DAWSON - Auksjonen.no
Contents
1. 0072 NSN YY INONY COW N VOC ne ee 1 NJHOS SN 183 31905 OL ISN LON Od L 04 01 335310 37 Y N m OOL OL OS NOISNIWIG HSIN 06 21925 0 Sl an NAROL 40 INSSNOD 538483 1 6 3 51 HIHA 63 1 NYHL 350 8 3 ANY 802 0 5 ALAVA GEHL V OL 03 03 28 108 ONY 530 NIHOL 40 ua v N 15 50 S 2 52903 5 onas 7 wa 1 1 98 21009 MVHS AONE 1102. 100 1 2 25 1117 UN wld BIEL 583455 2 25 3103 58 0 19081 0092 NOLINHLSNOJ 16 0 42 ae 023 0042 osava 3005 al nees 712 SM 8 12 80 BWEU 520 ON nV 5 E 097 1 8 L S 1 992065 114 5 96 855 MOLY ALVA 38 297 9018 1 4 7 lt COLI 287 70018 5 1208 8X ce 0 9 497 0019 1 298 78 i 196 7 7 90 E Z 0256 gt 987 DOLS 20085 909 10 FOL 69 TNV N3d TH NVH 405 52222 279 197 20 18 797 50 17 07 279 996 54 C16 ee oo 2 09 845 i 90E 90 6 085 840 7 0 z OMS ans 005 885 2 59 884 JL y 2
3. 94 6 NORDLOCK WASHERS M16 16 000 27 6 SOCKET HEAD SCREWS 1126 M16 X 55 0 16 055 02 92 2 LOCATION BOSS 18 003 07 0 91 6 HEAD SCREW M10 X 25 10 025 02 20 O RING 18 004 02 01 99 JVER PLATE 18 003 06 01 98 4 ELECTRO BRASSED SCREW No 6 X 1 2711 204 00 01 87 DENTIFICATION PLATE 1203 00 02 96 UCP TRANSFER 1201 00 01 85 HPH 2400 TRANSFER 2 200 00 01 84 SPRING TYPE 55 06X10 2 047 00 01 83 TOP COVER 2 017 00 01 82 DISC SPRING BUFFER SPACER 2 012 00 04 91 4 ACCUMULATOR 1040 00 06 80 JNTROL VALVE ASSEMBLY 2 018 00 01 79 2 IARDENED INNER BUS 18 LONG 2 098 00 01 18 SEAL RETAINER 5 990 111 007 1 091 01 01 77 CROSS OVER PLATE STEEL LIM S 1 091 00 01 76 4 SOCKET HEAD CAP SCREW 179 20 708 15 SPACER 00 0 T4 4 SOCKET HEAD CAP SCREW 129 8 95 2 101 00 01 73 FILTER DFBNHC240P10A10BYP FLUPAC 2 079 00 01 WE 21 X 70 1 086 00 01 4 SOCKET HEAD SCREW 129 20 90 1 044 00 10 3 DOG POINT SKT SET SCREW 1129 8 30 2 088 00 0 69 7 _ ANTI VIBRATION WASHER 8 4089 00 01 68 3 YLOC NUI 8 6945 67 1 HEIGHT ADJUSTING RAM 2 026 00 02 66 5 WASHER 24 2 071 00 01 65 6 SOCKET HEAD CAP SCREW
4. 0 00 800 2 MEMINYH OOYZHAH lt gt TRIN O 40 STONY 2985 VDA Sa 55 500 8 4 8 0 018 ANd ENE E 56 8810 SN SNOILYONJAKOJ3Y ANY OL HOV 0 00 00 2 HAIN 990 19289 1 1 SSONVETIOL NNT s 8 55 NV SIN3NOdNOD OL O42 211201 1 3850 0376 5 012804 1 7 3 SWIS TW 4 3N 03 E Q OL 208 20 N WINTA OL NOISY vas TW 40 0 72 08 2 1 ONd33 0150 0 NO 3015 3 WaS 535 8 08 OL LLL YOLVALIY 3101 ATINSON3 30N HV 30 SONJ H108 2190300 55 8 N 948 0 3075 3 MOTY 111531 30155309 WENE SE D ONNIN ana tano EX 100 HSH W C003 THIN Z 1 21546 HLM 3123108 38 01 51909 ONI MH 12058 152000 NE 2 380022044 91130 O 118489 O0 NOISE 9 ESNE ANN 40 38 INVADAN 53 0 LNW LON 00 18458 13488 ANA 01 Wie 8961 540583411 L SALON WUN 000 160 KEO q I 0 50 51035 El 1022800 094 052510050 Yad 9 5288 OMET WLO TWIN 41770077 9 LC a 6 0540 959 IWIN
5. Appendix 7 2 Accumulator Parts List and Instructions Important Safety Notes for Bladder Accumulators 1 Use nitrogen gas only 2 accumulators are supplied precharged to 100bar 1450 psi unless sent via air freight in which case they will be shipped unprecharged Always use the gas filling apparatus supplied by Dawson This equipment includes a regulator valve specifically designed for use with hammer accumulators where the precharge pressure is less than the supply cylinder pressure Read the instructions below fully before attempting to adjust the precharge in any accumulator Routine maintenance on the accumulator in situ or removal of the accumulator must only be carried out when the hydraulic system pressure has been completely removed Accumulator Pre charge Pressure Pre charge Procedure 1 2 Attach the Regulator Valve to the nitrogen cylinder see figure 2 2 9 10 11 12 High pressure accumulator 100 bar Low Pressure Accumulator 3 bar Figure 1 Remove Protective Cap 1 and Sealing cap 2 see figure 1 Attach the charging set 5 to the accumulator gas valve assembly 6 and connect charging hose 7 between the regulator and the charging set connection Back off handle 8 anticlockwise until loose Check gas bleed valve 9 on charging set is closed and screw hand wheel 1
6. y OBE 10 00 960 9 4 SNOISNIIXG C L ONANGO 5 38 NVI 31V d 3093545 IYNOILdO aeg UDISIA8N qup 99111044 51801 8 5214 XJAWL OL Nv Bulmeug SN 0057 NOILINYLSNOJ 96 3 6 1445 0070 NOSMYO Aq paze day 82 098 2 paidoJ yJeway uoisuauig 511 17 ONY S 1 X OO OG OG 5214 8581 VIS i E S s 903 SAlV Id 031710915 u 2 2 310 9 5 OSE 1 6 6660 22 i 51845 15 J oo of of p 8 a a 5 g foes lt 1 7 1 p ZS Fd 391 I I I Wet 2 3 4 4 WA
7. PILE CONFIGURATIONS LARSSEN W s AND 6 IN SINGLES PAIRS WITH STD INSERTS 6520 ALL FROUINGHAM PAIRS WITH STD INSERTS gt gt H PILES 305X305 UPWARDS WITH STD INSERTS CONCRETE TIMBER PILES UP 530X530 WITH STD LEGS TUBULAR PILES UP TO 530 WITH STD LEGS SPECIAL LEG GUIDES amp INSERTS AVAILABLE ON REQUES for ol JON 1 9 7 9 9 a gt 8 9 9 9 e ome J 2 U 1 1 IV 7 o is Z r PERFORMANCE SUMMARY d ERFURMANCE SUMM 530 600 ENERGY INTO PILE 2400 2 STROKE 70 STROKE 130 bpm A 000 Ka Refna Qnt Part name Material Dimension Remark WEIGH 190 6 E Drawn at Copied Checked Affirmed Scale 2 Replace Replaced by OPERATIN DRAULIC PRESSURE 240 bar File name Dale 4 05 s DAWSON 4 193 REQUIREMENT 150 4 CONSTRUCTION BASIC SPECIFICATION OF HPH2400 DIESEL 0 KW 7 Pam 2ispec Revision Date 5 Appr by LIFTING 4 WEIGHT HAMMER 6000 Kgs USE A DOUBLE LEG SLING amp SHACKLES SUIT s Re
8. NOLES va i n UF D S l 002800 0570 146 35 004 0 L SNE NOTA V CH 17130 NOLYTIY ISN ON wa NOS 119915 ON 19 4 NUVI TWAS 1 34 080 44 5 0 SWL aN SS a A ONO 303 AD 6 102 30 1318 99805 18 57 LLZL SLZL WN OL 221 x 4 ct 100 lt NYO WIS 3 OL ONTAMGSS 380334 SONJ H108 1V 105 NO 0211 38 OL 5105 30 NOLLWINGYO INMOHS 2 8 Win Gi ON SLE OL 3431 37890 TV NMOS LI OLN IONS lt INE 0 9 SMe ONDINE 234 TWISN 2 08 BLY OLNI 915 S 2400845 OINI 55344 8 OIN dYNS OL TWIS MOTY 1 ONY
9. 2 EL WLI SNS NOISHOL ONY 8 WIL 583 YAS x 99 10308 SY HONS N00dA0J 37145 3596 19 61 LHS IND 2 9 Wall 14 OL 0 s X 00 TE 1 012 0805 DHL 2 OM 8 ASSW 30 501 NLM 38 00 050 170 Jl ANO JHL OL 8 10 E90L 311201 HLM WIL 9 NY31J SINANOdWOI WSINYHJJW 40 00 0020 0060 41989 00 590 0520 0011 dJ 4 0 0 00 4 9 9 X OW 60 5 3 d 5 8 8 0 8 3 AN 09 5 20 10 050 6XS 19 96 60 12 20 00 050 1 Aquddy 8 98 JUD JU YY os SIN3LY LNOHLI NMV ma A0 017 10 00 250
10. 6 8 i VT N E DO DND 0115 1844 D 0 So CEE G 75 i 7 6 DOO 019 9 08 626269 00767 2616118 B E 50 COMPOUND PIN DIN 1481 TYPE SS 910 X 70 2 047 00 02 19 RAM CONNECTOR 2 009 00 04 58 A 5 SOCKET HEAD SCREW 129 M10 16 1 058 00 01 2 WEAR PAD 1 015 00 01 56 RAM GUIDE BLOCK 2 032 00 01 45 4 SPRING PIN 1 X 40 11 056 00 0 hh DROP WEIGHT 2 001 00 0 L HYDRAULIC RAM 2 008 00 02 42 PLATE 2031 00 0 41 20 SOCKET HEAD SCREW 1129 M24 X 60 1 054 00 0 40 4 ANTI VIBRATON WASHER PAIR M10 2 040 00 01 39 8 HEAD SCREW 1129 M10 X 35 074 00 0 38 2 RETAINER SPIGOT 2 082 00 0 37 4 SOCKET HEAD CAP SCREW 1129 M5 X 45 050 04 03 16 ROLLER OPERATED VALVE 050 00 03 35 2 SPACER 037 00 02 34 BOT
11. 040 0 00 420 4 250 9 55 0 00 1L0 2 LAN 95 1000 8080 8 LAN JOA 89 LC 000 80W0 8 201 040 5 69 0 00 880 4 OE X 8 4415 135 DS INOd 900 OL 70 00 4 0 4 42 45 434 8 5 L 9 0 9 0 90 0 0 899 SS E8 SV GSTIVISN 38 LSAW LAN ONY NYY JHL CO 00 LL0 Z UNV 0 00 600 4 31 adlaya 8 LON 8 LAN 0103 0 ONY 1 03 3H1 Luva 208 40 10159 ONIMDHS 40 1100109 7 SONGS JSU JHL SVJ NMOHS SV SINANOdWOJ OL A ENIS KSND SV 3 LAN V W TCH 3 OL 3HL ONY 209 AG SS SIV JH1 J JIM WAL 5 3405 125 8 8 05 5031 S OL 89 WALL N 8 OL OL WALI 0 15 one ON TEWISSY LAN A 511 d3 3V S Aldd JHL 0 5310 Ob W 3 1 OML 0103 0 JHL 70 1811 JHL 093 53514 OCL 30
