Dawson 5600D EMV550v3 Operator's Instructions/Spare Parts List
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Dawson 5600D EMV550v3 Operator's Instructions/Spare Parts List

Excavator mounted vibrator with metric hose kit
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INNOVATION
PILING
EQUIPMENT
HYDRAULIC PILING HAMMERS
EXCAVATOR MOUNTED
VIBRATORS
EXCAVATOR MOUNTED DRILLS
QUIET, VIBRATIONLESS
PUSH-PULL PILING
PILE EXTRACTION
SHEET PILE GUIDE FRAMES
SHEET PILE
CAPPING SYSTEMS
CFA CLEANERS
PILE POINTS
& SPLICERS
HANDLING / LIFTING
www.dcpuk.com
www.dcpuk.com
EMV-550 Metric
EXCAVATOR MOUNTED VIBRATOR
OPERATORS INSTRUCTIONS &
5600D EMV550v3 METRIC HOSE KIT
SPARE PARTS LIST

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Summary of Contents for Dawson 5600D EMV550v3

  • Page 1 EMV-550 Metric EXCAVATOR MOUNTED VIBRATOR INNOVATION OPERATORS INSTRUCTIONS & PILING EQUIPMENT SPARE PARTS LIST 5600D EMV550v3 METRIC HOSE KIT HYDRAULIC PILING HAMMERS EXCAVATOR MOUNTED VIBRATORS EXCAVATOR MOUNTED DRILLS QUIET, VIBRATIONLESS PUSH-PULL PILING PILE EXTRACTION SHEET PILE GUIDE FRAMES SHEET PILE...
  • Page 2 April 2013 V3 DAWSON CONSTRUCTION PLANT LIMITED DAWSON EMV 550 OPERATORS INSTRUCTIONS & SPARE PARTS LIST...

  • Page 3: Table Of Contents

    CONTENTS EC Declaration of Conformity 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 How does the EMV550 work? Mounting Instructions 4.1 Mounting the Vibrator...
  • Page 4 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...
  • Page 5 Figure 1 – Basic Technical Specifications EMV550 PERFORMANCE SUMMARY STATIC MOMENT 8.3 kgm FREQUENCY 2,500 vpm CENTRIFUGAL FORCE 550 kN AMPLITUDE – PEAK TO PEAK 13 mm HYDRAULIC PRESSURE MIN / MAX 280 – 350 bar HYDRAULIC FLOW RATE MIN /MAX 256 –...

  • Page 6: Basic Safety Points

    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.

  • Page 7: The Danger Area

    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 •...
  • Page 8 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.

  • Page 9: Mounting Instructions

    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.

  • Page 10: Hydraulic Hoses - Layout And Connections

    Hydraulic Hoses - Layout and Connections The EMV hydraulic fittings are Metric for the EMV550. The pressure and return lines (already connected to the vibrator) have 30S male fittings. The pressure line is usually connected to the bucket ram "extend" circuit and the return line to the bucket ram “retract”...

  • Page 11: Operating Instructions

    5.0 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 12: Extracting Piles

    Clear all personnel standing in the Danger Area and lift up the pile until it just hangs freely off the ground. 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.
  • Page 13 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.

  • Page 14: Maintenance

    • 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.
  • Page 15 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.
  • Page 16 Swivel Assembly Gear Box Oil Sight Glass Hard Jaws Breather/Filler Plug Clamp Cylinder Clamp Body Grease Point – for the Moving Jaw Gearbox Oil Drain Plug...

  • Page 17: Every 50 Working 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.

  • Page 18: 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 –...

  • Page 19: Emv Clamp Closes But The Unit Will Not Vibrate

    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.

  • Page 20: Oil Blowing Out Of The Motor Blow-Off Valve

    7.4 Oil blowing out of the motor blow-off valve. 7.4.1 Drain line restricted or blocked – stop work immediately. Motor Blow- Off Valve 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.

