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MKT V-22/HP-380T4 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-22/HP-380T4 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-380T4
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.
MANUAL NUMBER: V-22 / HP-380T4 001

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Summary of Contents for MKT V-22/HP-380T4

  • Page 1 Vibratory Pile Driver/Extractor System. 2. Do not start or operate the V-22/HP-380T4 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

    H. HP-380T4 CONTROL PANEL HYDRAULIC POWER UNIT AND PARTS LIST I. HP-380T4 ELECTRICAL CONTROL ASSEMBLY AND PARTS LIST J. REMOTE PENDANT/CABLE ASSEMBLY AND PARTS LIST K. HP-380T4 ELECTRICAL SCHEMATIC L. V-22/HP-380T4 HYDRAULIC SCHEMATIC AND PARTS LIST M. HP-380T4 HYDRAULIC HOSES (DOES NOT INCLUDE HOSE BUNDLE HOSES)

  • Page 4: Introduction

    380T4 hydraulic power unit is correspondingly designed to maintain the necessary hydraulic flow and pressure to the V-22 vibratory hammer. The V-22/HP-380T4 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-380T4 VIBRATORY PILE DRIVER/EXTRACTOR SYSTEM A. OPERATING DATA - V-22 DRIVER/EXTRACTOR Driving Force........... .

  • Page 6: Specifications

    II. SPECIFICATIONS FOR V-22/HP-380T4 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-380T4 COMPONENTS The essential components of a complete V-22/HP-380T4 Hydraulic Vibratory Pile Driver/Extractor System are: A. HP-380T4 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-380T4 HYDRAULIC POWER UNIT The HP-380T4 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 11,500 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-380T4 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

    PUMPS WITHOUT THE ASSISTANCE OF A FACTORY TRAINED SERVICE REPRESENTATIVE. The V-22/HP-380T4 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 V. START UP PROCEDURES (CONTINUED) E. HYDRAULIC CLAMP CYLINDER Whenever the hydraulic lines of the V-22/HP-380T4 system has been reconnected, THE CLAMP CYLINDER CIRCUIT MUST BE BLED OF ENTRAINED AIR. Lift the V-22 hammer vertically off the ground, switch the clamp selector switch to the "clamp close"...
  • 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-380T4 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-380T4 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-380T4 are described in the engine manufacturer's manual. C. Proper maintenance of the total V-22/HP-380T4 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-380T4 tank gauge before and during operation of the V-22/HP-380T4 system. DO NOT OPERATE THE V-22/HP-380T4 SYSTEM IF THE HYDRAULIC FLUID REGISTERS BELOW THE TANK FLUID GAUGE.
  • Page 21 VII. MAINTENANCE AND SERVICE INSTRUCTIONS (CONTINUED) H. The V-22/HP-380T4 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-380T4 hydraulic reservoir, V-22 exciter case and HP-380T4 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 4. DEF Tank Filter a. Change after every 2,000 hours or one year, whichever comes first. M. In general the field service that is done by the operators of the V-22/HP-380T4 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: Engine Lamp Identification Guide / Def-Related Warnings

    VIII. ENGINE LAMP IDENTIFICATION GUIDE / DEF-RELATED WARNINGS. Note: Must use Fleetguard® or diesel exhaust fluid that meets ISO22241 specifications. How to Perform A Manual Regeneration. Once the need is established by a lamp, please complete the request when convenient to do so, allow up to 40-60 minutes Set up a safe exhaust area.

