCH ITEM (IF SUCH MANUFACTURER OF SUCH ITEM IS NOT
MKT).
MKT EXCLUDES ALL LIABILITY FOR OR ARISING FROM ANY NEGLIGENCE ON ITS PART OR ON THE PART
OF ANY OF ITS EMPLOYEES, AGENTS OR REPRESENTATIVES WITH RESPECT TO THE MANUFACTURE OR
SUPPLY OF THE PRODUCT.
MKT shall not be liable to User or any third party for any loss of profits, loss of use, interruption of business, or any
indirect, incidental, special, punitive or consequential damages of any kind whatsoever related to the product or the
use or operation of the product. In particular, MKT assumes no liability for the results of User and its affiliates based
on User’s use of the products furnished by MKT. The maximum total liability of MKT shall be limited to the cost of
those parts which MKT has agreed to repair or replace. This limitation applies to all causes of action in the
aggregate, including without limitation, breach of contract, breach of warranty, negligence, strict liability,
misrepresentations, and other torts. In any jurisdiction in which the above limitations of liability are restricted, MKT’s
liability is limited to the greatest extent permitted by law.
Notwithstanding anything in this Agreement to the contrary, MKT shall not be responsible for any costs or charges of
User and/or any third party, including but not limited to transportation charges, shipping costs, cost of installation,
duty, taxes or any other charges whatsoever including but not limited to any charges or damages due to any delays.
If requested by MKT, products or parts for which a warranty claim is made are to be returned transportation prepaid
to MKT at MKT’s home office. Any improper use, including operation after discovery of defective or worn parts,
operation beyond rated capacity, substitution of parts not approved by MKT, or any alteration or repair by others in
such manner as in MKT’s judgment affects the Product materially and adversely, shall void this Warranty.
NO EMPLOYEE OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY IN ANY WAY OR
GRANT ANY OTHER WARRANTY UNLESS SUCH CHANGE IS MADE IN WRITING AND SIGNED BY AN
OFFICER OF MKT AT ITS HOME OFFICE.

TABLE OF CONTENTS
I. INTRODUCTION
II. SPECIFICATIONS
III. SYSTEM COMPONENTS
IV. SYSTEM SET UP INSTRUCTIONS
V. START UP PROCEDURES
VI. OPERATING INSTRUCTIONS
VII. MAINTENANCE AND SERVICE INSTRUCTIONS
VIII. DRAWINGS AND PARTS LISTS
A. V-22 GENERAL ASSEMBLY AND PARTS LIST
B. HYDRAULIC CLAMP ASSEMBLY AND PARTS LIST
C. ECCENTRIC SHAFT ASSEMBLY AND PARTS LIST
D. MOTOR SHAFT ASSEMBLY AND PARTS LIST
E. HP-365A GENERAL ASSEMBLY AND PARTS LIST
F. 150' HYDRAULIC HOSE BUNDLE ASSEMBLY AND PARTS LIST
G. HP-365A CONTROL PANEL-CUMMINS HYDRAULIC POWER UNIT AND
PARTS LIST
H. HP-365A ELECTRICAL CONTROL ASSEMBLY AND PARTS LIST
I. REMOTE PENDANT/CABLE ASSEMBLY AND PARTS LIST
J. HP-365A ELECTRICAL SCHEMATIC
K. V-22/HP-365A HYDRAULIC SCHEMATIC AND PARTS LIST
L. CAISSON CLAMP ASSEMBLY

I. INTRODUCTION
The MKT V-22/HP-365A Hydraulic Vibratory Pile Driver/Extractor System is used for
installing or removing piling. The three major components of an MKT V-22 Vibratory
Pile Driver/Extractor include rotating eccentric weights housed within a gear box
which generates the vibratory forces to drive or extract piles, a clamp housing to
transmit vibratory forces to the pile section, and an elastomer suspension to isolate
the vibratory forces from the crane line.
There are two rotating eccentric weights in the V-22 mounted in special heavy duty
cylindrical roller bearings. A fixed displacement piston-type hydraulic motor is used
to drive a pinion shaft and gears mounted directly to the eccentric weights. The
gearing system maintains proper timing of the eccentrics during operation. When
operating within its load capabilities, the V-22 vibrator is designed to deliver a driving
force of about 100 tons to a pile at a rate of 1,650 vibrations per minute. The HP-
365A hydraulic power unit is correspondingly designed to maintain the necessary
hydraulic flow and pressure to the V-22 vibratory hammer.
The V-22/HP-365A system can be controlled from the control panel or remotely by a
hand held pendant. Either set of controls allow the operator to start and stop the
hammer, control the clamping on and off the piles, and provides a green light
indicator for complete clamp closing.
-1-

