Emv450v6 metric hose kit - dcpuk.com metric hose kit.pdfvibrators excavator mounted drills quiet, vibrationless push-pull piling pile extraction sheet pile guide frames sheet pile

www.dcpuk.com

INNOVATIVEPILING

EQUIPMENT

HYDRAULIC PILING HAMMERS

EXCAVATOR MOUNTED VIBRATORS

EXCAVATOR MOUNTED DRILLS

QUIET, VIBRATIONLESSPUSH-PULL PILING

PILE EXTRACTION

SHEET PILE GUIDE FRAMES

SHEET PILE CAPPING SYSTEMS

CFA CLEANERS

PILE POINTS& SPLICERS

HANDLING / LIFTING

www.dcpuk.com

EMV-450 MetricEXCAVATOR MOUNTED VIBRATOR

OPERATORS INSTRUCTIONS & SPARE PARTS LIST

4450D.2M EMV450V6 METRIC HOSE KIT

May 2013 V6

DAWSON CONSTRUCTION PLANT LIMITED

EMV 450 OPERATORS INSTRUCTIONS & SPARE PARTS LIST

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 EMV450 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 looses grip on the pile

8.0 Hydraulic Metric Hose and Fitting List 9.0 Parts Lists for the EMV450 10.0 Appendix A – Caisson Beam Attachment (Optional)

2.0 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 EMV450 product is extremely versatile and readily adapts to most suit excavators from 25 to 45 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 : +44 (0)1908 240300 Fax: +44 (0)1908 240222

Email: [email protected] Website: www.dcpuk.com

600 lbs.in

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 EMV450 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 themselves 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 Regulator and Sequence Valve

Hydraulic Drive Motor

Transport Stand

Saddle Assembly with Swivel

Gearbox containing eccentric weights

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 EMV450.

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

Adaptor Bracket

Spacers Bushes

Shear Pin

4.2 Hydraulic Hoses - Layout and Connections The EMV hydraulic fittings are METRIC for the EMV450. The pressure and return

lines (already connected to the vibrator) have EWVD 25S male fittings. 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 EWVD 12S 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 5 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(∅1.5”) 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.

h. Ensure the vibrator jaws fully cover the pile before being closed with 54 tonnes of forces, otherwise damage may occur to the jaw and clamp assembly due to uneven loading.

5.2 Driving Piles

e. 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 secure through chain holder.

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 (the deflection is approximately 146mm (5.75”) at this point).

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 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 through chain holder. 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 amount shown below:

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 lifting chain from the pile lifting hole. i. Repeat steps b-i to continue.

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 EMV450 – 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 holder for damage. The chain and holder should be in good order, free from any structural damage or permanent deformation of any kind. The chains anchorage point should be in good order showing no signs of damage, wear or cracking. Remember if in doubt change it – Chains 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 1.5x1.5mm). 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 5x5mm.

Changing the Hard Jaws – Static Side Remove the two Cap Screws 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 two Cap Screws and tighten using a hexagonal wrench. Remember to install the washers on these screws. Changing the Hard Jaws – Moving (Cylinder) Side Release the 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 (1.5”) 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.

Breather/Filler Plug

Swivel Assembly

Gear Box Oil Sight Glass

Lifting Chain

Clamp Body Grease Point – for the Moving Jaw

Clamp Cylinder

Gearbox Oil Drain Plug

Hard Jaws

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 EPC 80W/90 GEARTEX SS 75W/90

Note: Maximum working ambient temperature +40ºC Minimum working ambient temperature –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

Clamp Cylinder

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 110-120 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 195 l/min (52 USgpm).

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

7.4 Oil blowing out of the motor blow-off valve.

7.4.1 Drain line restricted or blocked – stop work immediately.

7.4.1.1 Check the drain line hose for obvious restrictions at fittings, filters etc. 7.4.1.2 Check the drain hose for damage – look carefully as the bore of the hose

can be crushed even when the outside of the hose looks to be in good order at a casual glance.

7.4.1.3 Check the drain hose point of entry into the base machine hydraulic oil system – it is always best to run it directly to tank.

7.4.1.4 Do not work with quick disconnects as they can cause restriction or complete blockage when they appear to be correctly connected.

7.4.2 Drain line being pressurised – check that the line is not connected to a supply line e.g. the pressure line from a breaker circuit.

7.4.3 Long drain hose or the hose bore too small – either of these can contribute to an increase in back pressure.

7.4.4 Extremely cold weather – if the base machine hydraulic oil is of an inappropriate viscosity grade for the ambient temperature it may well be too thick. This will cause an increase in back pressure in the drain hose.

7.4.5 Faulty Blow-Off Valve on the motor casing – check that this has a minimum crack pressure of 5 bar. Replace if unsure using a new calibrated valve and a new sealing ring.

7.4.6 Leaking seals on the sequence valve cartridge leading to excessive drain line flow rate – remove the drain line from the EMV and measure leakage flow rate. Leakage in excess of 5 l/min (1.33 gpm) indicates either a seal kit problem with the sequence valve or high internal motor leakage. Split the sequence valve drain line and motor case drain line and measure leakage rates independently – the sequence drain line should have little or know leakage.

Motor Blow-Off Valve

7.5 Oil blowing out of the gearbox breather valve & the gear box is full of oil

The drive motor case seal has been blown, typically because the drain line pressure has been exceeded – see also section 7.4. The unit will need to be removed from the job site and repaired in a suitably equipped workshop. The oil in the box will be a mixture of hydraulic and gear oils. Once in the workshop drain the oil from the gearbox and inspect the oil for signs of debris. If only the seal has blown out without any damage to the motor casting then it may be possible to repair the motor with an authorised Volvo (VOAC) distributor, change the gear oil and rebuild the unit. If however, the motor casting has also been damaged in the area of the seal housing it will be necessary to completely inspect the inside of the gearbox. Remove the gearbox lid and inspect the gear teeth and inspect all bearings. Check the gears for any signs of damage. Remove all bearing covers from the gearbox sides and inspect the outer races for signs of grooves or any other contamination or damage – look at the rollers in each bearing. The bearings and all running faces should be in perfect condition, if not they will need to be replaced. Consult with the manufacturer at this stage or one of their approved distributors – it is strongly recommended that the unit be repaired by the manufacturer in order to ensure correct procedures and materials are used for an effective repair.

