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IHI IDH-J22 Field Service Manual

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1. TIVN _ ALV 1d HWVN 1 A 1 4 4 4 Surpee q 5 Rm MANOS 1564 4 uu ga 0 kx 0 00 8 Leoerer 9206707 ScOEv CP VcoEver ON Hed SEWE 5 5 N E amp 1248000 Eb amp 5 Ref No Part No J243030 4243031 4243032 4243033 4243034 243035 4243036 243050 1243051 RB 7 188 M12X 1 75 FUEL PUMP 3 3 Part Name FUEL SUPPLY REGULATING DEVICE ASS Y BEARING BOX PULLEY SPINDLB COLLAR type A COLLAR type B BOLT conical NUT 12 x 1 75 PIN tapered 3 x 28 Be 7 PUMP DRIVING DEVICE 1248100 a 23 50 X EY imde sb sb as yt Rotes ero 0 18 5 91 Sum 10 58 2509157 x 91 Sum 107 LON 9IN pus 8 O E X 5 ONTA 4 5 1701571 Surg
2. IdWOO ANIT TANA X jk 000 SXIEUIOM 44 44 Bl 0 HHHSVA ZI W 3014 OC X ZI W 8 Sp X ZI W 8 RT 4 6 0 7 1 9 9 BN BM dax 6 IdWOO ANIT TANA 4 ux B EH S 0007 32 31 3 gsortzr 8206070 2009 2900917 ON Hed 8 EWB ON JOU amp 12 Qu 5 2 N Ca On 2 Se ae mesa LES 1 b 8 TRIPPING DEVICE 7245000 En 7 EE 11 11 ILLI 1 1 UE ns RATCHET 5 2 syewoy M eA wo 0 e cL X TZ pear 8 x Ob x zc pearys 5914 Op X 8X OI ATA c Lb X 8 ONTHdS Yor 51 ONTIdS SIZ X 601 x Or 1981 OOH ZSZ X 601 X 0 915 X ZW 918 901 8 L108 x 08 X v6 9008819 x 902 4038 1104 gL 906 46 x x 9 444 37 0 7 1 261 X X 19 13 917 0 X 316p x 56 ose x 09 19
3. A Outer end ri Lower piston Fig 4 12 When striking without combustion pull the fuel stopping lever to stop fuel injection and moreover keep the setting of the fuel delivery rate at through 2 3 by adjust ing the fuel regulating pully Never perform striking without combustion by keeping the fuel regulator pulley turned fully counterclockwise fuel delivery rate is zero Otherwise disorder in the fuel pump may be caused Besides as the fuel delivery rate is to be adjusted by pulling the rope repeat practice many times beforehand delivery rate movement of the control rack When the pile hammer is running do not approach the hammer but stay at more than 4m distance from it After starting immediately lift up the starting device more than 80 cm higher than the hammer body and keep it at that height during running By this it is prevented from touching the ram during running and to cause troubles During running be sure to keep on holding the fuel regulator rope and control the fuel so that the jumping height of the upper piston does not exceed 2 5 m When the upper piston jumps up abnormally pull the fuel stopping rope at once and suspend the operation If the ground becomes soft suddenly during operation and the pile penetration per blow for the succeeding blows becomes more than about 10 cm pull the fuel stopping rope at once to stop the operation of the fuel syste
4. OR we 22 49 Important Items on Operations sn f t 23 PERIODICAL CHECKING AND MAINTENANCE 27 51 Daily Routine hh 27 5 2 Routine at Every 250 Hours of Net Running Time nee 27 53 Routine at Every 500 Hours of Net Running Time 28 5 4 Routine at Every 1 000 Hours of Net Running Time 28 5 5 Routine at Every 3 000 Hours of Net Running Time 28 29 TROUBLESHOOTING MAINTENANCE STANDARD 39 7 1 Disassembly and Reassembly of the Fuel Pump 39 72 How to Repair the Plunger and Barrel 40 7 3 Disassembly and Reassembly of the Nozzle 41 7 4 Adjustment of Injection Pressure of the Nozzle gt 42 7 5 Serviceable Limit of the Wearing Part n 43 45 8 1 Pile Resistance cnn 45 8 2 Selection of Hammer 47 8 3 Pile Size Suitable for the Diesel Pile Hammer 49 1 1 12 Chapter 1 INTRODUCTION Outline For the conventional impact atomization type diesel pile hammers the fuel pump is operated when the upper piston falls the fuel is injected and stays on the to
5. Even if too much oil is supplied at once it will burn Lubricate at every 15 20 minutes with adequate amount of oil Do not supply excessive oil for one lubrication 5 3 The needle valve of the nozzle is sticking So fuel is not atomized enough incomplete combustion is caused and the exhaust gas becomes dark In some cases white smoke is caused at the lower piston 5 3 1 5 3 2 Disassemble and clean the nozzle Or replace the nozzle tip assembly with a new one 6 The upper piston is colored dark 6 1 Lubricating oil in the oil basin of the upper piston has exhausted Or the oiler plug is inserted deeper than the normal depth and is closing the oil holes through which lubricating oil is to be sprinkled out Refer to F 4 7 6 1 1 Supply lubricating oil to the oil basin of the upper piston Or cut off the tail of the oiler plug which is projecting into the oil basin from the top of the upper piston Refer to F 4 7 7 Even if the ground becomes hard the jumping height of the upper piston is less than 1 0m Besides compressed air and exhaust gas are leaking By the compression test the time from A to B is less than 18 seconds 7 1 Compressed air is leaking because of strain of the spring of the grease nipple foreign matters such as carbon accumulated on the ball seat or damage to the seat or ball surface ball
6. lt about driving equipment If 911101101011814 1 Vulco 1 L Visit our companion_sit http u TAE E s 1 Terms and Conditions of Use All of the information data and computer software information presented on this web site is for general information only While every effort will be made to insure its accuracy this information should not be used or relied on for any specific application without independent competent professional examination and verification of its accuracy suit ability and applicability by licensed professional Anyone making use of this information does so at his or her own risk and assumes any and all liability resulting from such use The entire risk as to quality or usability of the information contained within is with the reader In no event will this web page or webmaster held liable nor does this web page or its webmaster provide insurance against liability for any damages including lost profits lost savings or any other incidental or consequential damages arising from the use or inability to use the information contained within This site is not an official site of Prentice Hall Pile Buck or Vulcan Foundation Equipment All references 10 sources of software equipment parts service or repairs do not constitute an endorsement INSTRUCTION MANUAL FOR DIESEL PILE HAMMER MODEL IDH J22
7. 1 1 2 Specifications 1 1527 kgs EUR 2 1 4 Theory of Operation k SY Q EM IER T 2 STRUCTURE AND FUNCTION OF EVERY PART 5 2 1 Hammer Body 5 22 Starting 6 2 3 Firing Mechanism 8 LUBRICATING OIL FUEL 13 3 1 Upper Piston Lubricating 13 3 2 Lower Piston Lubricating Oil 13 3 3 Lubricating 11517101611018 s s s w 13 BAO Rigel PDC ha Re eee D S 14 OPERATION AND HANDLING 15 4 Fixing Procedure of the Diesel Pile Hammer 2 15 4 2 Inspection and Lubrication before Starting the Operation 16 4 3 Pile Set up 18 4 4 Starting 44 vant ob Ca wren eee RUE eee sa 19 4 5 Cautions for Starting a Te S e i Re 20 4 6 Cautions during Running eae ee ee 4 21 47 Stopping lt s hne 22 4 8 Cautions for Stopping Qs E ev
8. NUT for NOZZLE TIP 72432 0 GD SPRING 2202200 4 SPRING SEAT 7245208 5 NOZZLE 7249211 2 NEEDLE VALVE gy NOZZLE HOLDER BODY 7243202 0 PRESSURE ADTUSTING SCREW 72032073 2 Loci NUT 7249200 20 REASSEMBLING PROCEDURE Cautions for Disassembling and Reassembling 12 3 4 To loosen nozzle tip fixing nut first clamp nozzle holder by a vice and loosen it by using a 19 mm ring spanner Do not use a pipe wrench Otherwise the nut may be deformed The nozzle tip and needle valve forms one assembly They are not inter changeable Screw in the pressure adjusting screw gently at first Keep it loose until the pressure is adjusted Apply lubricating oil to the needle valve and insert the needle valve into the nozzle tip At that time confirm that the valve can be inserted smoothly by its own dead weight by repeating this three or four times If it cannot be inserted smoothly or it does not reach the bottom end wash the parts with clean light oil Apply a small amount of commercially avairable brass polishing paste to the needle valve and lap it by rubbing against the nozzle tip Never use carborundum or lapping power Match the dowel pin for positioning the nozzle holder and nozzle tip and insert the nozzle tip Completely tighten the nozzle tip by using the 19 mm ring spanner
9. 7 1 1 Poke the ball seat surface with a piece of wire and remove the foreign matters sticked to the seat surface If exhaust gass still leaks after the above measure replace the grease nipple with a new one this seat with a prese of wire 1 5 mm y ex 7 Even if the ground becomes hard the jumping height of the upper piston is less than 1 0m Besides compressed air and exhaust gas are leaking By the compression test the time from A to B is less than 8 seconds Trouble Cause 7 Even if the ground becomes hard the jumping height of the upper piston is less than 1 0m Besides compressed air and exhaust gas are leaking By the compression test the time from A to B is less than 8 seconds 7 2 Carbon accumulated in the piston ring grooves of the lower piston So the piston rings are sticking and the free gap is reduced Or piston rings are worn out more than the service limit Thus the compressed air is leaking Remedy 7 2 1 Clean the piston ring grooves and remove the carbon deposits If the piston rings are worn out to the service limit replace them with new ones 7 3 The thread of the inspection plug is damaged or broken Or the seat surface at the tip of the inspection plug is damaged So the compressed air leaks 7 3 1
10. Deep slot closes fuel flows to Pump Fig 2 12 Fuel Tank E 12 31 Upper Piston L Applicable Season Manufacturer Shell Oil Mobil Oil Co ESSO Oil Gurf Oil Corp Lower Piston L Applicable Seasor Manufacturer Shell Oil ESSO Oil Gurf Corp Lubricating 1 Upper P 2 Lower F 3 Fuel Pu Chapter 3 LUBRICATING OIL FUEL 34 Upper Piston Lubricating Motor SAE 40 50 Applicable Season o Summer Severe cold region o On the operation 10 209 where it takes 0 over one hour to drive one pile Shell Oil Shell Rotell No 40 Shell Rotell No 50 pens E Mobil Oil Co Delvac 940 _ Delvac Oil 950 Delvac Oil 910 ESSO Oil Essolub HD 40 Essolub HD 50 Essolub HD 20 f Gurf Oil Corp Gulf Dieselub HD 40 Gulf Dieselub HD 50 Gulf Dieselub HD 30 3 2 Lower Piston Lubricating Oil Superheated Cylinder Oil Applicable Season o Spring o Summer i o Autumn o On the operation where it takes Manufacturer o Winter over one hour to drive one pile Shell Oil Shell Valvata Oil No 79 Shell Valvata No 85 Mobil Oil Mobil 600W Super Cylinder Mobil 600 W Super Cylinder ESSO Oil Sylesso 300 Sylesso 300 Gurf Corp Gulf M Cylinder Oil Gulf M Cylinder Oil 3 3 Lubricating Instructions 1 Upper Piston
11. SPRING SEAT 3243013 9 9 Match the center punch mark of the control PLUNGER GUIDE 2243014 rack to the match mark on the gear side 1 SNAP RING 1243015 10 o Insert after cleaning carefully o Insert the plunger gasket and spring seat o When inserting the plunger confirm that the match mark at the slit of the control gear 03 5 sleeve is matching to the marks on the two flat surfaces of the pump plunger beforehand aw Then apply oil and insert Besides be sure to put on the gasket without 6 2 fail 12 13 NOTE 1 After finishing to assemble push the plunger guide and confirm that it moves smoothly NOTE 2 After finishing to assemble confirm that the control rack can be moved to and fro smoothly NOTE 3 Protect the threaded parts until the suction and delivery pipes are connected to the fuel pump in order to prevent dust and foreign matters from entering 39 7 2 How to Repair the Plunger and Barrel Plunger Cylinder When the plunger has sticked by causing galling or seizure by the dust or foreign matter caught at the clearance between the plunger and barrel repair as described below 1 Leave the plunger and barrel which have caused galling or seizure as assembled in the fuel pump housing and disassemble the other parts as described in the section 7 1 DISASSEMBLING PROCEDURE 2 Insert a piece of soft wood such as a handle of a
