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Dawson EMV 220 Owner's Manual

Excavator mounted vibrator
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excavator mounted vibrator
EMV
220
excavator mounted vibrator
owners manual
DAWSON CONSTRUCTION PLANT LTD.
operators instructions
CHESNEY WOLD,
BLEAK HALL
spare parts list
MILTON KEYNES
safety precautions
MK6 1NE, ENGLAND
TEL: +44 (0) 1908 240300
maintenance
FAX: +44 (0) 1908 240222
Original Instructions
EMAIL: DAWSON@DCPUK.COM
EMV220 ver. 2024-01

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Summary of Contents for Dawson EMV 220

  • Page 1 DAWSON CONSTRUCTION PLANT LTD. operators instructions CHESNEY WOLD, BLEAK HALL spare parts list MILTON KEYNES safety precautions MK6 1NE, ENGLAND TEL: +44 (0) 1908 240300 maintenance FAX: +44 (0) 1908 240222 Original Instructions EMAIL: DAWSON@DCPUK.COM...

  • Page 3: Table Of Contents

    You will find the model and serial numbers on an ID plate located on the product. The descriptions and specifications in this manual are subject to change without notice. Dawson reserves the right to improve products. Some product improvements may have taken place after this manual was printed.

  • Page 5: Eu Declaration Of Conformity

    We declare that the machinery/equipment detailed below is in compliance with the applicable regulations and harmonised standards as listed. This declaration ceases to be valid if alterations are made the machinery/equipment without agreement with Dawson Construction Plant Ltd. Category Piling Equipment...

  • Page 6: Basic Technical Specifications

    basic technical specifications FIG.1 SPECIFICATIONS EMV220 UNITS METRIC STATIC MOMENT 2.3 kgm 200 in Ibs FREQUENCY 50 hz - 3,000 rpm CENTRIFUGAL FORCE 220 KN 50,236 lbs.F AMPLITUDE 12 mm 0.45 in REQUIRED HYDRAULIC FLOW 90 L/min 24 gpm RATE * MIN.

  • Page 7: Basic Safety Points

    basic safety points • The vibrator should only be operated by suitably qualified personnel. • The vibrator/clamps not to be used for lifting operations. • It is prohibited to leave an element suspended in the clamps of a vibrator, which is free hanging and out of operation.
  • Page 8 continued - basic safety points Personnel are at risk when within this area from: • Falling piles – should the pile be handled incorrectly • Liquids under high pressure and associated components • Mechanical failures of equipment components • Noise – wear ear protection equipment when inside this area •...

  • Page 9: Safety First - Quick Reference Guide

    The equipment is hired under C.P.A. conditions and as such any theft or damage caused by misuse or abuse will be charged accordingly. IN THE EVENT OF MALFUNCTION, DAMAGE OR LEAKAGE OF OIL, DAWSON CONSTRUCTION PLANT MUST BE NOTIFIED IMMEDIATELY.
  • Page 10 Check the screws, bolts, fitting etc. for tightness Check hydraulic hoses for leaks Check oil level in the excavator hydraulic tank Dawson Constrcution Plant Check the gear oil level in the vibrator. The level must be halfway up the sight glass Chesney Wold.

  • Page 11: How Does The Emv Work

    how does the emv 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 12 flow regulator & sequence valve gearbox saddle assembly hydraulic drive motor transport stands gearbox eccentric weight drive gear direction of motion resulting direction of force Motion of a pair of eccentrics Corresponding Sinusoide Time excavator mounted vibrator...

  • Page 13: Mounting Instructions

    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 14 continued - mounting instructions Connect to bucket ram extend hose Connect to bucket ram retract hose Connect drainline directly to excavator tank Ensure all hydraulic connections are clean prior to fitting and that no contamination is introduced into the hydraulic circuit during installation – this may cause internal component damage to the hydraulic system or faulty operation of the vibrator or excavator.

  • Page 15: Operating Instructions

    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 16 continued - operating instructions Start the vibrator and adjust (crowd) the hydraulic rams so that the vibrator is level and always sits directly on top of the pile as it goes into the ground. Do not over push the vibrator - stop pushing when the gearbox starts to vibrate against the rubber stops on the underside of the saddle.
  • Page 17 fasteners Top Buffers Lower fasteners Safety stops Maximum deflection of sandwich mounts is achieved during extracting when the gearbox casing hits the safety stops (100mm). When driving piles a maximum deflection of 146mm can be achieved. This is when the top fasteners are inline with the lower. www.dcpuk.com...

