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Dawson EMV 550 Owner's Manual

Excavator mounted vibrator
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EMV
excavator mounted vibrator
550
excavator mounted vibrator
owners manual
DAWSON CONSTRUCTION PLANT LTD.
operators instructions
CHESNEY WOLD,
BLEAK HALL
spare parts list
MILTON KEYNES
safety precautions
MK6 1NE, ENGLAND
TEL: +44 (0) 1908 240300
maintenance
FAX: +44 (0) 1908 240222
EMAIL: JON@DCPUK.COM
EMV550 ver. 2018-01

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  • Page 1 DAWSON CONSTRUCTION PLANT LTD. operators instructions CHESNEY WOLD, BLEAK HALL spare parts list MILTON KEYNES safety precautions MK6 1NE, ENGLAND TEL: +44 (0) 1908 240300 maintenance FAX: +44 (0) 1908 240222 EMAIL: JON@DCPUK.COM...

  • Page 3: Table Of Contents

    You will find the model and serial numbers on an ID plate located on the product. The descriptions and specifications in this manual are subject to change without notice. Dawson reserves the right to improve products. Some product improvements may have taken place after this manual was printed.

  • Page 5: Eu Declaration Of Conformity

    We declare that the machinery/equipment detailed below is in compliance with the applicable regulations and harmonised standards as listed. This declaration ceases to be valid if alterations are made the machinery/equipment without agreement with Dawson Construction Plant Ltd. Category Piling Equipment...

  • Page 6: Basic Technical Specifications

    basic technical specifications FIG.1 SPECIFICATIONS EMV550 UNITS METRIC STATIC MOMENT 8.23 kgm 714 in Ibs FREQUENCY 2,500 rpm CENTRIFUGAL FORCE 564 KN 125,592 lbs.F AMPLITUDE 13.7 mm 0.54 in MIN HYDRAULIC FLOW RATE 256 L/min 68 gpm MAX HYDRAULIC FLOW RATE 400 L/min 107gpm MAX.

  • Page 7: Basic Safety Points

    basic safety points • The vibrator should only be operated by suitably qualified personnel. • The vibrator/clamps not to be used for lifting operations. • It is prohibited to leave an element suspended in the clamps of a vibrator, which is free hanging and out of operation.
  • Page 8 continued - basic safety points 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 •...

  • Page 9: Safety First - Quick Reference Guide

    The equipment is hired under C.P.A. conditions and as such any theft or damage caused by misuse or abuse will be charged accordingly. IN THE EVENT OF MALFUNCTION, DAMAGE OR LEAKAGE OF OIL, DAWSON CONSTRUCTION PLANT MUST BE NOTIFIED IMMEDIATELY.
  • Page 10 Check the screws, bolts, fitting etc. for tightness Check hydraulic hoses for leaks Check oil level in the excavator hydraulic tank Dawson Constrcution Plant Check the gear oil level in the vibrator. The level must be halfway up the sight glass Chesney Wold.

  • Page 11: How Does The Emv Work

    how does the emv 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.
  • Page 12 Saddle Assembly with Swivel Flow Regulator Gearbox and Sequence containing Valve accentric weights Hydraulic Drive Motor Transport Stand drive gear gearbox eccentric weight direction of motion resulting direction of force Motion of a pair of eccentrics Corresponding Sinusoide Time excavator mounted vibrator...

  • Page 13: Mounting Instructions

    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.
  • Page 14 continued - mounting instructions HYDRAULIC HOSES - LAYOUT & CONNECTIONS 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.

  • Page 15: Operating Instructions

    operating instructions 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: 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.
  • Page 16 continued - operating instructions 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 146mm (5.75”).
  • Page 17 Maximum deflection of sandwich mounts is achieved during extracting when the gearbox casing hits the safety stops (140mm). When driving piles a maximum deflection of 146mm can be achieved. This is when the top fasteners are inline with the lower. www.dcpuk.com...