  • Page 21: Clamp Looses Grip On The Pile

    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.
  • Page 22 DAWSON DAWSON DAWSON DAWSON DAWSON CONSTRUCTION PLANT LIMITED 9.0 PARTS LIST FOR THE EMV550...
  • Page 23 ROUGH MACHINE N9 X . X = +/- 0.25 SPRING WASHER 0M20.000.21 EMV550 Sheet 1 of 1 Date 18/02/2013 FINE MACHINE N8 X . XX = +/- 0.05 DAWSON ANGLES +/- 0.5° CONSTRUCTION Drawing no. GRIND 5600D PLANT LTD. DIMENSIONS IN MILLIMETERS...
  • Page 24 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 25 X = +/- 0.5 ROUGH MACHINE N9 X . X = +/- 0.25 EMV550 Sheet 1 of 1 Date 17/11/2014 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 CONSTRUCTION ANGLES +/- 0.5° DRIVE GEAR ASSEMBLY Drawing no. GRIND 5040EMV-1 PLANT LTD.
  • Page 26 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 27 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.
  • Page 28 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 36 STANDARD LIFTING CHAIN ARRANGEMENT LIFTING CHAIN FOR 4681D DOUBLE CLAMP - TO MAINTAIN AMPLITUDE EMV MODEL IN EXCESS OF 4MM, MAX RECOMMENDED PILE MASS 1000KG 1400KG OVERALL VIEW FITTING TO CHAIN HOLDER...
  • Page 37 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 38 EXCAVATOR MOUNTED OR CRANE SUSPENDED VIBRATORS 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.
  • Page 39 TECHNICAL SPECIFICATIONS Excavator Mounted Vibro Model SPECIFICATION UNITS EMV70 EMV220 EMV300A EMV450 EMV550 in lbs STATIC MOMENT 8.23 FREQUENCY 3,000 3,000 2,400 2,460 2,500 15,730 50,236 67,420 100,000 125,592 CENTRIFUGAL FORCE 0.157 0.45 0.58 0.54 0.54 AMPLITUDE - PEAK TO PEAK 14.7 13.7 13.7...
  • Page 40 Clamps Mass 300 Universal Clamp 163 kg 450 Universal Clamp 273 kg 550 Universal Clamp 416 kg EMV300 Stand = 115kg Caisson Beam with Clamps 670 kg VIBRO MODEL SPECIFICATION UNITS EMV70 EMV220 EMV300A EMV450 EMV550 TRANSPORT WEIGHTS 1165 1300 1500 (approx) DIMENSION ON A...
  • Page 42 QUICK HITCH ADAPTOR When 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.
  • Page 43 EXCAVATOR MOUNTED DRILL 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 .
  • Page 45 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 46 A GUIDE TO EMV GENERAL MAINTENANCE PROCEDURE (USED WITH PDI CHECK SHEET) DEALER NETWORK GLOBAL SUPPLY, LOCAL SUPPORT. DAWSON CONSTRUCTION PLANT CHESNEY WOLD, BLEAK HALL, MILTON KEYNES, MK6 1NE ENGLAND TEL. +44 1908 240300 FAX. +44 1908 240222 EMAIL. DAWSON@DCPUK.COM...
  • Page 48 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 Severe wear to pin Wear to bush Wear to adaptor • Check for wear to post Old position of grease point on post •...
  • Page 49 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 •...
  • Page 50 HOSE ASSEMBLY Remarks: • Check general condition • Check spring guard condition Severe damage to hose assembly • Insure fittings are all tight • Check for running leaks...
  • Page 51 4mm new jaw 2mm acceptable wear level limit SECTION OF JAW CLAMP ASSEMBLY Remarks: • Check Static and Moving jaw wear on teeth and general damage • Inspect chain for damage Severe damage and wear to teeth on jaws on left, in comparrison new jaw on right Damage to chain link •...
  • Page 52 STAND Remarks: • Inspect general condition of stand...
  • Page 53 EMV-550 Metric EXCAVATOR MOUNTED VIBRATOR Dawson Construction Plant Ltd Chesney Wold. Bleak Hall, Milton Keynes, MK6 1NE, England Tel: +44 (0) 1908 240300 Fax: +44 (0) 1908 240222 D.C.P. RESERVES THE RIGHT TO DISCONTINUE EQUIPMENT AT ANY TIME, OR CHANGE SPECIFICATIONS OR DESIGNS WITHOUT NOTICE OR INCURRING OBLIGATIONS Ver.

This manual is also suitable for:

Emv-550 metric

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