7.6 Clamp looses grip on the pile Check the condition of the Hard Jaws – see section 6.1.f.

The clamp can also loose grip on the pile when clamped, with the vibrator not vibrating, if the check valve on the rear of the clamp cylinder has faulty/leaking seals or it the clamp cylinder piston seals are damaged/worn.

Alternatively there may be insufficient system operating pressure if the sequence

valve setting has been adjusted down in order to attempt running on an unsuitable excavator. Check the system operating pressure and excavator specification

8.0 HYDRAULIC METRIC HOSE AND FITTING LIST – EMV450Hose Kit Part Number 4700M.02 (EMV60-177 ONWARDS)

Item Part No. Description Quantity1 H00385 Hose Assembly 12 H00386 Hose Assembly 13 H00387 Short Hose Assembly 14 H00388 End Swivel Tee 15 H00389 Swivel Elbow 26 H00390 Swivel Elbow 27 H00391 Blanking Cap 28 H00392 Blanking Cap 19 H00393 Bulkhead Fitting /Nut 210 H00394 Equal Elbow 111 H00395 Bulkhead Fitting 1

12 11 6 8

4 3 59 710

8.0 HYDRAULIC METRIC HOSE AND FITTING LIST – EMV450Hose Kit Part Number 4700M.02

5

Item Part No. Description Quantity13 H00396 Hose Assembly 114 H00397 Hose Assembly 115 H00398 Tube Assembly 116 H00399 Male/Male Adaptor 318 H00400 Male/Female Adaptor 121 H00401 Dowty Washer 322 H00402 Hose Assembly 123 H00403 Adaptor Male/Male 224 H00404 Reducer 125 1-102-09-01 Dowty Washer 1

613 24

5

4

3

22

Item Part No. Description Quantity13 H00405 Hose Assembly 114 H00406 Hose Assembly 115 H00407 Tube Assembly 116 H00408 Male/Male Adaptor 318 H00409 Male/Female Adaptor 121 H00410 Dowty Washer 422 H00411 Hose Assembly 123 H00412 Adaptor Male/Male 224 H00413 Reducer 125 1-102-09-01 Dowty Washer 1


14

16

5

5

22

23

5

15

18

25

21

21


27 26 1328

Item Part No. Description Quantity26 H00414 Hose Assembly 127 4695 Blow-off valve 128 H00416 Adaptor 1


29

34

31 33

30

32

Item Part No. Description Quantity29 H00417 Adaptor Male/Male 130 H00418 Special Elbow & Test Point 131 H00419 Adaptor Male/Male 132 H00420 Tee 133 1-101-20-01 Dowty Washer 334 0M22.000.25 Dowty Washer 135 H00421 Adaptor Male/Male 236 H00422 Adaptor Male/Male 437 H00423 Male Stud Coupling 138 H00424 Hose 139 H00425 Hose 1

4

24

137


35

39

26 36

38

Item Part No. Description Quantity29 H00426 Adaptor Male/Male 130 H00427 Special Elbow & Test Point 131 H00428 Adaptor Male/Male 132 H00429 Tee 133 1-101-20-01 Dowty Washer 134 0M22.000.25 Dowty Washer 135 H00430 Adaptor Male/Male 236 H00431 Adaptor Male/Male 437 H00432 Male Stud Coupling 138 H00433 Hose 139 H00434 Hose 1

DAWSON CONSTRUCTION PLANT LIMITED

9.0 PARTS LIST FOR THE EMV450

- - - - - -

4450D-2

20/10/2008

peter watts peter watts

General Assembly

Qnt.

G

M

L

1 2 3

K

J

H

I

4 5 6 7 8 9

F

E

D

C

B

A

1 2 3 4 5 6 7 8 9

G

10 11 12 13 14 15 16 17 18 19

M

L

K

J

H

I

10 11 12 13 14 15

F

E

D

C

16 17 18

B

A

19

CopiedDesign by

Ref.no.Drawn by Checked

Part nameStandard ScaleAffirmed

Material Dimension Remark

Drawing no.

Sheet

Replace

Date

Replaced by

Qnt.Rf.nr Revision Appr.byDate Intro.

DAWSONCONSTRUCTION

PLANT LTD.