  • Page 18: Operating Instructions Driving Piles (Quick Reference Illustrations)

    operating instructions driving piles (quick reference illustrations) The illustrations below are to show visually a simplified version of the operating instructions given in part 5.2/5.3, driving / extracting piles. 5.1 preparation before driving / extracting piles must be read before these illustrations.
  • Page 19 Lower the pile slowly so that the pile can be correctly inserted into the clamp. Once firmly inserted, close the jaws. Manoeuvre the pile to the insertion point and push the pile slowly into the ground. Plumb the pile then ensure all personnel are out of 90°...

  • Page 20: Operating Instructions - Extracting Piles (Quick Reference Illustrations)

    operating instructions - extracting piles (quick reference illustrations) The illustrations below are to show visually a simplified version of the operating instructions given in part 5.2/5.3, driving / extracting piles. 5.1 preparation before driving / extracting piles must be read before these illustrations.
  • Page 21 Start the vibrator and allow the soil to loosen around the pile. Start to lift up the pile. Ensure the pile clutches are not rubbing together. Pay attention to the distortion of the rubber sandwich mounts - under no circumstances should these mounts be allowed to deflect by more than the stipulated amount shown on Figure 1 in section 2.0.

  • Page 22: Recommended Excavator Positions (Quick Reference Illustrations)

    (quick reference illustrations) These illustrations represent the recommended working, transport and resting positions for your Dawson EMV attachment when used with an excavator. 90° Recommended: Recommended: Starting Position Drive / Extraction Position the pile vertically in desired location Lower the excavator arm in a consistent and begin drive / extracting.

  • Page 23: Maintenance

    • 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.
  • Page 24 continued - maintenance jaw should not move up and down. Fit the Cap Screw and tighten using a hexagonal wrench. Remember to install the washers on these screws. Changing the Hard Jaws – Moving (Cylinder) Side Release the 8off Cap Screws that hold the Clamp Cylinder in place and remove the Clamp Cylinder. Undo the two clamp supply hoses, carefully marking them to ensure correct re-assembly.
  • Page 25 Swivel Assembly Breather/ Filler Plug Gear Box Oil Sight Glass Crush Hazard Clamp Cylinder Lifting Chain & Chain Clamp Hard Jaws Caution Surface Gearbox Oil Drain plug Clamp Body www.dcpuk.com...
  • Page 26 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.

  • Page 27: Troubleshooting

    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 –...
  • Page 28 continued - troubleshooting EMV CLAMP CLOSES BUT THE UNIT WILL NOT VIBRATE 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.
  • Page 29 Sequence valve 11.5mm (default setting) Flow Compensator 8.5mm (default setting) Clamp Pressure Limiter 12mm (default setting) Flow Regulator 12-13mm (default setting) OIL BLOWING OUT OF THE MOTOR BLOW-OFF VALVE Drain line restricted or blocked – stop work immediately. Motor Blow Off Valve Check the drain line hose for obvious restrictions at fittings, filters etc.
  • Page 30 Consequently the clamp can be driven closed again. Should this problem occur Dawson could supply a reverse flow check valve as a fix.

  • Page 31: Emv550 Hose Kit

    emv550 hose kit Fittings: 3/8” BSP to 9/16” JIC M/M adaptor + Dowty washer 6 off 1/4” BSP to 9/16” JIC BSP M/M adaptor + Dowty washer 2 off 22x1.5 to 3/4” JIC BSP M/M adaptor 1 off 1/4” BSP to 7/16” JIC + Dowty washer 6 off 1/2”...
  • Page 32 continued - emv550 hose kit Fittings: Part No. 3/8” BSP to 3/8” BSP M/M adaptor + Dowty washer 6 off H00152 1/4” BSP to 3/8” BSP M/M adaptor + Dowty washer 2 off 22x1.5 to 1/2” BSP M/M adaptor 1 off H00162 1/4”...
  • Page 33 continued - emv550 hose kit METRIC Fittings: 3/8” BSP to 12L stud coupling + WD 5 off 3/8” BSP to 12S stud coupling + WD 1 off 1/4” BSP to 12L stud coupling + WD 2 off M22x1.5 to 16S stud coupling + WD 1 off 1/4”...