12. 0 2 6 0 99 X 304 64 7 0 0 52 81 171 210 702 0 92 8 2 22 80 9 0 980 4 0 84 8 0 458 8 vaj E 0 80 5 9 0 62 8 0 0199 0 0 902 N 0 LZ 13 31 07108 404 SONY D SUNN SH1 10 05 810 2 438 Was 200 1035 0 LINS OL NBO 25401 031091 OO4NYW 13N a 96 01 01 50141510 Led CYT 8 33W 56 0 ONY 5 920 39 35 SYM LL 08 55 un Jus ncn U UU UEU L ou Bulmesg NOISHSA DNAS NO 401 540 11 NOWLINYLSNOI 56 11 10 A os JHOMAdOI 3H1 40 NOSS as SNYJW ANY 0320000930 jG LON q 925165 EV 099983 padoJ umeJg d Virussen Jed UuDISU UII JEIJEN 14 9 VHS JH J JH N 0 JU 0 10 0E0 280 i LON SI LYHL 05 NMOHS 0 15 3 10 20 0 YNI 7 WN 40 31 E0 E0 0E0 J CNY MJIS 139005 OL 0 2 90010 0 0 00
13. 3014140 Faea 1 982 0 OULNOD WIZ 7 i 1 d 6004 839300 30 07 1 01 33038 avg 0 55 ONDINOM Fave 38 uva 7002 490 OSL ONIMOVED JAYA 007 0 al OLY 38 2289 TVIONANWOO x 95 258 00 6 L UW 901 TdT 553 9 5 4 5 0 3543930 3NION3 Sere doc 2 022 01 c 1 3 432 12510 028 1 uve SV_OSSNVE 8 135 007 0 INNIS 03 4 3 LLLEV TA LEP VOSS NIRA aS 3 25 23 y ey AIAZ7 5 58 7 1 82 0102 HNO eer 1 910 3 51480 29 5 0 MAH YIWAYH 5 INT 128 00 89 5 1 39 9 3 15 5 3085 Ove 400 3NON3 ge 0 38330 135 0 184355 380438 13 01 SEO 28025 Tusa 2 3 83 JAYA MIH JIONY 0 M3WAVH 0076 D INN IYNSSIHd 9 5 2
14. DIN 17114 8 jdVHS DIN 1 15 3723105 7 NOS LON SI 340080 OLNI IN O 1835 8 SWANS WAS 40 NOILVTIVISN TON 5 TAY 11 N37084 ON 0 00 78 OZ OL NSLHOIL 8801 9 LI Lis TMa i 58 0 8 54 05 OL 3NBYOL 292 311201 9 8 SLI ONISN 13901 1708 2 3 ONLY 30438 211201 40 XVII 5 9 3109 380552 7 iQ WD NSN 8 VWI OL Z 0 pareyday aneyday 39535 856 padoz IP umesg 0 6530 Ed ENBW u jeg HLOOWS 118 3 300 INVd 3538030 9 8 9 SII 440 9 1915 JHL 1763 3HL SV ASSY 2185504 SV 0 0 180 dYJ 34 GL 0 8 SY 1639 38 01 0 Z0 480 JAVA 2 NOONE 1521 335 ASSY 380338 0370 38 OL WAL WAS ONY 7 WILD 040 780 JANA AVL 71531 39155389 21 15 5 lt 310 184155 00 590 FATWA 050 780 5 NOILISOd OLNI 1935 JHL 04 86 0 90 80 9 8 0 1531 33 SL
15. 55344 MOT 9 OVO 9 3119 BA0 5503 LHII 8 YOSNIS 01 6 JANA 8 0 YOSNAS WOLLOE 22 JANY Q Wi 8050 El WVA INT 1511 SSVdA8 JAWA 8 3505534 13 3081 380515 2 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 4 BSP carries the main high pressure oil supply to the hammer 2 Return line 1 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 specificatio
16. 10152 8 91 0 CENE ZE 202 90 INYONdd L MOTIIA ar I N 17 lt 5 ON ON 8 7 W E L 2 5 6 5 t 6 2 4 6 5 5 dalla T ons 4 4015 NDN 6 5 98 21 EST o 998 198 1531 0 5 av 3368 Lovy 686 80 f 4 MOM Q D2 8658 a 88 88 18811 6 B alee SL ua 8 6 R D 1 E oe Ow 99 of ANO LINA 19914031 08129 5010151000 360 vosnay PART NO 065 1 off 066 1 off 067 1 off 068 1 off 2 150 01 01 2 150 02 01 2 150 03 01 070 1 off 1 150 02 01 1 150 03 01 2 150 04 01 1 150 12 01 1 150 27 01 1 150 28 01 1 150 29 01 1 150 09 01 1 150 21 01 1 150 20 01 1 150 24 01 1 150 18 01 1 150 16 01 1 150 23 01 2 150 06 01 2 150 07 01 2 150 05 01 1 150 25 01 1 070 00 01 APPENDIX 7 5 HYDRAULIC HAMMER TOOL KIT PART NO 2 150 00 01 QTY DESCRIPTION 3mm Allen Key 4mm Allen Key 5mm Allen Key 6mm Allen Key 1 off 8mm Allen Key 1 off 12mm Allen Key 1 off 14mm Allen Key
17. os VAT S g g 219105 Ose 1 83100294 5 JAWA 823821 WEYE 4 8 2100 9230 32821 8 AGNOILONS asz 5 aoe 2 INO Nanay 5 GOW 08 543 8012051538 6 2 _ 08 94 24915 181 59 1 3 16 22 17 69 GON W W 458 01 GOW 2121 940 8042541531 53 2 08 GOW W W 8 2 1 7 2 RIN 5 03420 2 YIH lt YILT So vZIA9 NANIA wn NJA 7 no oO M 2 5700 40 105 1 09 W 7 06 wingz L avg 9 321480 eae wwgg 8 5500 dO 2 NC gt 10 0 20 40 2 277 F dod 08 FATWA lt 20 2 00 dod 3941815 2 k A L A 95 90 61 40 821 3 wwe TNC HIND 0100 dod AWA 7 ONILLIS 0738 ATINA 20 A T NT LIZO IHG t goozunadod 49018 S USHN MIO4INV 002 803430
18. 50 V 51114 OW OL 57 L _ HI Ol 67 WAL 01 13 3H1 13 40 51015 3405 YOLIINNOD 78801 801 JHM ONY NY 137205 9 1 lV 0 3 0 8 SON amp aS 050 FTaWaSSV 311901 5540 3 ANY 35 OLE 2010115 21L0 6 904 AdU OL MOTI 01169199 Kako a ava gva 10 10 60 2530 0 01 SH3NISVj OL OAH V Aquddy aeg 5 0 POWER PACK MAINTENANCE 5 1 Power pack specification 5 1 1 Basic specification Engine power output Engine maximum r p m Hydraulic flow output Max hydraulic pressure output Dimensions 1 x w x Weight 5 1 2 Lubrication specification Hydraulic oil type Hydraulic oil capacity Diesel engine oil type Diesel engine oil capacity Diesel fuel type Diesel fuel capacity 66 kW 2300 rpm 2300 150 l min 230 Bar 1900 x 1400 x 1800mm 2000 kg Fina Hydran LZ 32 or equivalent 465 litres 15 W 40 9 5 litres incl filter DIN 51601 DK 235 litres 5 2 Daily maintenance checks for full details of diesel engine maintenance see Cummins service manu
19. DAWSON CONSTRUCTION PLANT LIMITED HPH 2400 HYDRAULIC HAMMER AND POWER PACK USER S MANUAL HAMMER SERIAL HAMMER COMMISSION DATE POWER PACK SERIAL POWER PACK COMMISSION DATE ENGINE TYPE ENGINE SERIAL NO POWER TYPE V6 23 05 07 0 0 1 0 2 0 3 0 4 0 CONTENTS EC Declaration of Conformity 5 0 Introduction 1 1 Basic Safety Points Basic Specification of HPH 2400 Drawing Lifting the HPH 2400 amp Power Pack Drawing 1 2 Transportation and laying hammer down How does the Hammer Work Figure 1 Power Pack and Hammer Operation 3 1 Connecting the hydraulic hoses and 6 0 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 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 7 0 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 Hammer Maintenance 41 Daily maintenance 42 Planned 125 hour maintenance checks Fi
20. 6 9 Stroke height indicator will not move With the power pack running and control pendant connected check pressure gauges when T and are pressed If no readings check relevant valve and wiring fuses in power pack If readings are O K check hoses to hammer If these are O K check restrictor orifices for blockages these are the male male adaptors located on the inlet manifold If these are clear remove front leg guide and check height adjusting ram 2 026 00 01 and top sensor assembly APPENDIX 7 1 HPH 2400 HYDRAULIC HAMMER PARTS LIST 10 00 000 2 5 49 5 1 8788 H Pie e INI 9 9 si y wx 09 2 8 Pr 20 gt T e 9 balk gt Ex 0265 5 0 K ISW 9 U H
21. 601109 OCW 88 1108 X3 T L 2 ORE L0 00 090 1 OCW LAN JOTAN 5 OE 7 3ldNYX3 404 Z 1959 NOSN31X3 ON JIdAVX3 5 009 NASSHYT 9 5 15541 5 9 355 NOISNSLX4 DNA 500 15 SNOISN31X3 Fy lt Waet g B B cal 1 L le Hate o Com 028287 IIIS SV 6 61 a 1081 03 81 238 I TW iq pazeyday ada 2 2 5 pay 51 PUN Ie ou RY 2 L 5 458 2 1 ESA 9119 9 5 9 4 L 9 8 6 05 0 0 9654 458 7 EL 458 7 9 6 0 12 9 0 6 5 X SW 3825 9 0 42 1458 8 4
22. 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 6 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 REnr Revision Date Intro
