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MKT V-22/HP-365A Operating, Maintenance And Parts Manual

Hydraulic vibratory pile driver/extractor system with cummins engine
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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.
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
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.
Manual No. 140602

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Summary of Contents for MKT V-22/HP-365A

  • Page 1 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.
  • Page 2 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.

  • Page 3: Table Of Contents

    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...

  • Page 4: Introduction

    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.
  • Page 5 II. SPECIFICATIONS FOR V-22/HP-365A VIBRATORY PILE DRIVER/EXTRACTOR SYSTEM A. OPERATING DATA - V-22 DRIVER/EXTRACTOR Driving Force........... .

  • Page 6: Specifications

    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.
  • Page 7 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.

  • Page 8: System Set Up Instructions

    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.
  • Page 9 IV. SYSTEM SET UP INSTRUCTIONS (CONTINUED) B. CONNECTION OF HOSES (CONTINUED) 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"...
  • Page 10 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.
  • Page 11 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...

  • Page 12: Start Up Procedures

    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.
  • Page 13 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.
  • Page 14 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.
  • Page 15 V. START UP PROCEDURES (CONTINUED) G. START UP LIST (CONTINUED) 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. Run the engine at part throttle for approximately five minutes for warm-up.

  • Page 16: Operating Instructions

    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-...
  • Page 17 VI. OPERATING INSTRUCTIONS (CONTINUED) B. OPERATING THE V-22/HP-365A SYSTEM - EXTRACTING MODE 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.
  • Page 18 VI. OPERATING INSTRUCTIONS (CONTINUED) B. OPERATING THE V-22/HP-365A SYSTEM - EXTRACTING MODE (CONTINUED) 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.

  • Page 19: Maintenance And Service Instructions

    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...
  • Page 20 VII. MAINTENANCE AND SERVICE INSTRUCTIONS (CONTINUED) 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.
  • Page 21 VII. MAINTENANCE AND SERVICE INSTRUCTIONS (CONTINUED) H. The V-22/HP-365A system normally has the hydraulic reservoir, hose bundle, and hammer lines filled with hydraulic fluid. Whenever the system has been completely or partially drained (as when a new hose bundle section is replaced in the hose bundle), the hydraulic lines must be purged of air.
  • Page 22 VII. MAINTENANCE AND SERVICE INSTRUCTIONS (CONTINUED) WARNING: DO NOT START THE POWER UNIT IF THE CLAMP PUMP HAS BEEN INOPERABLE FOR A LONG PERIOD OF TIME WITHOUT FIRST CHECKING TO BE SURE THAT THE PUMP IS PRIMED (I.E., THE PUMP CASE FULL OF OIL). THIS WILL PREVENT THE STARTING OF THE PUMP WITHOUT LUBRICATION WHICH CAN CAUSE PUMP DAMAGE.
  • Page 23 VII. MAINTENANCE AND SERVICE INSTRUCTIONS (CONTINUED) J. The HP-365A hydraulic reservoir, V-22 exciter case and HP-365A pump drive have been filled with the proper fluids at the factory. Use the following list for adding fluids which are compatible with those used at the factory. 1.
  • Page 24 3. V-22 exciter case lube oil a. Change after every 50 hours of driving time M. In general the field service that is done by the operators of the V-22/HP-365A is limited to daily maintenance. The drawings and related parts for identification given in this manual are for reference while discussing troubles or symptoms of trouble with the service department of your authorized distributor.