II. SPECIFICATIONS FOR V-22/HP-365A VIBRATORY PILE DRIVER/EXTRACTOR
SYSTEM
A. OPERATING DATA - V-22 DRIVER/EXTRACTOR
Driving Force. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 TON
Free Hanging Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,650 CPM
Free Hanging Amplitude. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 - 1.00 INCH
Eccentric Moment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,600 IN-LBS
Maximum Hydraulic Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365A HP
Clamp Force @ 3,000 PSI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 TONS
Maximum Line Pull. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 TONS
Clamp Jaw Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3/8 INCH
Clamp Cylinder Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INCHES
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 INCHES
Width @ Throat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1/4 INCHES
Shipping Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 INCHES
Hammer Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9,300 LBS
Clamp Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3/4" I.D.
Drain Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3/4" I.D.
Motor Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 2 - 1 1/2" I.D.
Hose Bundle Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,750 LBS
B. OPERATING DATA - HP-365A HYDRAULIC POWER UNIT
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CUMMINS
Engine Horsepower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 HP
Engine Operating Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,250 RPM
Rated Hydraulic Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 GPM
Rated Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,500 PSI
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 GALLONS
Hydraulic Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 GALLONS
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 INCHES
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 INCHES
Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 INCHES
Net Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,000 LBS
NOTE: WEIGHTS AND DIMENSIONS ARE APPROXIMATE
-2-

II. SPECIFICATIONS FOR V-22/HP-365A VIBRATORY PILE DRIVER/EXTRACTOR
SYSTEM (CONTINUED)
C. HOSE BUNDLE
3 pieces - 50 ft. 1 1/2" I.D. Motor Pressure Line (4180043)
3 pieces - 50 ft. 1 1/2" I.D. Motor Return Line (4450290)
6 pieces - 50 ft. 3/4" I.D. Clamp Line (4200072)
3 pieces - 50 ft. 3/4" I.D. Drain Line (4200072)
*NOTE: Frequency and engine RPM are set to maximize performance on a
normal pile, and normal duty cycle. Should overheating occur to
either exciter or engine due to high duty cycle, it is important that the
unit be stopped and allowed to cool down. If overheating persists,
try reducing engine speed 100 to 200 RPM and monitor temperature.
If exciter housing temperatures consistently reach and exceed 200
degrees Fahrenheit consider replacing the exciter lube oil using
Shell Omala 220RL or Mobil SHC630.
-3-

III. V-22/HP-365A COMPONENTS
The essential components of a complete V-22/HP-365A Hydraulic Vibratory Pile
Driver/Extractor System are:
A. HP-365A diesel driven hydraulic power unit
B. Hydraulic hose bundle with five hoses(normally 150' long)
C. V-22 exciter fitted with a suspension assembly and hydraulic clamp assembly
D. 50' electrical remote control pendant and cable assembly
NOTE: The power unit reservoir is factory filled with hydraulic oil
meeting precise specifications for viscosity, viscosity index,
pour point and inhibitors. The oil used, or its equivalent, is
readily available from most major oil companies.
-4-