12. Ishikawajima Harima Heavy Industries Co Ltd Mass Produced Macineny Division TOKYO JAPAN 1970 7 1 PRECAUTIONS FOR PILE HAMMER OPERATION The following items should be strictly observed when operating the pile hammer Extreme care should taken as negligence will not only damage the hammer itself but also inpure the operators and nearby people furthermore damage the surrounding buildings MAX PENETRATING RATE PER BLOW When the ground is soft and low in resistance or the pile diameter is small let the banner free fall several times before starting normal operation In other words pull down the rope of the fuel stopping lever and left to cut the fuel supply and let the upper piston fall freely The wire rope connecting the lower part of the hammer and the pile cap will break if the pile penetrates more than 20 cm per blow The lower cylinder outer end ring and inner end ring will bend or Leak f the pile penetrates more than 27 cm per blow In order to prevent such serious damage conduct free falling without a fuel supply or operate the hammer with little fuel supply ROPE SPEED OF THE TRIPPING DEVICE Do not run the rope of the tripping device faster than 12 m per minute Especially when setting the hammer on the pile stop the winch temporarily and set the pile Excessive rope speed will damage the tripping device resulting in falling of the hammer and careless setting of the hammer w
13. Note In the above case the locking spindle sometimes moves up and down with a very small stroke because of the vibration caused by the operation Thus small quantity of fuel flows to the pump and the hammer stops after several times of combustion 1 4 A foreign matter has clogged 1 4 1 Clean inside of the filter in the filter or feed pipe feed pipe and the fuel and fuel does not flow tank 1 5 Air is contained in the fuel 15 1 Loosen the air bleeder pump screw of the fuel pump and deaerate the pump Then retighten it securely 1 6 The fuel pump regulator 1 6 1 Gradually turn the fuel pulley is fully turned regulator pulley clockwise counterclockwise and start 1 7 The stopping lever is kept 1 7 1 Pull the resetting rope of pulled The lever is inclined forward the stopping lever and put the lever to the position for running 1 8 Water is staying on the concave top surface of the lower piston and combustion is disturbed 29 1 8 1 Clean the concave top surface of the lower piston with a piece of dry cloth Trouble Cause 1 The hammer operation does not start even if the upper piston is dropped several times 1 9 Moisture is contained in fuel Or when operating in the rain moisture enters into the combustion chamber and causes poor combustion Exhaust gas contains steam and looks white 1 9 1 Drain the moisture in th
14. 30 1 12 1 Replace the assembly of the pump cylinder and pump plunger with a new one operation does not tart even if the pper piston is dropped several times TERES eS 1 1 1 The hammer 1 13 The temperature is i operation does not start even if the upper piston is dropped several times 1 13 1 Generally the hammer extremely low can be started normally after several blows without combustion pour very small quantity of gasoline through an exhaust port Or use ETHER 1 14 As the piston rings of the 1 14 1 Replace the piston rings fuel pump driving piston with new ones are worn out more than the service limit the fuel pump does not work 1 15 As the piston rings for the 1 15 1 Replace the piston rings upper and lower piston are worn out more than the service limit the compression pressure is low if the time between A and B is more than 8 seconds by the following compression test the piston rings are not worn out for the upper and lower pistons with new ones d 1 2 3 4 5 Upper piston Note Method of Compression Test Before the compression test fully pull down the rope of the fuel stopping lever and stop the fuel Lift the upper piston with the starting device and then drop it Read the second hand of your watch when the strikin
15. 10 q95NY TA 103 NITAQ Weg 101 101 ONILVaadO Y 4 E 76 9 9 11 2 20 Ns vY 8 4 4 08 64 24 xa HEEL 0018 22 eSslever 6106970 LLOLSLF 8092 01 tZr 901 vzf goLevar volever eolever zoLlever LoLever 0015 19 1248200 7 JV NOZZLE 5 Part Name fi X Remarks Ref Part No 4243200 4243202 K F BODY nozzle holder J243203 4 PIN dowel J243204 E gt ROD push 243205 i SEAT spring J243206 i SPRING J243207 2 SCREW adjusting J243208 5 5 NUT lock 3243209 WASHER for lock nut J243210 4 NUT nozzle tip fitting J243211 NOZZLE TIP 4243212 E GASKET nozzle tip d J243213 Ko ho 2 Z dt WO BOLT for nozzle holder fitting J243251 NA S 10 WASHER spring 10 gt 2 F 7248800 i ik O AL pt LEVER POSITION WHEN IT STOPS itt z 2 m z z 2 5 2 e 2 m SZ EN m WSA Ref No Part No J243300 J243301 4243302 1243303 1243304 1243305 1243306 1243307 1243308 124331
16. 41 14 Adjustment of Injection Pressure of the Nozzle o Never take off the tank filter o As the testing oil use the clean fuel which is to be used for the pile hammer commercially available light oil o Clean the pipe joint i o Mount the nozzle tip j so that it is inclined downward When mainting keep the pressure adjusting 51 screw fully loosened 3 o Fix to a suitable base by using the installation bolt holes Continue from the above drawing is pile hammer 9 6 9 MENT OF INTEC gt o Turn the grip handle counterclockwise and open the pressure circuit to the pressure gauge 5 E 9 ap o Move the tester lever up and down several times and feed the testing oil to the nozzle N B Let air and small particles of dust flow out completely through the injection parts of the nozzle tip o Then by observing the pressure gauge adjust the injection pressure to 100 kg cm2 by the pressure adjusting screw After pressure setting tighten the adjusting screw by the lock nut Adjust the injection pressure of the two nozzles right and left to the same value If the pressure setting is different fuel flows only to the nozzle with lower pressure setting and complete combustion is disturbed After adjusting the pressure protect the part to connect the oil feed pipe so that dust or foreign matter will not s
17. Supply upper piston lubricating oil required quantity is 7 D every day before starting If lubricating oil stops to come out from the discharge ports of the upper piston during running stop the pile hammer at once and supply lubricating oil 2 Lower Piston At every 20 minutes of net running time or after driving every pile supply lower piston lubricating oil to 4 grease nipples by a grease pump by 10 strokes per every nipple 3 Fuel Pump Driving Cylinder At every 20 minutes of net running time or after driving every pile supply lower piston lubricating oil to 4 grease nipples by a grease pump 10 strokes per every nipple 13 34 4 Inspection Plug 5 Starting Device 6 Stopping Device 7 Lead Pipe Fuel Oil Every day before starting the hammer pull out the inspection plug smear inspection plug lubricant Molibdenum Disulfide or Graphite and screw the plug in At least at every one week supply several drops each of upper piston lubricating oil by a hand oiler to every sliding part and moving part of the starting device Besides to the grease nipple of the pulley supply mineral grease at every one week by a grease pump by 10 strokes At least at every one week supply several drops each of upper piston lubricating oil by a hand oiler to every sliding part of the stopping lever and push rod Check every day before starting the ham
18. 7 J243010 0 7 J243019 7 J243025 gt 29 5 J243026 27 7 E F J243050 Tob 181117 12 5 J243051 Pu F KH 8 28 5850 1243036 wv E J243106 y C A x F J243105 27 7 7 F J243211 gt 2 2 4243212 gt b 2 J243213 STANDARD SPARE PARTS 1 2 Part Name oy Remarks RUBBER RING NIPPLE GREASE PACKING for fuel supply plug PACKING for drain plug RING piston PLUG oiler PLUNGER ACC Y DEFLECTOR GASKET GASKET delivery valve HOLDER delivery valve O RING SLEEVE control SCREW air bleeding GASKET NUT 12 x 1 75 PIN tapered 3 x 28 5 35 BOLT conical RING piston GASKET TIP nozzle GASKET nozzle tip SPRING N we N e Bm xS Part No 127002 J127001 1127088 1127024 1117072 1157008 1247001 1247002 1247003 1247010 1217023 1157052 1127005 1167057 1247054 1167058 1247056 1157054 1247058 1147051 1247060 1157062 1157060 1247063 1117012 NYE NYE 2385 FERRY RAB F X Z Z 5 4 PREY J 4 Z Z L L WYK CAbYIUYTHA 159 19 24x27 18 17 32 86 12 82 gt 19 TYTN fF A 78 Af 8 17 M
19. Bn Weight kg 2 000 6 000 p o End Diameter mm 3 Length Weight kg 1 Pile Resistance ton 200 500 49 Head Office Head Office ANNEX Kyobashi Office Toyosu Office Research Institute Toronto New York Francisco Mexico City Rio de Janeiro Buenos Aires Sydney i London Offices New Ohtemachi Bldg 2 1 2 chome Ohtemachi Chiyoda ku Tokyo Japan Cable Address IHICO TOKYO Telephone Tokyo 270 9111 Telex TK2232 Tokyo Boekikaikan Bldg 1 3 1 chome Ohtemachi Chiyoda ku Tokyo Japan Cable Address IHIANNEX TOKYO Telephone Tokyo 270 9111 Telex TK2388 2490 IHIANNEX Ishiko Bidg 6 chome 3 Yaesu Chuo ku Tokyo Japan Cable Address IHIHANYO TOKYO Telephone Tokyo 272 0511 3chome 2 15 Toyosu Koto ku Tokyo Telephone 531 5111 3 chome 2 15 Toyosu Koto ku Tokyo Telephone 531 5112 402 170 University Avenue Toronto Ontario Canada Telephone 416 362 1629 Cable Address IHICO TOR Telex 06 219597 Room 721 15 William Street New York N Y 10005 U S A Telephone 212 422 2 0544 6 212 422 2 0245 9 Cable Address IHICONO NEWYORK Telex 222670 420539 Room 1204 Merchants Exhange Bldg 465 California Street San Francisco Califo
20. Change the inspection plug with a new one The compressed air leaks because the inner surface of the lower cylinder has worn partially This is only for the case that the hammer is used for 100 hours or more after the piston rings are changed for new ones or after the inner surface of the cylinder is re bored 7 4 1 Re bore the cylinder and make it oversized 7 5 The compressed air leaks through the exhaust ports or the bottom end of the lower cylinder because longitudinal hairlines are caused on the inner surface of the lower cylinder or peripheral surface of the upper piston 7 5 1 Re bore the cylinder and make it oversized 7 6 A crack is caused at the lower cylinder especially near the combustion chamber and the compressed air leaks 35 Trouble Cause Remedy 8 Abnormal noise is heard when the upper piston jumps up Or it seems that the 8 1 The upper or lower cylinder is deformed because it was struck with a pile or some thing else 8 1 1 Remove deformation of the inner surface protuberance by a grinder upward and down 8 2 Any piston rings of the 8 2 1 Replace the piston ring ward speed of the upper piston has broken with a new one and take upper piston is the following counter slow Cause of Breakage measures if necessary a Burrs are caused at the a Remove the barrs at exhaust port ins
21. conduct the test prepare the supports such as tension piles and apply the load to the test pile with a jack Then determine the ultimate bearing force of the test pile by measuring the sinking amount of the pile The pile load test device using the tension piles is as shown in F 8 4 Selection of Hammer Capacity The hammer capacity is determined by considering the following factors 1 Enertia of the pile pile weight The weight of the upper piston should be more than 1 4 of that of the pile 2 soil friction resistance during the driving operation 3 Elasticity of the pile and the ground 4 Energy loss during driving 47 i pd 2 The most accurate selection of the hammer capacity can be made according to the diameter and length of the pile to be driven the N value of the pile point and the mean value N of the N value from the ground surface to the pile point Calculate the pile penetration resistance by using the Meyerhof s formula and calculate the hammer driving ability by using Hiley s formula Compare the two results and select the most suitable hammer capacity The ratio of the driving energy loss increases as the weight of the pile increases compared to the weight of the upper piston in the pile driving operation Therefore it is not recommended to use the pile more than 4 times heavier than the upper piston weight In the case of driving piles at an angle the radio of the driving energy
22. dimension 401 405 mm The clearance between the lead and hammer guide clamp should not exceed 7 mm when the hammer is pushed to one side 330 Lead center distance Guide clamp CClenrance 40 40 Guide clamp inside dimension Fig 4 4 Lead dimension and adjusting clearance 3 Take care not to introduce sand particles steel chips or welding slag into the cylinder as they may score the cylinder and upper piston a If the sand particles steel chips or welding slag is attached to the lead they will fall down from vibration into the cylinder Therefore clean the lead thoroughly to remove them b Place the protecting cap on top of the upper cylinder attach the protecting plate and plug the exhaust port when the welding or other maintenance is performed on the hammer above the exhaust port with the hammer attached to the lead Remove the welding slag and steel chips from the lead and hammer after welding is finished 23 4 Observe the following cautions measuring Negligence will cause the pawl of the starting device to engage in the wrong in position of the upper cylinder score the upper piston and break the pawl Then the cylinder surface will be damaged by the broken pieses of the pawl The El a When the laking device of the winch brake is set incompletely the brake locking 22 device will be disconnected causing the starting devi
