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Dawson HPH 1200 User Manual

Hydraulic piling hammers
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INNOVATIVE
PILING
EQUIPMENT
HYDRAULIC PILING HAMMERS
EXCAVATOR MOUNTED
VIBRATORS
EXCAVATOR MOUNTED DRILLS
QUIET, VIBRATIONLESS
PUSH-PULL PILING
PILE EXTRACTION
SHEET PILE GUIDE FRAMES
SHEET PILE
CAPPING SYSTEMS
CFA CLEANERS
PILE POINTS
& SPLICERS
HANDLING / LIFTING
www.dcpuk.com
www.dcpuk.com
HPH 1200
HYDRAULIC HAMMER

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Summary of Contents for Dawson HPH 1200

  • Page 1 HPH 1200 HYDRAULIC HAMMER INNOVATIVE PILING EQUIPMENT HYDRAULIC PILING HAMMERS EXCAVATOR MOUNTED VIBRATORS EXCAVATOR MOUNTED DRILLS QUIET, VIBRATIONLESS PUSH-PULL PILING PILE EXTRACTION SHEET PILE GUIDE FRAMES SHEET PILE CAPPING SYSTEMS CFA CLEANERS PILE POINTS & SPLICERS HANDLING / LIFTING www.dcpuk.com...
  • Page 2 DAWSON CONSTRUCTION PLANT LIMITED HPH 1200 HYDRAULIC HAMMER AND POWER PACK - USER'S MANUAL HAMMER SERIAL NO: ..........HAMMER COMMISSION DATE: ......POWER PACK SERIAL NO: ........POWER PACK COMMISSION DATE: ...... ENGINE TYPE: ............ENGINE SERIAL NO: ..........POWER PACK TYPE: ..........
  • Page 3 Basic Safety Points 5.1.2 Lubrication specification - Basic Specification of HPH 1200 - Drawing Daily maintenance checks - Lifting the HPH 1200 & Power Pack - Drawing Figure 6 Dolly wear Transportation and laying hammer down Planned maintenance checks 2.0 How does the Hammer Work? 5.3.1...