IV. SYSTEM SET UP INSTRUCTIONS
A. HP-365A HYDRAULIC POWER UNIT
The HP-365A hydraulic power unit is assembled on a skid base which also
serves as a fuel tank. The skid base is fitted with a lifting bail. The power unit is
thus designed to be lifted by a crane line capable of lifting the 10,000 pound unit.
Locate the HP-365A power unit on firm, level ground with an unobstructed
operator view to the intended operation of the V-22 hammer.
B. CONNECTION OF HOSES
All V-22 hammers are thoroughly tested at the factory and consequently all
hoses will be filled with hydraulic fluid. Generally, the hose bundle assembly
filled with oil is disconnected from the hydraulic power unit. Therefore, it is
necessary when reconnecting to make the correct hose connections to the power
unit. There are five hoses in the bundle, each 150' long, one 1 1/2" I.D. high
pressure line for the hydraulic motor supply, one 1 1/2" I.D. line for the motor
return, two 3/4" I.D. lines for the hydraulic clamp assembly and one 3/4" I.D. line
for the motor case drain. Hose connections at the hydraulic power unit are made
easily by quick disconnect assemblies with check valves. The quick couplers
have their plug and couplers alternately matched to prevent incorrect hose
connections.
-5-

IV. SYSTEM SET UP INSTRUCTIONS (CONTINUED)
B. CONNECTION OF HOSES (CONTINUED)
1. When the hoses are attached to the vibratory unit, care should be made to
have the bundle hanging free. Extreme care should be made at all times
not to kink any of the hoses.
As an example, the 1 1/2" motor line hoses have a minimum bend radius of
16 1/2". Even though these hoses have a minimum bursting pressure of
20,000 PSI, a kink will weaken the multiple spiral wire wrap reinforcement
and ruptures could result at high operating pressures.
NOTE: Any damaged hose within the hydraulic power unit, hose
bundle, or vibratory hammer should be replaced with hoses of
equivalent ratings.
2. Before making any hydraulic hose connections, assure that the connectors
are wiped clean of any dirt or contamination to prevent subsequent
contamination and damage to the components in the hydraulic system.
3. Do not permit mobile equipment to run over the hydraulic hose bundle. The
hydraulic hose in the bundle, even though filled with hydraulic oil, is
not able to withstand external compression forces.
4. The ends of the hoses in the hose bundle should be carefully wiped clean
and connected, according to size, to the short hose lengths straddling the
V-22 suspension assembly. If the hoses had previously been disconnected
at this point.
5. Make it a habit whenever the hydraulic lines are disconnected to
immediately cap or plug them to avoid contamination and damage to the
components of the hydraulic system. Assure that the caps and plugs are
wiped clean of any dirt or contamination before using.
-6-

IV. SYSTEM SET UP INSTRUCTIONS (CONTINUED)
C. V-22 DRIVER/EXTRACTOR
The V-22 hammer is factory fitted with its suspension assembly and is shipped
flat on its side. It is designed to receive a 7/8" multiple loop wire rope sling
properly sized and clamped to provide a factor of safety of five times the 45 ton
maximum line pull capacity of the hammer, which in turn, can be slipped over a
lifting crane hook. The V-22 hammer can be lifted from the horizontal to the
vertical without danger of excessive stresses upon its connecting parts or
structure.
1. Hanging in the air, the V-22 hammer should be hoisted, swung and
rotated to assure that the hose bundle hangs free of any loops or
entanglements.
2. Manipulating the V-22 hammer in the air during the foregoing
procedure, as well as later when setting the hammer on a pile, will be
made possible by fastening a ground handling rope to the V-22 clamp
housing before hoisting the hammer aloft.
D. V-22 JAW SHIELD
The jaw shield is generally shipped connected to the V-22 clamp assembly.
Before using the V-22 assure that the jaw shield is tightly connected (with four
hex head cap screws and lock washers) to the V-22 clamp assembly. The jaw
shield not only acts as a guide for positioning the V-22 on a standing pile, but is
also necessary to protect the jaws and the clamp assembly from unnatural
impact shock and resulting damage.
-7-

