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MKT V-5Esc/HP-185T3A Service, Operating, Maintenance And Parts Manual

Hydraulic vibratory pile driver/extractor system
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MANUFACTURING, INC.
1198 PERSHALL RD.
ST. LOUIS, MO 63137, USA
Telephone: 314-388-2254
Fax: 314-388-1218
Website: www.mktpileman.com
SERVICE, OPERATING, MAINTENANCE
AND PARTS MANUAL FOR V-5Esc/HP-185T3A
HYDRAULIC VIBRATORY PILE
DRIVER/EXTRACTOR SYSTEM
Proposition
65
OCCUPATIONAL HEALTH WARNINGS:
1. Construction equipment frequently operates at very high sound
levels. Such sound levels can be harmful to the human hear-
ing 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 install, operate, or service the V-5Esc until having thor-
oughly read this manual and having received instructions from
an MKT factory authorized service representative or properly
trained, experienced operator. Make this manual available to
all persons responsible for the operation, installation, ser-
vicing and maintenance of this product. Also wear proper
clothing and personal protection equipment such as, safety
shoes, safety goggles, hearing protection and hard hat.
WARNING
THIS PRODUCT MAY CONTAIN OR EMIT
CHEMICALS SUCH AS DIESEL ENGINE
EXHAUST AND SOME OF ITS CONSTITUENTS
THAT ARE KNOWN TO THE STATE OF
CALIFORNIA TO CAUSE CANCER, BIRTH
DEFECTS, AND OTHER REPRODUCTIVE HARM.
MANUAL NUMBER 101202

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Summary of Contents for MKT V-5Esc/HP-185T3A

  • Page 1 2. Do not install, operate, or service the V-5Esc until having thor- oughly read this manual and having received instructions from an MKT factory authorized service representative or properly trained, experienced operator. Make this manual available to all persons responsible for the operation, installation, ser- vicing and maintenance of this product.
  • Page 2 MANUFACTURE OR SUPPLY OF THE PRODUCT. MKT shall not be liable to User or any third party for any loss of profits, loss of use, interruption of business, or any indirect, incidental, special, punitive or consequential damages of any kind whatsoever related to the product or the use or operation of the product.

  • Page 3: Table Of Contents

    A. V-5Esc GENERAL ASSEMBLY & PARTS LIST B. V-5ESC HYDRAULIC CLAMP ASSEMBLY & PARTS LIST C. 100’ HYDRAULIC HOSE BUNDLE & PARTS LIST D. V-5Esc/HP-185T3A HYDRAULIC SCHEMATIC & PARTS LIST E. ECCENTRIC SHAFT ASSEMBLY & PARTS LIST F. MOTOR SHAFT ASSEMBLY & PARTS LIST G.

  • Page 4: Introduction

    All visitors or other personnel in the immediate area of operating equipment must wear all necessary personal protective equipment. The MKT V-5Esc Hydraulic Vibratory Pile Driver/Extractor System is used for installing or removing piling. The five major components of an MKT Vibratory Pile Driver/Extractor include rotating eccentric weights housed in a gear box that generate the vibratory forces to the pile,...

  • Page 5: Safety Instructions

    SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FAILURE TO COMPLY WITH THE FOLLOWING SAFETY INSTRUCTION AND LOCAL REGULATIONS WILL RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH. The following safety instructions are contained in the text of this manual. Read the entire manual before operating the hammer. Remember SAFETY IS UP TO YOU! Good safety practices not only protect you but also protect the people around you.
  • Page 6 To continue operations the obstruction must be removed or penetrated by switching to another driving system such as a larger vibro or a MKT diesel or air pile hammer.
  • Page 7 If a tool, procedure, work method or operating technique not specifically recommended by MKT is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the equipment will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
  • Page 8 SAFETY INSTRUCTIONS UNLESS INSTRUCTED DIFFERENTLY, PERFORM ALL MAINTENANCE AS FOLLOWS Stop the hammer or drill. Stop the engine. Disconnect the battery whenever performing any maintenance or before servicing the electrical system. If the engine has electric starters, disconnect and tape the battery ground leads to prevent accidental starting.
  • Page 9 SAFETY INSTRUCTIONS HOSES, LINES, AND TUBES Do not pull on, or attempt to move equipment, with hydraulic hoses. Move power unit closer to work if hoses do not reach. Do not operate this equipment with hydraulic hoses that are damaged or kinked. Replace damaged hoses immediately.
  • Page 10 SAFETY INSTRUCTIONS FIRE OR EXPLOSION PREVENTION All fuels, most lubricants, hydraulic oil, and some coolant mixtures are flammable. Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel and gasoline fumes are extremely explosive. Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting on them.
  • Page 11 Check wire rope clips for tightness, and check wire ropes for wear daily. If there are any questions about the weights, specifications, or performance of the hammer or drill, contact MKT before handling or operating the equipment. Do not attempt to connect the quick-disconnect couplers when the power unit is running.