23. SVM 6 L0 OL 80 L SYM 0 Wal 6 dy 5 1735 05 1 335 apg 05 9 HYDRAULIC HOSE DETAILS FOR 2400 Control Side of Hammer Sensor Side Assembly Number 2 110 00 01 Qty Description Hose Length Cut Length 2 off Hose Assy 965mm 3 8 R2T c w 20 x 1 5 heavy 12s fem E E 4 off Hose Assy 990mm 3 8 R2T c w 20 x 1 5 heavy 12s fem E E 4 off Hose Assy 750mm 3 8 R2T c w 20 x 1 5 heavy 12s fem E E 3 off Hose Assy 920mm 3 8 R2T c w 20 x 1 5 heavy 12s fem E E 3 off Hose Assy 1160mm 3 8 R2T c w 20 x 1 5 heavy 12s fem E E 30 off GE12 PSR ED 12s x 3 8 BSP Stud 2 off RHZ 12 PSR ED 12s x 3 8 BSP Stud check valve Height Adjusting Ram Hoses 1 off Hose Assy 560mm Y4 R2T c w 16 x 1 5 heavy 8s fem to 8s 45 fem 1 off Hose Assy 530mm R2T c w 16 x 1 5 heavy 8s fem to 8s 45 fem 2 off GE8 PSR ED 8s x BSP Stud 2 off GE8 PSR ED 8s x 3 8 BSP Stud Power Side of Hammer Supply Side Assy Number 2 111 00 05 1 off Hose Assy 2480mm Flange to Flange 14 c w 1 SAE 6000 Straight Flange Interlock type 1 off Hose Guard c w Cable Ties 1 off Hose Assy 1500mm Flange to Cone 1 4SH c w 42 x 2 heavy 30s fem to 1 SAE 6000 Straight Flange Interlock type 1 off Voss Flanged Elbow 195241 4 off 1 SAE 6000 Split Flange Clamps metric bolt holes 2 off 1 SAE 6000 Split Flange Clamps metric bolt holes 8 off M16 x 55 Socket Head Cap Screws 8
24. 129 8 X 30 1 061 00 01 55 6 SPRING WASHER 12 1 094 00 01 63 6 SOCKET HEAD CAP SCREW 179 12 X 40 2093 00 01 62 1 OVERTRAVEL VALVE 1 084 00 03 61 1 HAMMER CASING 2 003 00 01 60 OUDE BAR 1 2 021 00 01 59 5 IREASE NIPPLE 11 8 1 057 00 01 58 RETAINER SPIGUT 078 00 01 5i 1 SENSOR ASSEMBLY 1 030 00 05 56 1 CONNECTOR NUT 2 011 00 03 55 16 SPRING 2 022 00 01 5 2 USL SPRING GUIDE BUSH 2 015 00 02 53 2 SEATING WASHER 1 036 12 01 57 1 SPRING BUFFER WASHER 2 010 00 05 51 CONE PONT SKI SET SCREW 129 M10 X 12 1009 01 02 Ref no Qnt Part name Material Dimension Part number Drawn Copied Checked dar A0 Affirmed Scale 1 7 Replace Replaced by n m Fie name Date 4 07 PA 2400 LEG GUIDES 7 PLANT LTD GENERAL ASSEMBLY 00 UU 00 101 ou 0 404 SNOISNI E6 CL 9 aeg 80 814 06 4 13W Aq 2380098 228098 3825 5 815 pa do ubisag yJEWSy 018 9 E 077 g L0 L0 960 2 OLE NOISNSLX4 7 k 0 OBE NOISNSLX4 7 0 0 960 077 7
25. 17mm Allen Key 1 off 19mm Allen Key long series 1 off 22mm Allen Key 1 off 10mm Combination Spanner 1 off 19mm Combination Spanner 1 off 22mm Combination Spanner 1 off 24mm Combination Spanner 1 off 27mm Combination Spanner 1 off 18 Adjustable Spanner 1 off External Internal Circlip Pliers 1 off 5 16 Parallel Pin Punch 1 off Soft Hammer 2 off M24 Lifting Eye 1 off Sliding T Bar 1 off 34 200m Extension 1 off 65mm Socket 1 Square Drive 1 off Fem to 1 Male Convertor 1 off 24 A F Open End Spanner 1 off Grease Gun 1 off Gas Filling Apparatus
26. HS 114 SVMS 1 SFIVAINS 9 Ol L09 3110011 Add JY SSIVSUNS 1 9 SHS 9 E904 UIST 3SN LON SALANIA E Z AUT 340 0404 YJ Opona CNH 51 JH NV 3 5 8 INJATOS SI S E 90 01 201 ladV Wil 1955 HSN JANY Se 40 00 80 Z 11 INV 4 18 17 NOWINYLSNO 2 76 80 4 36 aweu Ag alday 8803 JBQUNN UDISU UI Jed L0 00 140 1 10 9 0 00 190 050 0090 9190014 0 20 80 2 004 5 340 0 40 80 380441 7 L107 LW 5 9 O02 X Nid 5 9 CO LO E80 L 09 409 LAN 403 03 SINJLYd 3H1 40 NOISSIAYSd HOla ANY 321004438 38 LON ISAW SIHL t gt L LAN 325 9314 9 ONY SALON Aq sddy 9 81 UDISIASY Jup J
27. Locknut anti clockwise remove the bladder from the Accumulator Lid Fitting of Bladder to Lid e Ensure O Ring Item 8 is fitted to new the Bladder s stem Push the stem through the central hole in the Lid Item 2 then fit Locknut Item 5 Fitting of Bladder amp Lid to Accumulator Body e Checking that all O Rings amp Back up Rings in Place Expel all nitrogen from the Bladder Item 2 to enable it to pass through the top opening in the Housing Item 1 e Insert the assembled Bladder amp Lid into the Accumulator Housing aligning the holes in the Lid with the M16 tapped holes in the Housing e Ensure the M16 Socket Head Cap Screws Items 13 are in good clean condition then install them together with the M16 Nordlock washers Items 14 into the top of the Housing e Tighten Items 13 to a torque of 231Nm 173 lbs ft e Re fit the Gas Valve Assembly Item 4 and tighten e Re fit the Protective Cap Item 6 and tighten Re Assembly is now complete and the accumulator is ready to be Pre charged see details at the top of this section PRIOR TO APPLYING HYDRAULIC PRESSURE TO THE SYSTEM THE ACCUMULATOR MUST BE PRECHARGED WITH NITROGEN IN ACCORDANCE WITH THE ABOVE INSTRUCTIONS FAILURE TO DO SO WILL RESULT IN BLADDER FAILURE APPENDIX 7 4 2400 POWER PACK PARTS LISTS please refer to Power pack manual for full details
28. MIM Ld30X3 SIONVAFIOL ALD 53 Fr 39 9 6 13437 Tana 4 6123 0 SATIVA LVLSOWHSHL 6000 JA 5020 0 8 0 AE 7353 80000 85 531003 su i TN 8276 dog 30 9 INIT gy ozo dod fog TWA NOHO gz anv a 19 9 POY 33 0815 0212080 135340 dal 8272 400 39 9 NI 8070 404 341 388 Goll 9201 t n 9 19 aca 1 29 lt 0 5 Zaz BY et Ss dod 38 8 1009 420 YINIVHLS M 0501 400 5 y anvo 9 051 400 I 38 8 714 NYL WAS 09 195 55 3lgviSnrqv lt SOL 420 35 9 INT z 7100 dod was 721 doc 00 1001 124056144 89145 BSA 8 00 8 5 dA31 2 62 5 0 C dod dnd ONVH ANIONS 30330 431002 GAH Sb 8 55284 58 55 433 2050 TA HLM 9319905 9 41 Sb IWAN 7 7100 43 02 200 491 823383 G 03 55333 4702 BD oe 871002 3 6072 dod 3909 2600 9201 1 1508871 61 81 Tal a Olez 7
29. 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 3 3 Starting power pack see fig 2 Prior to starting the power pack check that the hand control pendant is turned off Set the throttle control lever to half of full throttle 2 Turn on the battery isolator 1 Push the engine start push button 4 until the engine starts Allow the engine to reach working temperature by running it at 1500 r p m under zero load for 10 15 minutes Check all gauges and diagnostic lights for correct function of unit diagnostic lights should be off Notes 1 Ifany of the following L E D s 7 8 9 and 10 are on when the isolator switch 1 is turned the power pack will not start Rectify problem immediately 2 If L E D 11 is the power pack will start but the pendant will be dead until the hydraulic oil warm up procedure is carried out 3 3 1 Hydraulic Oil Warm up Procedure If the hydraulic oil temperature is less than 25 C L E D 11 will be on and the oil will require warming prior to using the hammer The hand control pendant will be dead for as long as L E D 11 is on To warm the oil a Run the engine at 1800 r p m Turn warm up run selector switch 5 to warm up The engine should go under load and the high pressure gauge 13 should read approx 200 bar Leave the pack in this condition unti
30. improved pile coverage This is a tried and tested technique see figure 3 With tubular piles for example the standard inserts can be removed and in place some simple bolt on plates added to centralise the hammer on the tube see figure 4 A further refinement if necessary is to weld a ring onto the underside of the anvil to give correct location on the tube PLEASE CONTACT THE MANUFACTURER IF YOU HAVE A SPECIFIC PILE DRIVING PROBLEM IT MAY HAVE BEEN DONE BEFORE 5 1035 13385 x NOILINYLSNOI N3SSUYT 258 NO YINWYH OO4ZHdH IW NMOHS SY 3 dlid 3825 QYeAUEYS pa223 pardoz 18 Aq usag Ea 1007 7 E anh Sones 80 CYVONVLS ISN 28 NVI XIWWYH F AM v TIM SNOSN41X4 ONIM 108 NI 5 ON 04 GaSA 39 NYJ MSW s2 NS N s A ONA
31. off M16 Spring Washer 4 off M12 x 45 Socket head Cap Screws 4 off M12 Spring Washer Fittings for underside of Inlet Manifold 2 off 3 8 BSP M M Adaptor restricted 0 79mm bore 1 off 1 BSP M M Adaptor 1 off 1 BSP M M Adaptor Part No 2 110 01 01 2 110 02 01 2 110 03 01 2 110 05 01 2 110 06 01 1 111 14 02 1 100 03 02 2 110 08 02 2 110 08 03 1 111 12 01 1 110 02 02 2 111 01 01 2 111 04 01 2 111 02 01 1 111 17 01 1 088 00 01 1 111 20 01 4056 1 090 00 01 1 111 24 01 1 094 00 01 1 100 02 02 1 101 08 01 2 111 03 01 Appendix 7 2 Accumulator Parts List and Instructions lt I a v gt u lt 2 at Ss v 1 D ee 2 Ki 5 S 5 gt D x z 5 2 5 5 8 l 5 g E 92 7 5 5 ols lt lt r F Z Z gt gt e LY 77 lt Ne 4 2 z lt ns U Late ON com uf J Prey N 53