3RD ANGLE

ROUGH MACHINE N9

FINE MACHINE N8

GRIND N6

UNLESS STATED OTHERWISESURFACE FINISH

X . X = +/- 0.25

ANGLES +/- 0.5°

MACHINING TOLERANCESUNLESS STATED OTHERWISE

X . XX = +/- 0.05

DIMENSIONS IN MILLIMETERS

X = +/- 0.5 A0

EMV 450

1 of 1

A

AB

B

SECTION B-BSECTION A-A

26

25 M20 x 20

33

23

45

22

31

32

34

37

44

16 0M24.035.01

8 0M10.035.01

7 0M10.010.09

15 0M20.120.0214

5

30

40

130M14.045.01

180M30.080.01

12

17

42

48

5020

12

90M10.055.02

37

38

2

100M12-035-0111

21

28

49

51

46

43

4722

13 0M14.045.01

52* 2 Dawson Sticker Dawson Sticker

51 1 ADAPTOR 7/8 UNF - 1/8 BSP 4730.1

50 1 Hose Kit 4700A-02

49 1 5 BAR PRESSURE RELIEVE VALVE BSP 1/8" 4695

48 1 Flow Reg & Sequence Valve 4680-1

47 1 O-RING 204-226-4470 4677

46 1 O-RING 200-048-4470 4676

45 1 Hydraulic Motor F12-060-MF-IH-D 4675

44 4 Cylindrical roller bearing 4632

43 4 O-RING 200-264-4470 4630

42 1 Saddle Assembly MKII 4620-2

41 1 EMV400/450 GASKET NASB6 1mm Thick 4619

40 1 Clamp Assembly 4618D

39* 4 Thrust Washer 4611

38 1 Drive Gear 4610

37 1 Driven Gear B 4609B-450

36* 1 Driven Gear A 4609A-450

35 2 Eccentric Weight BS 4360 En50B 4608-450

34 2 Main Shaft En 24 4607

33 1 Drive Shaft End Cap BS 4360 En50B 4606

32 4 Main Shaft End Cap BS 4360 En50B 4605

31 1 Cover Plate BS 4360 En50B 4604

30 1 Case Welded Assembly 4603

29* 1 Quick Hitch Assy BE4360 En50B 4589

28 2 450 Sticker 450 Sticker

27* 2 O-RING 204-025-4470 4079

26 1 Manifold Block 4071

25 1 Hex Hd Bolt M20 x 20 4061

24 1 SIGHT GLASS 4039

23 1 Dowty Washer M20 4038

22 1 6212-2RS1 4035

21 4 No6 x 1/2" Rivet 1-204-000-01

20 1 IDENTIFICATION PLATE 1-203-00-02

19 1 DRAIN PLUG VS-R 1 WD 1" BSP 1-064-00-01

18 10 HEX HD BOLT M30 x 80LG 0M30.080.01

17 10 NORD-LOCK WASHER M30 0M30.000.27

16 2 HEX HD BOLT M24 x 35LG 0M24.035.01

15 6 SOCKET HEAD CAP SCREW M20 x 120 0M20.120.02

14 6 SPRING WASHER M20 0M20.000.21

13 2 HEX HD BOLT M14 x 45LG 0M14.045.01

12 2 NORDLOC WASHER M14 0M14.000.27


10 4 HEX HD BOLT 8.8 M12 x 35LG 0M12-035-01

9 6 SOCKET HEAD CAP SCREW M10x55 0M10.055.02

8 26 HEX HD BOLT ZP GRADE 10.9 M10 x 35LG 0M10.035.01

7 8 LOW HD SHCS M10 x 10 M10 x 10 0M10.010.09

6* 4 SOC SET SCREW M10x10 0M10.010.05


4 32 SOCKET HEAD CAP SCREW 12.9 M10 x 35 LG 0M10-035-02


2 2 SPRING PIN Ø8 x 30 0M08.030.22

1* 1

Metric / JIC / BSP

4700M.01 /

A No.46 ADDED METRIC PART 28/04/10

* SEE MANUAL FOR TYPE USED

*41

19

24

ISO VIEW

4700M-01 / / 4700B

240.00

15.15

35

B TORQUE MEASUREMENTS ADDED 19/03/13

4

3

C M10 CAPHEADS ADDED 30/01/14

B TORQUE MEASUREMENTS ADDED 19/03/13

- - - - - -

4601

22/11/2010

MDBMDB

Qnt.Ref.no. Part name Material Dimension Remark

1 2

J

I

H

G

F

3 4 5 6

E

D

C

B

A

1 2 3 4 5 6

7 8 9 10 11 12

J

I

H

G

F

7 8 9 10

E

D

C

11 12

B

A

CopiedDesign by Drawn by Checked Standard ScaleAffirmed

Drawing no.

Sheet

Replace

Date

Replaced by


DAWSONCONSTRUCTION

PLANT LTD.

3RD ANGLE

ROUGH MACHINE N9

FINE MACHINE N8

GRIND N6


X . X = +/- 0.25

ANGLES +/- 0.5°


X . XX = +/- 0.05


X = +/- 0.5 A2

DRIVEN GEAR ASSEMBLY

1 of 1EMV450

8

9

16

15

11

137 0M24.035.01

60M20.120.02

40M10.010.09

5

16 4 Cylindrical roller bearing 4632

15 4 O-RING 200-264-4470

4630

14* 4 Thrust Washer 4611

13 1 Driven Gear B 4609B-450

12* 1 Driven Gear A 4609A-450

11 2 Eccentric Weight BS 4360En50B

4608-450

10 2 Main Shaft En 24 4607

9 4 Main Shaft End Cap BS 4360En50B

4605


7 2 HEX HD BOLT M24 x 35LG 0M24.035.01

6 6 SOCKET HEAD CAP SCREW M20 x 120 0M20.120.02


4 8 LOW HD SHCS M10 x 10 M10 x 10 0M10.010.09

3 4 SOC SET SCREW M10x10 0M10.010.05



16

10

ISO VIEW

2

A TORQUE MEASURMENTS ADDED 19/03/13 M.D.B

3

B M10 SET SCREW WAS LOW HD 07/11/13 PLW

3

DO NOT OVER TIGHTEN GRUB SCREWS AS THEY BOTTOM OUT ONTHE BEARING, ONLY HAND TIGHT AND SECURE WITH LOCITITE

1

C M10 CAPHEAD ADDED 30/01/14 MDB

D M10 HEX HEADS REMOVED 02/10/15 MDB

- - - - - -

4640

22/11/2010

MDBMDB


1 2

J

I

H

G

F

3 4 5 6

E

D

C

B

A

1 2 3 4 5 6

7 8 9 10 11 12

J

I

H

G

F

7 8 9 10

E

D

C

11 12

B

A


Drawing no.

Sheet

Replace

Date

Replaced by


DAWSONCONSTRUCTION

PLANT LTD.