  • Page 34: Parts Lists For The Emv550 - Assembly Drawing

    parts lists for the emv550 www.dcpuk.com...
  • Page 35 DIPPER PIN WASHER 5090 DIPPER PIN 5089E Manifold Block EN50B 5071 F12-80 WORK IN PROGRESS FOR INFORMATION ONLY EMV 550 ADAPTOR BRACKET 5063E Drive Shaft End Cap BS 4360 En50B 4606 ESTIMATED WEIGHT 1550Kg SPLIT PIN 4067 CLAMP FORCE 66Tonne...
  • Page 36 X = +/- 0.5 ROUGH MACHINE N9 X . X = +/- 0.25 EMV550 Sheet 1 of 1 Date 22/02/2011 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 CONSTRUCTION ANGLES +/- 0.5° Drawing no. GRIND 5501 DRIVEN GEAR ASSEMBLY PLANT LTD.
  • Page 37 Qnt. Revision Date Intro. Appr.by 3RD ANGLE O-RING 0.0 kg H00345 HYDRAULIC MOTOR F12-80 36.0 kg 5675.1 EMV 550 GASKET 0.5 kg 5619 Drive Gear 14.8 kg 5610 Cover Plate BS 4360 21.3 kg 5604 En50B Modified Case Welded 298.5 kg...
  • Page 38 ROUGH MACHINE N9 X . X = +/- 0.25 Sheet 1 of 1 Date Clamp Cylinder 18/08/2009 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 CONSTRUCTION ANGLES +/- 0.5° Drawing no. EMV550 GRIND 5616A PLANT LTD.
  • Page 39 ROUGH MACHINE N9 X . X = +/- 0.25 Sheet 1 of 1 Date Clamp Assembly 08/09/2009 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 CONSTRUCTION ANGLES +/- 0.5° Drawing no. EMV 550 5618D GRIND PLANT LTD. DIMENSIONS IN MILLIMETERS...
  • Page 40 ROUGH MACHINE N9 X . X = +/- 0.25 Sheet 1 of 1 Date Single chain adaptor assy 04/08/2010 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 CONSTRUCTION ANGLES +/- 0.5° Drawing no. GRIND 4684 ADPT PLANT LTD.
  • Page 42 ROUGH MACHINE N9 X . X = +/- 0.25 Sheet 1 of 1 Date Saddle Assembly 15/06/2009 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 CONSTRUCTION ANGLES +/- 0.5° Drawing no. EMV 550 5620 GRIND PLANT LTD. DIMENSIONS IN MILLIMETERS...
  • Page 43 X = +/- 0.5 ROUGH MACHINE N9 X . X = +/- 0.25 Sheet 1 of 1 Date EMV550 25/03/2011 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 CONSTRUCTION ANGLES +/- 0.5° Drawing no. 5941 GRIND PLANT LTD. DIMENSIONS IN MILLIMETERS...
  • Page 47 Sequence valve 11.5mm (default setting) Flow Compensator 8.5mm (default setting) Flow Regulator 12-13mm (default setting) Clamp Pressure Limiter 12mm (default setting)