32. s Hi 2 9 6 A 3425 dv 13 I X ON 7 15 401 ON 72 1111 guddy aeg 0 38 100 SLNN JOTAN YEW ON 3 7 PREVENTATIVE MAINTENANCE GUIDELINES FOR 1200 amp 2400 HYDRAULIC HAMMERS AND DIESEL ENGINED POWER PACKS DAILY OR REFUELLING EVERY 125 HOURS EVERY 250 HOURS EVERY 500 HOURS EVERY 1000 HOURS EVERY 2000 HOURS CHECK OIL LEVEL COOLANT LEVEL FAN INSPECTION DRIVE BELT INSPECT FUEL WATER TRAP DRAIN CHECK HYDRAULIC OIL LEVEL AIR INLET OUTLETS FREE FROM OBSTRUCTION CONDITION OF LIFTING POINTS amp SLINGS SHACKLES TEST DIAGNOSTIC LEDS INSPECT GAUGES CONDITION OF QUICK RELEASE COUPLINGS CHECK ALL EXTERNAL FASTENERS FOR TIGHTNESS DOLLY CONDITION SUSPENSION BLOCK amp SUSPENSION RING CONDITION LIFTING POINT CONDITION SERVICEABILITY OF SLINGS SHACKLES m MUST GREASE HAMMER FREQUENTLY HAMMER TEST RUN ON PILE 15 MINUTES TEST RUN ON PILE 15 MINUTES TEST RUN ON PILE 30 INUTES TEST RUN ON PILE 30 MINUTES TEST RUN ON PILE 30 MINUTES BEFORE AND AFTER CHECKING BEFORE AND AFTER CHECKING BEFORE AND AFTER CHECKING BEFORE AND AFTER CHECKING BEFORE AND AFTER CHECKING CHECK FOR HYDRAULIC OIL LEAKS amp RECTIFY CONDITION OF HOSES TIGHTNESS OF FASTENERS CONDITION
33. the Important Safety Notes at the beginning of this section Removal of Accumulator Pre charge Remove Protective Cap Item 6 from the Bladder Stem by unscrewing anti clockwise Remove the Sealing Cap from the Gas Valve Assembly Item 4 Connect Charging Set to the Gas Valve Assembly Release all the gas pressure by opening the Bleed Valve Item 9 on the gas Charging Set Disconnect the Charging Set from the Accumulator Removal of Accumulator Lid amp Bladder Remove M16 Socket Head Cap Screw Item 13 and washers Item 14 Remove Lid amp Bladder Item 2 from Accumulator Housing Item 1 Cleaning and Inspection Clean all metallic components with an organic solvent do not use on rubber components Inspect the Bladder Item 3 for any visible signs of damage Cracking or Surface Abrasion etc Inspect the Housing Item 1 and Lid Item 2 both inside and outside for signs of corrosion mechanical damage Replace any parts found or considered to be defective Replace the following parts irrespective of condition 1 O Rings items 7 8 10 11 and 12 2 Back up Ring item 9 If the unit was removed from the system the connecting O Rings items 11 and 12 should be replaced irrespective of condition Replacement Bladder having removed the Accumulator Lid e Unscrew the Gas Valve Assembly Item 4 from the Bladder Stem by turning anti clockwise e Remove the Locknut Item 5 from the Bladder Stem by turning the
34. 0 clockwise to open gas valve Open nitrogen cylinder valve by turning key 11 cylinder pressure will register on right hand gauge 12 This pressure should be checked against the required precharge pressure Turn handle 8 clockwise until outlet pressure on left hand gauge 13 registers 10 higher than required precharge pressure 110 bar or 3 5 bar When pressure on the charging set and outlet gauges are equal close nitrogen cylinder valve Turn hand wheel 10 anticlockwise to seal gas valve Crack bleed valve 9 to exhaust gas from charging hose and remove hose from charging set and replace hose connection sealing cap Close bleed valve turn hand wheel 10 clockwise to open gas valve and crack bleed valve 9 to vent down to required precharge pressure Close bleed valve Turn hand wheel 10 anticlockwise to reseal gas valve crack bleed valve and remove charging set from the accumulator Test accumulator gas valve for leaks using soapy water or similar Replace sealing cap 2 and tighten with pliers Replace protective cap using a wrench U QOD Accumulator Nitrogen Bottle Inspection and repair Accumulators Due to the nature of the design and specific assembly procedures it is recommended that the accumulators should only be inspected and repaired by a competent person Dawson Construction Plant Limited or their approved dealers will be happy to undertake this work as required Please note
35. 0 HAMMER MAINTENANCE SEE APPENDIX 7 1 4 1 Daily maintenance checks or every 10 hours a Apply Lithium based general purpose grease to hammer through each of five grease points part 1 057 00 01 Twenty operations of a grease gun on each grease point every shift will be adequate Check all external fasteners for tightness and re tighten where necessary Check that the dolly part 2 006 00 06 has not been damaged or worn beyond its serviceable limit If the dolly is replaced ensure that the O ring is replaced with it part 2 067 00 01 To inspect the dolly remove sixteen screws part 2 034 00 01 and drop the leg inserts 2 019 00 01 and 2 020 00 01 down far enough to view the dolly If the dolly is compressed past it s serviceable limit or if the dolly is cracked in many places replace it Please refer to figure 4 1 for guidance on acceptable dolly wear To replace the dolly insert a steel bar through one of the holes in the bottom of the anvil part 2 005 00 01 and drive the old dolly out using a hammer Insert a new dolly complete with O ring ensuring that it is pushed fully home Check the suspension blocks part 2 025 00 01 and suspension ring part 2 024 00 5 for wear damage and replace if necessary These must be in good condition at all times These items act as the hammers suspension system reducing the shock transmitted from the blow to the hammer and its components very important for keeping the hamm
36. 96 80 91 NOSMYO Aq 83 05 4 PIS pa223 paido 8 dYa ubisag J QUNU 8 uoisuawig Ou Jay 0 920 E WY 70 20 9 0 WYJ 0 0 9 0 LAVHS JUIN L0 70 5 0 1 0020 00410 L0 1Z 0E0 1 4 5 0 1 9E0 1 9 10 8 060 29 9 X IW 62 8 229 6 05 x 0 9 0 WYJ N 1015 4 JQINIOI LON SI dY9 JHL 05 NMOHS SV O3TWISN 39 OL WALI dD WN 30 81 V OL NV 8 3505 OVIH 133005 OL 0 2 5 3111301 Alaa L WIL SNS NOISUOL ONY 5 WIL 54349 5 99 10304 SV HINS 4 145 0359 840402 V E WIL 14 OL YaWWVH 0393 1305 3SN ASSY 40 SHH 451 48 OL SI ASSY 3H AINO JHL 01 SOLVAY Aldd 90 JOT 8 WIL N 30H OW 3H 3 SLNINOdWO3 40 55 3403389 A TeWASSY SLNANGdNOD y A BAS TN E dY 96 80 5 40 0 960 SYM L Wall Aquddy 280 UB x INO 39915509 h 11 0 38 5 E Z 903 OL 38 OL 5309505 OL LLL SOLVAY 4117 38 01 ONY Y HLI 5 4 5 0 LaM 1115 S 1 151 JHL WOud 311901 5539 3 ANY JAOWSY
37. Accumulator assemblies c Condition of the main feed hoses between the hammer and power pack Hoses with excessive amount of braiding exposed or damaged should be replaced 4 5 Planned 1000 hour maintenance checks run the hammer for 30 minutes before and after this maintenance work Check the following a Play in the main ram anchorage assembly b Condition of the Anvil c Play between the Drop Weight and Casing bore Note It is strongly recommeded that in order to achieve thorough and correct maintenance of this equipment that customer s service personnel should be fully trained by the manufacturer SCH UNS7 UN 9E 40 3000 011 JHL N 53 UNV 0 ISNOAJ d SJLONIW 0 OL 904 JSBYUEW OL IHEM dOa 00 112 Aq 535 83 98 7 553313 Je 0850 480 jd uoisuawg 2 2 Jed 1 8 0 00 800 4 E7 0 00 00 4040 40 00 600 C 0103 0 64 2 0 0 0 0 OLXOL SS 4 1 LBL 01 Nid 05 LL amp L0 0OLWO 3 5 135 1 5 INOd 5 50 00 0 0 YJHSYM 299409 050 25 00 5 0 HSNG 3005
