SHACKLE RELEASE GROUND - Dcpuk

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ULIC PILINGHAMMERSEXCAVATOR MOUNTEDVIBRATORSEXCAVATOR MOUNTEDDRILLSQUIET, VIBRATIONLESSPUSH-PULL PILINGPILE EXTRACTIONSHEET PILE GUIDEFRAMESSHEET PILECAPPING SYSTEMSCFA CLEANERSPILE POINTS& SPLICERSHANDLING / LIFTINGwww.dcpuk.comEURO GROUND RELEASE SHACKLEOPERATORS INSTRUCTIONS &SPARE PARTS LIST

01CONTACTSDawson Construction Plant LtdChesney Wold.Bleak Hall,Milton Keynes,MK6 1NE, EnglandTel: 44 (0) 1908 240300Fax: 44 (0) 1908 ----------------------------------------------

CONTENTS1.Contacts2.Contents3.Introduction & Features4.Method of operation5.Lifting piles correctly7.Safety checklist9.Installation diagram10.Release diagram11.Training12.Maintenance13.Technical SpecificationsUnder separate cover:·Individual Test Certificate & ThoroughExamination if required.·E.C. Declaration of Conformity02

03INTRODUCTIONThis robust pile lifting shackle was contractor designed and developedover many years of site use and abuse. The use of these shacklescompliments the “Feet on the Ground” approach to piling. When usedin conjunction with the Sheet Pile Threader, there is no need for siteoperatives to go above the safety of top frame level for interlocking sheetpiles or releasing the lifting shackles. The shackles are suitable for liftingall steel piles up to 28mm thick and within the safe working load of theshackle. The shackle is stiffened to resist spreading of the forks whenlifting at 90 to the axis of the pile. (See “Safety Check List”). Whenlifting sheet piles in pairs or individual piles weighing more than the SafeWorking Load of the shackle, it is necessary to use multiple shacklesin order to keep within the safe working load. Pairs of shackles can besupplied mounted on a two legged steel wire rope sling. The advantagebeing that the standard pair of shackles with lifting sling can be fitted toany pair of Larssen ‘U’ piles, Frodingham ‘Z’ piles, pipe or box piles. Noadditional parts or change of components is necessary. The ring at the topof the sling can be hooked directly onto a standard crane hook block, ‘D’shackle or fork anchor. Shackles can also be fitted onto a solid steel crosshead according to customers requirements.FEATURES. Robust High Strength cast steel body. High alloy steel plunger. Plunger mechanism concealed for maximum protection. Plunger mechanism easily detachable for maintenance. Heavy web stiffening to withstand side left (i.e. 90 to the axis)imposed when lifting piles from a stack.(See “Safety Check List” for correct working practice). Lifting ring at top of shackle to enable lifting from a variety of angles. Proof loading to twice the safe working load. Indicator bar to give clear visual indication that plunger hasengaged pile lifting hole completely. Shackle throat depth available in two sizes: 150mm (6”) or 250mm (10”)to suit all usual lifting hole positions. Quick coupling and release of shackle from piles ensuringmaximum productivity. ‘Safety ring’ to protect against accidental plunger release caused bypoor working practices.

METHOD OFOPERATION1. Tie a length of soft rope to the pull ring on the pull wire. Therope should be 1 metre (3 feet) longer than the pile length. Donot use a continuous loop as this will become snagged.2. Before positioning the lifting shackles, it is necessary toretract the plunger. Pull the pull wire until the trip mechanismholds the plunger in its retracted position.3. Separate the sheet piles on the stack to enable the bodyof shackle to be slid over the pile head. With the plunger tubeassembly uppermost, slide the fork of the shackle over thepile head with the pile in the throat of the shackle.4. With the plunger over the pile lifting hole, firmly tap theindicator bar end. If the plunger does not locate directlythrough the hole, move the shackle body until the plungergoes through the pile hole and into the shackle body on theunderside. The indicator bar should be flush with the plungertube assembly.5. Repeat this for both piles when lifting pairs of sheets.6. Install the safety ring over the plunger tube assembly asshown in the installation diagram.7. With the plunger properly located, the safety ring engaged,the piles can then be lifted into position for threading. It isadvisable to tie the shackle ropes to the sheet pile threader toprevent them being trapped, snagged or getting blown out ofreach in strong winds.8. To release the shackles after threading is complete, thesafety ring must first be unhitched by ‘flicking’ the releaserope, then simply pull on the release rope. If there is atendency to jam, then take the weight of the shackle on thecrane and pull again.9. Unauthorised alterations invalidate the test certificate.04

05LIFTING PILESCORRECTLYLIFTING PAIRS OF PILESWhen lifting sheet piles in pairs it is necessary to use apair of shackles.The ring at the top of the sling can be hooked directlyonto a standard crane hook block, D shackle or forkanchor. The sling also enables the shackles to beturned to fit opposite faces of box or tube piles using thestandard sling and shackles.Shackles can also be fitted onto a solid steel cross headaccording to customers requirments.60oDownrate in accordancewith national codes