  • Page 25: Drawings And Parts Lists

    MKT factory authorized distributors are properly equipped and should be contacted to provide such service. For the name and address of the nearest MKT factory authorized distributor call MKT Manufacturing Inc., St. Louis, Missouri at 314/388-2254. -22-...
  • Page 26 -23-...
  • Page 27 PARTS LIST V22 GENERAL ASSEMBLY (419 00 00) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 419 00 02 EXCITER CASE 419 00 15 GEAR/ECCENTRIC ASS’Y-MALE 419 00 16 GEAR/ECCENTRIC ASS’Y-FEMALE 419 00 12 BEARING COVER 913 02 19 O-RING 905 07 11...
  • Page 28 PARTS LIST V22 GENERAL ASSEMBLY (419 00 00) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 430 00 24 MOTOR GASKET 901 59 17 HEX HEAD CAP SCREW 902 05 15 FLAT WASHER 923 12 22 FLANGE ADAPTER 923 03 14...
  • Page 29 PARTS LIST V22 GENERAL ASSEMBLY (420 10 00) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 901 59 13 HEX HEAD CAP SCREW 416 01 21 SUPPORT MOTOR GUARD 430 00 52 HOSE BLOCK 901 57 21 HEX HEAD CAP SCREW...
  • Page 30 PARTS LIST V22 GENERAL ASSEMBLY (419 00 00) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 416 01 60 150’ HOSE BUNDLE 923 11 23 ADAPTER 419 00 28 HOSE ASSEMBLY-22” 901 63 15 HEX HEAD CAP SCREW-CLAMP -27-...
  • Page 31 V-22 HYDRAULIC CLAMP ASSEMBLY (416 01 30) -28-...
  • Page 32 PARTS LIST V-22 HYDRAULIC CLAMP ASSEMBLY (416 01 30) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 420 01 28 CLAMP HOUSING 495 00 76 CLAMP SLIDE 436 01 41 CLAMP JAW - FIXED 420 01 26 CLAMP JAW - MOVABLE...
  • Page 33 PARTS LIST V20B HYDRAULIC CLAMP ASSEMBLY (416 01 30) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 420 01 33 CLAMP JAW - SCREW TYPE - AS REQ'D FIXED 499 00 96 CLAMP JAW - DOUBLE SHEET AS REQ'D FIXED 420 01 36...
  • Page 34 OPTIONAL V-22 CLAMP JAWS -31-...
  • Page 35 -32-...
  • Page 36 PARTS LIST V22 ECCENTRIC SHAFT ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 419 00 15 ECCENTRIC - GEAR SUB ASSEMBLY m (USING GEAR PART NUMBER 419 00 07) 419 00 16 ECCENTRIC - GEAR SUB ASSEMBLY f (USING GEAR PART NUMBER 419 00 08)
  • Page 37 -34-...
  • Page 38 PARTS LIST V22 MOTOR SHAFT ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 419 00 13 MOTOR SHAFT COVER 905 07 09 SOCKET HEAD CAP SCREW 913 02 18 O-RING 914 01 26 SPHERICAL ROLLER BEARING 419 00 09 V22 ONE PIECE MOTOR PINION...
  • Page 39 HP-365A POWER UNIT ASSEMBLY -36-...
  • Page 40 HP-365A POWER UNIT ASSEMBLY -37-...
  • Page 41 HP-365A POWER UNIT ASSEMBLY -38-...
  • Page 42 HP-365A POWER UNIT ASSEMBLY -39-...
  • Page 43 PARTS LIST HP-365A GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 417 20 01 HP-365A ENCLOSURE 901 53 15 HEX HEAD CAP SCREW 920 00 08 HEX NUT WITH NYLON INSERT 943 04 27 U-TAPPED HOLE NUT 417 30 43...
  • Page 44 PARTS LIST HP-365AGENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 933 03 41 BATTERY 406 03 04 BATTERY HOLD DOWN 406 03 05 BATTERY HOLD DOWN ROD 920 00 18 HEX NUT WITH NYLON INSERT 933 03 48 BATTERY CABLE 4 ft.
  • Page 45 PARTS LIST HP-365A GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 923 00 66 ADAPTER-FUEL RETURN @ SKID 923 02 00 ADAPTER-FUEL RETURN @ SKID 923 11 84 ADAPTER-FUEL RETURN @ SKID 923 11 85 ADAPTER-FUEL SUCTION @ ENG.
  • Page 46 PARTS LIST HP-365A GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 903 06 09 LOCKWASHER 901 58 13 HEX HEAD CAP SCREW 911 02 38 HYDRAULIC PUMP DRIVE 911 01 99 HYDRAULIC PUMP 902 05 15 FLAT WASHER HARDENED...
  • Page 47 PARTS LIST HP-365A GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 944 00 31 RAIN CAP 933 03 31 TEMPERATURE SWITCH 923 00 16 ADAPTER-DRAIN @ BH 923 04 30 ADAPTER 923 03 80 ADAPTER 923 10 49 ADAPTER-PUMP...
  • Page 48 PARTS LIST HP-365A GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 927 00 48 DUST CAP 927 00 46 QUICK DISCONNECT 923 12 68 ADAPTER 923 10 76 ADAPTER-BULKHEAD 417 30 11 HOSE-PUMP PRESS. TO BH 923 09 50...
  • Page 49 PARTS LIST HP-365A GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 923 11 13 ADAPTER-CLAMP VALVE 923 11 28 ADAPTER SHUTTLE VALVE&CLAMP PUMP 417 30 41 HOSE-SHUTTLE VALVE TO PUMP 931 05 98 SUCTION STRAINER 923 01 92 ADAPTER-CLAMP SUCTION...
  • Page 50 PARTS LIST HP-365A GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 933 03 56 RING 931 06 31 MAGNETIC PLUG-TANK 411 00 21 NAMEPLATE "MOTOR RETURN" 411 00 23 NAMEPLATE "CLAMP CLOSE" 411 00 22 NAMEPLATE "CLAMP OPEN" 411 00 13 NAMEPLATE "DRAIN"...
  • Page 51 PARTS LIST HP-365A GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 927 00 05A QUICK DISCONNECT 417 30 42 HOSE-PUMP TO FILTER 923 12 18 ADAPTER-PUMP 923 12 19 ADAPTER-PUMP 923 10 12 ADAPTER 923 05 88 ADAPTER 923 09 18...
  • Page 52 PARTS LIST HP-365A GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 950 01 40 THREADED ROD 950 03 08 METRIC LOCK WASHER 923 13 60 SPLIT FLANGE 931 08 55 FILTER ELEMENT 923 13 60 SPLIT FLANGE 417 30 49 THROTTLE CONTROL ASSY.
  • Page 53 V-22 150' HYDRAULIC HOSE BUNDLE (416 01 60) -50-...
  • Page 54 PARTS LIST V-22 150' HYDRAULIC HOSE BUNDLE (416 01 60) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 923 08 77 ADAPTER 418 00 43 50' MOTOR INLET LINE 445 02 90 50' MOTOR RETURN LINE 923 04 73 ADAPTER 927 00 46...
  • Page 55 HP-365A CONTROL PANEL ASSEMBLY (417 30 44) -52-...
  • Page 56 PARTS LIST HP-365A CONTROL PANEL ASSEMBLY (417 30 44) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 417 30 46 CONTROL PANEL 411 00 31 HYD. POWER UNIT SPEC. TAG 699 02 77 SAFETY CAUTION SIGN 099 06 00 EAR PROTECTION DECAL...
  • Page 57 HP-365A/HP600 ELECTRICAL CONTROL ASSEMBLY (417 30 45) -54-...
  • Page 58 PARTS LIST HP-365A/HP600 ELECTRICAL CONTROL ASSEMBLY (417 30 45) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 417 30 47 ELECTRICAL CONTROL ENCLOSURE 933 02 06 STANDARD LEGEND PLATE, BLACK - POWER ON 933 01 49 GREEN LENS 933 04 00...
  • Page 59 PARTS LIST HP-365A/HP600 ELECTRICAL CONTROL ASSEMBLY (417 30 45) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 933 03 92 LENS BUTTON - GREEN 933 03 93 LEGEND PLATE, BLACK - START/CLAMP PSI 933 04 03 PENDANT RECEPTACLE 933 04 04 RECEPTACLE COVER &...
  • Page 60 PARTS LIST HP-365A/HP600 ELECTRICAL CONTROL ASSEMBLY (417 30 45) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 933 03 70 WIRE 60’ 933 02 98 STRANDED WIRE 63’ 943 04 30 LOCK NUT 417 24 02 SUBPLATE 933 04 31 TERMINAL BLOCK...
  • Page 61 REMOTE PENDANT AND CABLE ASSEMBLY (441 08 62) -58-...
  • Page 62 PARTS LIST REMOTE PENDANT AND CABLE ASSEMBLY (441 08 62) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 933 03 90 PUSHBUTTON ENCLOSURE 933 01 45 PUSHBUTTON - RED 933 02 61 STANDARD LEGEND PLATE, RED - STOP 933 01 51...
  • Page 63 PARTS LIST REMOTE PENDANT AND CABLE ASSEMBLY (441 08 62) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 933 03 21 CONTACT BLOCK 933 04 30 DROP GRIP 933 04 31 LOCK NUT 933 04 32 S-HOOK -60-...