IV. SYSTEM SET UP INSTRUCTIONS (CONTINUED)
E. REMOTE CONTROL PENDANT AND CABLE ASSEMBLY
The V-22/HP-365A system has a 50' long remote control pendant and cable
assembly that connects to the hydraulic power unit at the control panel.
CAUTION: THE REMOTE CONTROL PENDANT SHOULD NOT BE
CONNECTED IF THE HAMMER IS BEING OPERATED
FROM THE CONTROLS LOCATED ON THE CONTROL
PANEL.
The remote control pendant and control panel each have two (2) push buttons
and one (1) selector switch. The selector switch is used for jaw clamping or
unclamping. When adequate clamp pressure has been attained within the
hydraulic system a green light will be illuminated in the hammer start push
button. Until this light has been illuminated the hammer will not start. The large
red palm button is used for stopping the hammer.
-8-

V. START UP PROCEDURES
A. ENGINE FLUIDS
Make all lubricant, fuel, radiator, and preventive maintenance checks
recommended in the Engine Manufacturer's Operating and Maintenance Manual
before starting the diesel engine. WARNING: DO NOT USE ETHER. The
engine is equipped with an electric heater starting aid and the use of ether
may cause severe injury.
B. HYDRAULIC FLUID
Check the level of the hydraulic fluid in the reservoir in
the HP-365A power unit. Do not operate the HP-365A with the hydraulic oil level
below the gauge. If hydraulic fluid must be added to the system, do not allow
foreign matter to enter the hydraulic system and use proper hydraulic oil for the
HP-365A system. See the lubricant and hydraulic fluid requirements for the V-
22/HP-365A system described in this manual.
C. HYDRAULIC VALVES AND PUMPS
The hydraulic valves and pumps in the HP-365A power unit have already been
set for proper pressure during the factory break in and operating of the V-22/HP-
365A system. DO NOT MAKE ADJUSTMENTS TO THE VALVES OR PUMPS
WITHOUT THE ASSISTANCE OF A FACTORY TRAINED SERVICE
REPRESENTATIVE.
The V-22/HP-365A system utilizes two hydraulic filters to maintain clean oil
within the system. The charge oil for the main pump is filtered through a spin-on
type filter located on the bottom of the pump. Hydraulic fluid returning from the
motor is directed through the filter located on the back side of the power unit
bulkhead. This filter has a full size bypass valve that protects the filter element
and system with a minimum of pressure loss, therefore the filter as it becomes
clogged will bypass contaminated oil back into the hydrastatic loop. Rigid
schedules of the filter element changes should be followed to lengthen the life of
all the hydraulic components.
The hydraulic reservoir has a suction strainer located in each of the suction lines
leading to the pumps. When the hydraulic tank is drained for servicing, the
strainers should be cleaned.
D. EXCITER HOUSING OIL LEVEL
The lubricating oil level in the V-22 exciter housing must be maintained at all
times for proper lubrication of the gear train and eccentric bearings. Check the
lube oil level by holding the exciter in a vertical position and viewing the two
sight windows, if the oil is below the level sight gauge add oil. Too much oil in
the initial check may indicate oil expansion or leakage of hydraulic oil into the
exciter housing through the hydraulic motor seal.
-9-