23. is reached repair by machining and replace the parts as follows a Re bore the upper and lower cylinders and make them oversized b Make the piston ring grooves of the upper and lower piston oversized c Replace the catch piston ring and piston rings with oversized ones 3 Perform the leakage test of the plunger cylinders of the fuel pump and stopping device If the service limit is reached replace them with new ones 4 Measure the bore dia of the fuel pump driving cylinder and replace with new one if its service limit is reached 28 Trouble 1 The hammer peration does not tart even if the upper piston is dropped several times Trouble Chapter 6 Cause TROUBLESHOOTING Remedy 1 The hammer operation does not start even if the upper piston is dropped several times 1 1 Fuel is not contained in the fue tank 1 1 1 Supply fuel to the fuel tank 1 2 The locking spindle of the tank is at the CLOSED position 1 2 1 Put the locking spindle of the fuel tank to the OPEN position shallow slots T 1 3 The weld between the lock ing spindle of the fuel tank and the lever is disconnected Therefore even if the lever is set to OPEN the locking spindle is closing the outlet port and fuel does not flow to the fuel pump The weld of this par s disconnected Weld again 1 3 1 spindle
24. it If continuous is less than 1C increased If piston might j Set the pile up vertically by rotating or moving the mast forward and backward In case of Concrete Pile Spread a straw mattress or something as a buffer on the head of the pile 7 Set the pile hammer slowly down on the pile Note Do not set up the pile from the locking device side because the pile or the pile drawing rope may catch the ratchet locking device of the starting device and then these devices rotate resulting in the sudden fall of the hammer by opening of the right and left hooks 8 Reset the locking device to the starting position Starting 1 Put the locking spindle at the top of the fuel tank into the shallow slot to open the fuel cock Finish this step before erecting the pile in position 2 Loosen the air bleeder screw above the fuel inlet connector bolt of the fuel pump to deaerate the inside of the fuel pump When it stops to spurt bubbles tighten the air bleeder screw completely Finish this step before erecting the pile Note Be sure to deaerate before the initial operation after delivery and every time when the pile hammer is newly brought to a different construction site and also when the fuel is newly supplied after completely exhausting 3 Pull the resetting rope of the stopping lever and confirm that stopping lever is at the position for running 4 Rotate the
25. loss will increase as the angle of the hammer increases When the pile penetration resistance becomes great during the driving operation the amount of penetration per blow decreases resulting in the high compression stress on the pile and hammer In order to prevent the pile and hammer from damage determine the penetration resistance by measuring the penetration during the driving operation Stop the pile driving and make the pile short when the pile penetration resistance reaches the predetermined value 48 8 3 NORMAL GROUND Pile Size Pipe Pile 198 ew Sheet Pile Pile Resist I 8 3 Pile Size Suitable for the Diesel Pile Hammer ae b gu MODEL IDH 2 Outside Diameter mm 400 450 500 F3 Thickness mm 70 70 100 j 5 Length m 8 15 10 15 10 20 10 15 18 Weight kg 2 000 6 000 Outside Diameter mm 500 600 d Thickness mm 6 9 12 9 12 Length mm 20 20 15 15 10 10 i 60 60 45 45 30 30 Weight kg 2 000 6 000 9 Type No HI IV F Z45 2 Thickness mm 13 155 220 95 2157 12 5 9 5 Z Length 10 24 10 24 10 24 10 24 10 24 2 Weight kg 1 2 000 6 000 Height Width mm 300 x 300 350 x 350 400 x 400 Length mm 12 16 12 16 125 16 3 Length 20 20 20 15 15 15 T 60 60 60 4 4 45
26. piston weight t H Falling distance of the upper piston S Penetration depth at the upper piston falling distance H P Pile weight t n Restitution coefficient here n 0 K Temporary elastic compression amount of the cushion and pile 246 d 5 ENS PUSS Caceres ues 8 2 3 This for energy pile at t upper pi S is 1 1 deforma The det This is 1 normalh this test To con to Then amoun F 8 4 Selection The hammer 1 2 3 4 Enertiz The wt The so Elastic Energy 1 8 2 Se This formula calculates the pile penetration resistance better by considering the energy loss consumed to the temporary elastic deformation of the soil cushion and pile at the time of the upper piston blow and enertia of the weight of the pile and upper piston S is 1 10 of the pile penetration of the last 10 blows K is the amount of elastic deformation at the time of pile driving 3 The determining pile penetration resistance by the load test method This is most positive method of determining the pile resistance however it requires normally not only a large load but also considerable time and expense Therefore this test is usually applied only to special projects Pressure gauge Fig 84 To
27. push rod and valve body without returning to the original position and thus fuel is kept stopped To restart the hammer pull the rope of the pawl Then the stopping lever is pushed back by the return spring and returns to the original position the valve body is pulled up and the passage from the fuel pump to the nozzles is opened QUES ma Ti 2 gt lt Stopping Lever when running Stopping lever when stopped Fig 2 10 Fuel Stopping Device 5 Fuel Filter see 2 1 1 Primary filter Secondary filler Structure of the fuel filter is as shown in F 2 11 It consists of the primary filter and secondary filter The primary filter is of cylindrical type and is made of wire netting of 100 mesh The secondary filter is of corrugated barrel type and is made of layers Fig 2 11 Fuel Filter of wire nettings The filtering accuracy of element is 20 microns 6 Fuel Tank see F 2 12 The fuel tank is provided near the top of the lower cylinder The locking fuel cock is provided above the fuel outlet port of the fuel tank On the locking spindle seat shallow slot and deep slot are cut Before starting the pile hammer be sure to pull up the locking spindle and engage it to the shallow slot Thus the rubber valve at the bottom of the fuel tank opens and the fuel flows to the fuel pump Locking spindle
28. the head of the pile at the point when the pile is to be driven Set the locking device of the starting device to the locking position Caution a b Bolt When hoisting the hammer with the starting device check to see that the locking device is set to the normal position to support the hook and that hook holds the cylinder hoisting seat In the case when one of the two hooks holds the hoisting seat at the time of hammer hoisting it is because that the connecting rod or bolts are bent In this case replace or repair them Otherwise the hooks will be off and the hammer will fall down Cylinder hoisting seat P onnecling rod Ala 7 Hoisting gt Fig 4 9 lt Upper Hoisting Fig 4 10 4 Operate hammer hoisting winch drum and raise the hammer a little above the head of the pile 18 5 6 7 8 0 3 9 2 9 Q Set the pile 7 in case of Conc Spread a straw 1 Set the pile harr Note Do not pile drawi device ani hammer b Reset the lockir Starting 1 Put the locking fuel cock Fin Loosen the air to deaerate the air bleeder scre Finish this 516 Note Be sure t when the also wher Pull the resetti at the position Rotate the fue Move the starti piston Lift up the sta When it is lifte upper piston time return tk more than 80 If the pile pen the pile is stru pile bammer t piping and
29. the piston rings are worn out or causing thermal strain replace the defective parts with new ones 5 Disassemble and clean the fuel pump If any damage is found on the delivery valve seat or if any galling or hairlines are found on the plunger barrel make necessary repair or replace the defective part with a new one If the plunger spring is worn out replace it with a new one If any other part is worn out or causing any defect make necessary repair or replace the part with a new one 6 Inspect the starting device If any part is worn out repair or replace with a new one As for the tip of the pawl and the sharp end of the right left hooks for lifting the hammer body never repair by padding If they are worn out replace with new ones Routine at Every 1 000 Hours of Net Running Time 1 Perform the same checking and maintenance as in the case of 500 hours routine 5 3 2 Replace grease nipples of the lower cylinder with new ones 3 Disassemble and clean the stopping device If any galling or defect is found on the plunger or cylinder repair the defective part or replace with a new one If the stopping lever is worn out repair it by padding or replace with a new one Routine at Every 3 000 Hours of Net Running Special Checking amp Maintenance 1 Perform the same checking and maintenance as in the case of 1 000 hours routine 5 4 2 Measure the bore dia of the upper lower cylinders If the service limit
30. the upper piston becomes about 2 0 m and begin continuous operation Cautions for Starting Use the starting device at the upward and downward travelling speed of 10 12 m min Model IDH J22 diesel pile hammer has excellent ignitability Therefore if it is started by injecting the fuel at the maximum fuel delivery rate in such cases when lubricating oil for the upper piston sliding surface or superheated steam cylinder oil for lubricating the lower piston is staying on the concave surface of the lower piston excessive combustion pressure explosion may be caused and a serious accident such as jumping out of the upper piston may result Therefore when starting in such cases as mentioned below pay full attention to adjust the fuel regulator pully so that the fuel delivery rate for starting ignition becomes less than or pull out the inspection plug at the lower cylinder and wipe the concave surface of the lower piston with a piece of clean cloth before starting a Starting for the initial operation after delivery b Starting for the initial operation after newly bringing into a construction site c Starting just after oiling to the upper and lower pistons d Initial starting in the morning after stopping overnight Starting after stopping for more than 30 minutes 20 When the gro resistance is to is too light th the ground mc one blow In such case stopping lever combustion by ing the fuel i
31. 0 1243311 4243312 4243313 1243314 4243315 4243316 0459028 1243353 0451063 1243355 4243360 AK AZAR fh x F gt THA KIN A 8 128 N 5 d a H 4 SEHEXEC 5 2 2 M10 Ev T 9 8x25 7248800 7 STOPPING DEVICE Part Name A b Z23 gt Z F gt Z3 7 gt X Z STOP VALVE ASS Y A F gt 7 db VALVE stop a y Z a ROD push ES 5 v b NUT lock a PIN roll ZJ 7 jj yg v SPRING return gt 7 22 NIPPLE 77 x gt GASKET B BOSS for lever L 2 E PAWL SPRING 7 v B AXIS for lever BOLT for fitting boss BOLT for fitting stop valve body WASHER spring 12S WASHER M14 WASHER M10 PIN tapered 3 x 25 STOP LEVER COMPL Q ty 1 w T 99 LH 1 Remarks ID 111100 TANA o s 0 0 0 Ref 01 02 03 04 aks Part No J244000
32. 029 230 1245030 31 1245046 32 3245032 33 1245033 34 1245041 35 1245035 36 1245038 37 1245042 1245038 39 1245039 43 1245043 LACAN RATCHET _ J245000 di E X TRIPPING DEVICE 2 3 Part Name f Remarks 322222 1 9 9 2 5 ROD connecting 19 x 29 5 1 LF 1 0 1 8 6 RUBBER return 109 x 6 1 WN A IE 2 RING for spring stopping 2 R ev Kw 57x b SPINDLE ratchet 1 54F222 40x48x91 right hook 40 x 48 x 91 1 wv 6 x45 BOLT 10 x 45 M10 x 45 4 2 4 19 49 19 49 1 7 8 8 4 2 PLATE end 3t x 44 1 Xv BH 277 2 1 BOLT 27 7 x21 1 NA KR noy 7 DEVICE locking 1 4 J SPRING torsion 1 IK PAWL 1 5 gt gt 2 RATCHET 1 5 gt x b M RATCHET COMP 1 1 K A 4 S vo BOLT hex 1 Ref No Rae 5 Part No J125008 J155051 0459015 J155053 J145057 J145063 0461821 J125064 0461850 0461810 J155060 J155061 J155062 J145063 J245064 0461866 7245000 BE TRIPPING DEVICE 3 3 Part Name Ete 227 N060142 A M14 NAR S28 1 0 1 gt 7 M 2 4 x 7 7 h 2 Kv 1 1 0 25 5 x 3 0 2 F gt 7 XJ EY 6 x 5 5 wey 8x 8 0 2 gt 2 HA mer 4x 25 BEL me
33. 2119 5 g x 09 09 6 gs x 00 46 x 5 AGO AGIND Hed D 321 36 aL 1 tq Ar E xg 71 lt 20 8 0 1 R 8 re ecc4cA S yxdY 8 01X07 9 9 yond GCE 0 61 fax 9 8 6 841 90 8 21 80 TE 6 OA 4 A 261 6 381 d HALtEAeYE 9 5 7 0 3 tac 991x208 tax 09 99 08 8 0 9 0 6 A 00 SEF 2 0 1 W 7 f g E 1 0009722 2 ozosver 1508 prostrer 8 0991 yLosstr 8909117 8108217 LLosver 9109217 10921 1108217 9009917 70099 2004417 1009707 ON Hed 5 1245000 ea 98 9 QV E SES eL 2 E ux 4 7 08 TRIPPING DEVICE 2 S HHR HH pA 8 8 8 N 8 enu 8 LU OAG DG WS Ref No Part No 23 J245023 26 J115035 27 J155027 28 J155028 29 1245