  • Page 18: Operating Instructions Driving Piles (Quick Reference Illustrations)

    operating instructions driving piles (quick reference illustrations) The illustrations below are to show visually a simplified version of the operating instructions given in part 5.2/5.3, driving / extracting piles. 5.1 preparation before driving / extracting piles must be read before these illustrations.
  • Page 19 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. Plumb the pile then ensure all personnel are out of 90°...

  • Page 20: Operating Instructions - Extracting Piles (Quick Reference Illustrations)

    operating instructions - extracting piles (quick reference illustrations) The illustrations below are to show visually a simplified version of the operating instructions given in part 5.2/5.3, driving / extracting piles. 5.1 preparation before driving / extracting piles must be read before these illustrations.
  • Page 21 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 stipulated amount shown on Figure 1 in section 2.0.

  • Page 22: Recommended Excavator Positions (Quick Reference Illustrations)

    (quick reference illustrations) These illustrations represent the recommended working, transport and resting positions for your Dawson EMV attachment when used with an excavator. 90° Recommended: Starting Position Recommended: Drive / Extraction Position the pile vertically in desired location Lower the excavator arm in a consistent and begin drive / extracting.

  • Page 23: Maintenance

    • All service and maintenance work must be carried out by qualified personnel using original Dawson parts. The use of other parts will invalidate the whole warranty for the equipment. • The equipment should be inspected at ground level only and should be positioned so as to be stable at all times.
  • Page 24 continued - maintenance jaw should not move up and down. Fit the Cap Screw and tighten using a hexagonal wrench. Remember to install the washers on these screws. Changing the Hard Jaws – Moving (Cylinder) Side Release the 8off Cap Screws that hold the Clamp Cylinder in place and remove the Clamp Cylinder. Undo the two clamp supply hoses, carefully marking them to ensure correct re-assembly.
  • Page 25 FIGURE 6 Swivel Assembly Breather / Filler Plug Caution Crush Hazard Surface Clamp Cylinder Hard Jaws Lifting Chain & Chain Clamp Clamp body Grease Point - for Moving Jaw Front View Gearbox Oil Drain Plug Base View www.dcpuk.com...
  • Page 26 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.

  • Page 27: Troubleshooting

    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 28 continued - troubleshooting 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 29 Flow Compensator 15 mm (default setting) Sequence Valve Cartridge with Adjusting Screw & Locknut 11.5 mm (default setting) Clamp Pressure Limiter 12.5 mm (default setting) 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.
  • Page 30 Consequently the clamp can be driven closed again. Should this problem occur Dawson could supply a reverse flow check valve as a fix.

  • Page 31: Emv220 Hose Kit

    hydraulic circuit EMV220 hose kit Part No 220-028-00-01 Fittings 1 REDVDN20/16 reducer 1off 2 GEV10LR3/8WD stud coupling 6off 3 4BX12 fixed female 2off 4 GEV12LM22x1.5WD adaptor 1off 5 GEV16SR3/4WD stud coupling 5off 6 ELVD12L run tee 1off 7 GEV10LRWD stud coupling 2off 8 GEV12LRWD 1off...