  • Page 26: 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. -23-...
  • Page 27 -24-...
  • Page 28 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 29 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 30 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 31 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 -28-...
  • Page 32 V-22 HYDRAULIC CLAMP ASSEMBLY (416 01 30) -29-...
  • Page 33 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 34 PARTS LIST V22 HYDRAULIC CLAMP ASSEMBLY (416 01 30) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 499 00 96 CLAMP JAW - DOUBLE SHEET AS REQ'D FIXED 420 01 36 CLAMP JAW - DOUBLE SHEET AS REQ'D MOVABLE 420 01 38...
  • Page 35 OPTIONAL V-22 CLAMP JAWS -32-...
  • Page 36 CAISSON CLAMP ASSEMBLY (495 05 39) -33-...
  • Page 37 PARTS LIST CAISSON CLAMP ASSEMBLY (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...
  • Page 38 PARTS LIST 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...
  • Page 39 -36-...
  • Page 40 HYDRAULIC LOCKING CAISSON CLAMPS ADJUSTMENT READ THESE INSTRUCTIONS COMPLETELY BEFORE ATTEMPING TO ADJUST CAISSON CLAMPS ON BEAM 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.
  • Page 41 -38-...
  • Page 42 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 43 -40-...
  • Page 44 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 PINION...
  • Page 45 V-22 150' HYDRAULIC HOSE BUNDLE (416 01 60) -42-...
  • Page 46 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 47 -44-...
  • Page 48 -45-...
  • Page 49 PARTS LIST HP-380T4 GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 417 40 21 ENCLOSURE ASSEMBLY-HP380 901 53 15 HEX HEAD CAP SCREW 920 00 08 LOCK NUT 417 40 00 SKID –HP380T4 943 03 63 DOOR LOCK 946 00 27...
  • Page 50 PARTS LIST HP-380T4GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 930 02 00 PIPE NIPPLE 930 04 59 PIPE COUPLING 930 04 06 PIPE CAP 010 11 00 BUFFER BUMPER 923 02 00 HYD. ADAPTER 923 11 85 HYD. ADAPTER...
  • Page 51 PARTS LIST HP-380T4 GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 911 02 08 CLAMP PUMP 931 05 93 CLAMP CONTROL VALVE 931 07 64 RELIEF VALVE CARTRIDGE 931 05 88 VALVE SUBPLATE 931 08 47 FILTER ASSEMBLY 931 08 48...
  • Page 52 PARTS LIST HP-380T4 GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 931 06 33 PRESSURE SWITCH (90 PSI) 927 00 48 DUST CAP 927 00 46 QUICK DISCONNECT (SET) 923 10 76 HYD. ADAPTER 923 09 50 SPLIT FLANGE KIT...
  • Page 53 PARTS LIST HP-380T4 GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 923 11 48 HYD. ADAPTER 923 11 49 CAP NUT 933 04 15 CABLE TIE 933 03 56 TERMINAL RING 411 00 21 NAMEPLATE-MOTOR RETURN 411 00 23...
  • Page 54 PARTS LIST HP-380T4 GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 923 10 12 HYD. ADAPTER 923 05 88 HYD. ADAPTER 923 09 18 HYD. ADAPTER 923 01 87 CAP NUT 923 05 56 HYD. ADAPTER 943 04 43...
  • Page 55 PARTS LIST HP-380T4 GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 923 12 52 HYD. ADAPTER 950 01 40 THREADED ROD 950 03 08 METRIC LOCKWASHER 923 13 60 SPLIT FLANGE 417 40 44 PENDANT ASSEMBLY 933 04 17...
  • Page 56 PARTS LIST HP-380T4 GENERAL ASSEMBLY ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 923 10 56 HYD. FITTING 943 03 62 LOCK ROD 900 50 06 HEX NUT 901 58 17 HEX HEAD CAP SCREW 901 59 17 HEX HEAD CAP SCREW...
  • Page 57 HP-380T4 CONTROL PANEL ASSEMBLY (417 40 22) -54-...
  • Page 58 PARTS LIST HP-380T4 CONTROL PANEL ASSEMBLY (417 40 22) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 417 30 46 INSTRUMENT PANEL HP-365A 411 00 31 NAME PLATE, POWER UNIT SPEC. 699 02 77 NAME PLATE, SAFETY CAUTION 099 06 00...
  • Page 59 HP-380T4 ELECTRICAL CONTROL ASSEMBLY (417 40 23) -56-...
  • Page 60 PARTS LIST HP-380T4 ELECTRICAL CONTROL ASSEMBLY (417 40 23) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 417 40 24 ELECTRICAL ENCLOSURE 933 02 06 NAMEPLATE, “POWER ON” 933 01 49 GREEN PROTECTIVE LENS 933 04 00 SELECTOR SWITCH 933 03 21...
  • Page 61 PARTS LIST HP-380T4 ELECTRICAL CONTROL ASSEMBLY (417 40 23) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 933 02 51 MOUNTING KIT 933 03 28 RELAY (12 VOLT) 933 04 08 RELAY SOCKET 933 03 69 CONNECTOR 933 04 16 GUARD, PUSHBUTTON...
  • Page 62 PARTS LIST HP-380T4 ELECTRICAL CONTROL ASSEMBLY (417 40 23) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 933 05 03 CONNECTOR, MALE -59-...
  • Page 63 REMOTE PENDANT AND CABLE ASSEMBLY (417 40 44) -60-...
  • Page 64 PARTS LIST REMOTE PENDANT AND CABLE ASSEMBLY (417 40 44) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 933 03 90 PENDANT ENCLOSURE 933 01 45 PUSHBUTTON, STOP 933 02 61 NAMEPLATE, “STOP” 933 01 51 CONTACT BLOCK 933 03 91...
  • Page 65 PARTS LIST REMOTE PENDANT AND CABLE ASSEMBLY (417 40 44) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 933 05 11 TOGGLE SWITCH,VIB/ON/OFF 933 05 08 END CONNECTOR 933 05 19 BOOT, TOGGLE SWITCH 933 05 01 HOOD, ELE 933 05 02...

  • Page 66: Hp-380T4 Electrical Schematic

    HP-380T4 ELECTRICAL SCHEMATIC -63-...
  • Page 67 HP-380T4 HYDRAULIC SCHEMATIC -64-...
  • Page 68 PARTS LIST HP-380T4 HYDRAULIC SCHEMATIC ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 944 03 14 DIESEL ENGINE “CUMMINS” 911 02 78 HYDRAULIC PUMP DRIVE 911 01 99 HYDRAULIC PUMP 911 02 08 HYDRAULIC PUMP 931 05 99 SUCTION STRAINER 931 06 00...
  • Page 69 PARTS LIST HP-380T4 HYDRAULIC SCHEMATIC ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 931 06 64 DRIVE PRESSURE GAUGE 931 06 58 CLAMP PRESSURE GAUGE 417 30 28 HYDRAULIC RESERVOIR 931 05 96 SHUT OFF VALVE 934 00 19 HYDRAULIC OIL COOLER...

  • Page 70: Hp-380T4 Hydraulic Hoses

    HP-380T4 HYDRAULIC HOSES -67-...
  • Page 71 HP-380T4 HYDRAULIC HOSES -68-...
  • Page 72 HP-380T4 HYDRAULIC HOSES -69-...

  • Page 73: (Does Not Include Hose Bundle Hoses)

    PARTS LIST HP-380T4 HYDRAULIC HOSE PACKAGE (DOES NOT INCLUDE HOSE BUNDLE HOSES) ITEM QUANTITY MKT PART NO. DESCRIPTION REQUIRED 417 40 26 HYDRAULIC HOSE ASSEMBLY 417 40 27 HYDRAULIC HOSE ASSEMBLY 417 40 28 HYDRAULIC HOSE ASSEMBLY 417 40 29...

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