38. OF PAINTWORK BATTERY WATER LEVEL FUNCTION OF PENDANT amp CONDITION OF CABLE CHECK TIGHTNESS OF ALL HOSES FITTINGS AND FASTENERS INSIDE HAMMER CONDITION OF BOTH SENSORS WEAR LEVEL ON LEG INSERTS CHANGE LUBE OIL LUBE FILTER CHECK AIR CLEANER INTAKE SYSTEM CHARGE AIR COOLER CHECK BATTERY CHARGING CHANGE HYDRAULIC OIL FUEL FILLER FILTERS CHECK ACCUMULATOR NITROGEN PRECHARGE PRESSURES HAMMER FILTER FUNCTION OF OVERTRAVEL VALVE FUNCTION CONDITION OF PROBE ASSEMBLY AND BOTTOM TRIP DEVICE CHANGE RESILIENT WASHERS BETWEEN DROP WEIGHT amp HYDRAULIC RAM ON HPH 2400 ONLY CHANGE FUEL FILTER CHECK ANTI FREEZE CHECK PRESSURE OUTPUT OF PUMP FLOW OUTPUT OF PUMP CHANGE PRESSURE RETURN HYDRAULIC FILTERS CHECK CONDITION OF HEIGHT ADJUSTING RAM TIGHTNESS OF ACCUMULATORS CONDITION OF MAIN FEED HOSES TO HAMMER CHANGE RESILIENT WASHERS BETWEEN DROP WEIGHT AND HYDRAULIC RAM ADJUST CHANGE VALVE LASH CLEARANCE ANTI FREEZE CHECK CHECK FAN HUB DAMPER BELT TENSIONER BEARING BELT TENSION CHECK 9 CONDITION OF WIRING DRIVE COUPLING FOR WEAR CONDITION OF EXHAUST CHANGE HYDRAULIC OIL AND CLEAN OUT SYSTEM CHECK PLAY IN MAIN RAM ANCHORAGE ASSEMBLY CONDITION OF ANVIL PLAY BETWEEN DROP WEIGHT AND CASING BORE FOR FULL DETAILS SEE SECTIONS 4 AND 5 IN THE HAMMER MANUAL AND THE CUMMINS SERVICE MANUAL 4
39. Ram from the Drop Weight by hand and remove the other Disc Spring stack e Inspect the removed steel components for wear and replace those with signs of fretting or bruising Dispose of the old Disc Springs if there are any signs of radial cracking or unusual wear do not reuse them if in doubt f Ensure the Connector Nut threads are clean and fully degreased Pay particular attention to de greasing the Grub Screws threads and the Grub Screws as this will ensure the Loctite adhesive works correctly Failure to do this correctly may result in the assembly working loose g Re assemble the connection as in figure 5 ensuring the new Disc Springs are installed in pairs using adequate EP Moly grease Coat the Guide Bushes and Washers with EP Moly grease on all contact faces Tighten the Connector Nut until it is hand tight approximately 45 Nm 33ft lbs Tighten the Connector Nut further using a socket until the top Buffer Spacer is compressed by 2 5mm Align a Dog Point Grub Screw hole in the Connector Nut with one of the axial slots in the Ram Connector thread This may require the Nut to be tightened slightly further h Install the 3 no Dog Point Grub Screws using some Loctite 270 Studlock thread adhesive and fully tighten each in turn to the torque quoted on Figure 5 Next install the pairs of anti vibration washers onto each grub screw and lock the grub screws using new Nyloc nuts i Re assembly the Rear Leg Guide on the hammer The u
40. TOM SENSOR ASSEMBLY 036 00 05 33 4 SPRING 081 00 0 32 2 GUDE 2 2 038 00 01 31 PROBE ASSEMBLY 2 083 00 04 30 RAM ANCHOR 2 021 00 02 9 YLOC NUT M16 2 035 00 01 28 HEXAGON HEADED BOLT 88 M16 X 115 2 049 00 01 22 PIN RETAINER 2 014 00 01 6 LOWER RAM PIN 2 013 00 0 5 CIRCLIP 1300 0350 1 065 00 01 24 GUIDE BUSH 1 041 00 3 SOCKET HEAD CAP SCREW 1729 M24 130 1 053 00 22 33 SOCKET HEAD SCREW 1129 M24 X 200 2 055 00 y 21 RING 204 982 4470 2 061 00 0 0 2 SUSPENSION BLOCK 2 025 00 0 9 SUSPENSION RING 2 024 00 05 8 DULL 2 006 00 08 7 HARDENED INNER BUSH 40 LONG 2 091 00 0 6 ANVIL 2 005 00 0 5 REAR LEG GUIDE 2 002 00 0 L FRONT LEG GUIDE 2 004 00 0 3 3 WASHER PAIR 20 045 00 0 2 8 YLOC NUT 20 060 00 0 1 8 HEAD CAP SCREW 1129 20 50 1 059 00 0 0 2 BUFFER PAD 040 00 0 9 22 HEXAGON HEADED BOLT 88 12 X 4512 063 00 01 8 96 NYLOC NUT 12 052 00 0 7 32 PLAN WASHER 12 012 6 64 CSKSOCKET HEAD SCREW 129 12 X 35 7 051 00 0 5 20 SOCKET HEAD SCREW 1129 24 X 70 2 034 01 0 h 6 SANDWICH MOUNT 070 0600 14 2 0 43 00 02 1 4 LOCATON PLATE 2 042 00 03 2 REAR LEG INSERT 2 020 00 01 1 FRONT LEG INSERT 2 019 00 01 Ref no dnt Part name Material Dimension Part number Design Y Drawn at Copied Checked eG Affirmed Srale 1 7 Replace Replaced by WSO File name Date 44 2400 WITH LEG GUIDES PLANT LTO GENERAL ASSEMBLY 2 000 00 01
41. WAL 00 0 10 1804 90916 9 1531 TVIISAHd 0 80 480 1 SLLXLTLE 8 70 60 180 1 57 009 6 3A00u9 70 01 1780 SONBAS NOW JHL ONY SOV Id ANO 0 780 37 WYOS 01 83 17 01 ONY 5 HL 3733005 0 21 80 311437138 80 51855 10 amp 8 EL 1025 06 05780 Ws 0 SL ZIZ 3111301 8 Lb 1 DNSO 6 LI HLM ASSY OL ASSY d 30N3 380225 029 590 281 JV a Z Il 3808 DIN ATGWASSY 8200 10 NVI NSN 0519 GINO 9 OL SII E SNOLLINYLSNI 1935 0 69 0 X BW SMS 880 09 X 8 SARIS 50 90 920 Z X E EL 7 35 40 NOLVINSYO ONIMOHS NTIS 02 15130 SONIA X04 INY 0 530104 0 05 780 Ld 581131 HOH WaS 21 45 ON ON 0 ON ON 14 NO dWYIS X X 304 311180 WAL INVd 4 5 66 0 1735 0 86 80 9 re 0 00 780 01 7 0054 804 0353129 167172 53410132046 53 ISAI 52 0 _ 37 0 80 SYM EL WALI 10 60 980 1 8
42. al a Check hydraulic oil level must be visible in sight glass but not over half way in sight b Check diesel lubrication oil level c Ensure pump isolator valve is fully open d Ensure air inlet outlet panels are free from obstruction e Drain water from diesel water trap f Inspect lifting tackle and lifting points before being put into service g Check function of diagnostic L E D s by pressing test button h Check function of gauges i Check condition of quick release couplings j Check engine coolant level k Check condition of fan and drive belt 5 3 Planned maintenance checks For full details of diesel engine maintenance see Cummins service manual and for power pack maintenance procedures see section 5 4 5 3 1 Every 125 hours Check the following a Hoses pipework and fittings for any hydraulic oil leaks and rectify as required Tightness of all fasteners c Condition of body panels and paintwork Touch up where necessary d Battery water level e Condition and function of hand control pendant 5 3 2 Every 250 hours Check the following a Engine air cleaner b Engine intake system c Engine charge air cooler d Battery charging rate Change the following e Engine oil f Engine oil filter Hydrauic oil filling filter h Diesel fuel filling filter 5 3 3 Every 500 hours Check the following a Anti freeze in engine coolant b Pump output flow rate
43. ammer check by removing front leg guide for inspection Faulty bottom sensor assembly lay the hammer on timber blocks on level stable ground on its rear leg guide then remove front leg guide and check bottom sensor as follows 1 Cam spring operation does the cam rotate return freely and is the spring in good order 1 Check for correct lift on valve roller 4mm 11 Check arrangement for correct function part 2 083 00 04 amp 1 036 00 05 iv Itis possible to work the hammer for diagnostic purposes whilst it is laying on the ground However extreme caution must be exercised when doing so as incorrect operation will cause hammer damage Always ensure the pendant is in MANUAL mode and NOT automatic mode The anvil must be in the up position so as to ensure the trip device is off The hammer can be pressurised by tapping the start push button on the pendant power pack running very gradually building up enough pressure to move the drop weight Ifthe button is held for too long the drop weight will possibly impact the inside top of the hammer not a good idea However by careful application of this method it is possible to check pressure is reaching the relevant sensor If it is not then the problem may be with the overtravel valve part 1 084 00 02 not allowing oil flow to the control side of the hammer This can be confirmed by removing the main pressure feed to either sensor no oil flow when
