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Dawson CRH5000 Owner's Manual

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CRH
central ram hammer
5000
owners manual
operators instructions
spare parts list
safety precautions
maintenance
DAWSON CONSTRUCTION PLANT LTD.
CHESNEY WOLD,
BLEAK HALL
MILTON KEYNES
MK6 1NE, ENGLAND
TEL: +44 (0) 1908 240300
FAX: +44 (0) 1908 240222
EMAIL: DAWSON@DCPUK.COM
Original Instructions
CRH5000 ver. 2025-01

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  • Page 1 5000 owners manual operators instructions spare parts list safety precautions maintenance DAWSON CONSTRUCTION PLANT LTD. CHESNEY WOLD, BLEAK HALL MILTON KEYNES MK6 1NE, ENGLAND TEL: +44 (0) 1908 240300 FAX: +44 (0) 1908 240222 EMAIL: DAWSON@DCPUK.COM Original Instructions...

  • Page 3: Engine Type

    CRH5000 HYDRAULIC HAMMER & POWER PACK USER’S MANUAL HAMMER SERIAL No: 5003 HAMMER COMMISSION DATE: 2022 POWER PACK SERIAL No: 270DCP002 POWER PACK COMMISSION DATE: 2023 ENGINE TYPE: 270l/min Tier 4 CAT Engine ENGINE SERIAL No: .................. POWER PACK TYPE:...

  • Page 4: Table Of Contents

    You will find the model and serial numbers on an ID plate located on the product. The descriptions and specifications in this manual are subject to change without notice. Dawson reserves the right to improve products. Some product improvements may have taken place after this manual was printed.

  • Page 5: Eu Declaration Of Conformity

    We declare that the machinery/equipment detailed below is in compliance with the applicable regulations and harmonised standards as listed. This declaration ceases to be valid if alterations are made the machinery/equipment without agreement with Dawson Construction Plant Ltd. Category Piling Equipment...

  • Page 6: Introduction

    introduction FIG.1 The DCP 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 7: Transportation And Laying Down Hammer

    transportation and laying down hammer 55° 45° CENTRE OF GRAVITY 5k LIFT - WHEN LAYING DOWN THE HAMMER, support top of hammer at higher level than bottom of hammer. - TRANSPORTATION, support top of hammer at higher level than bottom of hammer. - Fit transport bolt for travel.

  • Page 8: Transportation And Laying Down Power Pack

    User manual 9 9 . . R R A A N N S S P P O O R R T T A A N N D D S S T T O O R R A A G G E E Power Packs transportation and laying down power pack General: consult the included Safety Guide before hoisting, transport and...

  • Page 9: How Does The Hammer Work

    This information can be recorded direct to a laptop via a Dawson software interface, and can be saved in standard spreadsheet formats, giving a blow by blow account of every pile driven and a day to day productivity record.

  • Page 10: Installation Of Power Pack

    installation of power pack 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: Power Pack Instrumental Panel

    power pack instrumental panel PRESSURE DISPLAY GAUGES INTERFACE SCREEN EMERGENCY STOP POWER HAND / AUTO START LOWER RAISE IDLE / RUN LOCAL / REMOTE HAMMER SOLENOID UP HAMMER SOLENOID DOWN OFF PILE www.dcpuk.com...

  • Page 12: History Page

    cont’d - power pack instrumental panel MAIN PAGE The left of the page contains an oil temperature bar display. The ‘M’ button bottom left selects the Maintenance page. The Reset button resets the adjacent blow counter. The Lap button resets another blow counter and freezes the adjacent blow count, a second press of the Lap button unfreezes the adjacent display.
  • Page 13 cont’d - power pack instrumental panel MIMIC PAGE DIAG PAGE All values on this page are in encoder pitch units (usually 6mm), velocities are pitch units per second. Hpos = hammer current position hpos_max = hammer maximum height during last blow hpos_min = hammer minimum height during last blow hveld_max = hammer downward velocity maximum during last blow hvelu_max = hammer upwards velocity maximum during last blow...

  • Page 14: Config Page

    cont’d - power pack instrumental panel CONFIG PAGE The ‘Load’ button loads values from the VS1202. Touching a numeric value brings up a keypad allowing entry of a new value. The ‘Save’ button saves the current values to the VS1202 where (excepting Enc Pitch mm and Hmr Mass kg) they are used immediately.
  • Page 15 270dcp iqan instructions Main Screen Engine Screen Remark, gauges marked with * are only visible when data is present. www.dcpuk.com...
  • Page 16 cont’d - 270dcp iqan instructions Hammer Screen Info Screen...

  • Page 17: Using The Hammer

    using the hammer Remove travel bolt before installing hammer on the pile BEFORE TRANSPORT FIT HERE TRAVEL BOLT Installing hammer on the pile The hammer must be sat correctly on the pile to avoid hammer or pile damage. The pile tops should be as level and square cut as possible.
  • Page 18 cont’d - using the hammer Set the ‘Auto/Man’ selector button to the required position: ‘Auto’ - hammer will continue running automatically when the ‘start’ push button is pressed once. ‘Man’ - hammer will only run whilst the ‘start’ push button is held down. Depress the ‘start’...
  • Page 19 - using the hammer Wider or special pile sections The CRH5000 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 20 hydraulic piling hammer...

  • Page 21: Hammer Maintenance

    hammer maintenance Daily maintenance checks (or every 10 hours): Apply lithium-based general purpose grease to the hammer through each one of five grease points (part 1-057-00-01). Six operations of a grease gun on each grease point before every shift will be adequate. Check all external fasteners for tightness and re-tighten where necessary.
  • Page 22 cont’d - hammer maintenance FIG. 4.1 Debris embedded in dolly, remove debris and Severely cracked 6500 dolly should be 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 overworked, the anvil body can break due to expansion of dolly material.