34. Etage Achenbachstrasse 141 D sseldorf West Germany Telephone 672428 Cable Address DUESSELDORF Telex 8586404 D 20th FI Bosman Bldg 99 Eloff Street j Johannesburg Republic of South Africa Cable Address IHIHEAVY JOHANNESBURG Telex 43 0035 JH Dada Chamber 2nd Floor Bunder Road Karachi West Pakistan Telephone 238471 237856 Cable Address KARACHI Telex 863 IHICO KAR 151 Floor United Commercial Bank Bldg Pariament Street New Delhi 1 India Telephone 383684 Cable Address NEWDELHI Sth Floor World Trade Center Bldg No 14 1B Ezra Street Calcutta 1 India Telephone 34 7013 7018 CAL Cable Address IHIHEAVY CALCUTTA c o Jurong Shipyard Limited Pulau Samulun Jurong Industrial Estate Singapore 22 Singapore Telephone 651766 Cable Address IHICOSO SINGAPORE Telex SETX318 IHICO SPORE Hotel Kartika Plaza Room Djl M H Thamrin 10 Djakarta Indonesia Telephone 41880 50899 Ext 12 Cable Address IHICO DJAKARTA Room No 644 AIU Bldg 6797 Ayala Avenue Cor Herrera Street Makati Rizai Philippines Telephone 882061 Local 238 Cable Address MANILA Telex 7425156 Room No 823 Centrat Bidg Pedder Street Hong Kong Telephone 236287 231783 Cable Address HONGKONG Telex HX 797 IHICOHK Room 702 Chia Hsin Bldg 96 Chung Shan N Road Sec 2 Taipei Taiwan Teleph
35. J244001 244002 J244003 J244004 J244005 J244006 J244007 J244008 J244009 J244010 4244011 1244012 4244013 1244014 4244015 244016 244017 1244018 4244022 4134026 4134020 4244021 J124004 J164010 F 7 4 DADS PAER 78 42 2 AH Z gt AYUAACRA f AJAA H H BY d A A X 2 gt F 7 wv 8 8 B SH A 2 bs 7 4 M A zx gt 5 E CA B 31 0 3 D Ry mz NR Bese HZ Foi E RR 7 A dg o E A E uv a y 7 y ED 3 gt gt FUEL LINE COMPL Part Name FILTER BODY BOLT connector for fuel pump PACKING for connector bolt UNION screw suction side UNION screw delivery side HOSE rubber HOSE rubber NUT union NIPPLE BRACKET for filter fitting ELEMENT filter UNION BAND for pipe holding PIPE PPE PPE PIPE D PACKING rubber for element SPRING for element holding FUEL FILTER RUBBER PLATE for pipe protecting SPINDLE for locking RUBBER VALVE locking spindle PACKING O Remarks
36. MPL TRIPPING DEVICE COMPL 21 04 2E gt CYLINDER LOWER 2241000 j 7 7241000 2 2 CYLINDER LOWER Part Name 8 Remarks Ref No Part No Q ty J241000 lt gt 01 4241001 0 CYLINDER lower 1 02 J151002 JU 7 gt 8 SLEEVE cylinder 1 03 J151003 9 7 END RING outer 1 04 J151004 W k J gt Z mua END RING inner 1 05 151005 b FH M33x207 BOLT conical M33 x 207 16 06 J121008 ev As ev 89x56 PIN for conical bolt 8 x 56 16 07 J151007 ty bh LS RBH 88 NUT for end ring locking 16 08 J151008 TAR 5 9 0 7 4 8 09 45 RING rubber 5904 4304 x 45 1 09 J151009 2 s 2 p 4 JAWS guide 4 10 1151010 274 M42 150 BOLTS jaws M42 x 150 12 gt 12 4151012 2 NM 4 F 2z s 7 NUTS jaws 12 13 4151013 NR Be 4 2 s gt WASHER guide jaws 12 16 J151016 K m PLUG inspection 1 17 J151017 FI ACFVENVA NIPPLE grease for anvil 4 18 J151018 7 5 gt g PLUG fuel supply 1 19 J151019 Ry Xovr 8 28 72 710 PACKING for fuel supply plug 1 21 4151021 ge ou Wa vv di PLUG for drain 1 22 J151022 Ry ty RB 77 7 2 7 PACKING for drain plug 1 23 1241023 38 NAME PLATE 1 24 J151024 22 PLUG safet
37. NM M M NM DISASSEMBLING TOOLS Part Name BAND ring installing upper piston BAND ring installing lower piston EXTRACTOR end ring PLIER piston ring installing SPANNER oiler plug LWRENCH BAND piston ring installing 750 DRAWING TOOL valve seat DRAWING TOOL stop ring L WRENCH 27 DRIVER screw 8 x 150 SPANNER single head ring 50 SPANNER single head 46 SPANNER single head 30 SPANNER single head 19 SPANNER double head 24 x 27 SPANNER doubl head 13 x 17 SPANNER double head 32 x 36 SPANNER hex key 12 SPANNER hex key 32 SPANNER single head 19 TOOL for snap ring TOOL BOX SPANNER hex key 8 SPANNER hex key 17
38. TON upper 1 02 J122004 Z I R B RING piston 6 03 4122106 UJ Zo 9 x RING catch 1 04 4152104 gt 3 PLUG oiler 1 H FUEL PUMP J243000 7 105800017 Jf 951 BH 2 A 2 Sxreurow amp WIS WIS WIS SHINIOd 10121103 56 3 5 11110032 HOV 5 1 ONIN 5 22101 samoy Surids 5 1eddn Surids 5 1edun d 65 WAC ITOH 12 1 0 772 3 18 5656 855 HATVA 0 LTASY HOIOTIJHG ASSY duind enj Weg TANA tiation Saige B uH Z hE lt 4 a 54 5 4x A lt Ma ox 2 6 Z C 6 t 4 os FE 0008727 tte Leoever 6Loever 97 910 vcf vLoever eLoever cloever LLOEVCP 0 029 Looerer 6 voogver 00 ON Hed SEWE Jol 8 FUEL PUMP 7248000 7
39. a long time Besides as this pile hammer is of air cooled type handling and maintenance are quite easy and a trouble such as freezing of cooling water in winter is completely eliminated Specifications 111 2 Overall length Total weight Upper piston weight Number of blow blow min Energy out put per blow kg m Fuel consumption Kerosene or Heavy Oil Ihr Lubricating oil consumption Fuel tank capacity Capacity of lubricating oil basin 1 3 pile hammer itself at the time of erecting the pile Structure Model 1 122 diesel pile hammer consists of the upper cylinder lower cylinder 7 upper piston which moves up and down in the cylinder lower piston which is housed in the lower cylinder fuel pump driving device Bosch type fuel pump nozzles fuel stopping device fuel tank around the top of the lower cylinder fuel filter starting device etc The upper part of the upper piston forms a lubricating oil basin and oil is sprinkled out through the small oil holes little by little during operation and lubricates the inner surface of the cylinders The fuel pump and the pump driving device are mounted in the middle in front of the lower cylinder and are driven by the pneumatic force of the air which is compressed by falling of the upper piston Thus they inject fuel into the combustion chamber through the nozzles by atomizing it En The starting device moves v
40. aust plug Safety f x ture Fig 4 5 moisture suppor from 1 so tha c 6 the oil from thi Oiler plug piston from and down t Perform tl n from the 4 grea grease pump Sup NOTE 1 Do not hoist the upper piston excessively or the upper piston supported by the pawl of the tripping device may be disengaged from the pawl and fall down NOTE 2 When hoisting the upper piston pull the rope of the fuel stop lever so that fuel may not be discharged c Remove the oiler plug on top of the upper piston and fill the lubricating oil from the oiler hole then replace the oiler plug Oiler plug removing tool Removing 1 stalling 4 For the initial break in operation pour 0 5 1 of motor oil around the upper piston from the top of the upper cylinder and actuate the upper piston up and down by the tripping device Perform this operation just before pile set up Inspection hole 6 Supply the grease to the lower Ins pectio Grease nipple piston from the 4 grease nipples using plug the grease pump Supply the grease every 20 minutes during the piling operation while greasing care should be taken not to allow the grease to go into the hollow of the lower piston 7 Supply superheaded cylinder oil 10 strokes to the inner surface of the fuel pump driving cylinder from the grease nipple using the grease pump During operation supply it 10 strokes every 20 minutes o
41. ce to fall from vibration but it giv Therefore make sure it is set completely b The upper piston will move up and down by the compressed air inside the cylinder for about 10 26 seconds after the operation has stopped Therefore do not let the starting device down until after the vibration has stopped rela ows 5 Cracking of the Lower Cylinder Extreme care should be taken during operation as the lower cylinder may crack when the pile hammer is subjected to the following conditions a The center of the hammer is not aligned with that of the pile or pile cap b The head of the pile pile cap is not flat c The hammer is operated continuously when the pile penetration is less than 5 mm per 10 blows 250 d The hammer is operated continuously without supplying lubricating oil by stopping the hammer every 15 20 minutes worn or broken damper rubber ring is used f The hammer is operated without cutting fuel oil even when the pile penetration is excessive more than 100 200 mm per blow 200 6 Never pad weld the pawl end of the tripping device and the craw of the right left hooks for the hammer The chipped pawl or hook is extremely dangerous to the operation 150 upper piston falling distance 00 24 3 thani EEE ETE EEN 7 The measuring procedure of the upper piston falling dis
42. d hook of the pile cap Provide sufficient slank in the Wire wire so that the lower piston Clip can slide down 15 20 cm Fexed three positions The specified wire thickness is over 20 mm Clip detail Inspection and Lubrication before Starting the Operation 1 Remove the following shipping fixtures Upper cylinder protecting cap Upper cylinder protecting plate Lower cylinder exhaust plug Upper piston safety bolt Lower piston safety fixture 2 Points to inspect and tighten daily before starting operation a b 9 4 3 fuel daily before starting operation The fuel tank capacity is about 50 1 Conical hexagon nuts on the guide jaw of the lower cylinder Fuel pump fixing nuts Conical hexagon nuts fixing the lower cylinder and the end ring Safet 4 Bolts connecting the upper cylinder and the lower cylinder Bolts and nuts for the guide gib of the starting device 4 Loosen the drain plug at the bottom of the fuel tank and drain the in the fuel tank once a week 5 the upper piston oil basin with lubricating oil in the following procedure a b Move down the tripping device slowly so that the pawl engage the ring groove of the upper piston Hoist the upper piston by the tripping device so that it protrudes about 2cm from the upper cylinder 16 Upper Piston About 2 Upper cylinder Fig 4 6 Protecting plate bolt Exh
43. d leftward by rotating the pully 03 When the pully is turned clockwise the fuel volume increases and it decreases when turned counterclockwise Nozzle holder body Pressure adjusting screw Dowel pin Push rod Gasket Fig 2 9 6 10 the needle valve opens d of the nozzle tip passage from the fuel y pulling the stoppin the spring 5 beco 2 2 1 223 GULLS gt Stoo valve Fuel Filter see Structure of th 1 2 11 It consis f 100 mesh The 6 barrel ee mmn Structure of the nozzle is as shown F 2 9 The fuel which is pushed out from the fuel pump enters into the chamber A in the nozzle tip through the fuel passage When the pressure of the fuel becomes the same as the spring loaded pressure of 100 kg cm the needle valve opens and the fuel is injected into the cylinder through two holes at the end of the nozzle tip being atomized in the fan shape 4 Fuel Stopping Device see 2 10 Structure of the fuel stopping device is as shown in F 2 10 This device is provided between the fuel pump and nozzles and is to stop the hammer by shutting off the fuel passage from the fuel pump to the nozzles by pushing down the push rod D and valve body Q by pulling the stopping lever 3 When the stopping lever is pulled the pawl 4 which was pulled by the spring 5 becomes horizontal and it keeps on pushing the
44. e fuel tank or change fuel for new batch which does not contain moisture 0 operation of the fuel pump plunger is stopped by sticking because a foreign matter is caught in the clearance between the pump cylinder and the pump plunger or rust is caused Or the plunger is broken Note In this case turn the fuel regulator pully clockwise or counterclockwise If it is hard to move or does not turn at all the plunger is sticking So overhall the fuel pump 1 10 1 When rust is caused or the plunger is broken replace the assembly of the plunger and cylinder with a new one 1 10 2 If the plunger and cylinder are sticking and causing galling or seizure by clogg ing of a foreign matter repair the plunger and cylinder if the defect is not serious As for the repairing method refer to the item 7 1 3 of this manual Or replace the assembly of the plunger and cylinder with a new one 1 11 The slit of the skirt of the control sleeve is broken and the plunger is at the position of ZERO for fuel delivery rate Note In this case pull out the holder and the delivery valve at the top of the fuel pump Then rotate the fuel regulator pully clock wise or counterclockwise and check if the top of the plunger turns or not 1 11 1 Replace the control sleeve with a new one 1 12 As the pump cylinder and the plunger are worn out fuel leaks through the clearance between them