3RD ANGLE

ROUGH MACHINE N9

FINE MACHINE N8

GRIND N6


X . X = +/- 0.25

ANGLES +/- 0.5°


X . XX = +/- 0.05


X = +/- 0.5 A2

DRIVE GEAR ASSEMBLY

1 of 1EMV450

6

8

7M20 x 20

10

11

12

13

14

15

1

16

17 1 ADAPTOR 7/8 UNF -1/8 BSP

4730.1

16 1 5 BAR PRESSURE RELIEVE VALVE BSP 1/8" 4695

15 1 O-RING 204-226-4470

4677

14 1 O-RING 200-048-4470

4676

13 1 Hydraulic Motor F12-060-MF-IH-D

4675

12 1 Drive Gear 4610

11 1 Drive Shaft End Cap BS 4360En50B

4606


9 2 O-RING 204-025-4470

4079

8 1 Manifold Block 4071

7 1 Hex Hd Bolt M20 x 20 4061

6 1 Dowty Washer M20 4038

5 1 6212-2RS1 4035


3 4 HEX HD BOLT 8.8 M12 x 35LG 0M12-035-01

2 6 SOCKET HEAD CAP SCREW M10x55 0M10.055.02

1 8 SOCKET HEAD CAP SCREW 12.9 M10 x 25 LG 0M10.025.02

5

17 7/8 UNF - 1/8 BSP

ISO VIEW

9

2 0M10.055.02

3 0M12-035-01

4

19 1 SEAL KIT FOR HYDRAULIC MOTOR 4678

A TORQUE MEASUREMENTS ADDED 19/03/13 M.D.B

B M10 CAPHEADS ADDED 30/01/14 M.D.B

1

H

G

F

2 3 4 5 6 7 8 9 10

H

G

F

E

7 8

D

C

B

9 10

A


Drawing no.

Sheet

Replace

Date

Replaced by


DAWSONCONSTRUCTION

PLANT LTD.

ROUGH MACHINE N9

FINE MACHINE N8GRIND N6


X . X = +/- 0.25

ANGLES +/- 0.5°


X . XX = +/- 0.05


X = +/- 0.5

E

D

C

B

A

1 2 3 4 5 6

3RD ANGLEE 4616D WAS 4616B PLW080212

F

K

J

1 2

I

H

G

3 4 5 6 7

E

D

C

B

A

1 2 3 4 5 6 7

F

8 9 10 11 12 13 14 15

K

J

I

H

G

8 9 10 11 12

E

D

C

13 14 15

B

A


Drawing no.

Sheet

Replace

Date

Replaced by


DAWSONCONSTRUCTION

PLANT LTD.

3RD ANGLE

ROUGH MACHINE N9



X . X = +/- 0.25

ANGLES +/- 0.5°


X . XX = +/- 0.05


X = +/- 0.5

A M5 CRACKING SCREW ADDED PLW27/04/09

B SEAL MATERIAL NUMBERS CHANGED PLW20/05/10

C 4616-8 2MM PITCH WAS4616-08 1.5MM PITCH PLW17/02/11

D 4760 ADDED TO BUILD PLW11/10/11

1

H

G

F

2 3 4 5 6 7 8 9 10

H

G

F

E

7 8

D

C

B

9 10

A


Drawing no.

Sheet

Replace

Date

Replaced by


DAWSONCONSTRUCTION

PLANT LTD.

ROUGH MACHINE N9



X . X = +/- 0.25

ANGLES +/- 0.5°


X . XX = +/- 0.05


X = +/- 0.5

E

D

C

B

A

1 2 3 4 5 6

3RD ANGLE

-----

4620-2 issue C

13/11/2012

peter wattpeter watt

Saddle Assembly MKII

-


1

H

G

F

2 3 4 5 6 7 8 9 10

H

G

F

E

7 8

D

C

B

9 10

A


Drawing no.

Sheet

Replace

Date

Replaced by


DAWSONCONSTRUCTION

PLANT LTD.

ROUGH MACHINE N9

FINE MACHINE N8

GRIND N6


X . X = +/- 0.25

ANGLES +/- 0.5°


X . XX = +/- 0.05


X = +/- 0.5 A3

E

D

C

B

A

1 2 3 4 5 6

3RD ANGLE

EMV 400/450

1 of 1

6

A

ASECTION A-A 16

8 7

5

12

15

11

10 1918

2017 21 13

22

14

2 4 1

3

23

General Notes:- Weight 295Kg

9

23 1 EMV400 MKII SADDLE 4617-2

22 4 SANDWICH MOUNT ADAPTOR 4104

21 2 SLEEVE 4069

20 2 FLANGED BUSH 4068

19 1 SPLIT PIN 4067

18 1 SHEAR PIN 4066

17 2 SPACER 4065

16 2 BUFFER 4028

15 1 BEARING 51214 4026

14 8 SANDWICH MOUNTING 4025A

13 1 LIFTING BOLT 4024 issue C

12 1 NUT 4023 issue D

11 1 BUSH bronze Z4022 4022

10 1 THRUST WASHER 4021

9 1 GREASE NIPPLE 1/8" BSP 1-057-00-01

8 2 WASHER M16 0M16.000.20

7 2 NYLOC NUT - TYPE T M16 0M16.000.12

6 16 SOCKET HEAD CAP SCREW M16 x 35 LG 0M16-035-02

5 2 Coiled Spring Pin 0M12.100.36

4 32 HEX HD BOLT M12 x 40LG 0M12.040.01

3 32 HEX HD BOLT ST.STEEL M12 x 25LG 0M12.025.04

2 96 WASHER ST.STEEL M12 0M12.000.20

1 32 NYLOC NUT - TYPE T M12 0M12-000-12

B

DETAIL B

gap here

C2 x Coil Pins was one, thread pitch now

4mm was 2mm, FITTING NOTE ADDEDPLW29/06/10 Intro.