SAFEAxial loadingSAFELifting off a stack at 90oto the axis of the pileALL ‘Z’ PROFILESTUBE PILE9 o’clockpostionALL ‘U’, ‘LARSSEN’PROFILES3 o’clockpostionor‘H’ PILE06

07SAFETY CHECK LIST1) PRE-INSTALLATION CHECKSPrior to installing a shackle onto any steelwork, check thefollowing:a. Establish the weight of the lift involved and ensure ashackle with appropriate Safe Working Load is being used.b. Ensure the lifting hole is at the correct distance from thetop of the steelwork i.e. 150mm for a 150mm throat depthshackle, 250mm for a 250mm throat depth shackle or300mm for a 300mm throat depth shackle.* Incorrect hole placement in steelworkmay cause shackle failurethroat depthc. The lifting hole should be neatly drilled or punched andof a suitable size to suit the plunger.d. The Safe Working Load rating of any shackle is basedon a purely tensile (axial) load. When lifting steelwork fromhorizontal to vertical or the reverse, remember that theshackle becomes de-rated by 50%i.e. a 10 tonne S.W.L. Ratchet Shackle should only beloaded to 5 tonne at the start of a horizontal lift.

2) Do not use the lifting shackles for pulling or extracting.3) Ensure that the pin has gone through both sides of theshackle body - check indicator bar position prior to lifting.4) Do not modify the lifting shackles or any part of thelifting apparatus. Keep the burning torch well clear!5) Keep the plunger mechanism well lubricated.6) Care should be taken to avoid the pull ropesgetting snagged.7) The angle between the two legs of the lifting strap,where applicable should not exceed 90 .8) Ensure that all appropriate laws, bye-laws andregulations are complied with.9) Always use the safety ring to preventaccidental release- it only takes an extra second or two!KEEP FINGERS OUT OF THE SHACKLE THROAT ATALL TIMES. (GLOVES SHOULD BE WORN.)DO NOT USE SHACKLE IN TEMPERATURESBELOW -15OC (5OF)CONSULT MANUFACTURE FOR FURTHERINFORMATION ON LOW TEMPERATURE SOLUTIONS.08

09INSTALLATIONDIAGRAMFITTING SHACKLE TO ‘U’ SHEET PILEIndicator bar out -Pin retracted - Do not lift!Slide throat of shackleover top of sheet pileHole position to suitdiameter ofappropriate shackleIndicator bar in flush with the barrelSafety pin inengaged positionAlign shackle pin withsheet pile lifting holePlace safety ring(the largest diameter ring)over the assembly barrelReady to lift!Release rope

RELEASE DIAGRAMFITTING SHACKLE TO ‘U’ SHEET PILEPile correctlypositionedRelease rope1. Whip the releaserope away from thetop of the pile2. A firm pull on therelease rope willretract the pin, theindicator bar willprotude outRatchet is nowready for next lift10

11TRAININGBefore allowing operators to use the Shackle, it isimportant to ensure they have received basic training inlifting and control of heavy loads.It is strongly recommended that the following areas arecovered:1Basic safety in lifting operations2.Supervision during lifting operations3.Detailed instruction on how the Euro Shackleoperates4.Safety Features of the Euro Shackle5.Dangers and Mal-practices6.Correct choice of Euro shackle for the job

MAINTENANCEThe Shackle is manufactured from high quality materialand assembled in a manner designed to offer longservice with a minimum of maintenance.In order to preserve the product in this state, it isnecessary to ensure that it is not mis-used or used forpurposes outside its recommended use and to carry outregular inspection and servicing.The shackle body should be checked regularly fordistortion arising from overload - if bent - bin.The pin should be checked for smooth travel and lightoiling applied at moving surfaces.If the product does not operate perfectly, contactthe manufacturer for advice, or return for immediateattention.Each unit is issued with a test certificate.If any parts of the shackle are replaced with non standardparts or in a non approved manner, the certificate is nolonger valid.Replacement of any load bearing components requires are-test to twice safe working load.12

13TECHNICAL SPEC.Drawing No.5983 -4T EGRS 150 Throat General Assembly5984 -7.5T EGRS 150 Throat General Assembly5985 -10T EGRS 150 Throat General Assembly5986 -7.5T EGRS 250 Throat General Assembly5987 -10T EGRS 250 Throat General Assembly5996 -40T EGRS 250 Throat General AssemblyGRS-017 ISSA - Optional Remote Release Detent Kit5919-01A General Assembly

7835ABCDRAWING 737714

152312

PARTS LISTItem No.QuantityPart Name11Socket Head Cap Screw598359840M06.016.0259855986598724Socket Head Cap Screw0M08-030-0234Washer0M08.000.2041Coiled Spring Pin0M08.040.3652No6 x 1/2” Rivet61EGRS 981M12 X 1.5 Plug5915591359161-204-00-0194Dowel Bushing101Detent Pin5919111Tube Assembly5922A-B121Compression Spring5926131Safety Pull Wire Assy5930A141Sleeve5931151M6 x Ø19 Washer5936161Guide Key5937171Shackle ID Plate5938181Compression Spring6935GENERAL ASSEMBLY15a