45. e second piston rings a groove is provided to hold the super heated steam cylinder oil for lubricating the lower cylinder The top of the lower piston has a concave spherical surface which watches the striking surface of the upper piston 3 Upper Cylinder The upper cylinder is provided with a groove for fixing the catch ring which is to prevent the upper piston from jumping out On the leader side a pawl groove is cut through which the pawl of the starting device travels On the outside of the upper cylinder a lifting hook seat is fixed by welding for lifting the hammer body by the starting device Besides the upper and lower cams for automatically lifting and dropping the upper piston at the time of starting are also welded The upper and lower cylinders are combined and centered by the spigot and socket joint 4 Lower Cylinder In the lower part of the lower cylinder a cylinder liner for the lower piston is inserted To prevent the lower piston from falling off an inner end ring of split type and an outer end ring to fix the inner end ring are provided Besides a rubber ring is fitted to the outer end ring in order to absorb the shock between the lower piston and the lower cylinder 2255 Chapter 2 STRUCTURE AND FUNCTION OF EVERY PARTS Oil hole 0 2 basin Sper Flange Spigot and socket joint Fuel tank piston Lower cylinder Catch ring Piston ring comb
46. egular and the difference is more than 20cm 2 Operation suddenly stops 2 6 Because of damage to the fuel filter element dust and Replace the fuel filter element with a new one foreign matters have clogged in the piping and fuel pump and fuel does not flow during continuous striking Clean the whole passage of fuel such as the fuel piping etc 2 7 A crack is caused in the fuel Replace the fuel piping pos piping and oil is leaking with a new one 2 8 The injection ports of the injection nozzles are clogged with dust foreign matters or carbon deposits and are blinded Disassemble and clean the nozzle tips Or replace the nozzle tip assembly with a new one At that time adjust its injection pressure to 100 kg cm by the nozzle tester 3 of the upper piston has become unusually high The max jumping height is 2 6m The striking frequency at that time is about 41 blows min Jumping height 3 1 Fuel injection rate is too large 3 2 The tip of the pile reached a hard stratum and the hammer is overloaded 4 Even if the ground becomes hard the jumping is irregular and the difference is more than 20cm 4 1 The needle valve of the nozzle is sticking So the fuel is not atomized satisfactorily 3 1 1 3 2 1 Reduce the fuel injection rate That is pull the fuel regulator ro
47. ertically along the lead pipes of the piling frame This is used for lifting the upper piston when starting the pile hammer and also for lifting the Theory of Operation refer to F 1 2 F 2 8 1 Starting Free Falling When the starting device is hoisted up the upper piston moves upward being 05 hooked by the pawl of the starting device When the upper piston reaches the specified height the tripping mechanism works and the upper piston falls automatically 2 Compression and Striking The upper piston which falls closes the air intake and exhaust ports of the cylinder keeps on falling by compressing the air in the cylinder strikes the lower piston at last and thus drives the pile into the ground by the impact force caused at that time 3 Combustion E the pneumatic pressure at the time when the upper piston strikes the lower piston the fuel pump works and injects fuel into the cylinder through the two nozzles Combustion begins at the same time as fuel injection and the pressure in the cylinder rises This combustion pressure works upon the fuel pump driving device and keeps it injecting the fuel Besides it also works upon the upper piston to make it jump up and presses the lower piston to promote penetration of the pile neo 4 Exausting When the upper piston moves up the exhaust ports open and the combustion gas the cylinder expands and is exhausted 5 Suction of Air When the upper piston fu
48. f operation Eq 8 2 Applying grease on the lead Apply cup grease slightly on the lead guide jaw and guide gib They will wear rather quickly without grease application Cleaning of the lower piston hollow Remove the inspection plug of the lower cylinder inspection hole and insert the cloth wound cleaning wire attached tool in order to remove dirty oil moisture and other dust particles from the lower piston hollow Then let the upper piston go down and clean the hump at the end of the upper piston by inserting the cleaning wire from the inspection hole After cleaning replace the inspection plug Caution Check to see if the thread of the inspection plug is oily An oily plug is hard to remove because it tends to burn and stick during operation Therefore apply MOLYBDENUM DISULFIDE or GRAPHITE to the threads of the inspection plug 43 Pile Set up 1 Sling the rope around the pile to bring the pile near the mast 2 3 Loking device Caution a Do not draw the pile positioned far from the mast because the mase will fall over b Put down the hammer when drawing the pile c If the pile does not move when drawing the pile from far sling the rope at the mast side from the center of the pile and draw the pile raising slightly on the mast side Move the position of rope to 1 m from the head of the pile when the pile comes near the mast Setting up the pile Set
49. fue regulator pully and adjust the fuel delivery rate to about 5 Move the starting device downward and hook the pawl to the flange of the upper piston 6 Lift up the starting device by the winch hammer lifting drum see Fig 4 11 When it is lifted about 90 cm the pawl of the starting device is released from the upper piston and then the piston falls down and the hammer is started At the time return the starting device immediately to its standard position by lifting it more than 80 cm above the hammer body 7 If the pile penetrating rate per blow is less than 10 cm combustion is repeated and the pile is struck continuously However for the initial starting after bringing the pile hammer to a new construction site air is sometimes contained in the fuel piping and it does not sometimes start by only one starting operation 8 If continuous combustion does not begin even if the pile penetrating rate per blow is less than 10 cm reset the fuel regulator pully so that fuel injection amount is increased If the fuel injection amount is set too large from the beginning the upper piston might jump out of the upper cylinder 19 9 4 5 0 2 Leave a distance of more than Standard position of Starting device When the starting device is lifted about 7067 the piston falls Fig 4 11 When continuous striking begins adjust the fuel delivery rate so that the jumping height of
50. g sound of the upper and lower pistons is heared The upper piston jumps up and the falls again Read the second hand again when the striking sound is heard If the time between the first and second striking sounds is less than 8 seconds carbon deposits are accumulated in the piston ring grooves the rings are sticking the free gap of the rings is reduced and the service limit is reached aropping height Time All right if more than 8 seconds 31 gt Trouble Cause _ Remedy 2 Operation suddenly stops during continuous striking 2 1 The locking spindle of the fue tank has moved from the position of OPEN to CLOSED by the vibration during operation Change the position to OPEN 2 2 The welded lever of the locking spindle has been disconnected Weld the lever again 2 3 During continuous operation 2 3 1 This is not caused by the tip of the pile has disorder in the pile reached a very soft stratum hammer itself and the pile penetrating Start again rate has become very large 2 4 The operation of the fuel 2 4 1 When rust is caused pump plunger is stopped replace the assembly of by sticking because a the plunger and cylinder foreign matter is caught with a new one in the clearance between the pump cylinder and the pump 2 4 2 If the plunger and cylinder plunger or rust is caught are
51. hammer or the like from the delivery valve holder side and take out the plunger by patting it gently and then take out the barrel 3 By using an oilstone polish gently only the defective portions caused by galling 5 or seizure on the outer surface of the plunger and the inner surface of the barrel If the defect is deep replace the plunger and barre as an assembly with new parts because they are not interchangeable 4 Apply the commercially available brass polishing paste on the outer surface of the plunger and the inner surface of the barrel Insert the plunger into the barrel and polish them by rubbing them against each other 5 Wash away the polishing agent Then apply lubricating oil to the plunger and barrel and polish them by rubbing against each other until the plunger can be inserted smoothly by its own dead weight when the barrel is placed vertically At that time rotate the plunger and confirm that it can be inserted smoothly at any rotated position 6 When the plunger can be inserted smoothly as described above reassemble the plunger and barrel 40 7 3 Disassembly and Cautions for 1 2 3 2 5 6 Othe o The chan 586 Kee o App nozi its o If it the bras noz o Nev o Mat inst o Coi 73 Disassembly and Reassembly of the Nozzle DISASSEMBLING PROCEDURE GASKET 7249212 6 PUSH ROD 7247204
52. ide of the exhaust port inside the cylinder of the cylinder and chamber b Burrs are caused at the joint of the upper and Chamferin lower cylinders 1 6 b Remove the burrs at the joint of the upper lower cylinders 9 When lifting 9 1 When the upper piston is 9 1 1 Repair the guide gib by the upper piston by lifted by the starting device padding or replace it with the starting device of which the guide gib is a new one the piston falls worn out more than the halfway Or the service limit the starting starting device device leans forward So does not begin to the pawl cannot be hooked lift the upper enough and the piston piston at once slips off PP When the guide jaw of the 9 2 1 Repair the guide jaw by hammer body wears out more than the service limit the hammer body leans forward Therefore the upper piston also leans forward the pawl cannot be hooked enough and the piston slips off 36 padding or replace it with a new one 9 3 The flange of the upper piston is worn out worn out part 9 4 The set key which is setting 9 4 1 Replace the set key with the tripping cam and tripping a new one lever is broken Tripping lever Sed 9 5 lower cam of the 9 5 1 Repair the lower cam by hammer body is worn out padding or mount a new or broken one by weldi
53. ill cause a wild blow LIMITATION THE HAMMER OPERATION When the upper piston jumps up to 1 8 m and the penetration of the pile is below 0 5 mm one blow below 5 mm 10 blows stop the hammer operation When the upper piston jumps above 2 6 m lower the volume of the fuel intake Continuous operation under these circumstances will cause severe damage to the piston and cylinder HAMMER GUIDE AND LEAD Maximum clearance between the hammer guide and the lead is 7 mm on both sides 3 5 mm one side The clearance above 7 mm will result in accidental falling of the hammer or breakage of the unit It is very dangerous to use the lead bent worn or improperly jointed because such a lead will only cause damage PILE SET UP When setting the pile be careful not to let the pile come in contact with the hammer Set the hammer center so that it comes in line with the pile center Otherwise the pile will sway causing damage or an accident HOISTING OF THE HAMMER When the hammer is hoisted by the tripping device make sure that the locking device is in the proper position and hold down the hooks and the hooks carry the hoisting seat of the upper cylinder before hoisting Do not go under the hammer or put your hands between the hammer and the pile If necessary insert a wood block i DAILY INSPECTION AND CLEANING Start the operation after making sure that all the bolts and nuts are tight and faste
54. is placed on the pile 11 1 As the tip of the right hook cam for preventing the accidental combustion is worn out or broken it cannot push the tip of the tripping lever when the body lifting hooks hold the body lifting hook seat 10 5 1 Replace the hook with a new one Never repair by welding 11 1 1 Repair the right hook cam by padding or replace it with a new one 11 2 The key or dowel pin which is setting the safety cam for preventing accidental combustion at the tip of the tripping lever is broken 38 11 2 1 Replace the key or dowel pin with a new one Disassembly and DISASSEMBLING PROCEDU pee ASS Y O RING H BARREL GASKET B RACK GUIDE SCREW CONTROL RACK CONTROL SLEEVE SPRING SEAT PLUNGER SPRING PLUNGER GUIDE SNAP RING NOTE 1 Afte NOTE 2 Aft smo NOTE 3 Pro pun UN H O RING 1243010 7 Chapter 7 MAINTENANCE STANDARD Disassembly and Reassembly of the Fuel Pump 4 e DISASSEMBLING PROCEDURE REASSEMBLING PROCEDURE PART NAME PART No 6 DELIVERY HOLDER J243009 DELIVERY SPRING 3243007 GASKET J243008 T TOOL REMARKS 1 Completely clean the pump housing with treaded oil Confirm that the plunger enters into the pump barrel smoothly by its ow