  • Page 12: Specifications

    SPECIFICATIONS III. SPECIFICATIONS SPECIFICATIONS FOR THE V-5ESC/HP-185T3A VIBRATORY PILE DRIVER/EXTRACTOR SYSTEM A. OPERATING DATA - V-5Esc DRIVER/EXTRACTOR Free Hanging Frequency ........1700 CPM Rated Drive Pressure .

  • Page 13: Excavator Requirements

    EXCAVATOR REQUIREMENTS | 11 EXCAVATOR REQUIREMENTS A. The excavator size, stick width and pin dimensions must be compatible with the Rototilt width and pin dimensions. B. The excavator must be equipped with a uni-directional auxiliary circuit that can supply 80 gpm to the V-5Esc at 3,000 psi. The auxiliary circuit flow must have priority over the boom and stick functions, or greater flow and additional modifications may be required to maintain hammer speed when operating boom or stick functions.

  • Page 14: System Set-Up Instructions

    12 | SYSTEM SET-UP INSTRUCTIONS SYSTEM SET-UP INSTRUCTIONS A. HP-185T3A HYDRAULIC POWER UNIT The HP-185T3A Hydraulic Power Unit is assembled on a Skid Base which also serves as a fuel tank. The skid base is fitted with a steel lifting bail with a lifting eye. The power unit is thus designed to be lifted by a crane line using a chain of adequate strength. Locate the HP-185T3A Power Unit on firm ground with an unobstructed operator view to the intended operation of the V-5Esc hammer.
  • Page 15 SYSTEM SET-UP INSTRUCTIONS | 13 5. Make it a habit whenever hydraulic lines are subsequently disconnected to immediately cap or plug them to avoid becoming dirty and introducing contamination, into and damage to, the components of the hydraulic system. Assure that the caps and plugs are wiped clean of any dirt or contamination before using.

  • Page 16: Start-Up Procedures

    C. HYDRAULIC VALVES The hydraulic valves in the HP-185T3A Power Unit have already been set for proper pressures during the factory break-in and operation of the V-5Esc/HP-185T3A system. DO NOT MAKE ADJUSTMENTS TO THE VALVES WITHOUT THE ASSISTANCE OF A FACTORY TRAINED SERVICE REPRESENTATIVE.
  • Page 17 START-UP PROCEDURES | 15 The hydraulic fluid from the reservoir passes through the suction strainer and manual shutoff valve. THE SHUTOFF VALVE SHOULD BE USED FOR MAINTENANCE PURPOSES ONLY. The flow from the reservoir continues through a suction hose and enters the gear-type pump. After the flow leaves the hydraulic pump it enters the directional control valve which will be used to operate either the clamp circuit or vibrate circuit. A quick and full movement of the right-hand control lever will operate the clamp close cylinder in a short amount of time.

  • Page 18: Operating Instructions

    16 | OPERATING INSTRUCTIONS VII. OPERATING INSTRUCTIONS DRIVING MODE A. OPERATING THE V-5Esc SYSTEM - DRIVING MODE 1. First, check that the lifting capacity of the excavator, at the working radius, exceeds the combined weight of the V-5Esc assembly and the pile. Then, lift the pile using an appropriately sized cable between the pad eye on the suspension assembly and the lifting hole in the pile. (Refer to figures 1 and 2). Once the pile is hanging nearly vertical, guide it into the hammer jaws or thread the pile into an already driven pile.
  • Page 19 To continue operations the obstruction must be removed or penetrated by switching to another driving system such as a larger vibro or a MKT diesel or air pile hammer.
  • Page 20 18 | OPERATING INSTRUCTIONS EXCAVATOR MOUNT B. OPERATING THE V-5Esc SYSTEM - EXTRACTING MODE 1. For pile extracting operations, the V-5Esc hammer should be fitted with a shackle and an auxiliary line attached to the pad eye on the suspension assembly. The V-5Esc hammer is clamped to a steel sheet pile to be pulled and the auxiliary line is fastened into a lifting hole in the pile.
  • Page 21 OPERATING INSTRUCTIONS | 19 WARNING! The hammer and suspension must be kept in alignment with each other, and with the pile, when driving or extracting. Failing to do so will result in damage to the jaws and clamp cylinders. 4” 2”...