34 5678 91610RevisionRf.nr Qnt.DateIntro. Appr.by125 A BR 10 0 445 4 4 Part Name 4ACHINING TOLERANCESNLESS STATED OTHERWISE /- 0.5. X /- 0.25. XX /- 0.05NGLES /- 0.5 MENSIONS IN MILLIMETERS2 40T EGRS 250 THROAT345GENERAL ASSEMBLY 6 7 11 2 DAWSON CONSTRUCTION PLANT LTD.112 1 1 Guide Key Shackle IDPlate 1 1 Design by6 Sleeve 40T Protective Sleeve40T Drawn byCopied DAWSONCONSTRUCTIONPLANT LTD.7CheckedStandard Affirmed CompressionSpring5998 5999ReplaceScale 6935Sheet 8 5997 40T Tube Assembly 59385995 59375994 40T Plunger H EGRS Machined40T Body 11 17 1 18 Drawingno.40T Safety Pull5930B Wire Assy 159368 M6 x Ø19 Washer910 116 Detent Pin 5919 ScaleAffirmedReplaceReplaced by CompressionSpring5926 SheetDate 5915 Standard 15 G 1-204-00-01 M12 X 1.5 Plug 0M10.000.21 13 0M10.045.02 Spring Washer Checked 0M08.070.36No6 x 1/2”Rivet 14 42 SocketHead Cap Screw 8 11 45Copied 0M06.016.02F Coiled SpringPin 10 7 SocketHead Cap Screw2 13 1E5996 196 Item QuantityNo. 5 Drawn by In 76 Design by D10Date 9RevisionGENERAL NOTE: WEIGHT 74KG 38 239 457 76Rf.nr Qnt. 5 3 50 80 2C 0 R 4 Drawing no.9 ReplaDate 10

PARTS LIST54321Ref. No11111Qnt.Detent PinDetent SpringNutCapSplit RingPart NameOPTIONAL REMOTE RELEASEDETENT KIT 5919-01AGENERAL litringRemarkDRAWING No. GRS-017 ISSA16a

ULIC PILINGHAMMERSEXCAVATOR MOUNTEDVIBRATORSEXCAVATOR MOUNTEDDRILLSQUIET, VIBRATIONLESSPUSH-PULL PILINGPILE EXTRACTIONSHEET PILE GUIDEFRAMESSHEET PILECAPPING SYSTEMSCFA CLEANERSPILE POINTS& SPLICERSHANDLING / LIFTINGwww.dcpuk.comA GUIDE TO CHANGING THE PULL WIRE ON ADAWSON GROUND RELEASE SHACKLE

01The Pull Wire may require changingif it is frayed, kinked or generallydamaged.02First remove the guide key.Unscrew the M6 cap head screw andwasher.03The guide key can now be retracted.04Remove the plug from the underside ofthe shackle body. The detent pin canbe left in the shackle body.01

0205Remove the 4 No. M8 cap headscrews holding the tube assembly tothe shackle body.06Carefully retract the assembly from thebody as shown.07The sleeve is attached to the plungervia a coiled pin. This needs to beremoved.Hold the sleeve securely.

08Drive the coiled pin out using a 5mmpunch.REMEMBER TO WEAREYE PROTECTION!!!With the sleeve removed the old PullWire can be extracted.09IMPORTANTThe new Pull Wire tail must bethreaded through the largest ring toensure correct orientation at finalassembly.10Thread the tail of the new Pull Wireinto position.11Locate tail end in plunger in the ovalslot as shown.03

0412The sleeve can now be replaced andcoiled pin hammered back in place. Anew coiled pin may be required if theold one is damaged.HINT: Ensure the coiled pin is flush onboth sides of the sleeve, this will allowsmooth operation in the shackle body.13The assembly can now be reattachedto the shackle body. A small amount offorce is required to push the assemblyagainst the spring to the shackle body.Tighten the 4 No. M8 cap heads.14The plug and guide key can now bereinserted and tightened into position.The guide key M6 cap head shouldhave a light coating of Loctite 270applied.

15Finally check correct operation of themechanism.Gloves should be worn for theseoperations!First operate the Pull Wire to retractthe plunger. This requires reasonableforce. The plunger should remain inthe retracted position.16A tap with a soft hammer shouldfire the pin forward.17The indicator bar (item just hit with thehammer) should be flush to the tubeassembly as shown– this is critical!If in doubt, contact the manufacturer.www.dcpuk.com05

NOTES

GROUNDRELEASESHACKLEDawson Construction Plant LtdChesney Wold.Bleak Hall,Milton Keynes,MK6 1NE, EnglandTel: 44 (0) 1908 240300Fax: 44 (0) 1908 240222D.C.P. RESERVES THE RIGHT TO DISCONTINUEEQUIPMENT AT ANY TIME, OR CHANGE SPECIFICATIONSOR DESIGNS WITHOUT NOTICE OR INCURRINGOBLIGATIONSREV.GRS005

ground release shackle tive a innov piling equipment hydraulic piling hammers or mounted t a v exca ors t vibra or mounted t a v exca drills tionless , vibra quiet piling push-pull pile extraction pile guide sheet frames pile sheet

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