V. START UP PROCEDURES (CONTINUED)
E. HYDRAULIC CLAMP CYLINDER
Whenever the hydraulic lines of the V-22/HP-365A system has been
reconnected, THE CLAMP CYLINDER CIRCUIT MUST BE BLED OF
ENTRAINED AIR. Lift the V-22 hammer vertically off the ground, switch the
clamp selector switch to the "clamp close" position to close the jaws. Using the
proper tools unscrew the vent valve screw located on the outboard end of the
clamp cylinder.
CAUTION: A STREAM OF FROTHING HYDRAULIC FLUID WILL
SHOOT FROM THE RELIEVED VENT SCREW.
After approximately thirty seconds, close the vent screw. Now switch the clamp
selector switch to the "clamp open" position to open the jaws and repeat the
process at the inboard vent valve screw. Repeat the procedure until an air free
stream of oil comes from each relieved vent screw.
CAUTION: FAILURE TO COMPLETELY BLEED THE CLAMP
CIRCUIT OF AIR MAY IMPAIR CLAMPING FORCE
AND DAMAGE JAWS.
SEE PAGE 28 FOR BLEEDING ILLISTRATION
F. HYDRAULIC CIRCUITRY
The repetitive functions of the V-22 hammer are powered by two pumps
contained within the HP-365A power unit. The hammer is first able to clamp
onto a pile, vibrate the pile, stop vibration and unclamp from the pile. Two
different types of hydraulic circuits are used to perform these functions.
The hydraulic clamp assembly is operated by the use of a pressure
compensated piston pump and directional control valve. This pump is bolted to
a mounting pad on the pump drive. Hydraulic fluid from the reservoir first
passes through a suction strainer and then into a suction hose before entering
the clamp pump. The hydraulic fluid leaving the pump is directed to the
directional control valve. The directional control valve is shifted by the use of 12
volt solenoid operators. The pressure compensator on the pump is set at 3,000
PSI. When this pressure has been reached in either the clamp open or clamp
close function, the pressure compensated pump will destroke and maintain itself
in a zero flow condition. If any additional fluid is required the pump will respond
to this need and again send fluid to the clamp open or clamp close function.
There is also a pressure relief valve set at 3,500 PSI contained within the clamp
directional control valve to act as a safety feature in case of a malfunction within
the pressure compensator on the pump. The clamp circuit of the V-22/HP-365A
system also has a pilot operated check valve on the clamp cylinder. In the event
of a broken clamp hose or other loss of clamp pressure, the check valve will
maintain clamp pressure on the pile.
-10-

V. START UP PROCEDURES (CONTINUED)
F. HYDRAULIC CIRCUITRY (CONTINUED)
The hydraulic motor on the V-22 hammer is powered by a piston pump operating
in a closed-loop circuit. A small amount of motor flushing oil is taken through an
orifice fitting on the clamp close line. The pressure compensated clamp pump
will continuously flush the motor with approximately 3/4 - 1 GPM of oil while the
clamp is in the closed position.
The hydraulic motor also has a relief valve installed in the case drain port. This
relief valve is set at 80 PSI to provide protection from over-pressurization of the
case drain line due to blockage or high internal motor leakage.
The pump is stroked from the zero position by the means of a hydraulic pilot
signal. The signal is received from a small, 12 volt solenoid operated, directional
control valve which may be located on the power unit skid or as an integral part
of the pump. The pump has its own charge pump built into the pump housing
and a pressure limiter system which destrokes the pump when a maximum
pressure has been reached. Hydraulic fluid returning from the V-22 hammer
motor is directed through a hydraulic filter before returning to the pump. The
filter is located just inside of the power unit behind the bulkhead. Charge
pressure oil on the pump is directed through a spin-on type filter located on the
bottom of the pump. Warm hydraulic fluid is split off from the closed-loop circuit
through a hot oil shuttle valve. The hot oil shuttle valve is mounted to a manifold
which also supports the hydraulic filter. Warm oil from the shuttle valve is
directed through the pump case and into a hydraulic oil cooler located in front of
the engine radiator. Oil is then routed from the cooler back to the hydraulic
reservoir.
G. START UP LIST
1. Open all enclosure doors.
2. Check engine water, fuel, and shut down solenoid to be sure it is locked in
the proper position. Check hydraulic fluid.
3. Connect electrical pendant if the hammer will be operated from the remote
pendant position.
4. Turn the control panel power switch to the remote or panel position. The
remote pendant should not be connected if the hammer is being operated
from the controls located on the control panel. A green lamp on the control
panel will indicate that the power is on.
-11-

