Dawson HPH 1200 Bedienungsanleitung

www.dcpuk.com

INNOVATIVE

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

HPH 1200

HYDRAULIC HAMMER

DAWSON

CONSTRUCTION PLANT LIMITED

HPH 1200 HYDRAULIC

HAMMER AND POWER PACK

- USER'S MANUAL

HAMMER SERIAL NO: ..............................................

HAMMER COMMISSION DATE: .............................

POWER PACK SERIAL NO: ......................................

POWER PACK COMMISSION DATE: ......................

ENGINE TYPE: ...........................................................

ENGINE SERIAL NO: ................................................

POWER PACK TYPE: .................................................

V8 05/06/06

C O N T E N T S

0.0 EC Declaration of Conformity

1.0 Introduction

1.1 Basic Safety Points

- Basic Specification of HPH 1200 - Drawing

- Lifting the HPH 1200 & Power Pack -

Drawing

1.2 Transportation and laying hammer down

2.0 How does the Hammer Work?

Figure 1

3.0 Power Pack and Hammer Operation

3.1 Connecting the hydraulic hoses and

control pendant

3.2 Checking the power pack

3.3 Starting the power pack

3.3.1 Hydraulic oil warm-up procedure

3.4 Using the hammer

3.4.1 Installing hammer on the pile

3.4.2 Bleeding air from the hammer

hydraulic system

3.4.3 Pile driving with the hammer

3.4.4 Cold running/overtravel

3.4.5 Refusal

Figure 2

3.5 Using the hammer underwater

3.6 Wider or special pile sections

Figure 3

Figure 4

3.7 Preventive Maintenance Guideline Chart

4.0 Hammer Maintenance

4.1 Daily maintenance

4.2 Planned 125 hour maintenance checks

4.3 Planned 250 hour maintenance checks

4.4 Planned 500 hour maintenance checks

4.4.1 Changing Resilient Washers

4.4.2 Other items

Figure 5

4.5 Planned 1000 hour maintenance checks

5.0 Power Pack Maintenance

5.1 Power pack specifications

5.1.1 Basic specification

5.1.2 Lubrication specification

5.2 Daily maintenance checks

Figure 6 Dolly wear

5.3 Planned maintenance checks

5.3.1 Every 125 hours

5.3.2 Every 250 hours

5.3.3 Every 500 hours

5.3.4 Every 1000 hours

5.4 Maintenance procedures

5.5 Setting procedures

6.0 Troubleshooting

6.1 Power pack engine will not start

6.2 Engine cuts out during running

6.3 Power pack does not generate any pressure

6.4 Power pack generates pressure but hammer

does not run

6.5 Hammer will lift but not drop

6.6 Hammer runs erratically

6.7 Excessive hose 'jumping'

6.8 Hammer 'jumping' excessively on pile top

6.9 Stroke height indicator will not move

6.10 Smoke from bottom end of hammer

7.0 Appendices

7.1 Hammer parts list

7.2 Accumulator parts list and instructions

7.3 See Cummins service manual

7.4 Power pack parts list

7.4.1 Hydraulic circuit schematic

7.4.2 Electrical circuit schematic

7.4.3 General assembly drawing - 3 off

7.5 Tool kit parts list

Description:

1. Hydraulic Piling Hammer

2. Power Pack - 93kW

Type:

1. Hyd Piling Hammer - HPH 1200

2. Power Pack - 1800/2400 Diesel Engine

Hydraulic

Serial Number:

1. HPH1200 –

2. Power Pack -

DAWSON

The responsible person:-

DAWSON CONSTRUCTION PLANT LIMITED

CHESNEY WOLD, BLEAK HALL

MILTON KEYNES MK6 1NE

ENGLAND

EC DECLARATION OF CONFORMITY

The above mentioned equipment conforms to the Machinery Directive 89/392/EEC(a)

as amended by Council Directive 91/368/EEC(b), Council Directive 93/44/EEC(c)

and Article 6 of Council Directive 93/68/EEC(d).

Signed for and on behalf of

Dawson Construction Plant Limited: .............................................................................

Name: .............................................................................

Position: .............................................................................

Date: ............./............./.............

1.0 INTRODUCTION

The D.C.P. Hydraulic Hammer has been designed and manufactured to meet the demands of today's

contractor. The hammer has many advantages over traditional piling hammers, including other

hydraulic hammers:-

- The hammer fits all British and most foreign single sheet piles as well as numerous 'H' piles using

one set of legs and inserts. It will also fit pairs of sheet piles and open bent corners with the same

configuration. This significantly improves productivity and reduces costs.

- The hammer does not have a single electrical component on it. This means no vulnerable

electrical cable running across the site and no delicate electronics on the hammer. All competent

fitters can understand this hammer.