  • Page 4: Ec Declaration Of Conformity

    MILTON KEYNES MK6 1NE ENGLAND EC DECLARATION OF CONFORMITY 1. Hydraulic Piling Hammer Description: 2. Power Pack - 93kW 1. Hyd Piling Hammer - HPH 1200 Type: 2. Power Pack - 1800/2400 Diesel Engine Hydraulic 1. HPH1200 – Serial Number: 2.
  • Page 5 1.0 INTRODUCTION The D.C.P. Hydraulic Hammer has been designed and manufactured to meet the demands of today's contractor. The hammer has many advantages over traditional piling hammers, including other hydraulic hammers:- - The hammer fits all British and most foreign single sheet piles as well as numerous 'H' piles using one set of legs and inserts.
  • Page 8 2.0 HOW DOES THE HAMMER WORK? (See fig. 1) The D.C.P. Hydraulic Hammer consists of a 'drop weight' driven up and down by a 'hydraulic ram' inside a 'casing.' The hydraulic ram is double acting which means the drop weight is accelerated both on the upstroke and on the downstroke.
  • Page 10 3.0 POWER PACK AND HAMMER OPERATION 3.1 Connecting the hydraulic hoses and control pendant (The power pack must be turned off at this time to enable correct installation of the hoses) There are four hydraulic hoses running between the power pack and the hammer, viz: 1.
  • Page 11 3.3 Starting the power pack (see fig. 2) Prior to starting the power pack, check that the hand control pendant is turned 'off.' Set the throttle control lever to half of full throttle (2). Turn 'on' the battery isolator (1). Push the engine start push button (4) until the engine starts.
  • Page 12 3.4.2. Bleeding air from the hammer hydraulic system - only required when running hammer after initial connection or following a repair When running the hammer for the first time after initial connection to the power pack, there will be air in the hydraulic system. The hammer will 'bleed' this air automatically but the following procedure must be applied:- a.
  • Page 13 It is good practice to start piling with the hammer set on minimum stroke, this limits unnecessary damage to both the hammer and the pile when the pile can be driven easily. The stroke may then be adjusted to suit the changing driving resistance. On certain piling jobs, it may be possible to start driving on pairs of sheet piles, changing over onto a single sheet pile as the driving resistance increases (this will give maximum productivity.) 3.4.4 Cold running/overtravel...
  • Page 15 THE MANUFACTURER. 3.6 Wider or special pile sections. The HPH 1200 hammer in standard format will drive a considerable range of steel piles. In some applications, however, where sheet piles are particularly wide or perhaps boxed together it is possible to use simple leg insert modifications and/or spreader plates to give improved pile coverage reducing pile head stress and improving productivity rates.
  • Page 18 3.7 PREVENTATIVE MAINTENANCE GUIDELINES FOR HPH 1200 & 2400 HYDRAULIC HAMMERS, AND DIESEL ENGINED POWER PACKS DAILY OR REFUELLING EVERY 125 HOURS EVERY 250 HOURS EVERY 500 HOURS EVERY 1000 HOURS EVERY 2000 HOURS CHECK CHANGE CHANGE ADJUST CHANGE •...
  • Page 19 4.0 HAMMER MAINTENANCE (SEE APPENDIX 7.1) 4.1 Daily maintenance checks (or every 10 hours) a. Apply Lithium based general purpose grease to hammer through each one of five grease points (part 1-057-00-01). Ten operations of a grease gun on each grease point every shift will be adequate.
  • Page 20 4.3 Planned 250 hour maintenance checks (run the hammer for 15 minutes before and after this maintenance work) Every 250 hours the following work should be carried out in addition to the work described in 4.1 and 4.2 above: a. Check the accumulator (part 1-048-00-04) precharge pressures using the gas pressure checking kit and a bottle of nitrogen gas.
  • Page 21 d. Retract the piston rod of the Hydraulic Ram from the Drop Weight by hand and remove the other Resilient Washer (part 1-016-00-01), Buffer Washer (part 1-010-00-01). e. Inspect the removed steel components for wear and replace those with signs of fretting or bruising.
  • Page 23 5.0 POWER PACK MAINTENANCE 5.1 Power pack specification 5.1.1 Basic specification Engine power output 55 kW (74 hp) @ 2300 rpm Engine maximum r.p.m. 2300 Hydraulic flow output 75 l/min Max hydraulic pressure output 240 Bar Dimensions (l x w x h) 1900 x 1400 x 1800mm Weight 2000 kg...
  • Page 24 FIGURE 6 Hammer Dolly photographs Debris embedded in dolly, remove debris Severely cracked 6500 dolly should be and continue. replaced. Overworked 6500 dolly stuck in anvil body If dolly is not replaced when it has been must be replaced or it can cause the anvil body overworked, the anvil body can break due to to break.
  • Page 25 5.3 Planned maintenance checks For full details of diesel engine maintenance see Cummins service manual and for power pack maintenance procedures see section 5.4.
  • Page 26 5.3.1 Every 125 hours Check the following:- a. Hoses, pipework and fittings for any hydraulic oil leaks and rectify as required. b. Tightness of all fasteners. c. Condition of body panels and paintwork. Touch-up where necessary. d. Battery water level. e.
  • Page 27 5.3.4 Every 1000 hours Check the following:- a. Engine fan hub. b. Engine belt tensioner bearing. c. Engine belt tension. d. Adjust valve lash clearance on engine. e. Condition of all wiring and tightness of electrical connectors. Wear on hydraulic pump flexible coupling. g.
  • Page 28 c. Change hydraulic return filter element. (i) Replacement element (ii) Remove filter bowl (iii) Remove and discard filter element (do not clean) (iv) Wash bowl thoroughly (v) Fit replacement element onto spigot (vi) Fill filter bowl with clean hydraulic oil (vii) Replace bowl O' ring if necessary (viii) Re-assemble filter d.
  • Page 29 g. Pipework. (i) For details of hose assemblies see hydraulic schematic drawing Appendix 7.4.1 (ii) In the event of steel pipe failure, 25mm 3 series fittings should be utilised in conjunction with 25mm bore x 3mm wall thickness tube (iii) Welded pipe ends are currently utilised and should it become necessary to disturb these fittings a replacement 'O' ring should be used h.
  • Page 30 6.0 TROUBLESHOOTING 6.1 Power pack engine will not start a. Check battery condition. b. Check diagnostics panel for fault LED showing (see fig. 2.) 6.2. Engine cuts out during running a. Check diagnostics panel for fault LED showing and rectify (see fig. 2.) 6.3.
  • Page 31 (iv) It is possible to work the hammer for diagnostic purposes whilst it is laying on the ground. However, extreme caution must be exercised when doing so as incorrect operation will cause hammer damage. Always ensure the pendant is in MANUAL mode and NOT automatic mode.
  • Page 32 6.6 Hammer runs erratically a. Air in hydraulic system - see section 3.4.2. b. 'Cold' hydraulic oil - see section 3.4.4. c. Accumulator pressures incorrect or bladders damaged. See Appendix 7.2.High pressure accumulator 100 bar (2 off) Low pressure accumulator 3 bar (2 off) d.
  • Page 33 6.10 Smoke from bottom end of hammer a. Most likely to be a worn or partially damaged plastic dolly. This does not mean the dolly has to be thrown away! Inspect the dolly as described in section 4.1. The dolly may only require dressing up and rotation prior to being re-used.