V. START UP PROCEDURES (CONTINUED)
G. START UP LIST (CONTINUED)
5. Start the engine at an idle speed of 600 - 800 RPM. Allow the engine
to idle until charge pressure registers on the gauges. Check engine
oil pressure.
6. Run the engine at part throttle for approximately five minutes for
warm-up. It may be necessary to run the engine longer in cold
weather conditions. After engine warm-up is completed bring engine
speed up to the operating speed of 2,250 RPM. Some of the
enclosure side doors may be closed at this time if desired.
7. Check the charge pressure gauges to be sure that the gauges register
between 300 - 400 PSI.
8. Lift the hammer vertically off the ground.
9. Turn clamp switch on the pendant (or the panel) to the closed
position, the clamp should close.
10. Check clamp pressure gauge to verify adequate clamping force (3,000
PSI). Bleed the clamp cylinder at the outboard end with the vent
screw. (CAUTION: Do not back the bleeder vent screw out all the
way, oil and air will come out of the bleeder, let it run until you
have a free stream of oil.)
11. Operate the clamp switch on the pendant (or the panel) to the open
position and bleed the inboard vent screw in the same manner. See
page 28 for Instructions.
12. Failure to bleed the clamp circuit may impair clamping force and
damage jaws!
13. After all the preceding steps have been taken hold the hammer
vertically in the air to check the lubrication oil level in the exciter case.
Sight glasses are located on the side of the exciter case. This level
should be checked twice per day.
14. Control panel power switch will determine which hammer controls will
be functional (remote pendant or panel).
15. Hammer start push button will become illuminated when adequate
clamp pressure has been attained. If the button is not illuminated the
hammer will not start.
-12-

VI. OPERATING INSTRUCTIONS
A. OPERATING THE V-22/HP-365A SYSTEM - DRIVING MODE
1. With a preset pile, the V-22 hammer with the clamp jaws open is hoisted
above, centered over and lowered onto the pile head section which is to be
gripped. CAUTION: BEFORE CLOSING THE JAWS, ASSURE THAT THE
PILE HEAD IS ENTERED COMPLETELY INTO THE OPENING BETWEEN
THE JAWS. GRIPPING THE PILE WITH MERELY THE LOWER END OF
THE JAWS WILL PUT UNNATURAL STRESSES ON THE JAWS AND
CLAMP SYSTEM RESULTING IN POTENTIAL FAILURE OF THE JAWS,
THE CLAMP SLIDE AND/OR OTHER CLAMP ASSEMBLY
COMPONENTS.
2. The clamp jaws will close upon the pile by operating the clamp close switch
on either the remote pendant or panel. A built in pilot operated check valve
system in the clamp cylinder assures that the jaws remain locked until
powered in the opposite direction.
3. A pile is driven with the V-22 hammer by completely relaxing the hoist line
after clamping the V-22 to a supporting pile.
4. The V-22/HP-365A hydraulic driver/extractor system responds as follows to
an overload from the pile-soil system. When a pile can be moved no further
and the hydraulic fluid pressure is at a maximum, the pressure limiters on
the hydraulic pumps will destroke and slow down the V-22 frequency.
5. The addition of driving weight to the suspension of the V-22 hammer may
aid to acquire some additional pile penetration. When a pile slows to a point
of little movement however, the user will usually find it economically wise to
discontinue trying to use the vibratory hammer and switch to some other
driving system, such as an MKT diesel or steam/air impact hammer.
6. Occasionally the inability of the V-22 hammer to continue to move a pile will
be the result of the pile striking an inpenetrable solid material or obstruction.
The observable action of the V-22 hammer and clamped pile will be noted
by a considerable fall-off of drive pressure and the exciter will "dance" in
place. This "dancing" often causes an erratic interaction of the V-22 exciter
and its suspension assembly. CAUTION: WHENEVER THE V-22
HAMMER IS OBSERVED "DANCING" IN PLACE, IT SHOULD BE
HOISTED UNTIL THE ACTION STOPS. SERIOUS DAMAGE MAY BE
DONE TO THE V-22 HAMMER IF IT IS OPERATED IN THIS TYPE OF
CONDITION.
To continue operation the obstruction must be removed or penetrated by
switching to another driving system, such as a MKT diesel or steam/air
impact pile hammer.
-13-