DRILLING PROCEDURE TO FIT PAIRS OF COIL PINSREQUIRES THE HOLES TO BE SLIGHTLY BIGGER THAN PREVIOUS SINGLE CENTRAL COIL PIN DESIGN OTHERWISE TOO DIFFICULT TO INSTALL HEAVY DUTY COIL PINS.TIGHTEN NUT FULLY SO THAT LIFTING BOLT CAN ONLY BE TURNED BY HAND USING 2 FOOT LONG BAR. PREVENT BOLT FROM TURNING, USING THE O 11.5 PRE-DRILLED PILOT HOLE ON THE SIDE THAT WILL TIGHTEN THE NUTDRILL THROUGH NUT, BOLT AND OTHER SIDE OF NUT TO O 12.2/ 12.3 CHAMFER LEAD OF HOLE, LUBRICATE AND FIT FIRST COIL PIN THEN REPEAT DRILLING FOR SECOND HOLEAND FITTING OF SECOND COIL PIN.

1.3mm THICK STEEL HEAVY DUTY COIL PIN TYPE 8748 = 120kN Double Shear1mm THICK STEEL NORMAL DUTY COIL PIN TYPE 8750 = 89kN Double Shear

1

H

G

F

2 3 4 5 6 7 8 9 10

H

G

F

E

7 8

D

C

B

9 10

A


Drawing no.

Sheet

Replace

Date

Replaced by


DAWSONCONSTRUCTION

PLANT LTD.

ROUGH MACHINE N9



X . X = +/- 0.25

ANGLES +/- 0.5°


X . XX = +/- 0.05


X = +/- 0.5

E

D

C

B

A

1 2 3 4 5 6

3RD ANGLE

1

H

G

F

2 3 4 5 6 7 8 9 10

H

G

F

E

7 8

D

C

B

9 10

A


Drawing no.

File

Replace

Date

Replaced by


DAWSONCONSTRUCTION

PLANT LTD.

ROUGH MACHINE N9



X . X = +/- 0.25

ANGLES +/- 0.5°


X . XX = +/- 0.05


X = +/- 0.5

E

D

C

B

A

1 2 3 4 5 6

3RD ANGLE

12

JIHGF

34

56

EDCBA

12

34

56

78

910

1112

JIHGF

78

910

EDC

1112

BA

Cop

ied

Des

ign

byD

raw

n by

Che

cked

Sta

ndar

dS

cale

Affi

rmed

Dra

win

g no

.

She

et

Rep

lace

Dat

e

Rep

lace

d by

Qnt

.R

f.nr

Rev

isio

nA

ppr.

byD

ate

Intr

o.

DA

WS

ON

CO

NS

TRU

CTI

ON

PLA

NT

LTD

.

3RD

AN

GLE

ROUG

H M

ACHI

NE N

9

FINE

MAC

HINE

N8

GRI

ND

N6

UNLE

SS S

TATE

D O

THER

WIS

ESU

RFA C

E FI

NISH

X . X

= +

/- 0.

25

ANG

LES

+/- 0

.5°

MAC

HINI

NG T

OLE

RANC

ESUN

LESS

STA

TED

OTH

ERW

ISE

X . X

X =

+/- 0

.05

DIM

ENSI

ONS

IN M

ILLI

MET

ERS

X =

+/- 0

.5

CAISSON BEAMBOLT FIXING ARRANGEMENT

EMV300 CLAMP ARRANGEMENT



STANDARD LIFTING CHAIN ARRANGEMENT

LIFTING CHAIN FOR DOUBLE CLAMP - 4681D

FITTING TO CHAIN HOLDER

OVERALL VIEW

EMV MODELTO MAINTAIN AMPLITUDE IN EXCESS OF 4MM, MAX

RECOMMENDED PILE MASS450 1000KG550 1400KG

SWL 1.6T

TIGHTENING TORQUES FOR SCREWS WITH STANDARD METRIC THREAD

Screw size

Preload values FM based on Grades in N

Tightening torques MA based on Grades in Nm

Wrench size for

Hex head screw Socket head screw

8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch

M4 x 0.7 3,900 5,700 6,700 3.1 4.5 5.3 7 9/32 3 -

M5 x 0.8 6,400 9,300 10,900 6.1 8.9 10.4 8 - 4 5/32

M6 x 1 9,000 13,200 15,400 10.4 15.5 18.0 10 - 5 -

M7 x 1 13,100 19,300 22,600 17.0 25.0 30.0 11 - - -

M8 x 1.25 16,500 24,200 28,500 25 37 43 13 1/2 6 -

M10 x 1.5 26,000 38,500 45,000 51 75 87 17 11/16 8 -

M12 x 1.75 38,500 56,000 66,000 87 130 150 19 3/4 10 -

M14 x 2 53,000 77,000 90,000 140 205 240 22 7/8 12 -

M16 x 2 72,000 106,000 124,000 215 310 370 24 61/64 14 9/16

M18 x 2.5 91,000 129,000 151,000 300 430 510 27 1-1/16 14 9/16

M20 x 2.5 117,000 166,000 194,000 430 620 720 30 1-3/16 17 43/64

M22 x 2.5 146,000 208,000 243,000 580 970 830 32 1-9/92 17 43/64

M24 x 3 168,000 239,000 280,000 740 1,060 1,240 36 1-7/16 19 3/4

M27 x 3 221,000 315,000 370,000 1,100 1,550 1,850 41 1-5/8 19 3/4

M30 x 3.5 270,000 385,000 450,000 1,500 2,100 2,500 46 1-13/16 22 7/8

M33 x 3.5 335,000 480,000 560,000 2,000 2,800 3,400 50 2 24 61/64

M36 x 4 395,000 560,000 660,000 2,600 3,700 4,300 55 2-3/16 27 1-1/16

M39 x 4 475,000 670,000 790,000 3,400 4,800 5,600 60 2-3/8 27 1-1/16

NOTE!Preload forces and ghtening torques are based on lightly lubricated screws and nuts (corresponds to medium fric on μG = 0.14). Nm = x 0.7375 = . lbs.

