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MKT V-5Esc/HP-200 Service, Operating, Maintenance And Parts Manual

Hydraulic vibratory pile driver/extractor system
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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-5Esc/HP-200 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
SERVICE, OPERATING AND MAINTENANCE
MANUAL FOR
V-5Esc/HP-200 HYDRAULIC VIBRATORY PILE
DRIVER/EXTRACTOR SYSTEM
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.

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Summary of Contents for MKT V-5Esc/HP-200

  • Page 1 Hearing protection should be worn by anyone and everyone within close proximity to a Vibratory Pile Driver/Extractor System. Do not start or operate the V-5Esc/HP-200 until having thoroughly read this manual and having received instructions from an MKT factory authorized service representative or properly trained,...
  • 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 NO EMPLOYEE OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY UNLESS SUCH CHANGE IS MADE IN WRITING AND SIGNED BY AN OFFICER OF MKT AT ITS HOME OFFICE. I. SAFETY INSTRUCTIONS The following safety instructions are contained in the text of this manual. Read the entire manual before operating the hammer.
  • Page 4 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. 12. CAUTION: When the V-5Esc side clamp assembly is attached to the exciter, the maximum line pull is limited to 15 tons and the maximum downcrowd force is limited to 10 tons.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION SPECIFICATIONS III. SYSTEM COMPONENTS SYSTEM SET-UP INSTRUCTIONS START-UP PROCEDURES OPERATING INSTRUCTIONS VII. MAINTENANCE AND SERVICE INSTRUCTIONS VIII. SERVICE TROUBLE SHOOTING...

  • Page 6: Introduction

    INTRODUCTION The MKT V-5Esc/HP-200 Hydraulic Vibratory Pile Driver/Extractor System is used for installing or removing piling. The three major components of an MKT Vibratory Pile Driver/Extractor include rotating eccentric weights housed within a gear box which generates the vibratory forces to the pile, an elastomer suspension system to isolate the vibratory forces from the crane or excavator, and a hydraulic clamp system to grip the pile.

  • Page 7: Specifications

    SPECIFICATIONS FOR THE V-5Esc/HP-200 SYSTEM OPERATING DATA - V-5Esc DRIVER/EXTRACTOR Free Hanging Frequency ..........1700 CPM Rated Drive Pressure.
  • Page 8 III. V-5Esc/HP-200 SYSTEM COMPONENTS The essential components of a complete V-5Esc/HP200 Hydraulic Vibratory Pile Driver/Extractor System are: HP-200 Diesel Driven Hydraulic Power Unit Hydraulic Hose Bundle with Five Hoses (normally 100 feet long) V-5Esc Exciter fitted with a Suspension Assembly and a Hydraulic Clamp Assembly Side Clamp Assembly/Rototilt assembly/wireless remote with pendant backup/hydraulic installation kit &...

  • Page 9: System Set-Up Instructions

    SYSTEM SET-UP INSTRUCTIONS HP-200 HYDRAULIC POWER UNIT The HP-200 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.
  • Page 10 SYSTEM SET-UP INSTRUCTIONS (CONTINUED) V-5Esc DRIVER/EXTRACTOR The V-5Esc 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 30-ton maximum line pull capacity of the hammer, which in turn, can be slipped over a lifting crane hook.

  • Page 11: Start-Up Procedures

    HYDRAULIC VALVES The hydraulic valves in the HP-200 Power Unit have already been set for proper pressures during the factory break-in and operation of the V-5Esc/HP-200 system. DO NOT MAKE ADJUSTMENTS TO THE VALVES WITHOUT THE ASSISTANCE OF A FACTORY TRAINED SERVICE REPRESENTATIVE.
  • Page 12 START-UP PROCEDURES (CONTINUED) HYDRAULIC SYSTEM CIRCUITRY Warm oil returning from the control valve back to the tank will be directed through an oil cooler then a return line filter before entering the tank. Cool oil will select a path which will bypass the oil cooler and enter the tank through the return line filter.

  • Page 13: Operating Instructions

    "DANCING OR CHATTERING" SHOULD BE CAUSE TO PROMPTLY ABANDON THE EFFORT BEFORE SERIOUS DAMAGE IS DONE TO THE HAMMER. TO CONTINUE OPERATIONS, THE OBSTRUCTION MUST BE REMOVED OR PENETRATED BY SWITCHING TO ANOTHER DRIVING SYSTEM SUCH AS A MKT DIESEL OR STEAM/AIR PILE HAMMER.
  • Page 14 OPERATING INSTRUCTIONS (CONTINUED) OPERATING THE V-5Esc/HP-200 SYSTEM - EXTRACTING MODE A pile is extracted by merely tensioning the V-5Esc hammer hoisting line. The amount of pull which can be exerted on the V-5Esc hammer and extraction is limited by the rating of the suspension assembly and the strength of the pile.
  • Page 15 OPERATING INSTRUCTIONS (CONTINUED) OPERATING THE V-5Esc/HP-200 SYSTEM - EXTRACTING MODE 4. The amount of pull which can be exerted on the V-5Esc hammer is limited by the rating of the suspension assembly, the strength of the pile and your rigging. DO NOT PULL IN EXCESS OF THE...
  • Page 16 V-5Esc SIDE CLAMP OPERATING INSTRUCTIONS 1. WARNING: KEEP HANDS CLEAR OF ALL THREE CLAMPS. When performing maintenance disable the hydraulic circuit to avoid the possibility of injury due to unexpected clamp closure. 2. WARNING: Leave the pile line attached to the pile at all times that the pile is not stuck securely in the ground.

  • Page 17: Maintenance And Service Instructions

    Maintenance procedures for the diesel engine in the HP-200 are described in the Engine Manufacturer's Manual. Properly maintaining the total V-5Esc/HP-200 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,...
  • Page 18 Exciter lube oil must be changed if seal failure occurs. (Page 14) The V-5Esc/HP-200 system normally has the HP-200 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 19 VII. MAINTENANCE AND SERVICE INSTRUCTIONS (CONTINUED) After start up and the V-5Esc is vibrating, check as follows: Inspect the hydraulic lines for leaks. Inspect the oil seal areas in the pump drive and control valves for leaks. Allow hydraulic oil temperature to come up slightly above the oil pour temperature, preferable to 30 degrees Fahrenheit before starting the hammer.
  • Page 20 Drive Pressure - 1200 to 3000 PSI Clamp Pressure - 2500 PSI Hydraulic Oil Temperature - 115 degrees Fahrenheit to 165 degrees Fahrenheit Replacement Filter Part Number Listing: DESCRIPTION MKT PART NUMBER QUANTITY Engine Oil Filter 945 04 04 Engine Fuel Filter Primary...
  • Page 21 III. SERVICE TROUBLE SHOOTING HYDRAULIC POWER UNIT 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. Clamp Will Not Open Or Close Clamp line quick disconnects may not be engaged completely or their check valves may be locked closed.

  • Page 22: Service Trouble Shooting

    VIII. SERVICE TROUBLE SHOOTING V-5Esc VIBRATORY HAMMER (CONTINUED) 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.