44. ammer hydraulic system see section 3 4 2 Damaged looped hose from sensor assembly check by removing front leg guide for inspection Faulty top sensor assembly see 6 4 as diagnosis is similar to faulty bottom sensor assembly Faulty bottom sensor assembly 1 6 valve is staying on see section 6 4 f for similar diagnosis 6 6 Hammer runs erratically f Air In hydraulic system see section 3 4 2 Cold hydraulic oil see section 3 4 4 Accumulator pressures or bladders damaged See Appendix 7 2 High pressure accumulator 100 bar 2 off Low pressure accumulator 3 bar 2 off Blocked filter on hammer see section 4 2 b Not enough hydraulic flow pressure from power pack check flow rate gauge and pressure gauge One or both sensors damaged contaminated see sections 6 4 and 6 5 6 7 Excessive hose jumping Check accumulator pressures condition see Appendix 7 2 6 8 Hammer jumping excessively on pile top reduce stroke immediately and or stop piling Too much hydraulic oil input set to 150 l min Cold hydraulic oil see section 3 4 4 and reduce stroke To warm the oil see section 3 3 1 Stroke adjuster set too high reduce immediately to continue working Suspension blocks 2 025 00 01 and ring 2 025 00 05 damaged Inspect and replace immediately if necessary Incorrect operation of top sensor assembly i e cam wear and or incorrect roller travel
45. and working pressure Change the following c Fuel filter d Hydraulic oil pressure and return filters 5 3 4 Every 1000 hours Check the following a Engine fan hub b Engine belt tensioner bearing c Engine belt tension d Adjust valve lash clearance on engine e Condition of all wiring and tightness of electrical connectors f Wear on hydraulic pump flexible coupling g Condition of exhaust Change the following h System hydraulic fluid 5 4 Maintenance procedures NOTE Before any of the following procedures are undertaken the battery isolator switch must be switched off a Changing fuel hydraulic oil inlet filler elements i ii iii iv vi Replacement element Remove filter bowl Remove and discard filter element do not clean Wash bowl thoroughly Fit replacement element into bowl Re assemble filter Prime hand pump b Changing hydraulic pressure filter element i 1 iii iv vi vii viii Replacement element Remove filter bowl Remove and discard filter element do not clean Wash bowl thoroughly Fit replacement element onto spigot Fill filter bowl with clean hydraulic oil Replace bowl O ring if necessary Re assemble filter Change hydraulic return filter element i Replacement element 1 Remove filter bowl 11 Remove and discard filter element do not clean iv Wash bowl thoroughly v Fit replaceme
46. er functioning correctly Check the condition of lifting tackle and lifting points prior to being taken into service 4 2 Planned 125 hour maintenance checks run the hammer for 15 minutes before and after this maintenance work Every 125 hours the following work should be carried out in addition to that described in 4 1 above a Remove each hammer leg guide in turn and check the condition and tightness of all hydraulic hoses and fittings bolts locking rings and visually check all components for condition Check the condition of each sensor assembly paying particular attention to cam wear roller operated valve travel and tightness of fixing bolts Each roller valve should have a travel of 4mm through full actuation of its associated cam This measurement is critical and if it is not achieved the hammer will not run correctly as with the ignition timing on a motor car Travel can be lost through excessive cam wear or with wear on the roller or roller pin at the end of the valve Check the condition of leg inserts to ensure correct fitting on pile sections The inner faces of each insert should touch the opposite insert If not the wear faces may require building up with hard facing Figure 4 1 Debris embedded in dolly remove debris and continue Overworked 6500 dolly stuck in anvil body must be replaced or it can cause the anvil body to break 5 i 4500 dolly starting to show signs of cracks after 150
47. et b Engine gauges replacement 1 There is a resistor fitted to all gauge power lines This must be replaced after maintenance to prevent damage to the gauges 6 0 TROUBLESHOOTING 6 1 Power pack engine will not start a Check battery condition b Check diagnostics panel for fault LED showing see fig 2 6 2 Engine cuts out during running a Check diagnostics panel for fault LED showing and rectify see fig 2 6 3 Power pack does not generate any pressure a Check L E D 11 to see if hydraulic oil is up to temperature see figure 2 If not perform warm up operation described in section 3 3 1 Check operation of main valve in power pack by turning selector switch 5 to warm up on the instrumentation panel fig 2 This gives 200 bar reading on pressure gauge c Check fuses or electrical connections to valve block if no reading from b d Check operation of relief valve if no reading from b e Check operation of hand control pendant and fuses in electrical box if reading is O K in b 6 4 Power pack generates pressure but hammer does not run a Anvil not pushed fully up into hammer casing see section 3 4 1 or the dolly is not sitting correctly in the anvil especially after transportation or laying on its side Air in hammer hydraulic system see section 3 4 2 c Hammer has been allowed to overtravel see section 3 4 4 to reset Damaged hose control side of h
48. fno Material Dimension Part number 4 N Design ho Checked Scale 25 Replace Replaced by DAWSON HAMMER File name Dale 20 03 5 lt de LETING PONTS 84 ifthammer Revision Dat intro Apprby 30 N KN J LIFTING POINTS EIGHT OF POWER PACK 2000 Kgs Part name Material Dimension Part number Fawn al coped Standard 15 98 2 Replace Replaced by 3 2288 1 200 1800 8 HPH2400 Tanner 1201 10 95 marin POWER PACK LIFTING PONTS lifippackeco 2 0 HOW DOES THE HAMMER WORK See fig 1 The D C P Hydraulic Hammer consists of drop weight driven up and down by a hydraulic 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 lifts the drop weight and oil supply 0 drops it The control valve itself has to be switched from one
49. gure 4 1 43 Planned 250 hour maintenance checks 4 3 1 Changing Disc Springs 4 3 2 Other items 4 4 Planned 500 hour maintenance checks Figure 5 4 5 Planned 1000 hour maintenance checks Power Pack Maintenance 5 1 Power pack specifications 5 1 1 Basic specification 5 1 2 Lubrication specification 5 2 Daily maintenance checks 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 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 Appendices 7 1 Hammer parts list 7 2 Accumulator parts list and instructions 7 3 Cummins service manual 74 Power pack parts list 7 4 1 Hydraulic circuit schematic 7 4 2 Electrical circuit schematic 7 4 3 General assembly drawing 7 5 Tool kit parts list 7 DAWSON The responsible person DAWSON CONSTRUCTION PLANT LIMITED CHESNEY WOLD BLEAK HALL MILTON KEYNES MK6 INE ENGLAND EC DECLARATION OF CONFORMITY Description Type Serial Number The above mentioned equipment conforms to the Machinery Directive 89 392 EEC a as amended by Council Di