EXCAVATOR MOUNTED OR CRANE SUSPENDED VIBRATORS

Driving / extracting when the movement is less than 1” (25mm) per minute is considered pratical refusal. Driving / extracting when movement is less than 1” (25mm) for more than 5 minutes of driving / extracting or driving at all when penetration is less than 1” (25mm) per minute and amplitude is greater than 1” (25mm) [ vibrator and pile are bouncing] is considered improper use and will void the warranty. Contact DCP for an alternative larger vibrator.

Principal Advantages. Compact, robust and reliable - no electrics!. Simple and fast attachment to excavator. Minimal height to maximise pile length. Slim design to drive single sheet piles. High power to weight ratio. Universal joint suspension for easy alignment of piles. Extremely low vibration transmitted to the excavator. Enviromentally friendly - low noise/localised directional vibration. Automatic hydraulic clamp operation. Flexiblity in application. Flow regulator prevents excessive oil supply to vibrator. Heavy saddles available for crane suspended models

Dawson excavator mounted vibrators have been designed specifically to work in place of an excavator bucket to drive and extract piles. The pile can be lifted to vertical using the built-in lifting chain where it is then gripped tightly in a powerful hydraulic jaw. Once secured, the pile is then vibrated with high frequency vibrations so as to ‘fluidise’ the soil resisting the pile. Down-crowd force applied by the excavator boom, coupled with the self-weight of the pile and the vibrator, provides sufficient force to push the pile into the ground.

Naturally, the process works in reverse for pile extraction. The equipment offers a highly productive and cost effective piling rig based around a standard, readily available excavator!

SPECIFICATION UNITS Excavator Mounted Vibro ModelEMV70 EMV220 EMV300A EMV450 EMV550

STATIC MOMENTin lbs 60 263 400 606 674

kgm 0.7 2.3 4.6 6.8 8.23FREQUENCY rpm 3,000 3,000 2,400 2,460 2,500

CENTRIFUGAL FORCElbs 15,730 50,236 67,420 100,000 125,592kN 70 220 300 453 564

AMPLITUDE - PEAK TO PEAK

in 0.157 0.45 0.58 0.54 0.54mm 4 12 14.7 13.7 13.7

MINIMUM REQUIRED FLOW RATE

gpm 8 24 35 52 68

L/min 30 90 130 195 256

MAXIMUM ALLOWABLEFLOW RATE

gpm 32 67 67 94 107

L/min 120 250 250 350 400

MINIMUM HYDRAULICPRESSURE

psi 3,480 4,060 4,060 3,915 4,060

bar 240 280 280 270 280

MAXIMUM HYDRAULICPRESSURE

psi 5,076 5,076 5,076 5,076 5,076

bar 350 350 350 350 350

MINIMUM HYDRAULICMOTOR POWER

hp 16 80 80 118 160

kW 12 50 60 88 120

DYNAMIC MASS INCLUDING UNIVERSAL

CLAMP

lbs 781 814 1,380 2,240 2,576

kg 355 370 625 1,008 1,150

TOTAL MASSINCLUDING UNIVERSAL

CLAMP

lbs 1,122 1,155 2,123 2,834 3,360

kg 510 525 965 1,275 1,500

MAXIMUM PILE MASSlbs 1,760 1,760 1,760 2,240 3,136

kg 800 800 800 1,000 1,400

MAXIMUM PUSH/PULLLOADING

lbs 6,171 16,500 33,600 33,600 49,500

kg 2,800 7,500 15,000 15,000 22,500

TYPICAL EXCAVATORWEIGHT

Ton 5.5 to 17 7.5 to 24 13 to 39 27 to 50 33 to 60

tonne 5 to 15 7 to 22 12 to35 25 to 45 30 to 55

CLAMP FORCE tonne 30 26.5 36 54 66

DIMENSIONSmm (inch)

A 445 (17.5) 445 (17.5) 615 (24) 615 (24) 646 (25.4)

B 40 (1.5) 40 (1.5) 25 (1) 32 (1.25) 50 (1.97)

C 275 (10.8) 275 (10.8) 250 (10) 230 (9) 370 (14.5)

D 431 (17) 431 (17) 582 (23) 640 (25) 708 (27.9)

E 431 (17) 431 (17) 429 (17) 510 (20) 555 (21.8)

F 850 (33.5) 850 (33.5) 927 (36.5) 945 (37) 11.37 (44.8)

G 1120 (44) 1120 (44) 1200 (47.25) 1250 (49) 1477 (58.2)

H 130 (5.1) 130 (5.1) 150 (6) 175 (6.9) 190 (7.5)

TECHNICAL SPECIFICATIONS

EDA

F G

HC

B

EMV300 Stand = 115kg

2 � 1 12

25

20

15

10

5

0

Radial distance from source (m)

Pea

k pa

rticl

e ve

loci

ty (m

m/s

)

EMV - Maximum Predicted vibration from piling operations - from BS5228

EMV 550EMV 450EMV 300EMV 70

30

Clamps Mass

300 Universal Clamp 163 kg



Caisson Beam with Clamps 670 kg

SPECIFICATION UNITSVIBRO MODEL

EMV70 EMV220 EMV300A EMV450 EMV550

TRANSPORT WEIGHTS(approx) kg 725 530 1165 1300 1500

DIMENSION ON A PALLLET (approx)

mmLxWxH 1.2x0.8x1.6 1.2x0.8x1.7 1.2x0.8x1.93 1.2x0.8x1.8 1.6x0.85x1.7

SE

LEC

TIO

N G

UID

ETh

ere

are

man

y va

riabl

es th

at d

eter

min

e ho

w e

ffect

ivel

y a

vibr

ator

y pi

le d

river

will

per

form

. Th

is g

raph

be

low

is a

gui

de, n

ot a

gua

rant

ee!