  • Page 64: Hp-365A Electrical Schematic

    HP-365A ELECTRICAL SCHEMATIC (417 30 50) -61-...
  • Page 65 HP-365A HYDRAULIC SCHEMATIC (417 00 12) -62- PARTS LIST...
  • Page 66 HP-365A HYDRAULIC SCHEMATIC (417 00 12) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 944 01 78 CUMMINS M11 ENGINE 911 02 10 HYDRAULIC PUMP DRIVE 911 01 99 HYDRAULIC PUMP 911 02 08 HYDRAULIC PUMP 931 05 99 SUCTION STRAINER...
  • Page 67 HP-365A HYDRAULIC SCHEMATIC (417 00 12) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 931 05 93 CLAMP CONTROL VALVE 931 05 94 RELIEF VALVE MODULE 931 05 95 VALVE SUBPLATE 931 06 08 DRIVE PRESSURE GAUGE 931 06 07 CLAMP PRESSURE GAUGE...
  • Page 68 CAISSON CLAMP ASSEMBLY (4 495 05 39) -65- PARTS LIST...
  • Page 69 CAISSON CLAMP ASSEMBLY (4 495 05 39) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 495 05 32 CAISSON CLAMP HOUSING 495 03 50 FIXED JAW 905 11 31 SOCKET HEAD CAP SCREW 903 04 21 LOCKWASHER 495 00 63 JAW SLIDE...
  • Page 70 CAISSON CLAMP ASSEMBLY FOR CAISSON BEAMS (495 05 39) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 913 02 02 GLASS FILLED TEFLON SEAL 495 04 23 PISTON 913 02 05 U-SEAL 931 07 54 CHECK VALVE 495 05 57 HOSE...
  • Page 71 HYDRAULIC LOCKING CAISSON CLAMPS ADJUSTMENT READ THESE INSTRUCTIONS COMPLETELY BEFORE ATTEMPING TO ADJUST CAISSON CLAMPS ON BEAM...
  • Page 72 Connect all hydraulic hoses to power unit. Suspend the vibratory pile driver vertically with bottom of clamp assemblies resting on a solid surface. Clean the lower sliding surfaces of the caisson beam to allow the clamp assemblies to slide without debris getting between the clamp assemblies and the caisson beam.

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