55. ith a special shape of groove which coincides with the port C of the plunger cylinder 6 The coinciding amount of the groove and port can be varied by rotating the plunger If the plunger is rotated to such position that the groove and the port do not coincide at all the fuel in the chamber at the top of the plunger is forced out to the two nozzles as a whole about 5cc If the plunger is at a position that the groove coincides with the port a part of the fuel is returned from the chamber at the top of the plunger to the suction chamber through the port when the plunger is pushed up The amount of returning fuel is in proportion to the coinciding amount of the groove and the port and thus the amount of fuel which is pushed out to the nozzles is adjusted It is also possible to adjust the rotating angle of the plunger so that the whole fuel is returned to the suction chamber and make the amount of fuel pushed out to the nozzles zero The plunger 3 is meshing with the control sleeve 9 On the outer surface of the control sleeve 9 gear teeth pinion are cut and the pinion is meshing with the control rack 49 The plunger is rotated by moving the control rack 9 rightward or leftward and thus the coinciding amount of the plunger groove and port is adjusted The control rack is connected to the fuel regulating device which is mounted on the outside of the fuel pump The control rack 49 can be moved rightward an
56. lace them when the clearance dimen sion A between the inner end ring and the contact surface of the lower piston reaches serviceable limit 2 Replace the damper rubber ring when the dimension B reaches the serviceable limit 3 Replace the damper rubber ring when it wears to the extent that the contact surface to the lower piston is reduced to 1 3 Name of Comporent Cylinder for driving the fuel pump 75 0 03 Piston Ring for driving the fuel pump Replace the cylinder when the inner surface wears about 0 3mm Outside Dia of the Piston Ring for driving the fuel pump Guide Jaw Guide Gib 44 Replace the piston ring when the flee clearance reaches the serviceable limit Replace the piston ring when it wears about 0 3nm Replace the guide jaw when the clearance between the lead and the guide jaw exceeds 7mm FERE 2 8 1 Pile Resist The following 1 The det formula This for of the ing to tl see F Among is the M directly where By usin be driv the Load Poin Pile resista Fig 8 1 Chapter 8 APPENDIX 8 1 Pile Resistance The following three formulae are used to calculate the pile penetration resistance 1 The determination of the pile penetration resistance with the statical calculation formula This formula assumes that the pile penetration resistance i
57. m and to perform striking without combustion or keep running by adjusting the fuel delivery rate to the adequate value 21 47 48 6 When the tip of the pile comes to a hard ground and the pile penetration per 10 blows becomes less than 5 mm stop the operation and change the hammer for one of larger capacity Otherwise the hammer might be damaged Stopping 1 When finishing to drive Q 1 a pile to the specified depth and proceeding to drive the next pile When pile driving is to be continued a Stop the fuel supply by pulling the rope of the fuel stopping lever and stop the hammer Move horigontall speed along the horizontal K Fig 4 13 record Paper 25 channel Penetrating rate Per 0 blow How to Measure the Pile Poneterting Rate b Put the locking device of the starting device to the locking position and 2 the hammer body by the winch and then lift the bottom end of the pile cap to about 50 cm above the ground surface c Move the piling frame to the position for driving the next sis d Place the hammer on the wooden plate ou e Prepare to erect the next pile When finishing the pile driving work a Stop the fuel by pully the rope of the fuel stopping lever and stop the hammer b Put the protective cover on the upper cylinder c Screw the threaded plugs into the exhaust ports Cautions fo
58. mer and smear mineral grease to those portions where grease is becom ing short 1 For all the year round it is recommended to use light oil light oil for diesel engines light oil of JIS No 1 2 and 3 etc 2 3 Any kind or brand will do It is also possible to use heavy oil A or heavy oil for diesel engines It is also possible to use kerosine any kind or brand However when using kerosine mix about 20 of upper piston lubricating oil to improve the lubricating effect Notes 1 2 Always use clean fuel oil and keep fuel oil free from mixing of dust rain etc When supplying fuel oil be sure to clean the oil inlet beforehand to prevent dust or foreign matters from entering olds i Fixing Procedure 1 Unload the the truck When wire ropes twe And when hoisting center of the gravit first The specified thick 2 Pass the wire starting device sec lower end of the 1 about 5m The specifie 20 mm for the on 3 Bind anothe the upper cylinde the lead 4 Hoist the hi ground and fix b of the lower on the other side the lead and the as the guide jaw Front viow Sic wire to the Chapter 4 OPERATION AND HANDLING 41 Fixing Procedure of the Diesel Pile Hammer 1 Unload the hammer around the lead from the truck When unloading the hammer sling the wire ropes two rope
59. n the fuel delive pile penetratio than about 10 If the pile pen more than 20 pile hammer breakage of th damage or def outer end ring When striking and moreover ing the fuel re the fuel regul Otherwise dis rate is to be a until you can delivery rate Cautions during When the pile than 4m dista After starting the hammer b from touching During runnir fuel so that 1 When the suspend the o If the ground blow for the stopping rope Striking withc to the adequ 4 4 6 2 3 4 6 until you can fully understand the relation between the rope movement and the fuel Cautions during Running When the ground is too weak and the resistance is too small or when the pile is too light the pile may penetrate into the ground more than about 10cm by one blow In such case pull the rope of the fuel stopping lever and strike without combustion by several blows by keep ing the fuel injection stopped Or set the fuel delivery rate small so that the pile penetration per blow becomes less than about 10 cm If the pile penetration per blow becomes more than 20 cm serious damage to the pile hammer may be caused such as breakage of the pile cap hanging ropes damage or deformation of the inner and outer end rings and so forth 7772 EIRENE 55 5 STS 7247
60. n dead weight 2 Note If not lap by the commercially available brass polishing paste Do not use carborundum DELIVERY VALVE J243006 ASS Y Tightening torque 30 60 kg m 7 Wrap the top of the threaded part with a piece of waste cloth or the like in order to prevent dust or foreign matter from entering BARREL J243003 3243004 This should match the spigot part at the top of the valve 5 NSS o Check if anything abnormal is found on the N contacting surface of the valve seat and valve REI 7 1243005 RACK GUIDE SCREW 1243018 If any apply small amount of carborundum No 600 to the seat surface only and it If the defect is larger replace the assembly of the valve and valve seat with a new one Insert by applying oil CONTROL RACK 3243017 7 Match the deflector hole of the valve to the 3 housing side and push the deflector in o Be sure to insert the gasket CONTROL SLEEVE SPRING SEAT 1243019 1243012 nsert the control rack so that the side which bears the center punch mark comes to the bottom side control sleeve side 8 o Fully tighten the guide screw by a screwdriver After tightening confirm again that the control rack moves smoothly PLUNGER SPRING PLUNGER 3243011 1243003 1243016 t 15
61. nd and on the lower end has the soil test sampler shown in F diameter 2 inches 51 mm length 2 ft 8 inches weight 15 Ib 6 8 kg The sampler collects the necessary soil sample for the soil test at the same time 2 The calculation of pile penetration resistance with the dynamic formula This formula determines the pile resistance by calculating the pile penetration resistance and is used widely as the test can be performed easily The Stuttgart University of Technology represents the formula for calculation of pile resistance for the diesel pile hammers and Hiley s formula as modified below This formula is adopted for standard foundation structures by Japan Architectual Association The allowable bearing force of the pile can be determined by dividing the calculated pile resistance with a safety factor The standard of the foundation of JAA specifies pencil more side Stick with wlse a constant Scotch tape speed of elastic deformation pile penetration 7 Support Beam angle or channel 8 5 Measuring method of the elastic deformation of the soil and pile that the safety factor should be 4 for the long term load and 2 for the short term load In other words the allowable pile bearing force is 1 4 long term load and 1 2 short term load of the calculated pile penetration resistance R 2WH Win2P S K WIP where R Pile penetration resistance or bearing force t W Upper
62. nder ong 10 AJON c Loogver 1 Bupjoojord 20 05 R 9009927 910018 med 05 a 4 x x 90032 0 1 00119 TAVd T HOLVO g H 091 0 1 0 1 00 18 Med amp MAA 1 18 Med zooover 1 UALSAL ATZZON Y 4 4 x 20 mam ON Hed ON 3 2111 3114 SHPHOSHOOV HY 98 Ref No Part No 4243307 1243308 1245032 2245033 3245035 1244008 1244009 1244011 3133506 1244014 A xm L 1 A 6 6 5 STANDARD SPARE PARTS 2 2 Part Name NIPPLE GASKET PLATE end BOLT lock SPRING torsion NUT union NIPPLE FILTER ELEMENT O RING PIPE A Remarks F 5 Ref Part No 7248000 Y D m 01 02 03 04 05 06 07 08 09 10 1 12 13 14 15 16 17 18 19 20 21 22 23 4151008 1 Re J151017 Fm 7 J151019 Ny tv 7 J151022 Ry by RER 2 IKE LER 75 J122004 y we 459 4 A F 4152104 Z gt X T 4 3 4243003 Z 32 gt 2 gt Fy X 7 3 J243004 gt 2 v 2 2 4243005 27 7 7 2 F J243008 Hayra Ba FU J243009 gt NY
63. ned with safety wire Be sure to replace the bolts if the threads are abraded If the worn bolts are left as they are they may cause damage Always keep clean the conbustion chamber the concave surface of the upper and lower cylinders The care exerci extend their useful lii responsible for the o suggestions on everyd instructions Identification of Pile A plate is attac showing the model ordering parts for the on correspondence t model and serial nun 6 reme PREFACE The care exercised in the operation and maintenance of IHI Diesel Pile Hammers will extend their useful fife and insure highly satisfactory and dependable service To those responsible for the operation and maintenance of the pile hammer this manual contains suggestions on everyday operation and care as well as periodical lubrication and maintenance instructions Identification of Pile Hammer A plate is attached to the front of the unit showing the model and serial number When ordering parts for the hammer or when carrying on correspondence be sure to mention the model and serial number of the hammer WHEN ORDERING PARTS BE SURE T0 MENTION Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 CONTENT 1 1 1 Outline oa
64. ng 9 6 The tip of the pawl of the 9 6 1 Replace the pawl with a starting device is worn out new one or broken Never repair by padding 9 7 When lifting the starting 9 7 1 If the guide gib is not device the tripping lever worn out off the touches some other part and part which the tripping returns So the pawl moves lever touches down This tends to occur when the guide gib is worn out 37 Trouble 10 When lifting the body by the starting device the lifting hooks do not hold the body lifting hook seat Or one hook holds it but the other does not hold 10 1 The connecting rod or the bolt is bent 10 2 Tension of the ratchet returning rubber is lost and the ratchet does not work 10 1 1 Replace it with a new one or straighten the bending 10 2 1 Replace the returning rubber with a new one 10 3 The body lifting hook seat at the upper cylinder is worn out or bent 10 3 1 10 4 The locking device does not function because the leaf spring for the ratchet or the claw of the locking device is worn out 10 4 1 Replace the ratchet or the locking device with a new one 10 5 The tip of the body lifting hook is worn out or broken 11 When lifting the body by the lifting device the pawl is not re leased but the upper piston is lifted together So accidental combustion is caused when the body