- Hydraulic hammers are inherently efficient, typically 80-90% of the potential driving energy

being transferred into the pile as opposed to 25-35% for diesel hammers.

- Rapid blow rate. The hammer is double acting, not only giving high energy output, but

increasing the speed of operation. This inevitably increases production and keeps the pile on the

move.

- Infinitely variable stroke controlled, between limits, at the touch of a button. This enables precise

energy control which is very important when commencing piling or when coping with delicate

operations.

- Robust construction. The hammer has been designed with full knowledge of what is required of

piling equipment. A quick look at the hammer sitting on a pile will confirm this.

- With the hammer weighing only 3 tonnes, it lends itself to being used on long reach jobs where

there are few economic alternatives.

- Noise levels are considerably lower than that of diesel or air hammers.

- Transmitted ground vibrations have been measured lower than that of a vibrator.

1.1 Basic Safety Points

- Ear protection should be worn when in close proximity of the hammer.

- Keep clear of the hammer and/or power pack when they are being lifted.

- Avoid standing directly below the hammer when it is piling.

- Adhere to maintenance requirements set out in this manual.

- Lift equipment using lifting points specified only (see figures over).

1.2 Transportation and laying down hammer

- BEFORE operating hammer first time AND after each lay-down use inspection holes to ensure

dolly is seated correctly in anvil before striking.

- WHEN LAYING DOWN HAMMER, support top of hammer at higher level than bottom of

hammer.

- TRANSPORTATION, support top of hammer at higher level than bottom of hammer.

2.0 HOW DOES THE HAMMER WORK? (See fig. 1)

The D.C.P. Hydraulic Hammer consists of a 'drop weight' driven up and down by a 'hydraulic ram'

inside a 'casing.' The hydraulic ram is double acting which means the drop weight is accelerated

both on the upstroke and on the downstroke. This gives the hammer its very efficient energy output

and high blow rate.

The oil supplied to the hydraulic ram comes from the power pack via a 'control valve' mounted

inside the top of the hammer. This control valve switches the oil supply on or off at the upstroke

side of the hydraulic ram i.e. oil supply 'on' lifts the drop weight and oil supply 'off' drops it.

The control valve itself has to be switched from one position to another at precisely the right times

for optimum performance. The control valve is switched by hydraulic pilot signals from two

mechanically actuated sensors mounted on the hammer casing. The 'bottom sensor,' when actuated

by the drop weight, switches the control valve to the on (lift) position and the 'top sensor' switches

the control valve to the off (drop) position. The stroke of the drop weight is adjusted by moving the

position of the top sensor e.g. moving the sensor down reduces the stroke or vice versa.

The position of the top sensor is altered by a small 'height adjusting ram' mounted inside the top of

the hammer. This is adjusted as required by the operator who can view an indicator on the side of

the hammer.

The hammer is fully controlled using a hand-held control pendant. This unit enables the hammer to

be started/stopped, run on single/automatic blows and have its stroke varied. The controller may be

used from a remote position.

3.0 POWER PACK AND HAMMER OPERATION

3.1 Connecting the hydraulic hoses and control pendant

(The power pack must be turned off at this time to enable correct installation of the hoses)

There are four hydraulic hoses running between the power pack and the hammer, viz:

1. Pressure line (1" BSP) carries the main high pressure oil supply to the hammer.

2. Return line (1¼" BSP) returns low pressure oil from the hammer to the power

pack.

3.} Height adjusting lines (3/8" BSP) used to deliver

4.} Oil to the height adjusting ram, as required.

The pressure/return hoses have the same specification. However, the return hose ends have larger

fittings than the pressure hose to avoid possible confusion. Similarly, the height adjusting hoses

have different end types. The hoses should be left connected to the hammer at all times - this

reduces the likelihood of oil contamination and reduces leakage problems. The hoses should be

connected/ disconnected at the outlets of the power pack. All these connectors are of the

'quick-release' type. The hoses should be disconnected from the power pack when moving the

power pack around to avoid straining the connectors.

Make sure that the connectors are thoroughly cleaned when making a connection

Having connected the hoses, next fit the hand control pendant connector block to the multi-pin

outlet from the power pack. This is positioned below the instrumentation panel of the unit. Check

that a clean connection is made and that no water is present in either half of the connection. The

'power' switch on the controller should be turned off.

3.2 Checking the power pack before starting

Having connected the hydraulic hoses and hand control pendant, as described in section 3.1, next

check fluid levels on the power pack. Check:

a. engine oil level

b. diesel fuel level

c. hydraulic oil level, and fill if required

Notes:-

1. The diesel fuel and hydraulic oil tanks have sight gauges on the side of the tanks.

2. The power pack will not run if the hydraulic oil level is too low.

3. The hammer will not run if the hydraulic oil temperature is too low. The auto warm-up routine

must be used to pre-warm the oil. See section 3.3.1.

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