50. hammer stroke may be altered using the T or push buttons to adjust the stroke height indicator To stop the hammer whilst it is running on Auto turn the Auto Man selector to Man or turn the power selector off It is good practice to start piling with the hammer set on minimum stroke this limits unnecessary damage to both the hammer and the pile when the pile can be driven easily The stroke may then be adjusted to suit the changing driving resistance On certain piling jobs it may be possible to start driving on pairs of sheet piles changing over onto a single sheet pile as the driving resistance increases this will give maximum productivity 3 4 4 Cold running overtravel The hammer jumps the pile top when trying to achieve full stroke if the hydraulic system is 010 If this happens the hammer will stop automatically Thus preventing internal damage to the unit The power pack will continue to run and pressure gauge will read approximately 240 bar In order to reset the hammer turn off the power selector on the hand control pendant and stop the power pack Allow the engine to stop for approximately 10 seconds then restart the unit Reduce the stroke of the hammer to minimum Run the hammer at this lower setting until the oil is warm enough to allow correct full stroke setting If reducing the stroke does not cure the problem warm the hydraulic oil as described in section 3 3 1 If the hammer over
51. he stroke height indicator to minimum using the push button Set the Auto Man turn button to Hold the start push button down for 2 3 seconds Repeat e three or four times until the hammer consistently gives one or two small blows each time Providing the hammer does not jump the pile hold the start push button down so that the hammer gives several consistent blows on the next operation Approximately 120 blows per minute If the hammer Jumps on the pile because the drop weight is hitting the top of the hammer casing the hammer will stop automatically To reset see section 3 4 4 Commence the piling operation using the hammer as required 3 4 3 Pile driving with the hammer Having the hammer sited on the pile and removed air from the hydraulic system if necessary as described above the hammer is ready for pile driving Increase the power pack engine speed to 2200 r p m having followed Starting the power pack section 3 3 Turn the hand control pendant power button on Adjust the stroke height indicator on the side of the hammer to minimum stroke by pressing the push button Set the Auto Man selector button to the required position Auto hammer will continue running automatically when the start push button is pressed once Man hammer will only run whilst the start push button is held down Depress the start push button as required by Auto Man During operation the
52. hrs of piling O K but if cracks extend to the outer edge or the underside of the dolly must be changed Severely cracked 6500 dolly should be replaced If dolly 15 not replaced when it has been overworked the anvil body can break due to expansion of dolly material M gt View showing underside of 4500 dolly after 150 hrs of work No signs of cracking O K 4 3 Planned 250 hour maintenance checks run the hammer for 15 minutes before and after this maintenance work Every 250 hours the following work should be carried out in addition to the work described in 4 1 and 4 2 above 4 3 1 Change the Disc Springs The flexible coupling between the main hydraulic ram and the drop weight must be changed The procedure is quite straightforward see figure 5 Failure to do this will result in an expensive repair a Lay the hammer on stable level ground on its Front Leg Guide packed on timbers Remove the Rear Leg Guide part 2 002 00 01 b Remove the 3 no Nyloc Nuts Dog Point Grub Screws and Anti Vibration Washers parts 6945 2 088 00 01 and 2 089 00 01 from the Connector Nut part 2 011 00 03 It may require a little heat to melt the Loctite on the grub screws c Unscrew the Connector Nut from the Ram Connector part 2 009 00 04 and remove the Nut together with the top stack of Disc Springs 2 022 00 01 Guide Bush 2 015 00 02 and Buffer Spacer 2 012 00 04 d Retract the piston rod of the Hydraulic
53. involved is briefly as follows a The stroke adjuster slot in the leg guide must be sealed with a cover b The insides of the hammer should be suitably greased to minimise the effects of corrosion c The gaps between hammer casing leg guides and top cover must be sealed with silicone mastic d The inspection holes near the bottom of the hammer casing must be plugged e A threaded compressed airline port must be added in the bottom end of the hammer casing or leg guide f The hammer must be run in conjunction with a 35 70 c f m 100 psi air compressor g The hammer grease nipples must be greased after every pile drive to ensure ample lubrication NOTE FOR DETAILED ASSISTANCE WITH THIS TYPE OF WORK PLEASE CONTACT THE MANUFACTURER 3 6 Wider or special pile sections The HPH 2400 hammer in standard format will drive a considerable range of steel piles In some applications however where sheet piles are particularly wide or perhaps boxed together it is possible to use simple leg insert modifications and or spreader plates to give improved pile coverage reducing pile head stress and improving productivity rates The standard leg inserts can have wing extensions bolted to correctly centralise the hammer on a single sheet pile Then either a special anvil can be used to give wider coverage or by dropping the inserts to a lower set of location holes a spreader plate can be added below the standard anvil to give
54. l the L E D 11 goes off The engine should come off load at the same time the L E D goes out and gauge 13 return to zero bar d Turn the warm up run selector switch 5 to run The power pack is now ready for use 3 4 Using the hammer 3 4 1 Installing hammer on the pile The hammer must be sat correctly on the pile to avoid hammer or pile damage The pile tops should be as level and square cut as possible The hammer anvil must be in good condition Lift the hammer onto the pile s to be driven Lower the hammer down until the handling slings lose their tension At this point the anvil should be seated correctly i e the rubber ring around the anvil should be compressed between the casing and the anvil If it is not and there is a gap here re site the hammer Note Before using the hammer and particularly after transportation check that the dolly is fitted correctly in the anvil There are inspection holes at the bottom of the hammer casing to check this 3 4 2 Bleeding air from the hammer hydraulic system only required when running hammer after initial connection or following a repair When running the hammer for the first time after initial connection to the power pack there will be air in the hydraulic system The hammer will bleed this air automatically but the following procedure must be applied a b g Run the power pack at 2200 r p m Turn on the control pendant power button Adjust t