65. on at site 5 1 Daily Routine 1 2 If any one ol missing retig 215101 11550 31510 J1511 Supply lubr Supply oil t Routine at Evt 1 2 3 4 6 Perform the If the rubb service limi Check the they are wi new ones Disassembl Dismount injection p valves If new ones mounting PERIODICAL CHECKING AND MAINTENANCE Chapter 5 For Model IDH diesel pile hammers periodical checking and maintenance are required as explained below The following running hours are for the operation at a place of normal conditions If the diesel pile hammer is used at such place where much dust and sand grains are contained in air it is necessary to shorten the interval for periodical checking and maintenance according to the actual condition at site 5 1 Daily Routine 1 If any one of the bolts and nuts as listed below is becoming loose or any locking is missing retighten the loosened ones Part No Part Name Remarks J151012 NUT for guide jaw 1155015 BOLT for guide grib 3151007 NUT for end ring J151102 BOLT tightening upper and lower cylinders 1 4 Pipe joints bolts and nuts for the fuel pump and fuel system 2 Supply lubricating Supply oil based on the section 3 4 Lubricating Instructions 5 2 Routine at Every 250 Hours of Net R
66. one 550346 550367 Ext 366 Cable Address IHICO TAIPEI Telex TP320 3rd Floor No 7 Akti Miaouli Street Piraeus Greece Telephone 426583 426584 Cable Address PIRAEUS Telex 212483 GR INT IDH 2 72 x x 1 FOR DIESEL PILE HAMMER MODEL IDH J22 d INDEX UNIT NAME GENERAL ASSEMBLY CYLINDER LOWER CYLINDER UPPER PISTON LOWER PISTON UPPER FUEL PUMP PUMP DRIVING DEVICE DISASSEMBLING TOOLS STANDARD SPARE PARTS 915 u3mo 301 E6068 L 3 1VN01193S 2321 20 2111 120 6 FEAL 1108 1 1 4 H3dd A i BE 1 131345579 55 x SERESA rre eemi x Ref No RHE 5 Part No J240100 1241000 4241100 4152000 1242100 4243000 4243100 1243200 4243300 4244000 J245000 3240100 2 GENERAL ASSEMBLY Part Name Remarks E J me 7 m F gt 7 gt F v Z X X 7 E GENERAL ASS Y CYLINDER LOWER PART CYLINDER UPPER PART UPPER PISTON RAM LOWER PISTON ANVIL FUEL PUMP PUMP DRIVING DEVICE NOZZLE STOPPING DEVICE COMPL FUEL LINE CO
67. p surface of the lower piston When the upper piston strikes the lower piston the fuel disperses being atomized mixes with the high temperature and high pressure air which is compressed by the upper piston and is ignited Therefore when the temperature of the machine parts especially of the top surface of the lower piston rises after running for some time the fuel supplied onto the top surface of the lower piston is gasified and ignited before the lower piston is struck So that the falling speed of the upper piston is reduced and the striking force is lowered This was the weak point of the conventional diesel pile hammers On the other hand for this nozzle atomization type diesel pile hammer the following combustion system is adopted That is the fuel pump is operated by utilizing the pressure of compressed air in the cylinder which becomes high when the upper piston falls and the fuel is injected by the nozzle being atomized into the compressed air of high temperature and high pressure just after the upper piston strikes the lower piston Therefore the fuel can be ignited without fail even when the ground is weak and the upper piston cannot strike the lower piston strongly because the pile is driven into the ground only by the pneumatic pressure of the air which is compressed by the falling upper piston So continuous striking performance is high and the striking force is not lowered by preignition even after continuous operation for
68. pe ever Connecting rod Zever returns Right hook lock ing deyile Left hook Fig 22 Fig 2 3 2 Lifting U When the st cam of the upper fixing the fishplat connecting the ce cam the starting tip of the pawl A is pushed in th fore the pawl do When the of the upper center A comes t Then because of the center A is released from thi automatically Lower cam 2 Lifting of Upper Piston see 2 4 F 2 5 When the starting device is moved downward the tripping lever touches the lower cam of the upper cylinder and moves upward arrowhead When the center A for fixing the fishplate to the tripping cam comes to the right side of the line which is connecting the center B for fixing the pawl and fishplate and the center C of the tripping cam the starting device is pulled up and the flange of the upper piston is hooked to the tip of the pawl Thus a force is applied in the direction of the arrowhead b the center A is pushed in the arrowhead direction the fishplate contacts the stopping bolt and there fore the pawl does not move downward and the upper piston is lifted as it is When the starting device is lifted up as it is the tripping lever touches the upper cam of the upper cylinder as show in 2 5 and moves downward arrowhead 4 So the center A comes to the left side of the line which connects the cente
69. pe counterclockwise When the pile penetrating rate per blow is less than 0 5mm stop the operation 4 1 1 4 1 2 Note 2 Disassemble and clean the nozzle Or replace the nozzle tip height of the upper and the explosion force is ass y with a new one piston is low Or weak Note 1 The nozzle tip and the the jumping height needle valve are not inter changeable Change them as the assembly When the nozzle tip is disassembled or replaced be sure to adjust the fuel injection pressure to 100 ke cm2 by the nozzle tester 4 3 The union nut in the fuel 4 2 The delivery valve holder is loosened and fuel is leaking piping is loosened and fuel is leaking 243372 4 2 1 Note 4 3 1 Retighten the delivery valve holder The tightening torque should be 30 60 kg m Retighten the union nut 2 5 Exhaust gas is dark Normal color of exhaust gas is bluish grey Cause is caused 5 1 As fuel injection rate is too large incomplete combustion 5 2 When too much lubricating oil is supplied to the lower piston oil flows on to the concave surface of the lower piston and burns This occurs only for the operation just after lubricating to the lower piston Remedy 5 1 1 Reduce the fuel injection 5 2 1 rate in the same way as the above item 3 1 1
70. per piston in case the combi and the piston jui the piston is prov By the oscillation it is sprinkled ou lubricate the pist the middle of the 10210 apply the space around the serves as the com 2 Lower Piste The lower rings Between t rings a groove is heated steam cyl lower cylinder a concave spheri striking surface 3 Upper The upper for fixing the ca upper piston fro side a pawl grot of the starting d On the outside seat is fixed by by the starting cams for autom piston at the ti upper and lowe centered by the 4 Lower Cy In the inserted To an outer end ri to the outer en cylinder 2 1 Hammer Body see F 2 1 1 Upper Piston Ram The upper piston is provided with 6 piston rings and a catch ring A catch ring is for preventing the upper piston from jumping out of the cylinder in case the combustion force is unusually strong and the piston jumps up abnormally The top of the piston is provided with the lubricating oil basin By the oscillation of lubricating oil during running it is sprinkled out through the small oil holes to lubricate the piston Besides a flange is cut near the middle of the piston somewhat toward the topto apply the pawl at the time of starting The space around the striking part at the bottom serves as the combustion chamber 2 Lower Piston Anvil The lower piston is provided with 5 piston rings Between the top and th
71. piston when starting device is lifting the hammer body Thus the accidental explosion is completely eliminated when the hammer body is placed on the pile Firing Mechanism 1 Fuel Piping Diagram Locking spindle Fuel filter Safety cam for preventing explosion Pump driving device 2 7 8 8 Tripping lever Right hook Right hock cam O 0 Tripping Cam Safety Cain far preventing accidental axploston Right hook cam Fig 2 6 2 Fuel Pump Di 8 Fuel Pump Structure of tt part of the fue increases and e driving piston For sealing the the piston is fi sprinkled to lu pump 7 Airbleeder screw Gasket Fig 2 8 Section 1 2 Fuel Pump Driving Device and Fuel Pump Fuel Pump Driving Device Structure of this device is as shown in F 2 8 and it is assembled into the lower part of the fuel pump to form an integrated structure When the pressure of the air increases and exceeds the force of the plunger spring 1 of the fuel pump the pump driving piston 2 is pushed up and thus operates the plunger 3 of the fuel pump For sealing the compressed air piston rings 4 are provided The concave part of the piston is filled with lubricating oil When the piston moves up and down oil is sprinkled to lubricate the inner wall of the cylinder 5 and the inside of the fuel 1 Delivery valve Molde 3 RE Delivery val
72. r 5 x 4 5 2 x gt aty FI 2 Wh JA 70 85 1 B F 3 Z Ov hj 2 9 IER SM 28 16 8 X16 2 2 5 1 4 2 10x90 2 7888 BALL BEARING radial WASHER M14 WASHER for plate spring NUT M24 x 2 NIPPLE grease 17 BOLT M10 x 25 PIN split for stop pin 5 x 30 PIN split for pawl axis 6 x 55 PIN split for hook axis 8 x 80 PIN split for stopping the return rubber 4 x 25 PIN split for ratchet axis 5 x 45 SNAP RING 70 WASHER for guide gib bolt SCREW M8 x 16 PIN tapered 2 50 x 14 PIN split for pulley axis n N N A m T Remarks NO6014Z I MYSZ 9 3 9 NId 9 SAS Lsoover NNO 72 2 KK x 4 195 1 3201 366 64 195 1 A SSV 0039 4 g x 67 RED 19 00 I WONAGEA TOW 0 24 TOOL ONILATT WVA 1109917 I OVE 4 E g 220 I OV 475 hG 6 00 21 I Ayoyes L108 4 at 900951 v ysneyxe ON Td 43 020911 2 dWV TO 5 009517 I 1909321 10 AOU qu amp oLogver 10 4404 n 6009vZr I 307100015 10 EY g009bzr I Sure
73. r B and the center C Then because of the force applied to the tip of the pawl in the arrowhead direction e the center A is pushed in the arrowhead direction f the pawl moves downward being released from the flange of the upper piston Thus the upper piston falls down automatically Upper cam Tripping lever Fig 2 4 Fig 2 5 2 3 If the starting device is not fully moved down before lifting the upper piston or when the tripping lever contacts something else and the center A comes to the left side of the line which is connecting the center B and C the pawl moves downward and is released from the flange of the upper piston Therefore it is impossible to lift the upper piston 3 Safety Bar for Preventing Accidental Combustion see F 2 6 The right hook cam is bolted to the right hook as shown in F 2 6 and a safety cam for preventing an accidental explosion is fixed to the end of the tripping lever shaft by a key When the right hook holds the lifting hook seat for lifting the hammer body arrowhead a the right hook cam moves clockwise to push up the safety cam arrowhead b j and moves the tripping cam counter clockwise arrowhead c So the center A is forcibly fixed on the left side of the line between the centers B and C as shown 2 5 Therefore when the starting device is lifted the pawl is released from the upper piston flange and the upper piston is placed directly on the lower
74. r Stopping In general stop the operation by pulling the fuel stopping rope Do not stop the operation by making the fuel delivery rate zero by pulling the fuel control rope and turning the fuel regurator pulley fully counterclockwise 2 However when the operation does not stop even if the fuel stopping rope is pulled 22 1 2 stop by pulling stopping d Important Do not dr In other w the pile ar center line Do not use dangerous The service Use a le L Adjust 1 E The cle when t 3 Take care cylinder a a If tl will The b Plac plat tot han aaah 49 stop the operation by tuming the fuel regulator pulley fully counterclockwise by pulling the fuel control rope This is only for the case when the fuel stopping device is out of order Important items on Operation 1 Do not drive the hammer without proper alignment In other words the center of the hammer has to hit positively the center of the pile and the head of the pile has to be flat and centered with the hammer center line 2 Do not use a worn lead as the hammer will come off the lead and fall It is very dangerous to use a worn or bent lead The servicable limit of the lead width is Use a lead of the following specification Lead outside dimension 398 400 mm Adjust the hammer guide clamp according to the following Hammer guide clamp inside