Vibr

ator

y dr

iver

s w

ork

at th

eir b

est i

n gr

anul

ar (g

rave

ls a

nd s

ands

) m

ater

ials

, whe

re th

e am

plitu

de in

the

pile

can

“flui

dise

” the

gro

und

and

allo

w th

e pi

le to

adv

ance

as

the

grou

nd re

arra

nges

itse

lf. T

hey

will

stil

l fun

ctio

n in

coh

esiv

e m

ater

ials

(cla

ys),

but p

iles

will

not

pen

etra

te a

s fa

r.

EX

CAV

ATO

R S

IZIN

G G

UID

EFo

r com

plet

ness

, the

flow

and

pre

ssur

e fro

m th

e ex

cava

tor t

o th

e E

MV

sho

uld

be c

heck

ed a

gain

st th

e sp

ecifi

catio

n sh

eets

to c

onfir

m a

dequ

ate

hydr

aulic

pow

er.

As

a gu

ide

the

EM

Vs

typi

cally

sui

t the

follo

win

g ba

se m

achi

ne s

izes

:E

MV

70 (r

equi

res

30 L

/min

, 240

bar

) 5.

5 - 1

7 t e

xcav

ator

E

MV

220

(req

uire

s 90

L/m

in, 2

80 b

ar)

7 - 2

2 t e

xcav

ator

EM

V30

0 (r

equi

res

130

L/m

in, 2

80 b

ar)

12 -

35t e

xcav

ator

EM

V45

0 (r

equi

res

195

L/m

in, 2

70 b

ar)

25 -

45t e

xcav

ator

EM

V55

0 (r

equi

res

256

L/m

in, 2

80 b

ar)

30 -

55t e

xcav

ator

EMV7

0EM

V300

EMV4

50EM

V550

1 2 3 4 5 6 7 8 9 10

PILE DRIVEN LENGTH (m)

EXA

MPL

E - A

5m

long

pile

, wei

ght 6

00kg

, gro

und

is g

ranu

lar a

nd m

ediu

m

dens

e. In

dica

tion

is th

at a

n E

MV

300

or la

rger

wou

ld b

e su

itabl

e.

1400

1200

1000

800

600

400

200

VERY

LOOSE

(SPT

<4)

LOO

SE (S

PT 4

-10)

MED

IUM

DEN

SE (S

PT 1

0-30

)

DEN

SE G

RAN

ULA

R O

R S

OFT

CO

HES

IVE

(SPT

30-5

0)

VER

Y D

ENSE

GR

ANU

LAR

OR

FIR

M C

OH

ESIV

E

(SPT

>50

)

PILE WEIGHT (kg)

EMV2

20

Part Number Quick Hitch Adaptor4586

QUICK HITCH ADAPTORWhen an excavator has a guide hitch fitted and a double acting breaker to supply the EMV, the Dawson quick hitch adaptor bracket supplies fast, easy connection to the end equipment while maintaining the same degree of movement.

Part Number Swan NeckSN01-000-01

SWAN NECKFor extended reach and greater pile clearance on your excavator arm, enabling longer piles to be driven.

CHAIN CLAMP For all lifting applications. The unit indexes along the links of the chain and locks into place giving a quick and simple chain lock for lifting.

Part Number Chain Type Safe Working Load4130 16 mm 8 tonnes

TLR 360 10 mm 3.2 tonnes4082 8 mm 2 tonnes

Features. SWL of 2000 kg for the 8 mm chain clamp 3200 kg for the 10 mm chain clamp 8000 kg for the 16 mm chain clamp. Robust high strength steel body. Designed to withstand vibration - no screws or bolts!. Minimal parts for durability. Proof loading to twice the safe working load. Quick coupling and release from load

NEW ADDITIONAL SAFETY LATCH

Part Number Caisson Beam Assembly4900

CAISSON BEAMCaisson beam jaw assemblies can be positioned to suit any tube size between Ø300 I.D & Ø1100 mm O.D.

Part Number Dimensions - mm

Dipper Pin Part Number

A B C D4063 340 60 175 140 4089

4063A 495 80 200 190 4089A4063C 458 89.5 225 190 4089C4063D 410 60 200 190 4089D4063E 458 60 225 190 4089E4063F 495 63.75 200 190 4089F4063M 458 63.75 225 190 4089M4063R 495 69.85 225 190 4089R

ADAPTOR BRACKETS

EX

CAV

ATO

R M

OU

NTE

D E

QU

IPM

EN

T

A

ØB

C

D

A

CB

Dawson’s excavator mounted drilling machine has been designed to fit via an adaptor plate to the stick arm of an excavator and runs via the flow and return lines that normally supply the bucket or a double acting breaker circuit .

There are five models to choose from starting at 17.5kNm up to 48.5kNm that cover a wide range of applications from drilling precise holes in many varied ground conditions, subject to the auger/drill bit, through to stirring the ground prior to using a Dawson EMV vibro piling machine.

By selecting the correct drill bit combined with the down-crowd force of the excavator the EMD will make light work of the most demanding conditions.

Another benefit of the EMD is that because its mounted on your excavator you can drill vertical holes, anywhere the excavator goes. It’s ideal for drilling over casings, on railway embankments, under bridges, or near power lines, + anywhere with low headroom constraints.