  • Page 22: Maintenance And Service Instructions

    B. Maintenance procedures for the diesel engine in the HP-185T3A are described in the Engine Manufacturer’s Manual. C. Properly maintaining the total V-5Esc/HP-185T3A system begins with cleanliness; assuring that no dirt or foreign material enters the hydraulic fluid circuit. Contamination of the components of the hydraulic system pumps, motors, valves, etc., will result in erratic operation, down-time, shortened equipment life, damaged parts and expensive repair or replacement parts costs.
  • Page 23 Exciter lube oil must be changed if seal failure occurs. H. The V-5Esc/HP-185T3A system normally has the HP-185T3A hydraulic reservoir, the hose bundle, and the V-5Esc hammer lines and components filled with hydraulic fluid. Whenever the system has been completely or partially drained (as when a new hose section is replaced in the hose bundle), the hydraulic lines must be purged of air.
  • Page 24 22 | MAINTENANCE AND SERVICE INSTRUCTIONS d) Look for any damage to the unit, in general that might cause it to fail when put into operation. e) Be sure there is fuel in the tank. f) Be sure there is cooling fluid in the radiator. g) Check the V-5Esc exciter case lube oil level. With exciter cold, lube level should be mid level of sight glass.
  • Page 25 3. Clamp Pressure - 2500 PSI 4. Hydraulic Oil Temperature - 115 degrees Fahrenheit to 165 degrees Fahrenheit L. Replacement Filter Part Number Listing: ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 944 02 43 ENGINE OIL FILTER 944 02 44...

  • Page 26: Service Trouble Shooting

    24 | SERVICE TROUBLE SHOOTING SERVICE TROUBLE SHOOTING A. HYDRAULIC POWER UNIT 1. Hydraulic Fluid Overheating Running the V-5Esc overloaded for long periods of time (drive pressure at 3000 PSI) dumps oil over the relief valve generating heat. Simply keep the V-5Esc operating but relax the load below the 3000 PSI level and the temperature should drop.
  • Page 27 SERVICE TROUBLE SHOOTING | 25 3. Internal Noise In Exciter Unusual noise in exciter generally means something is wrong - either a bearing is starting to fail, gear train restriction, or a hydraulic motor problem causing excessive drive loading. Lube oil level should be checked. 4.