55. n 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
56. nit is now ready for running 4 3 2 Other items a Check the accumulator part 1 048 00 04 precharge pressures using the gas pressure checking kit and a bottle of nitrogen gas The precharge pressures are High pressure 100 bar two accumulators Low pressure 3 bar two accumulators To gain access to the accumulators it is necessary to remove the top cover part 2 017 00 01 The two high pressure accumulators are on the left hand side viewed from the inlet manifold To check the precharge pressures see appendix 7 2 in this manual b Check the hammer filter part 2 079 00 01 for cleanliness First remove the top cover part 2 017 00 01 Then unscrew the filter bowl and remove the filter element Check the filter for damage and any unusual debris Wash the filter with clean diesel and blast through from inside the filter with compressed air Alternatively throw the element away if it is a non metallic filter PAY EXTRA CARE NOT TO ALLOW DIRT INTO THE FILTER ASSEMBLY ON RE FITTING c Check the function and condition of the bottom trip device d Check the function of the hammer s overtravel valve by intentionally overstroking the hammer when cold 4 4 Planned 500 hour maintenance checks run the hammer for 30 minutes before and after this maintenance work Besides work mentioned in 4 1 4 2 and 4 3 above the following work should be carried out a Condition and function of the Height Adjusting Ram b Tightness of the
57. nt element onto spigot vi Fill filter bowl with clean hydraulic oil vii Replace bowl O ring if necessary viii Re assemble filter d Pump removal re fitting 1 IMPORTANT NOTE the hydraulic pump should be returned to the manufacturer for repair overhaul This item must not be stripped or tampered with ii Isolate pump from hydraulic oil reservoir using pump isolator valve 11 Remove hoses from pump body iv Remove mounting screws from front flange of pump v Withdraw pump from coupling towards oil reservoir vi Remove bellhousing from engine mounting flange vii Reverse procedure for re assembly Fill case drain of pump with clean hydraulic oil prior to start up following removal from the system port located on the top of the pump with adaptor fitted e Cooler removal re fitting 1 Close pump isolator valve to prevent system syphoning ii Remove flexible hoses from cooler iii Remove mounting bolts from cooler iv To remove matrix remove top and bottom retaining strips from front of cooler and withdraw matrix from front of cooler assembly f Control valve assembly 1 Close pump isolator valve to prevent system syphoning 11 To replace solenoid coils remove plastic retainer from end of coil and withdraw coil from retaining tube iii To replace valve assemblies remove 4 off retaining screws from top of valve and replace component as necessary g Pipework i For details of hose assemblies
58. 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 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 PISDOP U swag 000 30 ea 58 aera E pepes fq 5 Hd 1810842 811 TONY LIINI INO j aIl HIH Lf
59. pressurising the system indicates overtravel valve problems and this item should be removed for inspection The overtravel valve can be removed through the wide slot in the side of the hammer encased by the rear leg guide and the hammer will require turning over to do this Turn the power pack off before removal When checking the overtravel valve first check the small restrictor dowel on its top face for any blockage The valve is unlikely to be faulty inside and if this is suspected the unit should be returned to the manufacturer for checking If pressure is reaching the sensor check that the pilot signal from the sensor is reaching the main control valve block at the top of the hammer when the roller valve is operated If not remove and inspect the roller valve f If this all appears to be in order check the top sensor mechanism in a similar manner to that described in e i and ii above as it may be that the top sensor is jammed on Note The spool inside the roller valve and the roller shaft are not connected so even though the roller returns when operated it does not follow that the spool has returned Check the tension on the roller shaft if there is none the spool may be stuck open g Ifall appears well the problem may be with the main control valve spool Contact the manufacturer for further details 6 5 Hammer will lift but not drop a Has the hammer been allowed to overtravel Check reset see section 3 4 4 Air in h
60. rective 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 Position 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
61. see hydraulic schematic drawing Appendix 7 4 1 ii In the event of steel pipe failure 25mm 3 series fittings should be utilised in conjunction with 25mm bore x 3mm wall thickness tube 11 Welded pipe ends are currently utilised and should it become necessary to disturb these fittings a replacement O ring should be used Changing system hydraulic fluid i 1 iii iv vi vii viii Change hydraulic fluid Remove cleanout cover and clean reservoir Replace fuel inlet and hydraulic fluid inlet filter elements Replace hydraulic pressure line filter element Replace hydraulic return line filter element Blow through cooler matrix to clear Replace solid pipe fitting O rings as necessary Replace tank cover gasket Check all electrical connections for tightness Check drive coupling for wear and replace or adjust if necessary 5 5 Setting procedures a Re setting pressure The pressure regulating adjuster is situated on the main control valve assembly To adjust i iii iv Loosen the lock nut and wind the centre spigot counter clockwise to reduce pressure Press the test button on the control panel to load the system Turn the centre spigot clockwise to raise the system pressure When the required pressure has been achieved max 230 bar tighten the lock nut NOTE Should the required pressure be exceeded wind the adjuster back and increase again Never wind the pressure downwards to s
62. travels again refer to the Troubleshooting section 6 0 THE HAMMER WILL NOT RUN IF IT IS NOT ALLOWED TO RESET CORRECTLY 3 4 5 Refusal Piling must stop with this hammer when the rate of driving reaches 10 blows per 25mm Continued use will result in hammer and or pile damage 1 2 3 4 5 Qnt Revision Date Intro 3RD ANGLE A O O N dep ISOLATOR OIL HOT OIL COLD OIL LOW VY FAST IDLE MANUAL AUTO START LOWER RAISE PENDANT PANEL m N gt N f N 2 2 Seog 2 ENGINE START ENGINE STOP WARM UP RUN FLOW 2 NY Z G NOTES G THIS DRAWING MUST NOT REPRODUCED BY ANY MEANS WITHOUT PRIOR PERMISSION OF THE COPYRIGHT OWNER Ref no Part name Material Dimension Remark Design by Drawn by Copied Checked Standard Affirmed Scale Replace Replaced by RUC 2 DAWSON WER PACK INSTRUM AN DA ee Date 15 04 2005 CONSTRUCTION Prawna ng PLANT LTD 00 SP 1 2 3 4 5 3 5 Using the hammer underwater It is possible to drive piles with this hammer underwater However the hammer must be prepared correctly in order to do so it can not be used underwater in standard format The work
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