  • Page 48: Appendix A- Auxiliary Equipment

    appendix a- auxiliary equipment...
  • Page 49 EMV - AUXILLARY EQUIPMENT ITEM DESCRIPTION ITEM No. WEIGHTS CAISSON BEAM 4900 Weight EMV300 = 1500kg + (adaptor bracket) Caisson beam jaw assemblies can be Weight EMV450 = 1700kg + (adaptor bracket) positioned to suit any tube size between Ø300 I.D & Ø1100 mm O.D. Weight EMV550 = 1800kg + (adaptor bracket) SWAN NECK 4939...
  • Page 51 CAISSON BEAM BOLT FIXING ARRANGEMENT EMV300 CLAMP ARRANGEMENT EMV450 CLAMP ARRANGEMENT EMV550 CLAMP ARRANGEMENT...
  • Page 52 Ref.no. Qnt. Part name Material Dimension Remark Design by Drawn by Copied Checked Standard Affirmed Scale Replace Replaced by peter watt peter watt Sheet 1 of 1 Date 04/02/2011 SWAN NECK DIMENSIONAL DATA DAWSON CONSTRUCTION Drawing no. PLANT LTD. SN01-000-01...
  • Page 53 ROUGH MACHINE N9 X . X = +/- 0.25 Sheet Date SWAN NECK 1 of 12 16/03/2012 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 CONSTRUCTION ANGLES +/- 0.5° Drawing no. GRIND PLANT LTD. 4931-000-01 DIMENSIONS IN MILLIMETERS...
  • Page 54 ROUGH MACHINE N9 X . X = +/- 0.25 Sheet 1 of 11 Date SWAN NECK 22/01/2013 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 WEIGHT 470 KG CONSTRUCTION ANGLES +/- 0.5° Drawing no. GRIND 4932 PLANT LTD.
  • Page 55 REMOVE ALL BURRS AND SHARP EDGES ROUGH MACHINE N9 X . X = +/- 0.25 Sheet 1 of 4 Date SWAN NECK 15/12/2015 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 WEIGHT 340 KG CONSTRUCTION ANGLES +/- 0.5° Drawing no. 1500MM GRIND 4934 PLANT LTD.
  • Page 57 ROUGH MACHINE N9 X . X = +/- 0.25 Sheet 1 of 1 Date Quick Hitch Assy 06/03/2012 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 CONSTRUCTION ANGLES +/- 0.5° Drawing no. GRIND 4586 PLANT LTD. DIMENSIONS IN MILLIMETERS...
  • Page 58 X . X = +/- 0.25 ADVISED WHEN PLACING ORDER Sheet 1 of 1 Date Quick Hitch Assy 01/03/2013 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 CONSTRUCTION ANGLES +/- 0.5° Drawing no. With integrated adaptor bracket GRIND 4589 PLANT LTD.
  • Page 59 STANDARD LIFTING CHAIN ARRANGEMENT LIFTING CHAIN FOR 4681D DOUBLE CLAMP - SWL 1.6T TO MAINTAIN AMPLITUDE EMV MODEL IN EXCESS OF 4MM, MAX RECOMMENDED PILE MASS 1000KG 1400KG OVERALL VIEW FITTING TO CHAIN HOLDER...
  • Page 60 ROUGH MACHINE N9 X . X = +/- 0.25 Sheet 1 of 1 Date Single chain adaptor assy 04/08/2010 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 CONSTRUCTION ANGLES +/- 0.5° Drawing no. GRIND 4684 ADPT PLANT LTD.
  • Page 61 TIGHTENING TORQUES FOR SCREWS WITH STANDARD METRIC THREAD Preload values F based on Tightening torques M Wrench size for Grades in N based on Grades in Nm Screw size Hex head screw Socket head screw 10.9 12.9 10.9 12.9 Inch Inch M4 x 0.7 3,900...
  • Page 62 PRE-DELIVERY INSPECTION SHEET EMV’S, VPC’S AND EMD’S MACHINE TYPE EMV550 EMV450 EMV400 EMV300 EMV70 EMD140 EMD70 ADAPTOR BRACKET / QUICK HITCH ASSEMBLY Serial No: Adaptor Pin Diameter Length Photo taken before dispatch: Bushes List Additional Spares Supplied HOSES SADDLE ASSEMBLY Hoses Condition Sandwich Mount Condition Spring Guard Condition...
  • Page 63 CFA CLEANERS PILE POINTS & SPLICERS SAFETY HANDLING / LIFTING EQUIPMENT SHEET PILE THREADERS excavator mounted vibrator emv550 DAWSON CONSTRUCTION PLANT LTD. CHESNEY WOLD, BLEAK HALL MILTON KEYNES MK6 1NE, ENGLAND TEL: +44 (0) 1908 240300 FAX: +44 (0) 1908 240222...

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