  • Page 28: 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.
  • Page 29 DRAWINGS AND PARTS LISTS | 27...
  • Page 30 28 | DRAWINGS AND PARTS LISTS V-5ESC GENERAL ASSEMBLY (405 11 00) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 901 59 23 HEX HEAD CAP SCREW 900 50 07 HEX NUT 903 06 10 LOCK WASHER 402 02 07 FILL PLUG...
  • Page 31 DRAWINGS AND PARTS LISTS | 29 V-5ESC GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 903 06 08 LOCK WASHER 405 12 03 SUSPENSION HOUSING 901 59 25 HEX HEAD CAP SCREW 923 05 88 ADAPTER 923 09 47...
  • Page 32 30 | DRAWINGS AND PARTS LISTS NOTE: Press fit pin, item 8, thru slide,item 3, and into hydraulic cylinder, item 15, shaft before assembling into clamp housing, item 1. CLAMP BLEEDING PROCEDURE THE FOLLOWING PROCEDURE MUST BE DONE TO ENSURE PROPER CLAMPING FUNCTION -JAW DAMAGE WILL OCCUR IF NOT DONE- 1 START HAMMER WITH HAMMER HANGING VERTICAL. 2 PULL AND HOLD CLAMP CLOSE LEVER ON POWER UNIT VALVE.
  • Page 33 DRAWINGS AND PARTS LISTS | 31 V-5ESC HYDRAULIC CLAMP ASSEMBLY(405 03 10) 405 03 07 CLAMP HOUSING 405 01 34 JAW SHIELD 405 03 11 CLAMP SLIDE 405 00 89 SLIDE KEY 405 02 84 SCREW TYPE JAW - FIXED END 405 00 76 SCREW TYPE JAW - MOVABLE END 405 00 91...
  • Page 34 32 | DRAWINGS AND PARTS LISTS...
  • Page 35 DRAWINGS AND PARTS LISTS | 33 HP-185T3A HYDRAULIC HOSE BUNDLE (170 01 10) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 923 00 08 ADAPTER 410 04 04 MOTOR LINE HOSE (50 FT.) 927 00 43 QUICK DISCONNECT COUPLING 923 00 07...
  • Page 36 34 | DRAWINGS AND PARTS LISTS V-5ESC/HP-185T3A HYDRAULIC SCHEMATIC 2 406 01 00...
  • Page 37 DRAWINGS AND PARTS LISTS | 35 V-5ESC/HP-185T3A HYDRAULIC SCHEMATIC (406 01 00) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 944 02 42 DIESEL ENGINE 911 01 88 PUMP DRIVE 911 01 87 HYDRAULIC PUMP 931 05 59 SHUT-OFF VALVE 406 00 03...
  • Page 38 36 | DRAWINGS AND PARTS LISTS...
  • Page 39 DRAWINGS AND PARTS LISTS | 37 V-5ESC ECCENTRIC SHAFT ASSEMBLY (420 10 05/06) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 416 01 53 ECCENTRIC GEAR 416 01 54 ECCENTRIC GEAR 430 00 41 ECCENTRIC KEY 430 00 13 ECCENTRIC SHAFT...
  • Page 40 38 | DRAWINGS AND PARTS LISTS...
  • Page 41 DRAWINGS AND PARTS LISTS | 39 V-5ESC MOTOR SHAFT ASSEMBLY (405 03 39) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 430 01 36 MOTOR SHAFT COVER - MACHINING 905 05 05 SOCKET HEAD CAP SCREW 430 00 22 GASKET, MOTOR SHAFT COVER...
  • Page 42 40 | DRAWINGS AND PARTS LISTS...
  • Page 43 DRAWINGS AND PARTS LISTS | 41...
  • Page 44 42 | DRAWINGS AND PARTS LISTS...
  • Page 45 DRAWINGS AND PARTS LISTS | 43 HP-185T3A HYDRAULIC POWER UNIT GENERAL ASSEMBLY ITEM QUANTITY PART NO. DESCRIPTION REQUIRED 944 02 42 DIESEL ENGINE 901 58 17 HEX HEAD CAP SCREW 911 01 87 HYDRAULIC PUMP 931 05 59 SHUT-OFF VALVE 406 00 03 HYDRAULIC RESERVOIR 931 05 57...
  • Page 46 44 | DRAWINGS AND PARTS LISTS HP-185T3A HYDRAULIC POWER UNIT GENERAL ASSEMBLY ITEM QUANTITY PART NO. DESCRIPTION REQUIRED 923 09 59 PUSH-ON FUEL LINE (SUPPLY) 923 09 60 PUSH-ON FUEL LINE (RETURN) 923 09 62 PUSH-ON COUPLING 923 09 63 PUSH-ON COUPLING 406 01 02 HOSE...
  • Page 47 DRAWINGS AND PARTS LISTS | 45 HP-185T3A HYDRAULIC POWER UNIT GENERAL ASSEMBLY ITEM QUANTITY PART NO. DESCRIPTION REQUIRED 411 00 15 NAMEPLATE - NO. 2 DIESEL FUEL 170 01 00 NAMEPLATE - PULL TO CLOSE 170 01 01 NAMEPLATE - PUSH TO OPEN 420 00 85 NAMEPLATE - HYDRAULIC FLUID 699 02 77...
  • Page 48 46 | DRAWINGS AND PARTS LISTS...
  • Page 49 DRAWINGS AND PARTS LISTS | 47...
  • Page 50 48 | DRAWINGS AND PARTS LISTS V5Esc SIDE CLAMP ASSEMBLY PARTS LIST ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 495 06 39 ADAPTER PLATE 405 12 52 SIDE CLAMP MACHINING 495 06 38 CYLINDER 495 05 98 924 00 72...
  • Page 51 DRAWINGS AND PARTS LISTS | 49...
  • Page 52 50 | DRAWINGS AND PARTS LISTS V5Esc MANIFOLD ASSEMBLY PARTS LIST ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 495 06 34 MANIFOLD 495 06 37 MOUNT BRACKET 901 59 17 HEX HEAD CAP SCREW 903 06 10 LOCK WASHER 923 00 13...
  • Page 53 DRAWINGS AND PARTS LISTS | 51...
  • Page 54 52 | DRAWINGS AND PARTS LISTS...
  • Page 55 DRAWINGS AND PARTS LISTS | 53...
  • Page 56 54 | DRAWINGS AND PARTS LISTS REMTRON RADIO REMOTE CONTROL BOX ELECTRICAL PLUG WIRE COLOR REMTRON FUNCTION PIN NUMBER CODE TERMINAL STRIP # 24 VOLT POSITIVE ORANGE CLAMP CLOSE GREEN ROTATE RIGHT WHITE TILT RIGHT RED/BLACK NOT USED NOT USED BLACK 24 VOLT NEGATIVE ORANGE/BLACK...

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