  • Page 23: Power Pack Maintenance

    power pack maintenance BEFORE PERFORMING MAINTENANCE • Stop the power pack and allow any oil pressure to depressurise. • Remove the ignition keys from the ignition. Wear protective clothing, gloves and safety goggles during maintenance activities on the power pack. Be careful when using metal tools in the surrounding of the battery in connection with sparks and danger of explosion.

  • Page 24: Service Interval

    cont’d - power pack maintenance SERVICE INTERVAL If the power pack is equipped with IQAN and the warning sign for maintenance appears in the display, contact DCP or your nearest DCP representative for a service appointment or for more information. If the power pack is not equipped with an IQAN, then the power pack is equipped with an hour counter.

  • Page 25: Maintenance Schedule

    cont’d - power pack maintenance While running idle, check the diesel engine: Follow the starting procedure on the inside of the control panel before starting the engine. Allow the motor to idle for approximately 5 minutes and check: • Whether there are any oil or coolant leaks. •...

  • Page 26: Filling Volumes

    cont’d - power pack maintenance DRAINING AND FILLING THE HYDRAULIC TANK • The hydraulic tank can be drained by removing a plug at the bottom of the tank. • The hydraulic tank can be filled by means of a hand pump. All oil that is pumped to the hydraulic tank goes through the return valve to guarantee that no contaminants enter the hydraulic system.

  • Page 27: Hydraulic Oil

    cont’d - power pack maintenance HYDRAULIC OIL New power packs are filled with hydraulic oil Q8 Holbein Eco 46, unless otherwise specified. Always check the label in the power pack for the correct type of oil. If the use of another type or brand of hydraulic oil is desired, contact DCP. SEVERE CONDITIONS •...

  • Page 28: Tightening Torques For Bolts

    cont’d power pack maintenance Danger Never weld on the diesel tank in connection with the danger of explosion. The diesel tank is integrated into the tubular frame of the power pack. Danger Never weld on the hydraulic tank in connection with the danger of explosion. The hydraulic tank is coated on the inside.

  • Page 29: Repairs

    repairs Danger All repair work must be performed by qualified and authorised staff only. All repair work is to be performed while the diesel engine is not running. Make sure that the main switch is turned “off”. Place a warning sign with do not operate at the main switch.
  • Page 30 hydraulic piling hammer...
  • Page 31 www.dcpuk.com...
  • Page 32 hydraulic piling hammer...

  • Page 33: Hydraulic Hose Details For Crh5000

    CRH5000 HP Hose Assembly LP Hose Assembly DHP1688 Power Pack - Parts List APPENDIX 7.4 Please refer to Power pack manual for full details Hydraulic Circuit Electrical Circuit Engine Type www.dcpuk.com...

  • Page 34: Drawings & Schematics

    drawings & schematics www.dcpuk.com...
  • Page 35 X = +/- 0.5 ROUGH MACHINE N9 X . X = +/- 0.25 File Date 13/04/2022 FINE MACHINE N8 X . XX = +/- 0.05 DAWSON HPH 5000 ANGLES +/- 0.5° CONSTRUCTION Drawing no. GRIND 50-000-00-01 PLANT LTD. DIMENSIONS IN MILLIMETERS...
  • Page 36 N9 (6.3 µm) MINIMUM 07/01/24 X = ± 0.5 WORKS DEPICTED ARE THE PROPERTY OF DAWSON CONSTRUCTION PLANT LTD. DAWSON CONSTRUCTION PLANT LIMITED. IT MAY PISTON ROD ASSEMBLY X.X = ± 0.25 Drawing No. ALL EDGES TO HAVE A 12/09/23...
  • Page 37 Replaced by X = +/- 0.5 ROUGH MACHINE N9 X . X = +/- 0.25 File Date 11/05/18 X . XX = +/- 0.05 DAWSON FINE MACHINE N8 MAIN VALVE ASSEMBLY CONSTRUCTION ANGLES +/- 0.5° Drawing no. GRIND 50-018-00-01 PLANT LTD.
  • Page 38 ROUGH MACHINE N9 X . X = +/- 0.25 PART SECTION THRO B-B File Date 07/06/23 FINE MACHINE N8 X . XX = +/- 0.05 DAWSON ROD DAMPER CONSTRUCTION ANGLES +/- 0.5° Drawing no. GRIND 50-009-00-02 PLANT LTD. DIMENSIONS IN MILLIMETERS...
  • Page 44 DCP1202 Connections...

  • Page 45: Appendix A - Crh5000 Tool Kit

    A - CRH5000 tool kit Part Description Part No. 3mm Allen Key 4mm Allen Key 5mm Allen Key 6mm Allen Key 8mm Allen Key 2-150-01-01 12mm Allen Key 2-150-02-01 14mm Allen Key 2-150-03-01 17mm Allen Key 19mm Allen Key - long series...
  • Page 46 2335 22.8 16889 2579 18654 2402 23.5 17373 HPH6500 Impact Blow Bearing Capacity at Final Set (blows/25mm) - tonnes CRH5000 Energy Rate b.p.m. ft lb Impact Blow Bearing Capacity at Final Set (blows/25mm) - tonnes Energy 2500 24.5 18082 Rate b.p.m.
  • Page 47 CFA CLEANERS PILE POINTS & SPLICERS SAFETY HANDLING / LIFTING EQUIPMENT SHEET PILE THREADERS hydraulic piling hammer CRH5000 DAWSON CONSTRUCTION PLANT LTD. CHESNEY WOLD, BLEAK HALL MILTON KEYNES MK6 1NE, ENGLAND TEL: +44 (0) 1908 240300 FAX: +44 (0) 1908 240222...

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