VI. OPERATING INSTRUCTIONS (CONTINUED)
B. OPERATING THE V-22/HP-365A SYSTEM - EXTRACTING MODE
1. A pile is extracted by merely tensioning the V-22 hammer hoisting
line. The amount of pull which can be exerted on the V-22 hammer
and extraction is limited by the rating of the suspension assembly and
the tensile strength of the pile.
CAUTION: DO NOT PULL IN EXCESS OF THE RATING OF THE V22
HAMMER'S SUSPENSION ASSEMBLY OR EXCESS STRESSES
WILL BE PUT ON THE SUSPENSION ASSEMBLY DAMAGING
ONE OR MORE PARTS. EXTREME CARE MUST BE TAKEN
DURING THE EXTRACTION PROCESS DUE TO THE HIGH LINE
PULL FORCE APPLIED BY THE PULLING CRANE. THE
REACTION DUE TO A SUDDEN LOSS OF LOAD MAY CAUSE THE
CRANE BOOM TO FALL BACKWARDS ACROSS THE CRANE
CAB.A SUDDEN LOSS OF LOAD COULD BE CAUSED BY A
PARTED CRANE LINE, UNEXPECTED LOSS OF CLAMPING
FORCE, OR SEPARATION OF THE PILE AT THE AREA HELD
WITHIN THE CLAMPING JAWS. ("BITTING THE TOP OUT OF
THE PILE")
CAUTION: A SECOND CRANE LINE SHOULD BE ATTACHED TO AN
ADJACENT PILE ("DEAD MAN") AND DRAWN TIGHT AS A
PRECAUTIONARY MEASURE AGAINST A SUDDEN LOSS OF
LOAD. CRANES USED FOR PILE EXTRACTION APPLICATIONS
SHOULD ALWAYS BE EQUIPPED WITH BOOM STOPS.
2. The ability of the V-22 hammer to switch instantly from driving to
extracting mode by merely pulling on its hoist line, has evolved a pile
driving procedure exclusive to vibratory usage. A hammer hanging on
the number one crane line is swung into the air. A sheet pile, for
example, is lifted from the ground on the number two crane line so
that the head of the pile is pulled between the clamp jaws of the
hammer. The jaws are then closed and the number two line is
slacked. Both hammer and pile are then held by the number one line.
The pile is stabbed in its location with the hammer. The hammer is
then turned on and the pile is worked into the ground. Usually out of
plumb at the outset, the pile is alternately driven and extracted until it
penetrates the soil sufficiently to be self supporting. It is then pulled
far enough to be straightened plumb and quickly driven. (Sheet piles
are usually driven only a few feet and the adjacent pile is set.)
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VI. OPERATING INSTRUCTIONS (CONTINUED)
B. OPERATING THE V-22/HP-365A SYSTEM - EXTRACTING MODE
(CONTINUED)
3. For pile extracting operations, a V-22 hammer is frequently fitted with
a shackle and a short auxiliary line attached the crane hook. The V-
22 hammer is clamped to a steel sheet pile to be pulled and the
shackle is fastened into the lifting hole in the pile. The V-22 hammer
is operated to extract the pile until the pile can easily be lifted out of
place exclusively by the line pull of the crane. The V-22 hammer is
then stopped by depressing the stop push button. The pile is then
pulled out of the ground, and the hammer and pile swung to where the
pile will be stacked. The lower end of the pile is set on the ground
and the V-22 hammer jaws are opened allowing the pile head to fall
away from the jaws and hang by the line and shackle. The V-22
hammer and dangling pile are lowered to the ground where the
shackle is disconnected from the pile.
C. SYSTEM SHUT DOWN PROCEDURES
1. Stop hammer and open jaws.
2. Reduce engine speed to idle (600 - 800 RPM) and allow to idle for several
minutes.
3. To stop engine turn engine start switch to the off position.
4. Turn the main power selector switch on the control panel to the off
position. The green indicator light on the panel will go off.
-15-