75. rnia U S A Telephone 986 2262 2263 Cable Address SANFRANCISCO Telex 27792 Paseo de Reforma 30 4 Piso Mexico 1 Mexico Telephone 5 35 52 07 5 35 52 16 Cable Address MEXICO Telex 017 72 560 TOSHIBA MEXICO Avenida Presidente Antonio Carlos 607 Sobreloja Rio de Janeiro Guanabara Brasil Telephone 31 1975 0090 Cable Address ISHIBRAS RIO DE JANEIRO Telex 3511031 RIO Edificio Safico Avenida Corrientes 456 10 104 Buenos Aires Argentina Telephone Buenos Aires 46 9081 Cable Address IHICONO BAIRES Telex 121948 AR 14th Floor Gold Fields House No 1 Alfred Street Sydney Cove NSW 2000 Australia Telephone 27 7657 27 4301 5 Cable Address IHIHEAVY SYDNEY Telex AA 20480 69 70 Mark Lane London E C 3 England Telephone 01 481 1822 01 481 1823 Cable Address LONDONEC VIA GREAT NORTHERN Telex 24287 27905 IHICO LONDON Oslo Rotterdam D sseldorf Johannesburg Karachi New Delhi Calcutta Singapore Djakarta Manila Hong Kong Taipei Greece _ Telephone 23 4821 23 4934 Huitfeldts Gate 15 Oslo 1 Norway Telephone Oslo 44 40 24 56 60 59 Cable Address IHICO OSLO Telex 16486 Calandstraat 49 Rotterdam 2 Netherland Telephone RDAM 129357 127045 Cable Address RDAM Telex 22462 1ste
76. rther moves up passing the exhaust ports fresh air is sucked into the cylinder through exhaust ports and thus the combustion gas is replaced Eos PISTON ANVIL with fresh air LOWER UPPER CYLINDER SAFETY BOLT SECTION FUEL PUNP PUMP DRIVING DEVICE 290 LOWER PISTON ANVIL N e 2 PN s 53 gt 3g q NN 5 T 1 LUND d i i 8 Pa Ses GENERAL ASSEMBLY DRAWING Fig 1 1 The pump driving piston and the fuel pump return to the original position because of decrease of pressure in the cylinder and a new batch of fuel enters into the fuel pump from the fuel tank These processes are finished before the upper piston reackes the upper dead point Then the upper piston falls again freely Thus every step of the operation is automatically repeated continuously OPED 40 STARTING DE UPPER CYLINDE PUMP DRIVING AR DEVICE Starting freeFalling Compression Striking Exhansting Suction of Ait Combustion Fig 1 2 4 Chapter Hammer Body The upper f rings and a catch up
77. s as shown in F 4 1 And when hoisting the hammer check the center of the gravity by hoisting slowly at first The specified thickness of the rope is over 14mm Sling the wire rope around the hook groove Fig 4 1 2 Pass the wire around the pully of the starting device see F 4 2 and fix it to the lower end of the lead and hoist the assembly about 5m The specified thickness of the wire is over 20 mm for the one pully device 3 Bind another wire rope to the hook of the upper cylinder and pull the hammer near the lead 4 Hoist the hammer about 30 mm from the ground and fix both the guide jaws on one side of the lower cylinder then attach the hammer unit to the lead Next fix the guide jaws on the other side of the lower cylinder and tighten them securely The clearance between the lead and the guide jaw should never exceed 7 mm Excessive clearance is dangerous as the guide jaw may come off the lead The clearance can be adjusted by inserting shims Hoist The clearance 40 50 mm Should never off the exceed 7 gm ground Insert shims to Top view the clearance Side view Shim 1 Hook the 2 3 Mate the 4 Guide jaw adjust wire to the guide jaw ment hook and the lead First fix the one guide jaw and then the other 4 3 15 42 5 Fixing the protective wire rope Run the protective wire rope through the hook on the lower part of the cylinder an
78. s equal to the sum total of the pile point bearing and the skin friction of the pile peripheral surface accord ing to the soil test results see 8 1 Among the Dole s Byerbaumer s Tertzagi s and Meyerhof s formulae shown here is the Meyerhof s formula with which the bearing force of the pile can be calculated directly using the N value NAp 5 5 where Q pile penetration resistance ton N standard penetration test value of the pile point Ap area of the pile point m2 N average standard penetration test value from the ground surface to the pile point As Spherical area of the pile 2 By using this formula the relation between the diameter and length of the pile to be driven can be calculated assuming Q to be ultimate hammer driving ability when the values of N and N are known Load Total skin friction Point bearing Pile resistance Fig 8 1 29464 Connector Head Fintsh thts area the wrench Drain hole 579 Sampltng Spoon Finish thts Driving area 7 Shoe 1 the wrench 7 2 76 76 Notes Standard penetration test N value The N value is the number of hammer blows required to drive the knocking head 1 ft 300 mm deep into the ground with a 140 Ib 63 5 kg standard hammer The hammer dropping height is 30 inches 760 mm The rod has the knocking head on the upper e
79. sticking and causing galling or seizure by Note In this case turn the fuel clogging of a foreign regulator pulley clockwise matter repair the plunger or counterclockwise If it and cylinder if the defect is hard to move or does not is not serious turn at all the plunger is Refer to the item 7 1 3 sticking Or replace the plunger So overhaul the fuel pump and cylinder assembly with a new 2 5 The slit at the skirt of the 7 2 5 1 When the slit at the skirt contro sleeve is broken and is broken replace the the plunger is at the position control sleeve with a new of zero for fuel delivery rate one Or the small flange at the bottom of the plunger is 2 5 2 When the plunger is broken Note broken To check the breakage of the slit at the skirt pull out the holder and the delivery valve at the top Rotate the regulator pulley clockwise or counterclockwise by looking at the top of the plunger through the hole at the top Thus judge if it is broken or not 30 replace the plunger and cylinder assembly with a new Trouble 2 Operation suddenly stops during continuous striking 3 Jumping height of the upper piston has become unusually high The max jumping height is 2 6m The striking frequency at that time is about 41 blows min 4 Even if the ground becomes hard the jumping height of the upper piston is low Or the jumping height is irr
80. tance a Measuring procedure with a diagram The mean falling distance can be determined with the diagram the upper piston falling distance by the number of blows per minute by measuring the number of blows per minute This diagram is made according to calculation but it gives the correct actually measured result The relation between the upper piston falling distance and the number of blows N the number of blows per minute t The required time for the upper piston to fall freely from the height h to the lower piston second t The required time for the upper piston to rise to the height h second h The upper piston falling distance cm g gravity acceleration 980 sec2 124 as NL I ES NUMEN E BEEN LI 2 1 H upper piston falling distance 40 8 5 number of blows minute 4 15 25 b Eye Measurement The falling distance of the upper piston can be measured by comparing the actual retum height of the upper piston with the diagram upper piston falling distance A approx h approx 4m 250 A approx 22m Chapter For Model IDH diesel pil explained below The following running hc diesel pile hammer is use is necessary to shorten actual conditi
81. tick to it until the nozzle tip is mounted to the When mounting the nozzle tip to the pile hammer be sure to fit the gasket for the nozzle tip copper packing without fail Mount the nozzle holder to the holder completely lock it by a piece of wire 42 hammer body with two bolts by fitting spring washer After tightening the nozzle PELIS LA 1 5 Serviceable Lim Name of Component Lower Cylinder Piston Ring Catch Piston Ring 275 76 Outside Dia meter of the Piston Ring 1 Inner End Ring Dumping Rubber Ring gt i i 7 5 Serviceable Limit of the Wearing Part m FE 390 0 05 0 390 3 Rebore lower cylinder when the inner surface wears about 0 3mm Reboring is possible 3 times Piston Ring Catch Piston Ring o pistonring 48mm o catch piston ring 48 8mm o piston ring 15mm o catch piston ring 25mm Outside Dia meter of the Piston Ring Inner End Ring Dumping Rubber Ring Dumping rubber ring A dimension 0 15mm B d 15 mm Lower piston dimension imm B 5mm 1 3 of the area contacting the piston 43 Replace the piston ring when the flee clearance reaches the serviceable limit Replace the piston ring when the Imm chamfering on the outer periphery is worn out 1 Rep
82. unning Time 1 Perform the same checking and maintenance as in the daily routine 5 1 2 If the rubber ring for shock absorbing for the lower cylinder is worn out to the service limit or broken change it for a new one 3 Check the guide jaw for the lower cylinder and guide gib for the starting device If they are worn out to the service limit repair them by padding or change them for new ones 4 Disassemble and clean the fuel filter 5 Dismount the nozzles remove the carbon deposits at the nozzle tip and test the injection pressure Disassemble the nozzles and check the nozzle tips and needle valves If any galling or hairlines by sliding are found repair them or replace with new ones After reassembling be sure to test the injection pressure before re mounting to the fuel pump 5 4 Routine at Every 500 Hours of Net Running Time 1 Perform the same checking and maintenance as in the case of 250 hours routine 5 2 2 Clean the piston ring grooves of the upper and lower pistons and completely remove carbon deposits Check the piston rings and replace them with new ones if worn out or thermal strain is caused 3 If the inner end ring is worn out to its service limit or damaged replace it with a new one 4 Disassemble and clean the fuel pump driving device and remove carbon deposits in the piston ring grooves If the cylinder is worn or if
83. ustion chambe 07 Holding groove Piston ring lower piston Fig 2 1 On the outside near the top of the lower cylinder a fuel tank is provided On the outer surface of the lower cylinder guide jaw mounting seat for sliding the pile hammer body and mounting seats for various component parts of the firing mechanism are fixed RE On the periphery of the lower cylinder four decompression holes are provided so that the combustion gass will escape when abnormal continuous striking occurs and thus to prevent the lower piston from striking the inner end ring and to avoide damage 2 2 Starting Device 1 Lifting of Hammer Body see F 2 2 F 2 3 When the locking device is not pushing the left hook as shown in F 2 2 the right and left hooks are open because of the torsion springs which are provided to the shafts of both hooks However when the lever is pulled as shown in F 2 3 the locking device pushes the left hook and the right hook is moved by the connecting rod Thus the lifting hook seat is held by the right and left hooks and the hammer body is lifted up As a ratchet gearing is provided to the locking device the lever returns to the original position being pulled by the returning rubber when the rope is released but the position of the locking device does not change When the rope is pulled again the locking device turns and the left hook is not pushed Thus the operation is repeated by pulling and releasing one ro
84. ve gasket Delivery valve spring 7 Airbleeder screw Delivery valve ass y gt 0 Gasket D Spindle O ring Pulley 00 Deflector Gasket Pump housing Barrel plunger Plunger 9 LZ zi 48 Control Sleeve T Spring seat upper Rack guide Screw Control rack 0 Plunger spring 7 Plunger guide 22 20 eh j 1 GAARA T 20 Jorim seat lower doring ring p Gasket Petes Grease nipple cT H Piston rod Fumo driving device Piston ring 4 Piston 2 Gasket Fig 2 8 Sectional View of Fuel Pump Fuel Pump Driving Device and Fuel Regulating Device 9 6 Fuel Pump see F 2 8 Structure of the fuel pump is as shown 2 8 and it is of Bosch type ones Fuel which is fed from the fuel tank through the fuel filter enters into the suction chamber around the plunger cylinder 6 through the intake port For air bleeding on the inlet side loosen the air bleeder screw 7 above the inlet port amp Fuel which has entered into the suction chamber around the plunger cylinder 6 goes into the chamber at the top of the plunger through the port of the plunger cylinder As the plunger 3 is pushed up by the pump driving piston the fuel in the top chamber is forced into the nozzles by pushing the delivery valve check valve 8 open The plunger 3 is provided w
85. y bar 4 50 4151007 toh AR 1628 88 2 NUT hex 2 12 JIS 83 1181 k 0278 51 J141054 x 885 WASHER 335 12 8 end ring 14 1241014 E Ue SAFETY BAR 2 15 1241015 CINCO M A lt SAFETY BAR 2 aaa ey ee MEE gt ie p EL _ ae i WaAddN WAGNITAO 91 0011722 5 Ref No _ Part No 41 01 02 50 12241100 EVJ vF CYLINDER UPPER Part Name E s F J ee E CYLINDER upper BOLT WASHER spring 24S 2 Libes 5 gama b d 1514 BA uojsid 10 0 NOLSId Sxieuroy YAMOT NOLSId 002017 20 100281 10 0002417 ON Hed ON Jed amp xu JE NOW 1 2 21 6 WVU 1211 m VIEW FROM A 7242100 EREZ CFA PISTON UPPER RAM LA E 5 Part Name Remarks Ref No Part No 4242100 A y F V m 01 J242101 2 RAM PIS

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