EXCAVATOR MOUNTED DRILL

DIMENSIONS (mm)TYPE A B C WEIGHT

(lbs) EMD 50 1250 700 465 690EMD 70 1250 725 500 710

EMD 100 1350 805 560 760EMD 140-120 1450 905 600 850

EMD 140 1450 905 600 850

0 50 100 150 200 250 300Nominal

350Max

EMD140 TORQUE @300 BAR = 42kNMEMD140-120 TORQUE @ 300 BAR = 36kNmEMD100 TORQUE @ 300 BAR = 30kNm

EMD70 TORQUE @ 300 BAR = 21kNm

EMD50 TORQUE @ 300 BAR = 15kNm

00.5

1

1.5

2

2.53

3.5

4 4.5

5

Pressure BAR

TOR

QU

E (x

10 k

Nm

)

0 100 200 300 400 500 600 7000

20

40

60

80

100120

140

160180200

220 EMD50 @ 700l/min220 rpm

EMD70 @ 700l/min158 rpm

EMD100 @ 700l/min 110 rpmEMD140-120 @ 700l/min 90 rpmEMD140 @ 700l/min80 rpm

Flow l/Min

rpm

Typical Hex Adaptor

A+1

55m

mA

PP

RO

X.

D.C.P. RESERVES THE RIGHT TO DISCONTINUE EQUIPMENT AT ANY TIME, OR CHANGE SPECIFICATIONS OR DESIGNS WITHOUT NOTICE OR INCURRING OBLIGATIONS

Dawson Construction Plant LtdChesney Wold.Bleak Hall,Milton Keynes,MK6 1NE, EnglandTel: +44 (0) 1908 240300Fax: +44 (0) 1908 240222

EMV-450 MetricEXCAVATOR MOUNTED VIBRATOR

Ver. EMV450M-06

MACHINE TYPEEMV550 EMV450 EMV400 EMV300 EMV70 VPC EMD140 EMD70

SADDLE ASSEMBLY Sandwich Mount Condition

Buffer Stop Condition

Top Swivel Condition Max gap 1mm (ideally no play)

Greased

Remarks:

CLAMP ASSEMBLYSerial No.

Static Jaw Condition

Moving Jaw Condition

GreasedChain Clamp (Serial No. )Lifting Chain (Serial No. )

Coupler (Serial No. )Remarks:

PRE-DELIVERY INSPECTION SHEET EMV’S, VPC’S AND EMD’S

Serial No:

Photo taken before dispatch:

ADAPTOR BRACKET / QUICK HITCH ASSEMBLYAdaptor Pin Diameter Length

Bushes ListAdditional Spares Supplied

GEARBOX ASSEMBLYOil Level

Leaks (Visual)

Case Breather Valve

Motor Blow off Valve

General Condition

Remarks:

HOSESHoses Condition

Spring Guard Condition

Running Leaks

Fittings

Additional Spares Supplied

Remarks:

Inspection Time / Date: Inspector Name:

Stand:Remarks:

VIBRO RUNNING CHECKSCycle Clamp x5 to Check Function

Close Clamp Stop Vibro & Leave for 5 mins (CLAMP MUST STAY CLOSED)

Run Vibro and Check for External Leaks Hoses

Fittings

Motor Blow Off Valve

QRC

Maximum gap allowed due to wear.(see photo)Check using a crowbar to force apart assembly, then insert a feeler gauge at least 20mm into gap, if more than 1mm change lifting bolt and nut immediately and check other components replacing as required.

www.dcpuk.com

DAWSON CONSTRUCTION PLANTCHESNEY WOLD,

BLEAK HALL,MILTON KEYNES,

MK6 1NEENGLAND

TEL. +44 1908 240300FAX. +44 1908 240222

EMAIL. [email protected]

DAWSON EMV INSPECTION PROCEDURE

WORLDWIDE DEALER NETWORK

GLOBAL SUPPLY, LOCAL SUPPORT.

A GUIDE TO EMV GENERAL MAINTENANCE PROCEDURE(USED WITH PDI CHECK SHEET)

ADAPTOR BRACKET ASSEMBLY

Remarks: • Check for wear on pin adaptor• Visual inspect weld condition• Check bushes for wear• Check pin is ok, free from warping

• Check for wear to post

• Grease

IMPORTANT! GREASE DAILY

SADDLE ASSEMBLY

Remarks: • Visual inspect saddle for cracks• Check sandwich mounts for splits / damage

• Check bump stops for damage

Severe wear to pin Wear to adaptor Wear to bush

When EMV is lifted, check there is no more than a 1mm gap here. A gap could mean wear to bearing or thrust washer

Old position of grease point on post

New position of grease point on end of saddle

GEARBOX ASSEMBLY

Remarks: • Check general condition• Check temperature of bearing - (Run on test pile for 15mins, check and compare, temperatures on bearing caps should be even)• Visual check for oil leaks - Bearing Cover / Gasket• Ensure all bolts are tight

• Check case breather valve

• Check oil levels

• Check motor blow off valve

Photo of EMV450

Damage to motor due to incorrect fitting of drain line

Temperature check on bearings with laser temperature gun

Photo of EMV300

HOSE ASSEMBLY

Remarks: • Check general condition• Check spring guard condition

• Insure fittings are all tight• Check for running leaks

Severe damage to hose assembly

Chain clamp on EMV300

CLAMP ASSEMBLY

Remarks: • Check Static and Moving jaw wear on teeth and general damage• Inspect chain for damage

• Inspect chain clamp where fitted for damage

Severe damage and wear to teeth on jaws on left, in comparrison new jaw on right

Damage to chain link

4mm new jaw

2mm acceptable wear level limit

SECTION OF JAW

STAND

Remarks: • Inspect general condition of stand

D.C.P. RESERVES THE RIGHT TO DISCONTINUE EQUIPMENT AT ANY TIME, OR CHANGE SPECIFICATIONS OR DESIGNS WITHOUT NOTICE OR INCURRING OBLIGATIONS

Dawson Construction Plant LtdChesney Wold.Bleak Hall,Milton Keynes,MK6 1NE, EnglandTel: +44 (0) 1908 240300Fax: +44 (0) 1908 240222

DAWSON EMV INSPECTION PROCEDURE

Documents

Emv450v6 metric hose kit - dcpuk.com metric hose kit.pdfvibrators excavator mounted drills quiet, vibrationless push-pull piling pile extraction sheet pile guide frames sheet pile