VII. MAINTENANCE AND SERVICE INSTRUCTIONS
A. The V-22 hammer and the HP-365A hydraulic power unit should be
inspected regularly to help keep it in good operating condition. The time
interval between necessary adjustments and repairs depends primarily on
how much and how hard the machine has been used. Repair or replace
broken or damaged parts as soon as they are discovered. Periodic cleaning
and repainting will help keep all parts in better working order and prolong the
machine's life.
B. Maintenance procedures for the diesel engine in the
HP-365A are described in the engine manufacturer's manual.
C. Proper maintenance of the total V-22/HP-365A system begins with
cleanliness; assuring that no dirt or foreign material enters the hydraulic fluid
circuit. Contamination of the components of the hydraulic system - pumps,
motors, valves, etc., will result in erratic operation, down time, shortened
equipment life, damaged parts and expensive repair or replacement costs.
To trap foreign material which might inadvertently enter the hydraulic circuit,
the V-22/HP-365A system contains several filters and strainers. The spin-on
type charge filter element located on the bottom of the main hydraulic pump
should be changed after the initial fifty (50) hours of driving time or after the
hydraulic fluid has been changed. During normal operation, this filter
element should be changed at least two (2) times per year or after every 200
hours of driving time.
The main hydraulic filter, located just within the HP-365A bulkhead, filters the
hydraulic oil in the closed-loop system before it re-enters the main hydraulic
pump. This filter element should also be changed on the intervals given for
the charge filter element mentioned above. The main filter also has a visual
indicator which will show if the filter is clogged and in a bypass condition. If
the hydraulic oil is bypassing this filter a red band will be visible under the
transparent dome of the indicator.
The hydraulic oil in the reservoir passes through a suction strainer before it
enters either of the pumps. These strainers should be cleaned whenever the
hydraulic tank is serviced.
D. The hydraulic fluid in the system should be maintained at all times. Leaks in
the hydraulic system, particularly noticeable after transport and set up of this
system, should be eliminated by checking and retightening the leaking parts.
Hose connections may leak as a result of manipulating and straightening the
lines and should be promptly tightened. THE CAUSE OF HYDRAULIC
LEAKS WHICH CANNOT BE CORRECTED SHOULD BE ELIMINATED BY
CALLING FOR FACTORY AUTHORIZED DISTRIBUTOR SERVICE
ASSISTANCE.
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VII. MAINTENANCE AND SERVICE INSTRUCTIONS (CONTINUED)
1. Check the hydraulic fluid level on the HP-365A tank gauge before
and during operation of the V-22/HP-365A system. DO NOT
OPERATE THE V-22/HP-365A SYSTEM IF THE HYDRAULIC
FLUID REGISTERS BELOW THE TANK FLUID GAUGE.
2 In normal, safe operation of the V-22/HP-365A system, the
hydraulic fluid temperature should remain in its typical range of 115
degrees Fahrenheit to 165 degrees Fahrenheit. This temperature
can be read on the thermometer located on the control panel.
CAUTION: IF THE HYDRAULIC OIL TEMPERATURE BECOMES
EXCESSIVE (ABOVE 180 DEGREES FAHRENHEIT) STOP
OPERATIONS AND CONSULT WITH THE NEAREST
FACTORY AUTHORIZED SERVICING DISTRIBUTOR.
A temperature switch will automatically turn on a red light on the control
panel if the temperature reaches 170 degrees Fahrenheit.
E. Make a daily check of all hoses in the hydraulic hose bundle for cuts or other
damage. Hoses are sometimes cut or bruised by dragging them across pile
heads while setting the V-22 hammer. Stop V-22 hammer operations that
may cause damage to the hoses and redirect the hose bundle to avoid
dragging and damage. Damaged hose sections must be replaced to
eliminate failure and down time during operations.
F. Inspect the V-22 hammer for normal hanging posture and loosened
fasteners, particularly on the suspension and clamp assemblies before and
during operation.
SAFETY WARNING: STAND AWAY FROM THE PILE AND FROM
BELOW THE V-22 DURING VIBRATING
OPERATIONS. ANY UNOBSERVED,
UNCORRECTED, LOOSE NUT OR OTHER
FASTENER MAY FALL.
G. Assure that the proper lube oil level is maintained in the V-22 exciter case. If
the level of oil is above the sight gauge or the lube oil volume is increasing
this may be an indication that the hydraulic motor is leaking hydraulic fluid
through the motor drive shaft seal. Any seal leakage must be corrected
immediately. The mixture of hydraulic oil and lube oil is not a lube problem
but the increasing level will add load to the rotating eccentrics and cause
excessive foaming.
The lube oil in the V-22 exciter case should be changed after every 50 hours
of driving time.
-17-