  • Page 34: Parts List

    APPENDIX 7.1 - HPH 1200 HYDRAULIC HAMMER PARTS LIST...
  • Page 45 HYDRAULIC HOSE DETAILS FOR HPH 1200 Control Side of Hammer (Sensor Side) - Assy Number 1.110.00.02 Description (Hose Length = Cut Length) Part No. 3 off Hose Assy 900mm " R2T c/w 20 x 1.5 heavy 12s fem E/E 1.110.05.02...
  • Page 46 Appendix 7.2 – Accumulator Parts List and Instructions...
  • Page 47 2. All accumulators are supplied precharged to 100bar (1450 psi) unless sent via air-freight – in which case they will be shipped unprecharged 3. Always use the gas filling apparatus supplied by Dawson. This equipment includes a regulator valve specifically designed for use with hammer accumulators where the precharge pressure is less than the supply cylinder pressure.
  • Page 48 Due to the nature of the design and specific assembly procedures it is recommended that the accumulators should only be inspected and repaired by a competent person. Dawson Construction Plant Limited or their approved dealers will be happy to undertake this work as required. Please note the Important Safety Notes at the beginning...
  • Page 53 APPENDIX 7.5 - HPH 1200 TOOL KIT (S/NO 1011 ONWARDS) (PART NO. 1.150.00.02) PART NO. QTY. DESCRIPTION 1 off 4mm Allen Key 1 off 5mm Allen Key 1 off 10mm Allen Key 1 off 17mm Allen Key 1.150.31.01 1 off 6mm Allen Key - long series 1.150.01.01...
  • Page 54 HPH 1200 HYDRAULIC HAMMER Dawson Construction Plant Ltd Chesney Wold. Bleak Hall, Milton Keynes, MK6 1NE, England Tel: +44 (0) 1908 240300 Fax: +44 (0) 1908 240222 D.C.P. RESERVES THE RIGHT TO DISCONTINUE EQUIPMENT AT ANY TIME, OR CHANGE SPECIFICATIONS OR DESIGNS WITHOUT NOTICE OR INCURRING OBLIGATIONS...