  • Page 32: Parts Lists For The Emv220 - Assembly Drawing

    hydraulic circuit EMV220 hose kit Part No 220-028-00-01 Hoses: A 1/4”EP 10L 90° to 10L 90° AOR 90° 1280mm CHL 1off B 1/4”EP 10L 90° to 10L 90° AOR 90° 1225mm CHL 1off C 1/4”EP 10L 90° to 10L straight 120mm CHL 1off D 1/4”EP 10L 90°...
  • Page 33 emv220 JIC hydraulic circuit...
  • Page 34 emv220 JIC hydraulic circuit...
  • Page 35 emv220 JIC hydraulic circuit...
  • Page 36 emv220 JIC hydraulic circuit...
  • Page 37 emv220 JIC hydraulic circuit...
  • Page 38 emv220 hose kit Fittings: REDVDN20/16 reducer 1off GEV10LR3/8WD stud coupling 6off 4BX12 fixed female 2off GEV12LM22x1.5WD adaptor 1off GEV16SR3/4WD stud coupling 5off ELVD12L run tee 1off GEV10LRWD stud coupling 2off GEV12LRWD 1off RVV20SWD non-return valve 1off GSV10L bulkhead fitting 1off GSV12L bulkhead fitting 1off Hose:...
  • Page 39 parts lists for the emv220 excavator mounted vibrator...
  • Page 40 SLEEVE TLR362 G10-8 COUPLER TLR361 10mm G80 CHAIN x 27 LINKS TLR360 10mm CHAIN CLAMP 4400-4A EMV 220 FULL STICKER SET 14 x4 4025A SANDWICH MOUNT 220-027-00-00 TRANSPORT STAND EMV220 220-010-00-00A SAFETY RESTRAINT 220-007-21-01 SADDLE STOP BOLT 14 x4 220-200-00-00 EMV 220 SADDLE ASSEMBLY...
  • Page 41 PROPERTY RIGHTS ON THIS DRAWING AND THE X = ± 0.5 WORKS DEPICTED ARE THE PROPERTY OF DAWSON CONSTRUCTION PLANT LTD. DAWSON CONSTRUCTION PLANT LIMITED. IT MAY EMV 220 GEARBOX X.X = ± 0.25 Drawing No. ALL E DGES TO HA VE A...
  • Page 42 PROPERTY RIGHTS ON THIS DRAWING AND THE X = ± 0.5 WORKS DEPICTED ARE THE PROPERTY OF DAWSON CONSTRUCTION PLANT LTD. DAWSON CONSTRUCTION PLANT LIMITED. IT MAY EMV 220 GEARBOX X.X = ± 0.25 Drawing No. ALL E DGES TO HA VE A...
  • Page 43 PROPERTY RIGHTS ON THIS DRAWING AND THE X = ± 0.5 WORKS DEPICTED ARE THE PROPERTY OF DAWSON CONSTRUCTION PLANT LTD. DAWSON CONSTRUCTION PLANT LIMITED. IT MAY EMV 220 GEARBOX X.X = ± 0.25 Drawing No. ALL E DGES TO HA VE A...
  • Page 44 PROPERTY RIGHTS ON THIS DRAWING AND THE X = ± 0.5 WORKS DEPICTED ARE THE PROPERTY OF DAWSON CONSTRUCTION PLANT LTD. DAWSON CONSTRUCTION PLANT LIMITED. IT MAY EMV 220 SADDLE ASSEMBLY X.X = ± 0.25 Drawing No. ALL E DGES TO HA VE A...
  • Page 46 Sequence Valve Cartridge with Adjusting Screw & Lockout 11.5 mm (default setting) Flow Compensator 15 mm (default setting) Clamp Pressure Limiter 12.5 mm (default setting)

  • Page 47: Appendix A- Auxiliary Equipment

    appendix a- auxiliary equipment...
  • Page 48 EMV - AUXILLARY EQUIPMENT ITEM DESCRIPTION ITEM No. WEIGHTS CAISSON BEAM 4900 Weight EMV300 = 1500kg + (adaptor bracket) Caisson beam jaw assemblies can be Weight EMV450 = 1700kg + (adaptor bracket) positioned to suit any tube size between Ø300 I.D & Ø1100 mm O.D. Weight EMV550 = 1800kg + (adaptor bracket) SWAN NECK 4939...
  • Page 50 DIM (mm) ØCC ØEE Ref.no. Qnt. Part name Material Dimension Remark Design by Drawn by Copied Checked Standard Affirmed Scale Replace Replaced by Sheet 1 of 1 Date 04/02/11 DAWSON SWAN NECK DIMENSIONAL DATA CONSTRUCTION Drawing no. SN01-000-01 PLANT LTD.
  • Page 51 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 52 CFA CLEANERS PILE POINTS & SPLICERS SAFETY HANDLING / LIFTING EQUIPMENT SHEET PILE THREADERS excavator mounted vibrator emv220 DAWSON CONSTRUCTION PLANT LTD. CHESNEY WOLD, BLEAK HALL MILTON KEYNES MK6 1NE, ENGLAND TEL: +44 (0) 1908 240300 FAX: +44 (0) 1908 240222...

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